Service Procedures Manual

MG 3
The Service Procedures Manual provides information about the specification, system introduction, service procedure and
adjustment of the new MG 3 vehicle.

After mastering the content of this manual and materials in the service bulletins of SAIC Motor Passenger Vehicle Co., the
technicians of Authorised Repairers of SAIC Motor Passenger Vehicle Co. can provide better service for MG 3 vehicle
owners.

For relevant information about product brands, part number or special tools mentioned in this manual, we recommend
you to contact with SAIC Motor Passenger Vehicle Co.

SAIC Motor Passenger Vehicle Co.

All Rights Reserved.

Information is due in February, 2018.

Without prior written approval from SAIC Motor Passenger Vehicle Co., no part of the manual shall be reproduced,
stored in retrieval system or transmitted in any form or by any means (including but not limited to electronic, mechanical,
photocopy and recording). The statement above applies to all texts, illustrations and tables.
How To Use This Manual NOTE statements emphasize a necessary characteristic of
General a diagnostic or repair procedure. NOTE statements are
designed to do the following:
To assist in the use of this Manual, it is divided into sections
and sub-sections. The relevant sub-section title is given at the • Clarify a procedure.
header of each page. • Present additional information for accomplishing a
procedure.
There is a single Contents section at the front of the Manual,
which is divided by section and sub-section. The book is • Give insight into the reason or reasons for performing a
numbered from page 1. The page number is given at the procedure in the manner recommended.
bottom of each page. • Present information that will help to accomplish a
procedure in a more effective manner.
The individual actions of the repair operations must be
followed in the sequence in which they appear. Item numbers • Present information that gives the technician the benefit
in the illustrations refer to the relevant numbered text under of past experience in accomplishing a procedure with
the illustration. greater ease.

Adjustment and repair operations include reference to Service TIP: Gives helpful information.
tool numbers and the associated illustration depicts the tool in References
use. Adjustment and repair operations also include reference
References to the LH or RH side given in this Manual are made
to wear limits, relevant data, torque figures, and specialist
when viewing the vehicle from the rear. With the engine and
information and useful assembly details. Each adjustment or
gearbox assembly removed, the crankshaft pulley end of the
repair operation is given a unique Repair Operation number.
engine is referred to as the front.
WARNINGS, CAUTIONS, NOTES and TIPS have the
Operations covered in this Manual do not include reference
following meanings:
to testing the vehicle after repair. It is essential that work
When encountering a WARNING, you will be asked to take is inspected and tested after completion and if necessary a
a necessary action or not to take a prohibited action. If a road test of the vehicle is carried out. This is of particular
WARNING is not heeded, the following consequences may importance where safety related items are concerned.
occur: Dimensions
• Serious bodily injury or death to the technician.
The dimensions quoted are to design engineering specification.
• Serious bodily injury or death to other technicians in the Service limits are included where applicable.
workplace area.
Our company are constantly seeking to improve the
• Serious bodily injury to the driver and/or passenger(s) of
specification, design and production of their vehicles and
the vehicle, if the vehicle has been improperly repaired.
alterations take place accordingly. While every effort has been
CAUTION call special attention to a necessary action or to a made to ensure the accuracy of this Manual, it should not be
prohibited action. If a CAUTION is not heeded, the following regarded as an infallible guide to current specifications of any
consequences may occur: particular vehicle.
• Damage to the vehicle.
• Unnecessary vehicle repairs.
• Unnecessary component replacement.
• Improper operation or performance of the system or
component under repair.
• Damage to any systems or components which are
dependent upon the proper operation of the system or
component under repair.
• Improper operation or performance of any systems
or components which are dependent upon the proper
operation or performance of the system or component
under repair.
• Damage to fasteners, basic tools, or special tools.
• The leakage of coolant, lubricant, or other vital fluids.

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Repairs and Replacements
Parts
When replacement parts are required it is essential that only
our company’s recommended parts are used.

Attention is particularly drawn to the following points

concerning repairs and the fitting of replacement parts and
accessories.

• Safety features and corrosion prevention treatments

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

All SMC recommended parts have the full backing of the vehicle
warranty.

SMC Dealers are obliged to supply only SMC recommended

parts.
Special tools
Special tools have been developed to facilitate removal,
dismantling and assembly of mechanical components in a cost
effective and time efficient manner. The use of special tools
also helps prevent the potential for damage to components.

Some operations in the manual cannot be carried out properly

without the aid of the relevant special tools.

Special tools can be obtained from the following supplier.

Shanghai Runyue Industrial Development Co., Ltd

Address: Skirt Building, Lianhua Building, 159 Tianzhou Road,

Shanghai

Post Code: 200233

Tel: 021-54234810

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 Contents
General Information ........................... 1 Flywheel-MT ................................................ 66
General Information .............................................1 Crankshaft Pulley.......................................... 68
General Precautions ........................................... 1 Timing Chain Upper Cover Plate................... 69
Safety Instructions .............................................. 2 Timing Chain Lower Cover Plate................... 70
Environmental Precautions.................................. 3 Timing Chain................................................ 72
General Fitting Instructions................................. 5 Camshaft Cover ........................................... 74
Ball and Roller Bearings ...................................... 6 Camshaft - Intake or Exhaust ........................ 76
Oil Seals ............................................................ 7 Mechanical Tappet ........................................ 79
Joints and Joint Faces .......................................... 8 Valve............................................................ 80
Locking Devices ................................................. 8 Cylinder Head Assembly............................... 81
Screw Threads ................................................... 9 Cylinder Head Check ................................... 83
Fasteners Identification....................................... 9 Cylinder Gasket ........................................... 88
Flexible Pipes and Hoses................................... 11 Lower Crankcase ......................................... 89
Fuel Handling Precautions................................. 12 Connecting Rod Bearing Shell Check............. 90
Electrical Precautions ....................................... 13 Piston Check................................................ 91
Supplementary Restraint System Crankshaft Check......................................... 92
Precautions...................................................... 14 Rear Crankshaft Oil Seal ............................... 94
SRS Component Replacement Policy................. 20 Oil Strainer .................................................. 95
Air Conditioning System Precautions ................ 21 Oil Pump ..................................................... 96
Air Conditioning Compressor Oil Control Valve ......................................... 97
Replacement .................................................... 23 Engine Oil Filter ........................................... 98
Vehicle Identification Number ...........................24 Engine Oil Pressure Check............................ 99
Vehicle Identification Number........................... 24 Intake Manifold Gasket.................................. 99
Position Of Other Plates .................................. 25 Exhaust Manifold Gasket ............................. 102
Lifting & Towing...................................................26 Cylinder Pressure Test ................................ 103
Lifting .............................................................. 26 Special Tools .................................................. 104
Roadside Assistance ......................................... 27 Engine Cooling System .....................................106
Lubrication & Maintenance ................................29 Specifications ................................................. 106
Capacity .......................................................... 29 Torque ....................................................... 106
Fluid ................................................................ 29 Parameter .................................................. 107
Lubricating Fluid............................................... 30 Description and Operation............................. 108
Engine................................................. 31 System Layout ............................................ 108
Description ................................................ 110
Engine Mechanical...............................................31
Operation .................................................. 112
Specifications ................................................... 31
Service Procedures......................................... 114
Torque ......................................................... 31
Coolant - Drain and Refill ........................... 114
Parameter .................................................... 33
System Pressure Test .................................. 115
Description and Operation............................... 41
Pressure Seal Cap - Pressure Test................ 116
System Layout .............................................. 41
Coolant Expansion Tank.............................. 116
Description .................................................. 54
Cooling Fan................................................ 117
Operation .................................................... 56
Cooling Fan Low Speed Resistor ................. 117
Service Procedures........................................... 58
Radiator..................................................... 118
Powertrain Remove and Refit - AT ................ 58
Radiator Water Inlet Hose.......................... 120
Powertrain Remove and Refit - MT ............... 61
Radiator Water Outlet Hose ...................... 120
Powertrain Mount ........................................ 64
Heater Water Inlet Hose ............................ 121
Torque Converter Drive Plate - AT ............... 65

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 Contents
Heater Water Outlet Hose......................... 121 Fuel System - Pressure Relief - 1.5L ............. 156
Engine Overflow Pipe - 1.5L........................ 122 Fuel System - Pressure Test - 1.5L ............... 157
Radiator Drain Valve................................... 122 Tank-Drain & Refill ..................................... 158
Radiator Upper Shock Pad .......................... 123 Filler Neck ................................................. 158
Radiator Lower Shock Pad .......................... 123 Electronic Throttle Self-learning - UMC
Wind Scooper - Left................................... 124 System ....................................................... 159
Wind Scooper - Right ................................. 124 Special Tools .................................................. 160
Thermostat - 1.5L ...................................... 125 Engine Manifold & Exhaust System .................161
Water Pump............................................... 126 Specifications ................................................. 161
Transmission Oil Cooler Inlet Pipe Torque ....................................................... 161
Assembly - 4AT .......................................... 126 Description and Operation............................. 162
Transmission Oil Cooler Outlet Pipe System Layout ............................................ 162
Assembly - 4AT .......................................... 127 Description ................................................ 164
Special Tools .................................................. 128 Operation .................................................. 165
Engine Fuel & Management .............................129 Service Procedures......................................... 166
Specifications ................................................. 129 Air Filter Assembly ..................................... 166
Torque ....................................................... 129 Air Filter Element ....................................... 166
Parameter .................................................. 130 Air Inlet Pipe Assembly ............................... 167
Description and Operation............................. 131 Electronic Throttle ..................................... 167
System Layout ............................................ 131 Front Exhaust Pipe Assembly ...................... 168
System Control Diagram............................. 132 Rear Exhaust Pipe Assembly........................ 169
Description ................................................ 134 Exhaust Passage Heat Shield........................ 170
Service Procedures......................................... 142 Fuel Tank Heat Shield ................................. 170
Spark Plug .................................................. 142 Engine Electrical System ..................................171
Ignition Coil ............................................... 142 Specifications ................................................. 171
Engine Control Module (ECM) .................... 143 Torque ....................................................... 171
Engine Coolant Temperature Sensor Description and Operation............................. 172
(ECT) ........................................................ 143
System layout ............................................. 172
Engine Oil Temperature Sensor ................... 144
Description ................................................ 173
Crankshaft Position Sensor ......................... 144
Operation .................................................. 175
Camshaft Position Sensor ........................... 145
Service Procedures......................................... 176
Camshaft Phase Modulator ......................... 145
Alternator.................................................. 176
Oil Pressure Switch .................................... 147
Auxiliary Drive Belt .................................... 177
Knock Sensor............................................. 148
Auxiliary Drive Belt Tensioner..................... 178
Fuel Rail ..................................................... 148
Starter Motor ............................................ 178
Fuel Injector............................................... 149
Battery Positive Cable................................. 179
Oxygen Sensor........................................... 150
Battery Negative Cable............................... 180
Downstream Oxygen Sensor ...................... 150
Battery....................................................... 181
Manifold Absolute Pressure/Temperature
Sensor ....................................................... 151 Battery Tray ............................................... 181
Charcoal Canister ...................................... 151 Battery Tray Front Bracket.......................... 182
Carbon Canister Control Valve ................... 152 Battery Tray Rear Bracket ........................... 182
Pipe Assembly - Body Underfloor Fuel Accessory Belt Idle Pulley ........................... 183
Lines .......................................................... 152
Transmission .................................... 185
Fuel filter .................................................. 153
Tank - Fuel ................................................. 154 Shift Lock Control-NEW 4AT..........................185
Fuel pump .................................................. 155 Specifications ................................................. 185

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 Contents
Torque ....................................................... 185 Oil Pump Oil Seal ....................................... 261
Description and Operation............................. 186 Filter Assembly........................................... 262
System Layout ............................................ 186 Automatic Transmission Oil Cooler Pipe
Description ................................................ 187 Connector ................................................. 262
Service Procedures......................................... 189 Special Tools .................................................. 263
Shift Lever Knob - Automatic ...................... 189 Transmission-MT ...............................................264
Shift Lever Assembly - Automatic ................ 190 Specifications ................................................. 264
Gear Panel ................................................. 191 Torque ....................................................... 264
Shift Lock Control-MT......................................192 Parameter .................................................. 265
Specifications ................................................. 192 Description and Operation............................. 267
Torque ....................................................... 192 System Layout ............................................ 267
Service Procedures......................................... 193 Description ................................................ 276
Shift Lever Knob and Sleeve - Manual........... 193 Operation .................................................. 277
Gear Shift Mechanism Assembly - Service Procedures......................................... 279
Manual ....................................................... 193 Manual Transmission Assembly.................... 279
Transmission-AT................................................195 Gear Selection/Shift Shaft Oil Seal -
Specifications ................................................. 195 Manual ....................................................... 281
Torque ....................................................... 195 Transmission Fluid - Drain and Refill ............ 282
Parameter .................................................. 196 Reverse Lamp Switch.................................. 283
Description and Operation............................. 198 Left Differential Oil Seal.............................. 283
System Layout ............................................ 198 Right Differential Oil Seal ............................ 284
System Control Diagram............................. 203 Manual Transmission Disassembling ............. 284
Description ................................................ 207 Drive Shaft Assembly .................................. 290
Operation .................................................. 217 Driven Shaft Assembly ................................ 291
diagnosis ........................................................ 235 Differential Assembly .................................. 293
Overview ................................................... 235 Special Tools .................................................. 295
Machinery Diagnosis ................................... 236 Clutch .................................................................296
Service Procedures......................................... 246 Specifications ................................................. 296
Hydraulic Pressure Test .............................. 246 Torque ....................................................... 296
Automatic Transmission Assembly............... 247 Parameter .................................................. 297
Automatic Transmission Fluid - Drain and Description and Operation............................. 298
Refill .......................................................... 249 System Layout ............................................ 298
Automatic Transmission Fluid - Refill ........... 251 Description ................................................ 300
Transmission Control Module (TCM)........... 252 Operation .................................................. 301
Automatic Transmission Harness................. 252 Service Procedures......................................... 302
Neutral Start Switch ................................... 253 Clutch Assembly......................................... 302
Neutral Start Switch - Check and Clutch Release Bearing ............................... 303
Adjustment ................................................ 254 Clutch Master Cylinder............................... 304
Input Speed Sensor..................................... 255 Clutch Slave Cylinder.................................. 305
Output Speed Sensor ................................. 255 Clutch Pipeline System Bleeding .................. 305
Automatic Transmission Housing End Oil Special Tools .................................................. 306
Seal............................................................ 256
Torque Converter Housing End Oil HVAC System.................................. 307
Seal............................................................ 257
HVAC Structure ................................................307
Hydraulic Torque Converter ....................... 258
Specifications ................................................. 307
Valve Body Cover ....................................... 258
Torque ....................................................... 307
Valve Body Assembly .................................. 259

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 Contents
Parameter .................................................. 307 System Control Diagram............................. 342
Description and Operation............................. 308 Description ................................................ 343
System Layout ............................................ 308 Operation .................................................. 344
Description ................................................ 311 Service Procedures......................................... 345
Service Procedures......................................... 316 A/C Panel - MTC ....................................... 345
Refrigerant Recovery and Refill ................... 316 Temperature Damper Cable........................ 345
Compressor - 1.5L ..................................... 317 Mode Damper Cable .................................. 346
Compressor Breather Hose - 1.5L .............. 318 Recirculated Damper Actuator.................... 346
Compressor Exhaust Hose - 1.5L................ 319
Steering System .............................. 347
A/C Hard Pipe Assembly - 1.5L ................... 320
Pressure Switch .......................................... 321 Front Wheel Steering .......................................347
Condenser ................................................. 321 Specifications ................................................. 347
A/C Box Assembly ..................................... 322 Torque ....................................................... 347
Evaporator Core ........................................ 323 Parameter .................................................. 348
Expansion Valve.......................................... 323 Description and Operation............................. 349
Heater Core .............................................. 324 System Layout ............................................ 349
Blower Motor Assembly ............................. 325 Description ................................................ 352
Blower Speed Regulation Resistor ............... 325 Operation .................................................. 353
A/C Filter Cover ....................................... 326 Service Procedures......................................... 358
A/C Filter Element ..................................... 326 Power Steering System - Pressure
Test ........................................................... 358
A/C Drain Pipe........................................... 327
Steering Gear Outer Tie Rod...................... 359
Instrument Panel Air Duct .......................... 327
Steering Gear Boot..................................... 359
Body Relief Valve - Left ............................... 328
Steering Gear Inner Tie Rod ....................... 360
Body Relief Valve - Right ............................. 328
Steering Gear Subassembly ......................... 360
HVAC-ETC.........................................................329
Power Steering Pump ................................. 362
Specifications ................................................. 329
Oil Inlet Pipe (Reservoir to Steering
Torque ....................................................... 329 Pump) ........................................................ 364
Description and Operation............................. 330 Oil Inlet Pipe - Steering Pump to Steering
System Layout ............................................ 330 Gear .......................................................... 364
System Control Diagram............................. 332 Steering Gear Oil Outlet Pipe ..................... 366
Description ................................................ 333 Steering Cooling Pipe ................................. 367
Operation .................................................. 335 Reservoir Oil Return Pipe Assembly............ 368
Service Procedures......................................... 336 Power Assisted Steering (PAS) System
A/C Controller Assembly - ETC.................. 336 Bleeding ..................................................... 368
A/C Panel - ETC......................................... 336 Special Tools .................................................. 369
Temperature Damper Actuator................... 337 Steering Wheel and Column ...........................370
Mode Damper Actuator ............................. 337 Specifications ................................................. 370
Internal/External Recirculated Damper Torque ....................................................... 370
Actuator .................................................... 338 Service Procedures......................................... 371
Evaporator Core Temperature Steering Wheel Assembly ........................... 371
Sensor ....................................................... 338 Steering Wheel
HVAC-MTC........................................................339 Positioning/Adjustment ............................... 371
Specifications ................................................. 339 Combination Switch ................................... 372
Torque ....................................................... 339 Steering Wheel Entertainment
Description and Operation............................. 340 Switch........................................................ 373
System Layout ............................................ 340 Upper Steering Column .............................. 373

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 Contents
Intermediate Shaft ...................................... 374 Specifications ................................................. 406
Steering Column Lower Trim Cover............ 375 Torque ....................................................... 406
Mechanical Steering Column Lock ............... 375 Parameter .................................................. 407
Service Procedures......................................... 408
Suspension System.......................... 377
Wheel........................................................ 408
Wheel Alignment ..............................................377 Tyre Pressure Monitoring Controller........... 409
Specifications ................................................. 377 Tyre Pressure Sensor .................................. 409
Torque ....................................................... 377
Parameter .................................................. 377 Brake System................................... 411
Description and Operation............................. 378 Brake ..................................................................411
Description ................................................ 378 Specifications ................................................. 411
Service Procedures......................................... 379 Torque ....................................................... 411
Four-wheel Alignment................................. 379 Description and Operation............................. 412
Front Suspension ...............................................380 System Layout ............................................ 412
Specifications ................................................. 380 Description ................................................ 413
Torque ....................................................... 380 Service Procedures......................................... 414
Specifications.............................................. 380 Low Brake Fluid Level Indicator Switch -
Description and Operation............................. 381 RHD.......................................................... 414
System Layout ............................................ 381 Master Cylinder and Fluid Reservoir............ 414
Description ................................................ 384 Brake Servo ............................................... 415
Service Procedures......................................... 386 Brake pedal ................................................ 417
Front Hub .................................................. 386 Brake lamp switch ...................................... 418
Front Hub Bearing ..................................... 388 Brake Caliper – Front ................................. 418
Front Lower Arm ...................................... 389 Brake Pads – Front .................................... 419
Front_Lower_Ball_Pin ................................ 390 Brake Disc – Front ..................................... 420
Front Lower Arm Rear Bush....................... 390 Thickness and Run-Out Check-Front Brake
Disc ........................................................... 421
Front Lower Arm Front Bush...................... 391
Brake Drum ............................................... 422
Front Damper ............................................ 391
Brake Shoes - Rear ..................................... 422
Anti Roll Bar .............................................. 393
Brake Shoes – Manually Adjust .................... 423
Anti Roll Bar Bush ...................................... 393
Hydraulic Wheel Cylinder........................... 424
Anti Roll Bar Link ....................................... 394
Brake System Bleed .................................... 424
Front Subframe Assembly ........................... 394
Electronic Vacuum Pump............................. 425
Special Tools .................................................. 396
Special Tools .................................................. 426
Rear Suspension ................................................398
Park Brake .........................................................427
Specifications ................................................. 398
Specifications ................................................. 427
Torque ....................................................... 398
Torque ....................................................... 427
Specifications.............................................. 398
Description and Operation............................. 428
Description and Operation............................. 399
System Layout ............................................ 428
System Component Layout ......................... 399
Description ................................................ 429
Description ................................................ 402
Service Procedures......................................... 430
Service Procedures......................................... 403
Handbrake Cable - Adjust ........................... 430
Rear Damper Assembly .............................. 403
Handbrake Cable – Equaliser....................... 430
Rear Spring ................................................ 403
Handbrake Cable – Rear............................. 431
Rear Hub Bearing ....................................... 404
Handbrake Lever ........................................ 432
H Frame Assembly ..................................... 404
Brake Module.....................................................433
Tires and Wheels ..............................................406

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 Contents
Specifications ................................................. 433 Rear Coat Rack .......................................... 457
Torque ....................................................... 433 Carpet ....................................................... 457
Description and Operation............................. 434 Luggage Compartment Side Trim
System Layout ............................................ 434 Panel.......................................................... 458
System Control Diagram............................. 435 Luggage Compartment Sill Trim Panel........... 459
Description ................................................ 436 Tail Gate Interior Trim Panel ....................... 459
Service Procedures......................................... 437 Roof Interior Trim ...................................... 460
ABS Sensor - Front..................................... 437 Sun Visor and Bracket................................. 461
ABS Sensor - Rear ...................................... 437 Insulation Pad of Engine Compartment
Heat Shield................................................. 461
Brake Modulator ....................................... 438
Front Insulation Pad.................................... 462
Driveline/Axle.................................. 439 Driver Side Glasses Box.............................. 463
Driveline/Axle ....................................................439 Inner Roof Handle ...................................... 463
Specifications ................................................. 439 Fascia and Console ...........................................464
Torque ....................................................... 439 Specifications ................................................. 464
Description and Operation............................. 440 Torque ....................................................... 464
System Layout ............................................ 440 Service Procedures......................................... 465
Description ................................................ 442 Instrument Panel End Cover Plate
Assembly ................................................... 465
Diagnostic...................................................... 443
Driver Side Lower Trim Panel
Diagnosis ................................................... 443 Assembly ................................................... 465
Mechanical Check....................................... 443 Glove Box Assembly................................... 466
Service Procedures......................................... 444 Instrument Panel Side Air Outlet
RH Shaft & Both Joints................................ 444 Assembly ................................................... 466
LH Shaft & Both Joints ................................ 445 Central Instrument Panel Air Outlet
Outer CV Joint Gaiter ................................ 446 Assembly ................................................... 467
Inner joint .................................................. 446 Central Control Panel and Entertainment
Switch of Instrument Panel.......................... 468
Inner Joint Gaiter ....................................... 447
Instrument Panel IPK Frame
Special Tools .................................................. 448 Assembly ................................................... 469
Interior Fitting................................. 449 Instrument Panel Assembly ......................... 469
Instrument Panel Beam Assembly ................ 472
Interior Trim and Paneling ...............................449
Centre Console Upper Trim Panel
Specifications ................................................. 449
Assembly and Switch Assembly ................... 473
Torque ....................................................... 449
Centre Console Assembly .......................... 474
Service Procedures......................................... 450
Centre Console Heater Closing Plate
Front Door Interior Trim Panel and Assembly ................................................... 474
Waterproof Membrane............................... 450
Seats ...................................................................475
Front Door Inner Handle............................ 451
Specifications ................................................. 475
Rear Door Interior Trim Panel and
Torque ....................................................... 475
Waterproof Membrane............................... 452
Description and Operation............................. 476
Rear Door Inner Handle ............................. 453
System Layout ............................................ 476
A Pillar Upper Trim Panel............................ 454
Description ................................................ 477
A Pillar Lower Trim Panel ........................... 454
Operation .................................................. 478
B/C Pillar Upper Trim Panel ........................ 455
Service Procedures......................................... 479
B/C Pillar Lower Trim Panel ........................ 455
Front Seat .................................................. 479
D Pillar Upper Trim Panel ........................... 456
Front Seat Squab ........................................ 479
D Pillar Lower Trim Panel ........................... 456
Front Seat Backrest Cover .......................... 480

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 Contents
Front Seat Cushion..................................... 481 Description and Operation............................. 504
Front Seat Cushion Cover .......................... 481 System Layout ............................................ 504
Front Seat Outer Trim Panel ....................... 482 System Control Diagram............................. 505
Rear Seat Cushion ...................................... 482 Description ................................................ 506
Rear Seat Squab Hinge................................ 483 Operation .................................................. 507
Rear Seat Squab.......................................... 483 Service Procedures......................................... 509
Windshield Wiper Blade Assembly.............. 509
Exterior Fitting................................ 485
Windshield Wiper Arm Assembly ............... 509
Fixed Windows ..................................................485 Windshield Wiper Linkage Mechanism
Service Procedures......................................... 485 Assembly - Energized.................................. 510
Front Door Quarter Window..................... 485 Washer Reservoir Assembly ....................... 510
Rear Door Quarter Window ...................... 485 Washer Pump Assembly ............................. 511
Windshield................................................. 486 Windshield Washer Pump Hose.................. 511
Rear Window............................................. 486 Rear Window Washer Pump Hose.............. 512
Bumpers, Fascias and Grille .............................487 Rear Window Wiper Arm Assembly ........... 513
Specifications ................................................. 487 Rear Window Wiper Motor ....................... 514
Torque ....................................................... 487 Special Tools .................................................. 515
Service Procedures......................................... 488
Lighting Systems ............................. 517
Front Bumper and Bracket .......................... 488
Front Bumper Beam ................................... 489 Lighting...............................................................517
Rear Bumper and Bracket ........................... 489 Specifications ................................................. 517
Rear Bumper Beam .................................... 490 Torque ....................................................... 517
Exterior Trim and Paneling ..............................491 Description and Operation............................. 518
Specifications ................................................. 491 System Layout ............................................ 518
Torque ....................................................... 491 System Control Diagram............................. 519
Service Procedures......................................... 492 Description ................................................ 520
A/C Air Inlet Grille Assembly...................... 492 Operation .................................................. 521
Front Wheelhouse Liner............................. 492 Service Procedures......................................... 522
Rear Wheelhouse Liner .............................. 493 Interior Lamp Assembly .............................. 522
Bottom Deflector....................................... 494 Rearview Mirror and Lamp Leveling
Switch........................................................ 522
A Pillar Exterior Trim Panel......................... 495
Lamps .................................................................523
Mirrors................................................................496
Specifications ................................................. 523
Specifications ................................................. 496
Torque ....................................................... 523
Torque ....................................................... 496
Description and Operation............................. 524
Description and Operation............................. 497
System Layout ............................................ 524
System Layout ............................................ 497
System Control Diagram............................. 525
System Control Diagram............................. 498
Description ................................................ 526
Description ................................................ 499
Operation .................................................. 528
Operation .................................................. 500
Service Procedures......................................... 530
Service Procedures......................................... 501
Headlamp Assembly.................................... 530
Exterior Rearview Mirror Assembly ............ 501
Integrated High/Low Beam Bulb .................. 530
Exterior Rearview Mirror Cover ................. 501
Front Position Lamp ................................... 531
Interior Rearview Mirror ............................ 502
Front Direction Indicator Lamp................... 531
Wipers and Washer ..........................................503
Bulb – Indicator – Side Repeater ................. 532
Specifications ................................................. 503
High-mounted Stop Lamp Assembly ............ 532
Torque ....................................................... 503

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 Contents
Tail Lamp Assembly .................................... 533 Bonnet Release Cable and Handle ............... 557
Tail Lamp Assembly Bulb ............................. 533 Rear Closures.....................................................558
Rear License Plate Lamp Assembly .............. 534 Specifications ................................................. 558
Torque ....................................................... 558
Body Systems ................................. 535
Service Procedures......................................... 559
Door....................................................................535 Tail Gate Gas Spring and Mounting
Specifications ................................................. 535 Bracket ...................................................... 559
Torque ....................................................... 535 Tail Gate Assembly and Hinge ..................... 560
Service Procedures......................................... 536 Tail Gate Adjustment .................................. 561
Front Door Adjustment.............................. 536 Tail Gate Lock Assembly ............................. 562
Front Door Assembly and Hinge ................. 536 Tail Gate Lock Catch .................................. 562
Driver Side Door Outside Handle and Fuel Filler Door Assembly........................... 563
Private Lock ............................................... 537 Fuel Filler Door Release Cable
Driver Door Lock Body Assembly............... 538 Assembly ................................................... 563
Front Passenger Door Outside Horns ..................................................................564
Handle ....................................................... 539 Specifications ................................................. 564
Rear Door Adjustment ............................... 539 Torque ....................................................... 564
Rear Door Assembly and Hinge .................. 540 Service Procedures......................................... 565
Rear Door Outer Handle ........................... 541 Tweeter ..................................................... 565
Rear Door Catch/CDL Motor..................... 541 Body Control Module........................................566
Front Door Upper Molding......................... 542 Specifications ................................................. 566
Rear Door Upper Molding .......................... 543 Torque ....................................................... 566
Door Window Outer Weatherstrip ............ 543 Description and Operation............................. 567
Front Door Window Glass ......................... 544 System Layout ............................................ 567
Rear Door Window Glass .......................... 544 System Control Diagram............................. 568
Front Door Window Regulator................... 545 Description ................................................ 569
Rear Door Window Regulator.................... 545 Operation .................................................. 572
Front Door Window Regulator Service Procedures......................................... 574
Adjustment ................................................ 546
Body Control Module (BCM) ...................... 574
Rear Door Window Regulator
Adjustment ................................................ 546 Add Key and Disable Key ............................ 574
Front Door Glass Channel .......................... 547 Body Repair ..................................... 575
Rear Door Glass Channel ........................... 547
Panel Repair.......................................................575
Front Door Division Bar ............................. 548
Roof Panel ................................................. 575
Rear Door Division Bar .............................. 548
Engine Compartment Panel......................... 576
Power Window Switch - Driver .................. 549
Dash Panel ................................................. 577
Power Window Switch - Others ................. 549
Bodyside Panel ........................................... 578
Central Control Door Lock Switch ............. 550
Front Floor ................................................ 580
Front Closures ...................................................551
Rear Floor ................................................. 581
Specifications ................................................. 551
Door Panel ................................................ 582
Torque ....................................................... 551
Bonnet Panel Assembly............................... 583
Service Procedures......................................... 552
Tail Gate Panel Assembly ............................ 584
Fender ....................................................... 552
Collision Repair .................................................585
Front-end Module....................................... 553
Body Material ............................................. 585
Bonnet Assembly and Hinge........................ 554
Damage Diagnosis ...................................... 586
Bonnet Adjustment..................................... 555
Repair Plan Determination .......................... 588
Bonnet Lock Assembly ............................... 556

8 1.0
 Contents
Body Correction ........................................ 589 Description ................................................ 676
Panel Repair ............................................... 591 Operation .................................................. 677
Sheet Metal Replacement............................ 592 Service Procedures......................................... 678
Painting...............................................................596 Anti-theft Coil............................................ 678
Overview ................................................... 596 Seat Belts ..........................................................679
Painting Process.......................................... 598 Specifications ................................................. 679
General Film Coating Defects ..................... 603 Torque ....................................................... 679
Seal .....................................................................607 Description and Operation............................. 680
Overview ................................................... 607 System Layout ............................................ 680
Sealing Performance Test ............................ 609 System Control Diagram............................. 681
Sealant Position Information........................ 610 Description ................................................ 682
Gasket Position Information........................ 623 Operation .................................................. 684
Corrosion Protection .......................................626 Service Procedures......................................... 685
Overview ................................................... 626 Front Seat Belt Assembly ............................ 685
Anti-corrosion Products and Front Seat Belt Buckle ................................ 686
Construction.............................................. 629 Rear Seat Belt Assembly ............................. 686
Welding Process ................................................635 Rear Seat Belt Buckle.................................. 688
Welding Process Overview ......................... 635 Rear Middle Seat Belt Assembly .................. 689
Welding Protection Measures...................... 636 Supplemental In�atable Restraints .................690
Welding Parts Remove................................ 637 Specifications ................................................. 690
Welding Information of OEM ...................... 639 Torque ....................................................... 690
Body Dimension ................................................657 Description and Operation............................. 691
Point to Point Dimensional Information........... 657 System Layout ............................................ 691
Bodyside and Top Information..................... 657 System Control Diagram............................. 692
Bottom Plate Information ........................... 659 Description ................................................ 693
Rear End Information.................................. 660 Operation .................................................. 696
Internal Information.................................... 661 Service Procedures......................................... 698
Front End Information ................................ 662 Steering Wheel Airbag................................ 698
Gap Information............................................. 663 Instrument Panel Airbag.............................. 698
Body Side and Fuel Filler Cap Airbag Control Module............................... 699
Information ................................................ 663
Side Impact Sensor ..................................... 700
Front End Information ................................ 664
Park Assistant System ......................................701
Rear End Information.................................. 666
Description and Operation............................. 701
Sunroof Information ................................... 667
System Layout ............................................ 701
Safety and Restraints ...................... 669 System Control Diagram............................. 702
Vehicle Access....................................................669 Description ................................................ 703
Description and Operation............................. 669 Operation .................................................. 705
System Layout ............................................ 669 Service Procedures......................................... 706
System Control Diagram............................. 670 Ultrasonic Sensor ....................................... 706
Description ................................................ 671 Camera...................................................... 706
Operation .................................................. 672 Information and
Alarm System....................................................674 Entertainment ................................. 707
Description and Operation............................. 674
Entertainment and Navigation ........................707
System Layout ............................................ 674
Specifications ................................................. 707
System Control Diagram............................. 675
Torque ....................................................... 707

1.0 9
 Contents
Description and Operation............................. 708
System Layout ............................................ 708
System Control Diagram............................. 709
Description ................................................ 711
Operation .................................................. 716
Service Procedures......................................... 717
Radio Antenna............................................ 717
Front Door Woofer ................................... 717
Rear Door Woofer..................................... 718
Tweeter ..................................................... 718
Player......................................................... 719
Microphone................................................ 720
Displays and Gauges..........................................721
Specifications ................................................. 721
Torque ....................................................... 721
Description and Operation............................. 722
System Layout ............................................ 722
System Control Diagram............................. 724
Description ................................................ 725
Operation .................................................. 729
Service Procedures......................................... 730
Instrument Pack ......................................... 730

Power and Signal ............................. 731

Power and Signal ...............................................731
Specifications ................................................. 731
Torque ....................................................... 731
Service Procedures......................................... 732
Engine Compartment Fuse Box ................... 732
Instrument Panel Harness ........................... 732
Body Harness............................................. 733
Front Door Harness ................................... 739
Rear Door Harness .................................... 739
Centre Console Power Socket .................... 740
Glossary List ......................................................741

10 1.0
 General Information
General Information Health Protection Precautions
General Precautions The following precautions should be observed at all times.
Dangerous Substances
• Wear protective clothing, including impervious gloves
Modern vehicles contain many materials and liquids which if not where practicable.
handled with care can be hazardous to both personal health • Avoid prolonged and repeated contact with oils,
and the environment. particularly used engine oils.
Warning: Many liquids and other substances used in • Do not put oily rags in pockets.
vehicles are poisonous and should under no circumstances • Avoid contaminating clothes (particularly those next to
be consumed and should, as far as possible, be kept the skin) with oil.
from contact with the skin. These liquids and substances
• Overalls must be cleaned regularly. Discard heavily soiled
include acid, antifreeze, brake fluid, fuel, windscreen
clothing and oil impregnated footwear.
washer additives, lubricants, refrigerants and various
adhesives. • First aid treatment should be obtained immediately for
open cuts and wounds.
Warning: Always read carefully the instructions printed
• Apply barrier creams before each work period to help
on labels or stamped on components and obey them
prevent lubricating oil from contaminating the skin.
implicitly. Such instructions are included for reasons of
your health and personal safety. Never disregard them. • Wash with soap and water to ensure all oil is removed
(proprietary skin cleansers and nail brushes will help).
Synthetic Rubber
• Use moisturisers after cleaning; preparations containing
Many O-rings, seals, hoses, flexible pipes and other similar lanolin help replace the skin's natural oils which have been
items which appear to be natural rubber, are in fact, made removed.
of synthetic materials called Fluoroelastomers. Under normal
• Do not use petrol/gasoline, kerosene, diesel fuel, oil,
operating conditions this material is safe and does not present
thinners or solvents for cleaning skin.
a health hazard. However, if the material is damaged by fire
or excessive heating, it can break down and produce highly • Where practicable, degrease components prior to
corrosive Hydrofluoric acid. handling.
• If skin disorders develop, obtain medical advice without
Contact with Hydrofluoric acid can cause serious burns on
delay.
contact with skin. If skin contact does occur：
• Wear eye protection (e.g. goggles or face shield) if there
• Remove any contaminated clothing immediately. is a risk of eye contamination. Eye wash facilities should
• Irrigate affected area of skin with a copious amount of be provided in close vicinity to the work area.
cold water or limewater for 15 to 60 minutes.
• Obtain medical assistance immediately.

Should any material be in a burnt or overheated condition,

handle with extreme caution and wear protective clothing
(seamless industrial gloves, protective apron etc.).

Decontaminate and dispose of gloves immediately after use.

Lubricating Oils
Avoid excessive skin contact with used lubricating oils and
always adhere to the health protection precautions.
Warning: Avoid excessive skin contact with used engine
oil. Used engine oil contains potentially harmful
contaminants which may cause skin cancer or other
serious skin disorders.
Warning: Avoid excessive skin contact with mineral oil.
Mineral oils remove the natural fats from the skin, leading
to dryness, irritation and dermatitis.

1.0 1
General Information
Safety Instructions • Observe absolute cleanliness when working with
Jacking hydraulic components.

Caution: It is best to use the lift when working under the Cooling System Caps and Plugs
vehicle. Be sure to hold the wheels with chocks and apply expansion tank caps and coolant drain or bleed screws when
parking brake. the engine is hot, especially if it is overheated. To avoid
Always use the recommended jacking points. the possibility of scalding, allow the engine to cool before
attempting removal.
Always ensure that any lifting apparatus has sufficient load
capacity for the weight to be lifted.

Ensure the vehicle is standing on level ground prior to lifting

or jacking.

Apply the parking brake and chock the wheels.

Warning: Do not work on or under a vehicle supported

only by a jack.Always support the vehicle on safety stands.

Do not leave tools, lifting equipment, spilt oil, etc. around or

on the work bench area. Always keep a clean and tidy work
area.
Brake Shoes and Pads
Always fit the correct grade and specification of brake linings.
When renewing brake pads and brake shoes, always replace as
complete axle sets.
Brake Hydraulics
Observe the following recommendations when working on the
brake system:

• Ensure that hoses run in a natural curve and are not

kinked or twisted.
• Ensure that hoses run in a natural curve and are not
kinked or twisted.
• Fit brake pipes securely in their retaining clips and ensure
that the pipe cannot contact a potential chafing point.
• Containers used for brake fluid must be kept absolutely
clean.
• Do not store brake fluid in an unsealed container, it will
absorb water and in this condition would be dangerous
to use due to a lowering of its boiling point.
• Do not allow brake fluid to be contaminated with mineral
oil, or put new brake fluid in a container which has
previously contained mineral oil.
• Do not re-use brake fluid removed from the system.
• Always use clean brake fluid or a recommended
alternative to clean hydraulic components.
• After disconnection of brake pipes and hoses,
immediately fit suitable blanking caps or plugs to prevent
the ingress of dirt.
• Only use the correct brake fittings with compatible
threads.

1.0 2
 General Information
Environmental Precautions Discharges to Water
General Oil, petrol, solvent, acids, hydraulic oil, antifreeze and other
This section provides general information which can help to such substances should never be poured down the drain and
reduce the environmental impacts from the activities carried every precaution must be taken to prevent spillage reaching
out in workshops. the drains.
Emissions to Air Handling of such materials must take place well away from the
Many of the activities that are carried out in workshops emit drains and preferably in an area with a kerb or wall around it, to
gases and fumes which contribute to global warming, depletion prevent discharge into the drain. If a spillage occurs it should
of the ozone layer and/or the formation of photochemical be soaked up immediately. Having a spill kit available will make
smog at ground level. By considering how the workshop this easier.
activities are carried out, these gases and fumes can be Checklist
minimised, thus reducing the impact on the environment.
Always adhere to the following disposal and spillage prevention
Exhaust Fumes instructions.
Running car engines is an essential part of workshop activities • Never pour anything down a drain without first checking
and exhaust fumes need to be ventilated to atmosphere. that it is environmentally safe to do so, and that it does
However, the amount of time engines are running and the not contravene any local regulations.
position of the vehicle should be carefully considered at all
• Store liquids in a walled area;
times, to reduce the release of poisonous gases and minimise
• Protect bulk storage tanks from vandalism by locking the
the inconvenience to people living nearby.
valves;
Solvents
• Transfer liquids from one container to another in an area
Some of the cleaning agents used are solvent based and will away from open drains;
evaporate to atmosphere if used carelessly, or if cans are left
• Ensure lids are replaced securely on containers;
unsealed. All solvent containers should be firmly closed when
• Make sure that taps on liquid containers are secure and
not needed and solvent should be used sparingly. Suitable
cannot be accidentally turned on;
alternative materials may be available to replace some of the
commonly used solvents. Similarly, many paints are solvent • Have spill kits available near to points of storage and
based and the spray should be minimised to reduce solvent handling of liquids.
emissions. Spill Kits
Refrigerant Special materials are available to absorb a number of different
Discharge and replacement of these materials from air substances. They can be in granular form, ready to use and
conditioning units should only be carried out using the correct bought in convenient containers for storage. Disposal of used
equipment. spill-absorbing material is dealt with in 'Waste Management'
section.
Engines:
Land Contamination
Always adhere to the following.
Oils, fuels and solvents etc. can contaminate any soil that
• Don't leave engines running unnecessarily; they are allowed to contact. Such materials should never be
• Minimise testing times and check where the exhaust disposed of by pouring onto soil and every precaution must be
fumes are being blown. taken to prevent spillage reaching soil. Waste materials stored
Materials: on open ground could also leak, or have polluting substances
washed off them that would contaminate the land. Always
• Keep lids on containers of solvents;
store these materials in suitable robust containers.
• Only use the minimum quantity;
Checklist
• Consider alternative materials;
Always adhere to the following.
• Minimise over-spray when painting.
Gases: • Don't pour or spill anything onto the soil or bare ground;

• Use the correct equipment for collecting refrigerants; • Don't store waste materials on bare ground, see 'Spillage
prevention' list.
• Don't burn rubbish on site.

1.0 3
General Information
Local Issues Dispose of waste in accordance with the following guidelines.
A number of environmental issues will be of particular concern • Fuel, hydraulic fluid, anti-freeze and oil: keep separate
to residents and other neighbours close to the site. The and dispose of to specialist contractor.
sensitivity of these issues will depend on the proximity of the • Refrigerant: collect in specialist equipment and reuse.
site and the layout and amount of activity carried on at the site.
• Detergents: safe to pour down the foul drain if diluted.
Car alarm testing, panel beating, hammering and other such • Paint, thinners: keep separate and dispose of to specialist
noisy activities should, whenever possible, be carried out contractor.
indoors with doors and windows shut or as far away from
• Components: send back to supplier for refurbishment,
houses as possible.
or disassemble and reuse any suitable parts. Dispose of
Be sensitive to the time of day when these activities are carried the remainder in ordinary waste.
out and minimise the time of the noisy operation, particularly • Small parts: reuse any suitable parts, dispose of the
in the early morning and late evening. remainder in ordinary waste.
Another local concern will be the smell from the various • Metals: can be sold if kept separate from general waste.
materials used. Using less solvent, paint and petrol could help • Tyres: keep separate and dispose of to specialist
prevent this annoyance. contractor.
Local residents and other business users will also be concerned • Packaging: compact as much as possible and dispose of
about traffic congestion, noise and exhaust fumes, be sensitive in ordinary waste.
to these concerns and try to minimise inconvenience from • asbestos material ： keep separate and dispose of to
deliveries, customers and servicing operations. specialist contractor.
Checklist • Oily and fuel wastes (e.g. rags, used spill kit material):
Always adhere to the following. keep separate and dispose of to specialist contractor.
• Air filters: keep separate and dispose of to specialist
• Identify where the neighbours who are likely to be
contractor.
affected are situated;
• Rubber/plastics: dispose of in ordinary waste.
• Minimise noise, smells and traffic nuisance;
• Hoses: dispose of in ordinary waste.
• Prevent litter by disposing of waste in the correct
manner; • Batteries: keep separate and dispose of to specialist
contractor.
• Have waste containers emptied regularly.
Waste Management • Airbags - explosives: keep separate and dispose of to
specialist contractor.
One of the major ways that pollution can be reduced is by the
• Electrical components: send back to supplier for
careful handling, storage and disposal of all waste materials that
refurbishment, or disassemble and reuse any suitable
occur on sites. This means that it is necessary to not only know
parts. Dispose of the remainder in ordinary waste.
what the waste materials are, but also to have the necessary
documentation and to know local regulations that apply. • Catalysts: can be sold if kept separate from general waste
• Used spill-absorbing material: keep separate and dispose
Handling and Storage of Waste
of to specialist contractor.
They should be stored in such a way as to prevent the escape
of the material to land, water or air.

They must also be segregated into different types of waste

e.g. oil, metals, batteries, used vehicle components. This will
prevent any reaction between different materials and assist in
disposal.
Disposal of Waste
Disposal of waste materials must only be to waste carriers who
are authorised to carry those particular waste materials and
have all the necessary documentation. The waste carrier is
responsible for ensuring that the waste is taken to the correct
disposal sites.

1.0 4
 General Information
General Fitting Instructions • Never inspect a component for wear or dimensional
Component Removal check unless it is absolutely clean; a slight smear of grease
can conceal an incipient failure.
Whenever possible, clean components and surrounding area
before removal. • When a component is to be checked dimensionally
against recommended values, use the appropriate
• Blank off openings exposed by component removal. measuring equipment (surface plates, micrometers,
• Immediately seal fuel, oil or hydraulic lines when dial gauges etc.). Ensure the measuring equipment is
apertures are exposed; use plastic caps or plugs to calibrated and in good serviceable condition.
prevent loss of fluid and ingress of dirt. • Reject a component if its dimensions are outside the
• Close the open ends of oilways exposed by component specified tolerances, or if it appears to be damaged.
removal with tapered hardwood plugs or conspicuous • A part may be refitted if its critical dimension is exactly
plastic plugs. to its tolerance limit and it appears to be in satisfactory
• Immediately a component is removed, place it in a condition. Use 'Plastigauge' for checking bearing surface
suitable container; use a separate container for each clearances.
component and its associated parts.
• Clean bench and provide marking materials, labels and
containers before dismantling a component.
Dismantling
Observe scrupulous cleanliness when dismantling components,
particularly when brake, fuel or hydraulic system parts are
being worked on. A particle of dirt or a cloth fragment could
cause a serious malfunction if trapped in these systems.

• Blow out all tapped holes, crevices, oilways and fluid

passages with an air line. Ensure that any O-rings used
for sealing are correctly replaced or renewed, if disturbed
during the process.
• Use marking ink to identify mating parts and ensure
correct reassembly. Do not use a centre punch or
scriber to mark parts, they could initiate cracks or
distortion in marked components.
• Wire together mating parts where necessary to prevent
accidental interchange (e.g. roller bearing components).
• Attach labels to all parts which are to be renewed, and
to parts requiring further inspection before being passed
for reassembly; place these parts in separate containers
from those containing parts for rebuild.
• Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its correct
replacement has been obtained.
Cleaning Components
Always use the recommended cleaning agent or equivalent.
Ensure that adequate ventilation is provided when volatile
degreasing agents are being used. Do not use degreasing
equipment for components containing items which could be
damaged by the use of this process.
General Inspection
All components should be inspected for wear or damage
before being reassembled.

1.0 5
General Information
Ball and Roller Bearings • In the case of grease lubricated bearings (eg. hub
General bearings) fill the space between bearing and outer seal
with the recommended grade of grease before fitting
When removing and installing bearings, ensure that the
seal.
following practices are observed to ensure component
serviceability. • Always mark components of separable bearings (eg.
taper roller bearings) when dismantling, to ensure
• Remove all traces of lubricant from bearing under
correct reassembly. Never fit new rollers in a used outer
inspection by cleaning with a suitable degreasant;
ring; always fit a complete new bearing assembly.
maintain absolute cleanliness throughout operations.
• Hold inner race of bearing between finger and thumb of
one hand and spin outer race to check that it revolves
absolutely smoothly. Repeat, holding outer race and
spinning inner race.
• Rotate outer ring gently with a reciprocating motion,
while holding inner ring; feel for any check or obstruction
to rotation. Reject bearing if action is not perfectly
smooth.
• Lubricate bearing with generous amounts of lubricant
appropriate to installation.
• Inspect shaft and bearing housing for discoloration or
other markings which indicate movement between
bearing and housing.
• Ensure that shaft and housing are clean and free from
burrs before fitting bearing.
• If one bearing of a pair shows an imperfection, it
is advisable to replace both with new bearings; an
exception could be if the faulty bearing had covered a
low mileage, and it can be established that damage is
confined to only one bearing.
• Never refit a ball or roller bearing without first ensuring
that it is in a fully serviceable condition.
• When hub bearings are removed or displaced, new
bearings must be fitted; do not attempt to refit the old
hub bearings.
• When fitting a bearing to a shaft, only apply force to the
inner ring of the bearing. When fitting a bearing into a
housing, only apply force to the outer ring of the bearing.

1.0 6
 General Information
Oil Seals
General
Always renew oil seals which have been removed from their
working location (whether as an individual component or
as part of an assembly). NEVER use a seal which has been
improperly stored or handled, such as hung on a hook or nail.

• Carefully examine seal before fitting to ensure that it is

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

• Grease outside diameter of seal, place square to housing

recess and press into position using great care, and if
possible a 'bell piece' to ensure that seal is not tilted. In
some cases it may be preferable to fit seal to housing
before fitting to shaft. Never let weight of unsupported
shaft rest in seal.

1.0 7
General Information
Joints and Joint Faces Locking Devices
General General
Fit joints dry unless specified otherwise. Always replace locking devices with one of the same design.

• Always use the correct gaskets as specified. Tab Washers

• When sealing compound is used, apply in a thin uniform Always release locking tabs and fit new locking washers. Do
film to metal surfaces; take care to prevent sealing not re-use locking tabs.
compound from entering oilways, pipes or blind tapped Locking Nuts
holes.
Always use a backing spanner when loosening or tightening
• If gaskets and/or sealing compound is recommended for
locking nuts, brake and fuel pipe unions.
use; remove all traces of old sealing compound prior to
reassembly. Do not use a tool which will damage the Roll Pins
joint faces and smooth out any scratches or burrs using Always fit new roll pins of an interference fit in the hole.
an oil stone. Circlips
• Prior to reassembly, blow through any pipes, channels or
Always fit new circlips of the correct size for the groove.
crevices with compressed air.
Keys and Keyways
Remove burrs from edges of keyways with a fine file and clean
thoroughly before attempting to refit key.

Clean and inspect key closely; keys are suitable for refitting only
if indistinguishable from new, as any indentation may indicate
the onset of wear.
Split Pins
Always fit new split-pins of the correct size for the hole in the
bolt or stud.

1.0 8
 General Information
Screw Threads Fasteners Identification
General Bolt Identification
Metric threads to ISO standards are used.

Damaged nuts, bolts and screws must always be discarded.

Cleaning damaged threads with a die or tap impairs the
strength and fit of the threads and is not recommended.

Always ensure that replacement bolts are at least equal in

strength to those replaced.

Castellated nuts must not be loosened to accept a split-pin,

except in recommended cases when this forms part of an
adjustment.

Do not allow oil or grease to enter blind threaded holes. The

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

Encapsulated bolts and screws have a microencapsulated

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

Unless a specific repair procedure states otherwise,

encapsulated bolts may be reused providing the threads are
undamaged and the following procedure is adopted:

• Remove loose adhesive from the bolt and housing

threads.
• Ensure threads are clean and free of oil and grease.
• Apply an approved locking agent.

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

Where bearing preload is involved, nuts should be tightened in

accordance with special instructions.
Self-locking Nuts

Self-locking bolts and screws, i.e. nylon patched or trilobular

thread can be reused providing resistance can be felt when the
locking portion enters the female thread.

Nylon patched bolts and screws have a locking agent

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

DO NOT fit non self-locking fasteners in applications where a

self-locking nut, bolt or screw is specified.
Nut Identification A

A nut with an ISO metric thread is marked on one face or on

one of the flats of the hexagon with the strength grade symbol
8, 12, or 14. Some nuts with a strength grade 4, 5 or 6 are

1.0 10
 General Information
Flexible Pipes and Hoses Hose Orientation and Connection
General
When removing and installing flexible hydraulic pipes and
hoses, ensure that the following practices are observed to
ensure component serviceability.

• Clean end fittings and the area surrounding them as

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

Clean hose externally and blow through with airline.

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

• Absolute cleanliness must be observed with hydraulic Hose Clip

components at all times.

After any work on hydraulic systems, carefully inspect

for leaks underneath the vehicle while a second operator
applies maximum brake pressure to the brakes (engine
running) and operates the steering.
Fuel System Hoses

Markings (1) are usually provided on the hose to indicate the

correct clip position. If no markings are provided, position the
clip directly behind the retaining lip at the end of the stub as
shown. Worm drive clips should be oriented with the crimped
side of the drive housing (2) facing towards the end of the hose,
or the hose may become pinched between the clip and the stub
pipe retaining lip. Worm drive clips should be tightened to 3
All fuel hoses are made up of two laminations, an armoured Nm unless otherwise stated. Ensure that hose clips do not foul
rubber outer sleeve and an inner viton core. If any of the fuel adjacent components.
system hoses have been disconnected, it is imperative that the
Heat Protection
internal bore is inspected to ensure that the viton lining has
not become separated from the armoured outer sleeve. A Always ensure that heatshields and protective sheathing are
new hose must be fitted if separation is evident. in good condition. Replace if damage is evident. Particular
care must be taken when routing hoses close to hot engine
Cooling System Hoses
components, such as the exhaust manifold and the Exhaust Gas
The following precautions MUST be followed to ensure that Recirculation (EGR) pipe. Hoses will relax and deflect slightly
integrity of cooling hoses and their connections to system
components are maintained.

1.0 11
General Information
when hot; ensure this movement is taken into account when Fuel Handling Precautions
routing and securing hoses. General
Fuel vapour is highly flammable and in confined spaces is
also explosive and toxic. The vapour is heavier than air
and will always fall to the lowest level. The vapour can be
easily distributed throughout a workshop by air currents;
consequently, even a small spillage of fuel is potentially very
dangerous.

The following information provides basic precautions which

must be observed if fuel is to be handled safely. It also
outlines other areas of risk which must not be ignored. This
information is issued for basic guidance only, if in doubt consult
your local Fire Officer.

Always have a fire extinguisher containing FOAM, CO2, GAS

or POWDER close at hand when handling or draining fuel or
when dismantling fuel systems. Fire extinguishers should also
be located in areas where fuel containers are stored.

Always disconnect the vehicle battery before carrying out

dismantling or draining work on a fuel system.

Whenever fuel is being handled, drained or stored, or when

fuel systems are being dismantled, all forms of ignition must be
extinguished or removed; any lead lamps must be flameproof
and kept clear of spillage.
Warning: No one should be permitted to repair
components associated with fuel without first having
specialist training.

Warning: Do not remove fuel system components while

the vehicle is over a pit.
Fuel Tank Draining
Fuel tank draining should be carried out in accordance with
the procedure outlined in the FUEL DELIVERY section of this
manual and observing the following precautions

Warning: Do not remove fuel system components while

the vehicle is over a pit. Extraction or draining of fuel
must be carried out in a well ventilated area.

The capacity of containers must be more than adequate for

the amount of fuel to be extracted or drained. The container
should be clearly marked with its contents and placed in a safe
storage area which meets the requirements of local authority
regulations.
Fuel Tank Removal
When the fuel line is secured to the fuel tank outlet by a
spring steel clip, the clip must be released before the fuel line
is disconnected or the fuel tank is removed. This procedure
will avoid the possibility of fumes in the fuel tank being ignited
when the clip is released.

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

• Always ensure electrically related items are dry and oil

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

Having confirmed a component to be faulty:

• Switch off the ignition and disconnect the battery.

• Remove the component and support the disconnected
harness.
• When replacing the component keep oily hands away
from electrical connection areas and push connectors
home until any locking tabs fully engage.

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

1.0 14
 General Information
• Ensure the ECU is always installed correctly. SRS ECU.
SRS ECU There must not be any gap between the ECU
and the bracket to which it is mounted. SRS ECU
An incorrectly mounted ECU could cause the system to
malfunction.
• Do not supply power to the ECU are connected. SRS
before all SRS components SRS ECU before all SRS
components.

Caution: Ensure SRS components are not contaminated

with oil, grease, detergent or water.

Caution: Torque wrenches should be regularly checked for

accuracy to ensure that all fixings are tightened to the
• Remove the handset from the docking station. correct torque.
• Disconnect both battery leads, earth lead first. Caution: Following seat belt pretensioner deployment,
• Wait 10 minutes for SRS ECU the SRS ECU back-up the seat belts can still be used as conventional seat
power circuit to discharge. belts, but will need to be replaced as soon as possible to
re-establish full SRS protection.
The SRS system uses energy reserve capacitors to keep
the system active in the event of electrical supply failure Caution: If the SRS component is to be replaced, the bar
under crash conditions. It is necessary to allow the capacitor code of the new unit must be recorded.
sufficient time to discharge (10 minutes) in order to avoid the SRS Component Testing Precautions
risk of accidental deployment.
Caution: Disconnect the battery before starting the SRS
operation. Disconnect the battery negative terminal first.
DO NOT disconnect the battery in the reverse order.
Installation
In order to ensure system integrity, it is essential that the
SRS system is regularly checked and maintained SRS so that
it is ready for effective operation in the event of a collision.
Carefully inspect SRS components before installation. SRS
Do not install a part that shows signs of being dropped or
improperly handled, such as dents, cracks or deformation.

Warning: The integrity of the SRS system is critical for

safety reasons. The SRS components are triggered using relatively low
Ensure the following precautions are always adhered to: operating currents, always adhere to the following precautions:

• Never install used SRS components from another vehicle Warning: Do not use a multimeter or other general
SRS or attempt to repair an SRS component. purpose test equipment on SRS system components
or accidental deployment may occur. Only use the
• Never use the SRS parts without a clear identification
recommended diagnostic equipment to diagnose system
SRS label.
faults.
• Never use an airbag or SRS ECU that has been dropped.
Warning: Do not use electrical test equipment on the SRS
• When repairing an SRS system only use SRS genuine new
harness while it is connected to any of the SRS system
parts.
components. It may cause accidental deployment and
• Never apply electrical power to an SRS component personal injury.
unless instructed to do SRS so as part of an approved
test procedure.
• Ensure the bolts are tightened to the correct torque.
Always use new fixings SRS when replacing SRS
components.

1.0 15
General Information
Handling and Storage

Warning: Store the airbag module with the deployment

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

Caution: Do not apply grease or cleaning solvents to seat

belt pretensioner units, component failure could result.
Always observe the following precautions SRS with regards to
SRS system electrical wiring:

• Never attempt to modify, splice or repair SRS wiring.

1.0 16
 General Information
• Never install electronic equipment (such as a mobile Never fit cover on seat which fitting side airbag.
telephone, two-way radio or in-car entertainment
Children under 12 years old should not sit in the front seat.
system) in such a way that it could generate electrical
interference in the airbag harness. Seek specialist advice Only genuine accessory parts are allowed to be installed.
when installing such equipment. Only authorised people can remove airbag modules, ECU, SRS
Note: SRS system wiring can be identified by a special system wiring harness and connectors. SRS ECU and SRS
yellow outer sleeve protecting the wires (black with yellow system wiring harness and connectors.
stripe protective coverings are sometimes used). If the airbag and seat belt pre-tensioner are deployed during an
accident, SRS ECU must be replaced and discarded.

Every SRS system on every car SRS has been paired and
identified, SRS illegally adding or modifying the SRS system
and the wiring harness could injure people.

Modifying the vehicle structure or SRS system is strictly not

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

Do not place any object on the steering wheel or instrument

panel that could penetrate an inflating airbag or be a thrown
item likely to cause injury.

1.0 17
General Information
4. Bar code. The code number must be recorded if the
rotary coupler is to be replaced.

A The need for caution when working in close proximity to

SRS components. SRS in close proximity to SRS components.
Bar Codes
B Refer to the publication where the procedures, SRS
instructions and advice can be found (usually Workshop Bar codes SRS are fitted to SRS system components and
Manual or Owner's Handbook) for working on the SRS components SRS which are critically related to SRS operation.
system. The code number(s) must be recorded if the component is to
be replaced.
C Do not use rear facing child seats in the front passenger seat
if the vehicle is fitted with a passenger airbag. Components featuring bar codes include the following:

Warning: It is imperative that before any work • Driver's front airbag module – label attached to rear of
is undertaken on the SRS system the appropriate module housing
information is read thoroughly. • Passenger front airbag module – label attached at side of
module housing
The following list indicates possible locations and content
for warning labels. Exact positions and content may vary • SRS ECU Included SRS ECU on label on top of ECU
dependent on model year, legislation and market trends. • Rotary coupler – several labels on front face
Vehicle Recovery
Towing SRS Components Not Deployed
Normal towing procedures are unlikely to cause an airbag to
deploy. However, as a precaution, remove the handset from
the docking station and then disconnect both battery leads.
Disconnect the negative ‘-’ lead first.
Towing SRS Components Not Deployed
Once the driver＇s airbag has been deployed, the vehicle must
have a suspended tow. However, as a precaution remove the
handset from the docking station and then disconnect both
battery leads. Disconnect the negative ＇-＇ lead first.
SRS Components Deployed
Do not use rear facing child seat in front passenger seat of
vehicles fitted with passenger airbag. If a vehicle is to be scrapped and contains an undeployed airbag
module, the module must be manually deployed.
Rotary Coupler
Always observe the following precautions:
1. The need for caution when working SRS in close
proximity to SRS components. Warning: Only personnel who have undergone the
2. Refer to Workshop Manual for detailed instructions. appropriate training should undertake deployment of
airbag and seat belt pre-tensioner modules.
3. Ensure the wheels are in the straight ahead position
before removal and refitting. Warning: A deployed airbag or seat belt pre-tensioner is
very hot, DO NOT return to a deployed airbag module
until at least 30 minutes have elapsed since deployment.

1.0 18
 General Information
Warning: Only use approved deployment equipment, Warning: Compliance with the following precautions
and only deploy SRS components in a well-ventilated MUST be ensured:
designated area. Ensure SRS components are not • Only use deployment equipment approved for the
damaged or ruptured before deployment. intended purpose.
Warning: Contact with chemicals from deployed and • Before commencing deployment procedure, ensure
damaged SRS components could present a health hazard, the deployment tool functions properly.
wear protective clothing when handling. DO NOT eat, • Deployment of airbag/pre-tensioner modules should
drink or smoke when handling SRS components. be performed in a well ventilated area which has
Warning: Deployment of airbag modules and seat belt been designated for the purpose.
pre-tensioners can cause injury to personnel in the close • Ensure airbag/pre-tensioner modules are not
vicinity of the deploying unit. In case of injury seek urgent damaged or ruptured before attempting to deploy.
medical advice. Possible sources of injury include: • Notify the relevant authorities of intention to deploy
• impact - due to inflating airbag or pretensioner airbag and pretensioner units.
operation causing component 'kick'. • When deploying airbag and seat belt pre-tensioner
• hearing - due to noise produced by deploying airbags units, ensure that all personnel are at least 15 metres
and seat belt pretensioner units. away from the deployment zone.
• burns - hot component parts and gases. • When deploying seat belt pretensioners in the
• irritation to eyes and lungs - from deploying gases or vehicle, ensure the pre-tensioner unit is fully secured
combustion residue. to its fixing point.
• When removing deployed airbag and seat belt
Warning: Ensure the SRS component to be deployed is
pre-tensioner modules, wear protective clothing.
securely fastened to its mounting.
Use gloves and seal deployed units in a plastic bag.
• Following deployment of any component of the SRS
system within the vehicle, all SRS components must
be replaced. DO NOT re-use or salvage any parts of
the SRS system.
• Do not lean over airbag modules or seat belt
pre-tensioner units when connecting deployment
equipment.

1.0 19
General Information
SRS Component Replacement Policy • SRS ECU
Impacts Which Do Not Deploy the Airbags or • Side impact crash sensors (both sides of vehicle)
Pre-tensioners
In addition, the following should be inspected for damage and
Check for structural damage in the area of the impact, paying
replaced as necessary:
particular attention to bumper armatures, longitudinals, crash
cans and bracketry. • Front seat belts (retractors, webbing, tongue latching, 'D'
loop and body anchorage points)
Impacts Which Deploy the Airbags or
Pre-tensioners • Rear seat belt buckles (webbing, buckle covers, tongue
latching and body anchorage)
The replacement and inspection policy is dependent on the
type and severity of the crash condition. SRS. The following • Front seat frame (if there is evidence of external or airbag
guidelines are the minimum that should be exercised as a result deployment damage to seat frame)
of the deployment of specific SRS components: • 'BC' post internal finishers and fixings
Front Airbag Deployment (driver and passenger) • Door casings
If the front airbags are deployed, the following parts must be • Seat belt automatic height adjusters on 'B' post
replaced: • Rear seat belt escutcheons in parcel shelf trim
• Driver airbag module Inflatable Curtain Structure (ICS) Airbags
Modules
• Passenger airbag module
If the Inflatable Curtain Structure airbag modules are deployed,
• Flyleads (where applicable) connecting SRS front airbag
the following parts must be replaced, (ICS) on the side of the
modules to SRS harness
vehicle for which deployment occurred:
• Seat belt pre-tensioners
• ICS airbag module
• Driver's seat belt retractor
• Link lead between airbag gas generator SRS and SRS
• Rotary coupler
harness
• SRS ECU
• Airbag retaining clips above window aperture
In addition, the following should be inspected for damage and • 'A' post internal finisher
replaced as necessary:
• Front seat belt pre-tensioners
• Front passenger's seat belt retractor (webbing, tongue • SRS ECU
latching, 'D' loop, body anchorage point)
• Side impact crash sensors (both sides of vehicle)
• Rear seat belt buckles (webbing, buckle covers, body
anchorage and tongue latching function) In addition, the following should be inspected for damage and
replaced as necessary:
• Fascia moulding adjacent to passenger airbag module
• Steering wheel (if damage is evident) • Headlining

• Front seat frames and head restraints (if there is evidence • ICS mounting brackets
of damage to the seat frame or cushion pan) • Alarm sensor
• Steering column (if adjustment is lost or there are signs • Front seat belts (retractors, webbing, tongue latching, ‘D'
of collapse) loop and body anchorage points)
• Seat belt automatic height adjusters on 'BC' posts • Rear seat belt buckles (webbing, buckle covers, tongue
• Rear seat belt escutcheons in parcel shelf trim latching and body anchorage)

Side (Thorax) Airbags • 'BC' post upper finisher and fixings

If the side (thorax) airbags are deployed, the following parts • Door casing
must be replaced, on the side of the vehicle on which the • Seat belt automatic height adjusters on ‘B' post
deployment occurred: • Rear seat belt escutcheons in parcel shelf trim
• Seat (thorax) airbag module Rear Impacts
• Seat squab foam Rear impacts may cause the seat belt pretensioners to deploy.
• Seat squab cover If this occurs, all pretensioner units must be replaced. In
addition, the following components should be inspected for
• Front seat belt buckle pre-tensioners
damage and replaced as necessary:

1.0 20
 General Information
• Front seat frames Air Conditioning System Precautions
• Seat belt automatic height adjusters on ‘B'- post General
• Front seat belts (retractors, webbing, tongue latching, 'D' The air conditioning system contains fluids and components
loop and body anchorage points) which could be potentially hazardous to the service engineer
• Rear seat belt buckles (webbing, buckle covers, tongue or the environment if not serviced and handled correctly. The
latching and body anchorage) following guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the importance
• Rear seat belt escutcheons in parcel shelf trim
of ensuring the integrity of the air conditioning operating
• SRS ECU
conditions and components fitted to the vehicle.
Periodic Replacement of SRS Components
Where necessary, additional specific precautions are detailed
The performance of the propellants within airbags and in the relevant sections of this Manual which should be referred
pre-tensioners will deteriorate over a period of time. As a to prior to commencing repair operations.
result, it is essential that the airbags and pre-tensioners are
periodically replaced to maintain occupant safety. Airbags, The refrigerant used in the air conditioning system is HFC-134a
seat belt pre-tensioners and the rotary coupler should be (Hydrofluorocarbon) R134a.
replaced at 12 year intervals. Warning: Servicing must only be carried out by personnel
familiar with both the vehicle system and the charging and
testing equipment. All operations must be carried out in
a well ventilated area away from open flame and heat
sources.

Warning: R134a is a hazardous liquid and when handled

incorrectly can cause serious injury. Suitable protective
clothing, consisting of face protection, heat-proof gloves,
rubber boots and rubber apron or waterproof overalls,
must be worn when carrying out operations on the air
conditioning system.
Remedial Actions
If an accident involving R134a should occur, conduct the
following remedial actions:

• If liquid R134a enters the eye, do not rub it. Gently run
large quantities of eye wash over affected eye to raise the
temperature. If an eye wash is not available, cool, clean
water may be used to flush the eye. After rinsing, cover
the eye with a clean pad and seek immediate medical
attention.
• If liquid R134a is splashed onto the skin, run large
quantities of water over the affected area to raise the
temperature. Implement the same action if the skin
comes in contact with discharging cylinders. Wrap
the contaminated body parts in blankets (or similar
materials) and seek immediate medical attention.
• If the debilitating effects of inhalation of R134a vapour
is suspected, seek fresh air. If the affected person is
unconscious, move them away from the contaminated
area to fresh air and apply artificial respiration and/ or
oxygen and seek immediate medical attention.

1.0 21
General Information
Warning: Due to its low evaporating temperature, R134a • Whenever the refrigerant system is opened, the
must be handled with care. R134a splashed on any part receiver/drier must be renewed immediately before
of the body will cause immediate freezing of that area. evacuating and recharging the system.
Also, refrigerant cylinders and replenishment trolleys • Use alcohol and a clean lint-free cloth to clean dirty
when discharging will freeze skin to them if contact is connections.
made.
• Ensure that all new parts fitted are marked for use with
Service Precautions R134a.
Observe the following precautions when handling components Refrigerant Oil
used in the air conditioning system: Refrigerant oil easily absorbs water and must not be stored for
• Air conditioning units must not be lifted by their hoses, long periods. Do not pour unused refrigerant oil back into the
pipes or capillary lines. container. Always use an approved refrigerant oil.
• Hoses and lines must not be subjected to any twist or When replacing components in the A/C system, drain the
stress; the efficiency of the system will be impaired by refrigerant oil from the component being replaced into
kinks or restrictions. Ensure that hoses are correctly a graduated container. On assembly, add the quantity of
positioned before tightening couplings, and ensure that refrigerant oil drained to the new component.
all clips and supports are utilised.
Compressor
• Flexible hoses should not be positioned close to the
A new compressor is sealed and pressurised with Nitrogen gas.
exhaust manifold (less than 100 mm) unless protected
When fitting a new compressor, slowly release the sealing cap;
by heat shielding.
gas pressure should be heard to vent as the seal is broken.
• Completed assemblies must be checked for refrigeration
lines touching metal panels. Any direct contact of Caution: Do not remove the cap(s) until immediately
components and panels may transmit noise and so must prior to connecting the air conditioning pipes to the
be eliminated. compressor.

• The appropriate torque wrench must be used when Rapid Refrigerant Discharge
tightening refrigerant connections to the stipulated If the air conditioning system is involved in accident damage and
value. An additional spanner must be used to hold the the system is punctured, the refrigerant will discharge rapidly.
union to prevent twisting of the pipe when tightening The rapid discharge of refrigerant will also result in the loss
connections. of most of the oil from the system. The compressor must be
• Before connecting any hose or pipe, ensure that removed and all the remaining oil in the compressor drained
refrigerant oil is applied to the seat of the new O-rings, and refilled as instructed in the air conditioning section of this
BUT NOT to the threads of the connection. manual.
• All protective plugs must remain in place to seal the Precautions for Refrigerant Recovery, Recycling
component until immediately prior to connection. and Recharging
• Ensure components are at room temperature before When the air conditioning system is recharged, any existing
uncapping, to prevent condensation of moisture from refrigerant is first recovered from the system and recycled.
the air that enters it. The system is then charged with the required weight of
• Components must not remain uncapped for longer than refrigerant and volume of refrigerant oil.
15 minutes. In the event of a delay, the caps must be Warning: Refrigerant must always be recycled before
fitted. re-use to ensure that the purity of the refrigerant is high
• When disconnecting, immediately cap all air conditioning enough for safe use in the air conditioning system.
pipes to prevent ingress of dirt and moisture into the
Warning: Recycling should always be carried out with
system.
equipment which is design certified by Underwriter
• The receiver/drier contains desiccant which absorbs Laboratory Inc. for compliance with SAE J1991. Other
moisture. It must be positively sealed at all times. A equipment may not recycle refrigerant to the required
receiver/drier that has been left uncapped must not be level of purity.
used, fit a new unit.
Warning: A R134a Refrigerant Recovery Recycling
• The receiver/drier should be the last component
Recharging Station must not be used with any other type
connected to the system to ensure optimum dehydration
of refrigerant.
and maximum moisture protection of the system.

1.0 22
 General Information
Warning: Refrigerant R134a from domestic and Air Conditioning Compressor Replacement
commercial sources must not be used in motor vehicle air Replacement Instructions
conditioning systems.
A new compressor is supplied filled with a full charge of
Caution: The system must be evacuated immediately refrigerant oil. The new compressor must be drained and a
before recharging commences. Delay between evacuation calculated quantity of oil added before fitting. To calculate the
and recharging is not permitted. quantity of oil to be added, carry out the following procedure:

1. Remove the filler/drain plug from the old compressor.

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

1.0 23
General Information Vehicle Identification Number

Vehicle Identification Number

Vehicle Identification Number
Vehicle Identification Number (VIN)
Example : LSJZ14E3XJSXXXXXX
Figures Code Description
1–3 LSJ Manufacturer's Identifier
4–5 Z1 Vehicle Type
Vehicle Body Structure,
6 4
4 = 2–compartment & 5–door
7 E Engine E = 1.5L Gasoline Engine
Occupant Restraint System

3 = Safety belt, driver and front-seat

8 3,6 passenger airbag

6 = Safety belt, driver and front-seat

passenger airbag & seat-side airbag
Check bit (represented by any figure
9 X
from 0 to 9 or letter X)
Model Year
10 J
J = 2018
Assembly Plant
11 S
S = Lingang, Shanghai
6 digits = Production Sequential
12–17 XXXXXX
Number

VINis also stamped in the following locations:

• On a plate behind the LH lower corner of the windshield.

• On the right dash panel of the engine compartment.
• On the vehicle identification plate.

Location of Vehicle Identification Label

The vehicle identification plate is located under the right D
pillar striker. For details, please refer to the specific VIN plate.

1.0 24
Vehicle Identification Number General Information
Position Of Other Plates
Engine Number (1.5L Engine)
Printed on the left rear of the cylinder block, as shown in the
arrow.

Automatic Transmission Number - 4AT

Printed on the top surface of the front part of the transmission
housing.

Manual Transmission Number - 5MT

Attached on the top surface of the front part of the
transmission housing.

1.0 25
General Information Lifting & Towing

Lifting & Towing

Lifting
Lifting Description
Note the following points before lifting the vehicle from the
ground:

• The vehicle should be parked on a level and firm ground.

• Apply the hand brake.
• The transmission is in P or N.

To avoid damage to the lower body components of the vehicle,

be sure to follow the support procedures below:

DO NOT place the jack or the axle support under the

Vehicle Jack
following components:

• Body Structural Parts

• Bumper
• Fuel Line
• Brake Line
• Front Suspension Arm
• Steering Linkage
• Rear Suspension Arm
• Fuel Tank
• Engine Oil Pan
• Transmission Case
Note: Jacking and supporting the front of the vehicle The jack of the vehicle is only applied to replace wheels in
should only be done under the customer front jacking emergency. Never use it for other purposes.
points and/or the jacking bracket on the front section of
If using the jack to replace wheels, be sure to place the jack on
the front subframe.
a solid level ground and position it under the supporting point
Lifting and Supporting Vehicle near the wheel to be removed. Note that the snap head of the
Front and Rear Supporting Points of Vehicle jack must be placed in the appropriate groove of the deck.
Place the head of the jack on the supporting points of the front Hydraulic Jack
and rear sills on the vehicle. The hydraulic jack must have a load capacity of at least 1,500
Caution: Do not jack or support the vehicle on any other kg (3,300 lbs).
points than those indicated. Failure to comply is likely to Column Lifter
result in damage to the body or chassis components.

Warning: Always chock the wheels when jacking.

Warning: Do not work on or under a vehicle supported

only by a jack.Always support the vehicle on safety stands.

Warning: Do not commence work on the underside of the

vehicle until suitable safety supports have been positioned
under the sill reinforced brackets.

1.0 26
Lifting & Towing General Information
Put the mat under the jacking point on the sill. Roadside Assistance
Instructions for Roadside Assistance
It is recommended that a rescue trailer or a two-wheel rescue
vehicle shall be used. In emergency, use a towing vehicle with
front towing point.
Front Towing Eye

In the front of the vehicle, removable towing eye can be used

for rescue operation. The front towing eye is usually kept in
the vehicle toolbox and should be put back after using. When
fitting the towing eye, remove the towing eye cover at the right
side of the front bumper first, then screw the towing eye into
the mounting position of the front bumper assembly (bumper
beam).
Manual Transmission
For four wheels towing, operate from the front via the towing
eye.

Before towing, release the hand brake, put the shift lever at
the neutral gear and the ignition switch at “ON” position. The
towing speed shall not exceed 50km/h (30mph).

The following precautions must be taken:

In order to ensure that the vehicle still has steering capability

when it is towed, it is necessary to insert the ignition key and

1.0 27
General Information Lifting & Towing

put it to “ON” position. This state must be maintained when Note: A vehicle with an automatic transmission cannot be
the vehicle is moving. started by towing or pushing.

• When the transmission or drive shaft fails, the vehicle Vehicle Shipping
could not be towed.
If your vehicle needs to be shipped, we recommend you to use
• Ensure that the shift lever is at the neutral gear and special transporter to ship.
parking brake is disabled.
• If the engine is not in operation during towing, more care
must be taken in brake and steering operation.

Caution: If the transmission case occurs malfunction and

the transmission fluid level is too low, the four wheels of
the vehicle cannot be towed absolutely.
Automatic Transmission
Generally, vehicles with automatic transmission should be
towed with the front wheels off the road (with front wheels
hanged up).

Fix the vehicle on the transporter as follows:

• Apply the parking brake and place the transmission shift
lever in P or N position.
• Position the brake pads on the front and rear wheels.
• Fit the tether around the tyre and secure it to the trailer,
tighten the tether to fix the vehicle firmly.
Caution: A rear suspended tow must not be used for
vehicles with an automatic transmission, as serious
damage will be caused to the transmission.

In order to ensure that the vehicle still has steering capability

when it is towed, it is necessary to insert the ignition key and
put it to “ON” position. This state must be maintained when
the vehicle is moving.

For vehicles with automatic transmission, when towing the

four wheels from the front, attention must be paid to the
followings:

Warning: When the vehicle is being towed.

• The selector must be at ‘N'.
• The vehicle must not be towed at speeds greater than
30 km/h or for a distance exceeding 50 km.
• Do not tow if the gearbox or a drive shaft is faulty.
• Ensure the gear lever is in neutral and the parking
brake is released.
• Remember that greater effort than normal will be
necessary to operate the brakes and steering if the
vehicle is being towed without the engine running.
Caution: Do not tow on four wheels if the gearbox or drive
shafts are touching the body or frame.

1.0 28
Lubrication & Maintenance General Information
Lubrication & Maintenance Fluid
Capacity Fuel
Liquid Capacity Following recommended oils must be applied:
The following capacity values are merely approximate value for For gasoline engines
the corresponding system. 92# and above gasoline RON is recommended. DO NOT use
Component/System Capacity gasoline containing methanol.
Fuel Tank : 45L Antifreeze Fluid
Engine Oil - 1.5L: The mixture with 50% water and 50% OAT shall be used.
The antifreeze containing organic acid technology (OAT)
Refill from Dry State 4.4L
preservative and summer coolant or ethylene-glycol-based
Replacement of the Engine Oil 4.1L antifreeze (methanol not contained) are applied to protect
and Oil Filter the cooling system. Only the antifreeze with OAT antiseptic
Manual Transmission Oil - 5MT: can be used.

Refill 1.8L Do not use other types of antifreeze to supplement or refill

the cooling system. In emergency, if the antifreeze of this
Refill from Dry State 2.0L type is unavailable, the clean water can be used to fill the
Auto Transmission Oil - 4AT： cooling system. However, this may lower the frost protection
capability. The correct antifreeze concentration must be
Refill 4.85L
recovered as soon as possible.
Cooling System Coolant:
When it is time for inspection specified in the Maintenance List,
Expansion Tank 0.7L drain the cooling system and clean it, then refill the cooling
Cooling System 4.9L system with appropriate coolant.

Steering System 0.96L After refilling antifreeze, attach the warning label at a
prominent position of the vehicle to show the type of
Brake Fluid for Brake System:
antifreeze used in the cooling system, so that correct antifreeze
Refill from Dry State 0.63–0.73L can be used for next refill.
Windshield Washer Reservoir 2.5L Concentration of Antifreeze Fluid
The overall antifreeze concentration shall not be less than 50%
of the volume, meanwhile make sure the antisepsis property
of the coolant. Antifreeze concentration more than 60% is not
recommended as it will weaken the cooling efficiency.

The antifreeze capacity recommended in the following table

shall provide frost protection at -37℃ - -40℃.
Engine :

Concentration 50%
Capacity of Antifreeze Fluid 2.8L

Brake Fluid
Use brake fluid DOT 4 only.
PAS Fluid
Use the liquid that conforms to the Dexron III specification.

1.0 29
General Information Lubrication & Maintenance

Lubricating Fluid Lock, Lock Body and Hinge

Overview Do not apply any lubricating grease on the fixing end of the
The engine and other lubrication systems are filled with torsion bar spring, however, Krupp Isoflex Topas L32CN
high-performance lubricating fluid to extend the service life. lubricating grease is recommended for its rotating end.

Caution: Always use a high quality oil of the correct Washer Fluid
viscosity range in the engine. The use of oil of the Use QX-35 washer fluid.
incorrect specification can lead to high oil and fuel
consumption and ultimately to damaged components.

The use of the engine oil of recommended specifications

containing additives may decrease the corrosive acid caused
by combustion and prevent formation of residues. These
residues may block the oil passage. Other engine oil additives
should not be used.

Repair and maintenance must be carried out within the

specified interval.
Engine Oil
1.5L engine uses 5W–30 engine oil in compliance with ACEA
A1/B1 specification, 5W–30 engine oil in compliance with
ACEA A5/B5 specification and 0W-20 engine oil in compliance
with C5 specification.

The engine oil viscosity/temperature range refers to the

following table:

Transmission Fluid
Failure to use specified transmission fluid may result in serious
damage to the transmission.
Manual Transmission - 5MT
Refill or fill up with MTF94 oil.
Automatic Transmission - NEW 4AT
Refill or fill up with AW-1 oil.
General Lubricating Grease
Use FN745/94 lubricating grease produced by Fuchs.

Bonnet Lock Body

Use FN745/94 lubricating grease produced by Fuchs.

1.0 30
Engine Mechanical Engine
Engine Mechanical
Specifications
Torque

Description Value
Bolt-Under The Tie-bar Bracket to Automatic Transmission (45-55)Nm+(85-95)deg
Bolt-Under The Tie-bar Bracket to Under The Tie-bar (81-99)Nm+(85-95)deg
Bolt-Steering Fluid Pipe Bracket to Steering Pump 7-10Nm
Nut-Steering Fluid Pipe to Steering Pump 36-40Nm
Nut-Oil-cooled Pipe to Automatic Transmission 33-37Nm
Bolt-Oil-cooled Pipe Bracket to Automatic Transmission 7-10Nm
Bolt-Under The Tie-bar Bracket to Manual Transmission （45-55）Nm+（85-95）deg
Bolt-Under The Tie-bar Bracket to Under The Tie-bar （81-99）Nm+（85-95）deg
Bolt-Slave Cylinder to Manual Transmission 40-50Nm
Bolt-Engine Mount to Engine (63-77)Nm+(85-95)deg
Bolt-Engine Mount to The Right Side Rail 90-110Nm
Bolt-Engine Mount to Body 26-34Nm
Bolt-Automatic Transmission Mount to The Left Side Rail 55-65Nm
Nut-Automatic Transmission Mount to Automatic (63-77)Nm+(85-95)deg
Transmission Mount Bracket
Bolt-Manual Transmission Mount to The Left Side Rail 55-65Nm
Nut-Manual Transmission Mount to Manual Transmission (63-77)Nm+(85-95)deg
Mount Bracket
Bolt-Flywheel to Crankshaft 35Nm+60°
Bolt - flywheel to crankshaft (32-38)Nm+60°±5°
Bolt-Torsion Vibration Damper to Crankshaft 60Nm+120°
Bolt - cover upper front to cylinder head 8-12Nm
Bolt - cover lower front to cylinder block and crankcase 8-12Nm
lower
Bolt - water pump pulley to water pump 23-27Nm
Bolt-Engine Mounting Bracket to Cylinder Body 40Nm+60deg
Bolt-Chain Guide Rail And Chain Tensioner Rail 20-24Nm
Bolt - chain guide rail upper to cylinder head front cam 8-12Nm
bearing
Bolt - timing chain tensioner to cyclinder head 18-22Nm+(22-28°)
Bolt - oil pump procket to oil pump 22-28Nm
Bolt-Cam Bearing Cap to Cylinder Head 7-10Nm
Bolt - ignition coil 8-12Nm
Bolt-Cam Bearing Cap to Cylinder Head 7-11Nm
Bolt - VCT unit to camshaft 70-80Nm
Bolt - cylinder head to cylinder block 30Nm （ 90°+60°)
Bolt - patch cylinder head to cylinder block 8-12Nm
Bolt - thermostat to cylinder head 8-12Nm
Bolt - crankcase lower to cylinder block 27-33Nm
Bolt -Connecting Rod (13-17)Nm+（77-83）°

1.0 31
Engine Engine Mechanical

Description Value
Bolt-Piston Cooling Jets to Crankcase 22-28Nm
Bolt - bearing cap to cylinder block (20±2)Nm+（90°+45°）±5°
plug blanking-plug blanking to crankcase 35-45 Nm
Bolt - bearing cap to cylinder block 8-12Nm
Bolt - oil pump to crankcase lower 8-12Nm
Bolt -baffle plate to crankcase lower 8-12Nm
Bolt - ocv to cylinder head 5-7Nm
Oil filter 16-20Nm
Plug - crankcase lower 35-40Nm
Nut-Intake Manifold to Crankcase 22-28Nm
Bolt-to Cylinder Block 8-12Nm
Bolt-Exhaust Manifold to ENG 22-28Nm
Bolt-Intake Manifold Housing 7-10Nm

1.0 32
Engine Mechanical Engine
Parameter
1.5DVCT - Main Block
Model 1.5 L gasoline engine, with 16 valves, dual overhead camshaft,
variable intake/exhaust cam timing
Cylinder Arrangement 4-cylinder, in-line, transverse, 1st cylinder at the front of engine
Cylinder Bore Diameter 75mm
Stroke 84.8mm
Displacement 1498cm 3

Ignition Sequence 1-3-4-2

Compression Ratio 11.5:1
Direction of Rotation Clockwise when viewed from engine front end
Rated Power 86kW@6000rev/min(AT);80kW@6000rev/min(MT)
Max. Torque 150Nm@4500rev/min(AT);135Nm@4500rev/min(MT)
Idle Speed 740rev/min
Max. Speed of Engine 6800rev/min
Weight 115.7kg

1.0 33
Engine Engine Mechanical

1.5DVCT - Crankshaft
Crankshaft
Crankshaft Axial Clearance 0.205 ± 0.1mm

Service Limit 0.34mm

Main Bearing Bore Diameter:

Grade A 53.690-53.700mm

Grade B 53.680-53.690mm
Main Journal Tolerance:

Grade 0 49.993-50.000mm

Grade 1 49.992-49.984mm

Crankshaft Connecting Rod Journal Diameter 43.000-42.984mm

Max. Out-of-Roundness 0.005mm

Main Bearing Shell:

Quantity 5 pieces each up and down

Model Steel backed, alloy steel and top half bearing shell has oil
passages.
Two halves of thrust washer on the left and right at the third
Thrust Washer
main bearing shell, sticks to the thrust surface.
Thrust Washer Thickness 2.810-2.855mm
Bearing Clearance 0.026-0.070mm

1.0 34
Engine Mechanical Engine
1.5DVCT - Cylinder Block and Piston

Cylinder Block:
Material Cast Iron, HT250

Type of Cylinder Liner No cylinder liner, honing process of spiral bevel gear motion

Cylinder Liner Diameter 74.985-75.000mm

Cylinder Block Size Correction:

Connecting Rod:
Model Fractured Connecting Rod, Material C70S6

Distance Between Centres 143.7 ± 0.05mm

Piston Pin Model Full-floating type

Fitted Connecting Rod Clearance

Length 44.8-45mm
Connecting Rod Bearing Shell:
Clearance 0.020-0.071mm

Axial Endplay 0.100-0.246mm

Piston:
Model Aluminum alloy, graphite finish, NANO anti-friction coated
skirt surface, offset to piston pin during thermal expansion
Piston Diameter:
74.941-74.959mm
Tolerance in Piston Pin Bore
0.005-0.013mm
Max. Ovality
0.002mm
Piston Ring:
Model: 2 compression rings, 1 oil ring

Top Compression Ring Half-barrel faced excircle, PVD treated surface

Second Compression Ring Nose shaped, phosphate coated surface

Oil Ring Three-piece oil ring, PVD treated blade

Tolerance Between Piston Ring and Ring Groove:

Top Compression Ring 0.040-0.080mm

Second Compression Ring 0.030-0.070mm

Oil Ring 0.03-0.16mm

Piston Ring Assembly Clearance in Bore (measured at 20mm
from cylinder liner bore):
0.20-0.30mm
Top Compression Ring
0.40-0.60mm
Second Compression Ring
0.20-0.70mm
Oil Ring
Width of Piston Ring:

Top Compression Ring 0.970-0.990mm

Second Compression Ring 0.970-0.990mm

1.0 35
Engine Engine Mechanical

Oil Ring 1.870-1.980mm

1.0 36
Engine Mechanical Engine
1.5DVCT Cylinder Head and Valve

Cylinder Head:
Material Aluminum alloy
Cylinder Head Height:

New 118.95-119.05mm

Flatness 0.08mm
Camshaft:
Model Double overhead camshaft directly acted on mechanical tappet
Bearing 5 for each camshaft, in-line
Drive Chain drive at crankshaft gear
Camshaft Axial Clearance: 0.06-0.19mm

Service Limit 0.30mm

Bearing Clearance: The first one 0.025-0.066mm, the rest four 0.03-0.07mm

Service Limit 0.15mm

Mechanical Tappet:
Mechanical tappet, DLC coated surface, directly driven by
Model
camshaft
Outside Diameter of Mechanical Tappet f29.964mm-f29.980mm
Valve Timing:
Intake Valve:

ON 20.5°ATDC

OFF 78.5°BTDC

Max. Lift 9.2mm

Exhaust Valve:

ON 65.5°BBDC

OFF 10°ATDC

Max. Lift 8.1mm

Valve:

Valve Stem Diameter:

Intake Valve f4.967-f4.981mm

Exhaust Valve f4.957-f4.971mm

Clearance Between Valve Stem and Valve Guide:

Intake Valve 0.019-0.053mm

Exhaust Valve 0.029-0.063mm

Valve Stem Fit Height:

New Intake Valve 50.033-50.893mm

New Exhaust Valve 49.948-50.808mm

Service Limit 0.26mm

1.0 37
Engine Engine Mechanical

Valve Head Diameter:

Intake Valve f30.02-f30.18mm

Exhaust Valve f25.6-f25.8mm

Valve Seat Width

1.1mm-1.3mm
Intake Valve
1.369mm-1.828mm
Exhaust Valve
Intake 150°, 90°, 65°
Valve Seat Surface Angle - Intake Valve & Exhaust Valve
Exhaust 90°, 60°
Valve Surface Angle - Intake Valve & Exhaust Valve 45°
Intake Valve: 0.17-0.23mm
Valve Clearance
Exhaust Valve: 0.27-0.33mm
Valve Spring:

Free Length 40.2mm

Mounting Length Intake side 33.6mm; Exhaust side 33.1mm

Assembly Load (L1=17mm) Intake side 115±9.2Nm; Exhaust side 125±10Nm

Intake Valve Open Load (L2=28mm) 297±14.8Nm

Exhaust Valve Open Load (L2=28mm) 291±14.6Nm

1.0 38
Engine Mechanical Engine
Lubrication
Lubrication:

Model Cast Aluminum Lower Crankcase

Oil Pump Model: Driven by belt

Outer and Inner Rotor Mesh Clearance 0.03-0.11mm

Rotor to Pump Cover End Clearance 0.05-0.086mm

Free Length of Pressure Relief Valve Spring 67.95 ± 1mm
Oil Filter Rotary Full-flow Oil Filter
Cutoff Pressure of Pressure Relief Valve at 3500rev/min 540-660 kPa

1.0 39
Engine Engine Mechanical

Usage Times of Bolt

Part No. Name Usage Times
BLT200010 Bolt - Main Bearing Cover 1
90004180 Screw - Crankshaft Sensor Signal Wheel 1
BLT200011 Bolt - Connecting Rod 1
90003592 Bolt - Oil Pump to Oil Pan 1
90003620 Stud - Intake Manifold to Cylinder Head 1
99000073 Cylinder Head Bolt 1
99000007 Bolt - Cylinder Head to Engine Block 1
BLT200012 Bolt - Crankshaft Shock Absorber 1
90004291 Bolt - Front Cover to Cylinder Head 1
90000433 Bolt - Lower Front Cover to Engine 1
Block
BLT200013 1
Bolt - Flywheel
BLT200015 1
Bolt - Tensioner
90000829 1
Hexagonal Flange Bolt - Exhaust
Manifold

1.0 40
Engine Mechanical Engine
Description and Operation
System Layout
NSE Engine Layout

1. 1.5DVCT Engine

1.0 41
Engine Engine Mechanical

Cylinder Block Exploded View

1. Cylinder Block 17. O-ring - Lower Crank Case to Cylinder Block (Oil
2. Bolt - Connecting Rod Passage)
3. Crankshaft Assembly 18. Plug - Oil Passage
4. Main Bearing (Upper) 19. Plug - Oil Pressure Switch
5. Main Bearing (Lower) 20. Washer - Cylinder Block Oil Passage Plug
6. Connecting Rod Big End Bearing 21. Plug - Timing Hole
7. Main Bearing Thrust Plate 22. Location Pin - Main Bearing Cap
8. Cylinder Block Rear End Surface Cover Plate 23. Bolt - Main Bearing Cap
9. Crankshaft Sensor Signal Plate 24. Top Ring
10. Crankshaft Rear Oil Seal 25. 2nd Ring
11. Screw - Crankshaft Sensor Signal Plate 26. 3rd Ring
12. Bolt - Crankshaft Rear Oil Seal 27. Piston
13. Location Pin - Crankshaft Sensor Signal Plate 28. Connecting Rod
14. Location Pin - Between Crankshaft and Flywheel 29. Piston Pin
15. Location Pin - Cylinder Block to Transmission Case 30. Main Bearing Cap
16. Location Pin - Front Cover to Cylinder Block 31. Main Bearing Cap

1.0 42
Engine Mechanical Engine
Camshaft Cover Exploded View

1. Ignition Coil 6. Oil Filler Cap

2. Spark Plug 7. Camshaft Cover
3. Stud - Camshaft Cover 8. Seal Ring - Camshaft Cover (Inner)
4. Bolt - Camshaft Cover 9. Seal Ring - Camshaft Cover (Outer)
5. Seal - Oil Control Valve Body

1.0 43
Engine Engine Mechanical

Cylinder Head Exploded View

1. Cylinder Head Assembly 15. Stud - Intake Manifold

2. Upper Body Assembly 16. Cylinder Head Plug
3. Oil Control Valve 17. Bolt - Camshaft Front Shaft
4. Bolt - Oil Control Valve 18. Bolt-Camshaft Bearing Cap
5. Intake Camshaft Assembly 19. Check Valve
6. Exhaust Camshaft Assembly 20. Cylinder Head Plug
7. Oil Check Valve 21. Cylinder Head Plug
8. Tappet 22. Locating Pin - Timing Belt Upper Front Cover
9. Valve Lock Clamp 23. Cylinder Head Gasket
10. Valve Spring Seat 24. Locating Pin - Cylinder Head To Engine Block
11. Valve Spring 25. Stud - Exhaust Manifold
12. Valve Stem Seal 26. Bolt - Cylinder Head
13. Exhaust Valve 27. Bolt - Cylinder Head
14. Intake Valve 28. Bolt - Cylinder Head

1.0 44
Engine Mechanical Engine
Oil Pump and Oil Filter Exploded View

1. Oil Pump 6. Oil Pump Pulley

2. Bolt - Oil Pump To Lower Crankcase 7. Bolt - Oil Pump Pulley
3. Oil Pump Belt 8. Oil Mounting Stud
4. Locating Pin - Oil Pump To Lower Crankcase 9. Oil Filter
5. Crankshaft Pulley - Oil Pump Drive

1.0 45
Engine Engine Mechanical

Lower Crankcase Exploded View

1. Lower Crankcase 8. Oil Baffle Plate

2. Locating Pin - Lower Crankcase 9. Bolt - Oil Baffle Plate
3. Pin Bush - Air Compressor to Lower Crankcase 10. Bolt - Oil Suction Pipe to Lower Crankcase Assembly
4. Oil Drain Plug 11. Oil Dipstick
5. Gasket - Oil Drain Plug 12. Bolt -Lower Crankcase to Crankcase Block
6. Oil Suction Pipe Assembly 13. Plug
7. O-ring - Oil Suction Pipe to Engine Oil Pump

1.0 46
Engine Mechanical Engine
Timing Chain System Exploded View

1. Front Upper Cover 12. Bolt - Front Upper Cover to Cylinder Head
2. Front Lower Cover 13. Bolt - Crankshaft Vibration Damper
3. Crankshaft Front Oil Seal 14. Bolt - Intake Phase Modulator
4. Timing Chain 15. Rock Rail
5. Crankshaft Sprocket - Timing Drive 16. Upper Guide Rail
6. Intake Phase Modulator 17. Chain Guide Rail
7. Exhaust Phase Modulator 18. Bolt - Chain Tensioner to Engine Body
8. Bolt - Front Lower Cover to Engine Body 19. Timing Hydraulic Tensioner
9. Bolt - Front Lower Cover to Engine Body 20. Engine Oil Control Sleeve
10. Bolt - Sprocket Upper Guide Rail to Cylinder Head Front 21. Damper Vibration Pulley
Bearing Cap
11. Bolt - Front Upper Cover to Cylinder Head

1.0 47
Engine Engine Mechanical

Exhaust Manifold Exploded View

1. Exhaust Manifold Assembly 3. Bolt - Exhaust Manifold

2. Exhaust Manifold Gasket 4. Nut - Exhaust Manifold

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Engine Mechanical Engine
Intake Manifold Exploded View

1. Intake Manifold Assembly 7. Bolt - Canister Solenoid

2. Bolt - Intake Manifold Pressure Stabilizing Cavity 8. Canister Desorption Control Valve Bracket
3. Nut - Intake Manifold 9. Gasket - Throttle Body
4. Pipeline Assembly - Canister Control Solenoid To 10. Intake Manifold Gasket
Manifold 11. Clamp - Canister Control Valve Pipeline
5. Canister Desorption Control Valve 12. Clamp - Canister Control Valve Pipeline
6. Canister Solenoid Rubber Sleeve

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Engine Engine Mechanical

Accessory Belt System

1. Accessory Belt 4. Belt Idler Pulley Bracket

2. Accessory Belt Tensioner 5. Belt Idler Pulley
3. Bolt - Idler Pulley Bracket 6. Bolt - Tensioner

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Engine Mechanical Engine
Engine Sensor

1. Oil Temperature Sensor 11. Front Oxygen Sensor Assembly

2. Oil Temperature Sensor Gasket 12. Crankshaft Sensor Assembly
3. Intake Air Temperature/Pressure Sensor 13. O-Ring - Crankshaft Sensor
4. Bolt - Intake Air Temperature/Pressure Sensor 14. Screw - Crankshaft Sensor
5. Knock Sensor 15. Oil Pressure Switch Cover
6. Screw - Knock Sensor 16. Rear Oxygen Sensor Assembly
7. Oil Pressure Switch 17. Clip - Oxygen Sensor
8. Oil Pressure Switch Gasket 18. Front Oxygen Sensor Bracket
9. Camshaft Position Sensor 19. O-Ring - Camshaft Position Sensor
10. Screw - Camshaft Position Sensor

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Engine Engine Mechanical

Water Pump and Thermostat

1. Water Pump 3. Water Pipe

2. Thermostat

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Engine Mechanical Engine
Fuel Rail Assembly

1. Fuel Rail Assembly 4. O-Ring - Fuel Injector

2. Fuel Injector 5. Clip - Fuel Injector
3. Bolt - Fuel Rail

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Engine Engine Mechanical

Description engine is at rest, pin of an elastic load locks both halves of the
Overview modulator; when the engine operates, they are loosened in a
hydraulic way to ensure stable starting.
The NSE engine features in-line 4-cylinder, 16-valve, DOHC,
timing chain drive and electronically-controlled multi-point fuel Two oil control valves are fitted on the front camshaft bearing
injection system. cap and fixed with an O-ring and a bolt respectively. The
control valve is a four-way proportioning valve and consists of
It is mainly composed of cylinder block, cylinder head,
an oil inlet port, an oil return port and two oil ducts connected
crankshaft, connecting rod and camshaft. The cylinder head
with the phase modulator working chamber.
is made of cast aluminum and connected with the cast iron
cylinder block through the multi-layer cylinder gaskets by using Cylinder Block Components
10 high-strength bolts, and there are 3 additional high-strength The cylinder block is constructed from cast iron material
bolts directly connected with the cast iron cylinder block, HT250, this provides high overall strength, reducing the
providing high overall strength and reliable structure. likelihood of deformation. The cylinder liner is formed by
Cylinder Head Component cylinder hole honing. Y-shaped water passages are processed
between two adjacent cylinders to ensure heat dissipation
The cylinder head adopts 4 valves per cylinder structure
effect of the cylinder block.
with a spark plug mounted at the centre of the combustion
chamber. Due to adoption of overhead valve structure, The aluminum alloy thermal expansion piston is provided with
powerful whirlpool will be formed in the combustion chamber a full-floating piston pin which can rotate freely to reduce the
to make the mixed gas evenly distributed, which is good for friction resistance and the generation and delivery of heat, so
transmission of flame to improve combustion condition, so that the reliability and smoothness of high speed of engine
as to enhance the fuel economy, power performance and rotation can be enhanced.
emission performance of the engine.
The forging steel connecting rod has the structure of the
The mechanical tappets are fitted at the top of each valve H-section. The big end of connecting rod moves on the
and directly driven by the camshaft. The bottom bosses bearing shell of crankshaft journal. The connecting rod adopts
of the mechanical tappets are grouped by size, and the forging+cracking process.
valve clearance is optionally fitted with appropriate grouped
The crankshaft has four balance weights and is supported by
mechanical tappets. The valve stem oil seal is press-fitted on
five bearing shells. The end float is controlled by the thrust
the cylinder head oil seal seat and can be used as the valve
washer on the top of the central main bearing shell. The radial
spring seat to support the valve spring.
clearance of the bearing shell is optional, which is controlled
The exhaust valve is of a carbon deposit removal type, and the by the bearing shells of two different grades. The oil groove
valve stem with a machined side can clean the carbon buildup offered in the upper half part of the main bearing shell supply
at the end of valve duct and in combustion chamber so as to oil to the connecting rod big end bearing shell through the oil
prevent valve from seizing. hole in the crankshaft.

The metal cylinder gasket is of a multi-layer structure, the Lower Crankcase Components
cylinder opening adopts a pressing ring structure, which The lower crankcase assembly consists of lower crankcase, oil
enhances sealing at cylinder opening; local rubber coat pump assembly, oil strainer and oil filter.
technology is adopted to ensure the sealing performance.
The aluminum lower crankcase is designed into a shape that is
There are four oil ducts at the front bearing cap of the suitable for accumulating oil around the strainer, the oil pump
camshaft, one oil inlet duct, one oil return duct and two and oil strainer are fitted to bottom of crankcase after being
operating oil ducts. Oil enters the oil control solenoid valve combined, and oil passes through the oil strainer with screen
via the oil ducts. The tail end of the intake/exhaust camshaft and then the oil filter by pressurization of the oil pump.
is equipped with a camshaft signal wheel to provide signals
Clean oil is distributed to the main bearing and cylinder head
for the camshaft position sensor. There is a timing pin hole
via the main oil passage of the engine block to lubricate the
on the camshaft for controlling camshaft timing phase during
crankshaft, connecting rod and camshaft, etc. The mating
assembly.
surface of the lower crankcase and engine block is sealed with
A phase modulator is fitted at the drive ends of the intake and sealant and secured with bolts, and the oil drain plug is located
exhaust camshafts, which is fixed by bolts. Main parts of the at the left side of the lower crankcase (in the direction of engine
phase modulator are made of aluminum. The housing (stator) front end surface).
driven by timing chain is connected with inner rotor through
five blades fixed at camshaft end in a hydraulic way. When the

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Engine Mechanical Engine
Engine Accessories intake system vacuum level, then sends it to the cylinder for
combustion, so as to reduce the air pollution.
The accessories are a single 5-ribbed belt drive system driven
by crankshaft pulley, the system drives the water pump, Oil and gas in the crankcase are separated via an oil separating
alternator and A/C compressor and tensions the belt via a device in the camshaft cover, and oil flows back to the
damping tensioner. crankcase.
Crankcase Ventilation
The ventilation system redirects the exhaust gas escaped to
the crankcase back into the intake system with the help of

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Engine Engine Mechanical

Operation
Lubricating Oil Circuit

1. Cylinder Head Oil Duct 6. Engine Oil Pump

2. Cylinder Block Main Oil Duct 7. Main Oil Duct
3. Crankshaft Cross Oil Duct 8. Timing Chain Tensioner
4. Engine Oil Inlet Pipe 9. Oil Control Valve
5. Engine Oil Filter

The lubrication system is a full-flow filtration, forced oil supply is blocked, this valve will open and ensure the free flow of oil,
system. Oil is drawn from the oil pan through the oil strainer but the oil filter shall be replaced as soon as possible.
by the oil pump, and the oil strainer is equipped with a screen
Then, the oil enters into the main oil passage, and lubricates the
which can prevent impurities from entering the oil pump.
main bearing shell directly via the cross oil circuit. The cross oil
The oil pump with a pressure limiting valve is driven by the circuit on the crankshaft delivers the oil from the main bearing
crankshaft via a belt. When the oil pressure reaches a certain shell to the connecting rod big end bearing shell.
value, the pressure relief valve will open, the excess oil returns
The cylinder head has two side oil passages connecting with
to the inlet side of oil pump, and this helps maintain the oil
the main oil passage of the engine block. After entering the
pressure within a certain operating pressure range and ensure
side oil passages, the oil flows into 2 horizontal oil passages of
the normal operation of engine. Oil flowing from the oil pump
the standard length and is supplied to each mechanical tappet
outlet enters into the full-flow oil filter.
and camshaft journal.
The full-flow oil filter is directly fitted on the oil pan. The oil
filter is equipped with a by-pass valve. When the filter element

1.0 56
Engine Mechanical Engine
The oil splashed by the crankshaft lubricates the cylinder the piston pin from the connecting rod small end through the
wall, the oil collected by the lower side of the piston crown oil circuit.
lubricates the connecting rod small end, and oil is supplied to

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Engine Engine Mechanical

Service Procedures
Powertrain Remove and Refit - AT
Remove
1. Disconnect the battery negative.
2. Drain the coolant.

Coolant Drain
3. Drain the automatic transmission fluid.

Automatic Transmission Fluid Drain

4. Recycle the refrigerant.
Refrigerant Recycle
5. Remove the air filter assembly.
12. Disconnect the clamp fixing the radiator water outlet
Air Filter Assembly Remove hose to the engine.
6. Remove the front/rear brackets of the battery tray.

Front Bracket of Battery Tray Remove

Rear Bracket of Battery Tray Remove

7. Remove the left drive shaft assembly.
Left Drive Shaft Assembly Remove
8. Remove the right drive shaft assembly.

Right Drive Shaft Assembly Remove

9. Remove the front exhaust pipe assembly.

Front Exhaust Pipe Assembly Remove

10. Disconnect the clamp fixing the engine overflow pipe
to the thermostat. 13. Disconnect the clamp fixing the water inlet/outlet pipes
of the heater core to the thermostat.

11. Disconnect the clamp fixing the radiator water inlet

hose to the thermostat. 14. Remove 1 bolt (1) fixing the bracket of the automatic
transmission oil cooler pipe to the automatic
transmission.
15. Remove the automatic transmission oil cooler pipe to
fix to the automatic transmission (2).

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Engine Mechanical Engine
steering fluid pump.

16. Disconnect the harness connector connecting to the

automatic transmission TCM. 22. Disconnect the fuel vapor pipe from the canister
17. Remove the clip fixing the automatic transmission cable solenoid.
to the automatic transmission.
18. Remove the automatic transmission cable rocker arm
to fix to the automatic transmission ball joint.

23. Disconnect the fuel pipe from the fuel rail.

19. Remove the A/C compressor.

Compressor Remove
20. Disconnect the clamp fixing the pipeline (reservoir to
water pump) to the water pump.

24. Disconnect all harness connections of the automatic

transmission.
25. Fix the engine with special tools T10007 and
TEN00070.

21. Remove 1 bolt fixing the steering fluid pipeline to the

steering pump and the nut fixing the pipeline to the

1.0 59
Engine Engine Mechanical

check the torque.

6. Remove the special tools T10007 and TEN00070.
7. Connect all harness connections of the automatic
transmission.
8. Connect the fuel pipe to the fuel rail.
9. Connect the fuel vapour pipe to the canister solenoid.
10. Fit 1 bolt fixing the bracket of the steering fluid pipeline
to the steering pump, tighten to 7-10Nm, and check
the torque.
11. Fit 1 nut fixing the steering fluid pipeline to the steering
pump, tighten to 36-40Nm, and check the torque.
12. Fit the A/C compressor.
26. Remove the powertrain mount.
Compressor Refit
Powertrain Mount Remove
13. Fix the automatic transmission oil cooler pipe to the
27. Remove and discard 1 bolt fixing the lower tie rod to automatic transmission, tighten to 33-37Nm, and
the lower tie rod bracket (1). check the torque.
28. Remove and discard 3 bolts fixing the lower tie rod 14. Fit 1 bolt fixing the bracket of the automatic
bracket to the automatic transmission (2). transmission oil cooler pipe to the automatic
transmission, tighten to 7-10Nm, and check the
torque.
15. Fit the clamp fixing the water inlet/outlet pipes of the
heater core to the thermostat.
16. Fit the clamp fixing the radiator water outlet hose to
the engine.
17. Fit the clamp fixing the radiator water inlet hose to
the thermostat.
18. Fit the clamp fixing the engine overflow pipe to the
thermostat.
19. Fit the front exhaust pipe assembly.
Front Exhaust Pipe Assembly Refit
29. Raise the vehicle on a lift.
20. Fit the left axle shaft assembly.
30. Support the powertrain with hydraulic jack.
Left Drive Shaft Assembly Refit
31. Fix the powertrain to the hydraulic jack, and remove
21. Fit the right axle shaft assembly.
the special tools T10007 and TEN00070.
Right Drive Shaft Assembly Refit
Refit
22. Fit the front/rear brackets of the battery tray.
1. Fix the powertrain to the hydraulic jack, and place at
Front Bracket of Battery Tray Refit
the bottom of the body.
2. Lower the vehicle, place the engine in the engine Rear Bracket of Battery Tray Refit
compartment, and fix the engine with special tools 23. Fit the air filter assembly.
T10007 and TEN00070. Air Filter Assembly Refit
3. Fit the powertrain mount. 24. Fill the refrigerant.
Powertrain Mount Refit Refrigerant Refill
4. Fit 3 new bolts fixing the lower tie rod bracket 25. Fill the automatic transmission fluid.
to the automatic transmission, tighten to Automatic Transmission Fluid Refill
(45-55)Nm+(85-95)deg, and check the torque. 26. Fill the coolant.
5. Fit 1 new bolt fixing the lower tie rod to the lower tie Coolant Refill
rod bracket, tighten to (81-99)Nm+(85-95)deg, and
27. Connect the battery negative.

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Engine Mechanical Engine
Powertrain Remove and Refit - MT
Remove
1. Disconnect the battery negative.
2. Drain the coolant.
Coolant Drain
3. Drain the manual transmission fluid.

Manual Transmission Fluid Drain

4. Recycle the refrigerant.

Refrigerant Recycle
5. Remove the air filter assembly.

Air Filter Assembly Remove 13. Disconnect the clamp fixing the radiator water outlet
6. Remove the air intake pipe Assembly. hose to the engine.

Air Intake Assembly Remove

7. Remove the front/rear brackets of the battery tray.

Front Bracket of Battery Tray Remove

Rear Bracket of Battery Tray Remove

8. Remove the left drive shaft assembly.

Left Drive Shaft Assembly Remove

9. Remove the right drive shaft assembly.

Right Drive Shaft Assembly Remove

10. Remove the front exhaust pipe assembly.

Front Exhaust Pipe Assembly Remove

11. Disconnect the clamp fixing the engine overflow pipe 14. Disconnect the clamp fixing the water inlet/outlet pipes
to the thermostat. of the heater core to the thermostat.

12. Disconnect the clamp fixing the radiator water inlet 15. Disconnect the connector of the reverse lamp switch.
hose to the thermostat. 16. Pay attention to the mounting position, and disconnect
2 cable ball joints of the gear selection/shift rocker arm
of the manual transmission.

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Engine Engine Mechanical

17. Loosen the clips fixing the gear selection/shift cable to 21. Remove 1 bolt fixing the steering fluid pipeline to the
the bracket. steering pump and the nut fixing the pipeline to the
steering fluid pump.

18. Remove 2 bolts fixing the slave cylinder to the manual

transmission.
22. Disconnect the fuel vapor pipe from the canister
Caution: Don’t hang the slave cylinder for a long time ，
solenoid.
or the hose of slave cylinder will become deformed.

23. Disconnect the fuel pipe from the fuel rail.

19. Remove the A/C compressor.
Compressor Remove
20. Disconnect the clamp fixing the pipeline (reservoir to
water pump) to the water pump.

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Engine Mechanical Engine
Refit
1. Fix the powertrain to the hydraulic jack, and place at
the bottom of the body.
2. Lower the vehicle, place the engine in the engine
compartment, and fix the engine with special tools
T10007 and TEN00070.
3. Fit the powertrain mount.
Powertrain Mount Refit
4. Fit 3 new bolts fixing the lower tie rod bracket to
the Manual transmission, tighten to （45-55） ）Nm+
（ 85-95） ）deg, and check the torque.
Caution: Yielding technique is applied to this bolt . For
24. Fix the engine with special tools T10007 and virgin installation, the bolt is allowed to use twice. For
TEN00070. second use of bolt in the same station, the bolt must be
loosened to zero Nm, then tighten it according to specified
technique; when the bolt is used over twice or unknown
times, new bolt must be taken.

5. Fit 1 new bolt fixing the lower tie rod to the lower tie
rod bracket, tighten to （ 81-99） ）Nm+（ （85-95） ）
deg, and check the torque.
Caution: Yielding technique is applied to this bolt . For
virgin installation, the bolt is allowed to use twice. For
second use of bolt in the same station, the bolt must be
loosened to zero Nm, then tighten it according to specified
technique; when the bolt is used over twice or unknown
times, new bolt must be taken.
25. Remove the powertrain mount. 6. Remove the special tools T10007 and TEN00070.
Powertrain Mount Remove 7. Connect the fuel pipe to the fuel rail.
26. Remove and discard 1 bolt fixing the lower tie rod to 8. Connect the fuel vapour pipe to the canister solenoid.
the lower tie rod bracket (1). 9. Fit 1 bolt fixing the bracket of the steering fluid pipeline
27. Remove and discard 3 bolts fixing the lower tie rod to the steering pump, tighten to 7-10Nm, and check
bracket to the Manual transmission (2). the torque.
10. Fit 1 nut fixing the steering fluid pipeline to the steering
pump, tighten to 36-40Nm, and check the torque.
11. Fit the A/C compressor.
Compressor Refit
12. Fit 2 bolts fixing the slave cylinder to the manual
transmission, tighten to 40-50Nm, and check the
torque.
13. Connect the clips fixing the gear selection/shift cable
to the bracket.
14. Connect 2 cable ball joints of the gear selection/shift
rocker arm of the manual transmission.
15. Fit the clamp fixing the water inlet/outlet pipes of the
28. Raise the vehicle on a lift. heater core to the thermostat.
29. Support the powertrain with hydraulic jack. 16. Fit the clamp fixing the radiator water outlet hose to
30. Fix the powertrain to the hydraulic jack, and remove the engine.
the special tools T10007 and TEN00070. 17. Fit the clamp fixing the radiator water inlet hose to

1.0 63
Engine Engine Mechanical

the thermostat. Powertrain Mount

18. Fit the clamp fixing the engine overflow pipe to the Remove
thermostat. 1. Disconnect the battery negative.
19. Fit the front exhaust pipe assembly. 2. Remove the front/rear brackets of the battery tray.
Front Exhaust Pipe Assembly Refit Front Bracket of Battery Tray Remove
20. Fit the left axle shaft assembly. Rear Bracket of Battery Tray Remove
Left Drive Shaft Assembly Refit 3. Fix the powertrain with special tools T10007 and
21. Fit the right axle shaft assembly. TEN00070.
4. Remove and discard 1 nut (1) fixing the automatic
Right Drive Shaft Assembly Refit
transmission mount to the automatic transmission
22. Fit the front/rear brackets of the battery tray. mount bracket.
Front Bracket of Battery Tray Refit 5. Remove and discard 4 bolts (2) fixing the automatic
transmission mount to the left longitudinal beam.
Rear Bracket of Battery Tray Refit
23. Fit air intake pipe assembly.
Air Intake Pipe Assembly Refit.
24. Fit the air filter assembly.

Air Filter Assembly Refit

25. Fill the refrigerant.

Refrigerant Refill
26. Fill the Manual transmission fluid.

Manual Automatic Transmission Fluid Refill

27. Fill the coolant.

Coolant Refill
6. Remove and discard 1 nut (1) fixing the Manual
28. Connect the battery negative.
transmission mount to the Manual transmission mount
bracket.
7. Remove and discard 4 bolts (2) fixing the Manual
transmission mount to the left longitudinal beam.

8. Remove and discard 1 bolt (1) fixing the engine mount

to the body.
9. Remove and discard 2 bolts (2) fixing the engine mount
to the right longitudinal beam.
10. Remove and discard 3 bolts (3) fixing the engine mount
to the engine.

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Engine Mechanical Engine
Torque Converter Drive Plate - AT
Remove
1. Remove the automatic transmission.

Automatic Transmission Remove

2. Remove the plug from the timing hole of the engine
block.
3. Rotate the drive plate, when the flywheel mounting pin
hole of the crankshaft is horizontally aligned with the
air intake side, the flywheel timing pin hole is aligned
with the pin hole of the engine block.
4. Insert into the drive plate pin hole through the engine
block timing hole with the TEN00002 to lock it up.
11. Remove the powertrain mount.
Refit
1. Fit 3 new bolts fixing the engine mount to the engine,
tighten to (63-77)Nm+(85-95)deg, and check the
torque.
2. Fit 2 new bolts fixing the engine mount to the right
longitudinal beam, tighten to 90-110Nm, and check
the torque.
3. Fit 1 new nut fixing the engine mount to the body,
tighten to 26-34Nm, and check the torque.
4. Fit 4 new bolts fixing the automatic transmission mount
to the left longitudinal beam, tighten to 55-65Nm, and
check the torque.
5. Unscrew 6 bolts fixing the drive plate to the crankshaft
5. Fit 1 new nut fixing the automatic transmission mount
and discard them.
to the automatic transmission mount bracket, tighten
to (63-77)Nm+(85-95)deg, and check the torque.
6. Fit 4 new bolts fixing the Manual transmission mount
to the left longitudinal beam, tighten to 55-65Nm, and
check the torque.
7. Fit 1 new nut fixing the Manual transmission mount
to the Manual transmission mount bracket, tighten to
(63-77)Nm+(85-95)deg, and check the torque.
8. Remove the special tools T10007 and TEN00070.
9. Fit the front/rear brackets of the battery tray.

Front Bracket of Battery Tray Refit

Rear Bracket of Battery Tray Refit

6. Remove the drive plate from the crankshaft.
10. Connect the battery negative.

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Engine Engine Mechanical

Flywheel-MT
Remove
1. Remove the clutch assembly.

Clutch Assembly Remove

2. Remove the plug from the timing hole of the engine
body.
3. Rotate the flywheel, observe from the flywheel end,
when the flywheel mounting pin hole is horizontally
aligned with the air intake side, the flywheel timing pin
hole is aligned with the pin hole of the engine body.

7. Remove the special tool TEN00002 for flywheel

timing pin.
Refit
1. Use a saw to make two saw cuts on the bolt removed
from the drive plate at an angle of 45° to the bolt
shank, and clean the bolt hole on the crankshaft with
the sawed bolt.
2. Clean the mating face of the drive plate and the
crankshaft.
3. Fit the drive plate to the crankshaft.
4. Fit the new glue bolts, but do not tighten them.
4. Insert the flywheel timing pin special tool
5. Rotate the drive plate,when the flywheel mounting pin TEN00002into the flywheel pin hole through the
of the crankshaft is horizontally aligned with the air engine body timing hole to lock the flywheel.
intake side, insert the flywheel timing pin special tool
TEN00002 into the engine block timing hole to lock
it up.
6. Tighten the bolt to 35Nm+60° using a diagonal
sequence.

5. Unscrew 6 bolts fixing the flywheel to the crankshaft

and discard.

7. Remove the special tool TEN00002 of the drive plate

timing pin.
8. Refit the plug.
9. Fit the automatic transmission.

Automatic Transmission Refit

1.0 66
Engine Mechanical Engine

6. Remove the flywheel from the crankshaft. 7. Remove the flywheel timing pin special tool
TEN00002.
8. Fit the plug.
9. Fit the clutch assembly.
Clutch Assembly Refit

7. Remove the flywheel timing pin special tool

TEN00002.
Refit
1. Use a saw to make two tooth grooves on the bolt
removed from the flywheel at an angle of 45°to the
bolt shank, and clean the bolt hole on the crankshaft
with the sawed bolt.
2. Clean the joint face of the flywheel and crankshaft.
3. Fit the flywheel to the crankshaft.
4. Fit new bolts coated with adhesive and tighten them
by hand.
5. Rotate the flywheel, observe from the flywheel. When
the flywheel mounting pin hole is horizontally aligned
with the air intake side, insert the flywheel timing pin
special tool TEN00002to lock the flywheel.
6. Tighten the bolt to (32-38)Nm+60°±5°in diagonal
sequence.

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Engine Engine Mechanical

Crankshaft Pulley
Remove
1. Disconnect the battery negative.
2. Raise the front of the vehicle.
Warning: Do not work on or under a vehicle supported
only by a jack.Always support the vehicle on safety stands.
3. Remove the camshaft cover.

Camshaft Cover Remove

4. Remove the right front wheel.

Wheel Remove
5. Remove auxiliary drive belt.
Refit
Auxiliary Drive Belt Remove
1. Insert the TEN00002 into the engine body timing pin
6. Fix the crankshaft pulley with the TEN00008. hole and flywheel pin hole to lock the flywheel.

7. Loosen and remove the bolt fixing the pulley to the 2. Rotate the camshaft with the timing hole up, and lock
crankshaft, and discard the bolt. the camshaft phase with the TEN00004.

8. Remove the crankshaft pulley.

Caution: Avoid damaging the crankshaft front oil seal lip

when removing the pulley.

1.0 68
Engine Mechanical Engine
Timing Chain Upper Cover Plate
Remove
1. Disconnect the battery negative.
2. Remove the engine mount.
Powertrain Mount Remove
3. Remove the auxiliary drive belt.
Auxiliary Drive Belt Remove
4. Remove the camshaft cover.
Camshaft Cover Remove
5. Release 8 bolts securing the timing chain upper cover
plate.
3. Push the crankshaft pulley to the crankshaft sprocket
for contact.
4. Fix the crankshaft shock absorber with a special tool
TEN00008.
5. Fit the pulley bolt, tighten to 60Nm+120°, and check
the torque.
6. Fit the camshaft cover.

Camshaft Cover Refit

7. Fit the auxiliary drive belt.

Auxiliary Drive Belt Refit

8. Fit the right front wheel.

Wheel Refit 6. Remove 8 bolts securing the timing chain upper cover
plate.
9. Lower the vehicle.
Caution: When removing the timing chain upper cover
10. Connect the battery negative.
plate, ensure that the cover plate does not deform.

7. Remove the timing chain upper cover plate.

Refit
1. Check the timing chain upper cover plate.
Caution: Ensure that there is no damage on the timing
chain upper cover plate, otherwise, it may cause oil leak.

2. Along the seal strip, apply glue (width: 1.5 – 2.0mm) to

the mating face of the timing chain upper cover plate
and the cylinder head.

1.0 69
Engine Engine Mechanical

Timing Chain Lower Cover Plate

Remove
Warning: Always replace both crankshaft front oil seal and
timing chain lower cover plate together.
1. Disconnect the battery negative.
2. Remove the engine mount.

Powertrain Mount Remove

3. Remove the engine mount bracket.
4. Drain the engine oil.

Engine Oil Filter Remove

5. Remove the crankshaft pulley.
3. Fix the timing chain upper cover plate to the cylinder
Crankshaft Pulley Remove
head, fit 8 bolts and tighten to 8-12Nm.
6. Remove the pulley of water pump with the pulley
refit/remove special tool TEN00009.

4. Fit the camshaft cover.

Camshaft Cover Refit
7. Remove the bolt fixing the lower timing chain cover.
5. Fit the auxiliary drive belt.

Auxiliary Drive Belt Refit

6. Fit the engine mount.

Powertrain Mount Refit

7. Connect the battery negative.

8. Remove the lower timing chain cover and discard the

front crankshaft oil seal and lower timing chain cover.
Caution: Be sure to keep the flatness of the timing chain
lower cover plate when removing it, otherwise, it will
cause oil leak.

1.0 70
Engine Mechanical Engine

Refit 5. Locate the timing chain lower cover plate assembly

1. Clean the sealant on the engine block and the contact to the cylinder block, fit and tighten 16 bolts in the
surface of the timing chain lower cover plate, ensure sequence of 1 - 16 as shown, complete the installation
there is no sealant residue on the engine block. within 3 to 5 minutes and tighten to 8-12Nm.
2. Clean the journal of the crankshaft pulley.
3. Fit the lower cover plate locating pin of the timing chain
(no need to refit it if not removed).

6. Fit the water pump pulley with the special tool

TEN00009, the tightening torque is 23-27Nm.
7. Fit the crankshaft pulley.
Crankshaft Pulley Refit
8. Fit the engine oil filter.

Engine Oil Filter Refit

9. Fit the engine mount bracket, the tightening torque is
40Nm+60deg.
10. Fit the engine mount.

Powertrain Mount Refit

11. Refill the engine oil.

Lubricating Fluid Refill

12. Connect the battery negative.

4. Apply sealant of about 2.5mm in width with an

appropriate tool according to the path shown in the
following figure, ensure continuity of the sealant.

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Engine Engine Mechanical

Timing Chain
Remove
1. Raise the front of the vehicle.

Warning: Do not work on or under a vehicle supported

only by a jack.Always support the vehicle on safety stands.
2. Drain the engine oil.

Engine Oil Filter Remove

3. Remove the upper cover plate of the timing chain.

Timing Chain Upper Cover Plate Remove

4. Remove the lower cover plate of the timing chain.

Timing Chain Lower Cover Plate Remove

9. Remove the guide rail pivot pin, take out the tensioner
5. Remove the timing chain tensioner, and discard the rail and chain guide rail from the upper end of the chain
sealing washer. locker.

6. Remove the upper guide rail. Refit

1. Remove the plug in the timing pin hole of the engine
body.
2. Rotate the flywheel until the flywheel pin hole is aligned
with the pin hole of the engine body.
3. Insert the TEN00002 into the engine body timing pin
hole and flywheel pin hole to lock the flywheel.

7. Remove and discard the intake & exhaust phase

modulator bolts.
8. Remove the crankshaft sprocket - timing drive and
timing chain.

4. Rotate the camshaft with the timing hole up, and lock
the camshaft phase with the TEN00004.

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Engine Mechanical Engine
and hang the chain onto the upper rail mounting boss.
9. Fit phase modulators to the intake and exhaust
camshafts, mount the chains into the two sprocket, and
pre-tighten the bolts.
10. Fit the upper guide rail to the front bearing cap of the
camshaft, fix with two bolts, the tightening torque is
8-12Nm.

11. Fit a new timing hydraulic tensioner washer, screw the

timing hydraulic tensioner into the cylinder head, and
tighten to 18-22Nm+(22-28°).

5. Check parts for handling mark, oil stain, rust or dirt

before assembly. If handling mark exists, do not use it,
if oil stain exists, wipe off it.
6. Put in the chain guide rail from the upper right side of
the guide rail locker, fit the pivot pin and secure it in
sequence, then tighten to 20-24Nm.
7. Put in the tensioner guide rail from the upper left side
of the guide rail locker, fit the pivot pin and tighten it to
20-24Nm.

12. Fit the oil pump sprocket with the TEN00006, the
tightening torque is 22-28Nm.

8. Fit a crankshaft sprocket-timing drive into the front

end of the crankshaft. Put in the timing chain from the
upper end of the cylinder head guide rail locker, fit the
crankshaft sprocket into the lower end of the chain, 13. Fit the crankshaft sprocket - oil pump drive into the

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Engine Engine Mechanical

front end of the crankshaft, then fit the oil pump belt. Camshaft Cover
Caution: At the foot of the crankshaft sprocket-oil pump
Remove
teeth side is a dent mark that is used to distinguish it with 1. Disconnect the battery negative.
the crankshaft sprocket-timing chain. 2. Remove the dipstick.
14. Fit the lower cover plate of the timing chain.

Timing Chain Lower Cover Plate Refit

15. Fit the upper cover plate of the timing chain.

Timing Chain Upper Cover Plate Refit

16. Fill the engine oil.

Lubricating Fluid Refill

17. Lower the vehicle.

3. Drain the engine oil.

Engine Oil Filter Remove

4. Release and remove the harness bracket bolt, release
and remove the high voltage coil bolt, confirm the
position of each bolt and keep the bolts properly.

5. Remove the ignition coil and the ignition coil bracket.

Ignition Coil Remove
6. Release the clips of the full load breather pipe and the
part load breather pipe.

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Engine Mechanical Engine
3. Position the camshaft cover on the cylinder head.
4. Fit the bolt and tighten to 7-10Nm in sequence shown
in the figure below.

7. Remove the full load and part load breather pipe.

8. Loosen and remove 19 bolts securing the camshaft
cover and confirm the position of each bolt.
5. Fit the ignition coil and the ignition coil bracket, and
tighten the retaining bolts to 8-12Nm.

Ignition Coil Refit

6. Fill the engine oil.

Lubricating Fluid Refill

7. Fit the dipstick.
8. Connect the battery negative.

9. Remove the camshaft cover, pay attention to the

protection of check valve diaphragm and keep it clean.
10. Remove the jack.
Refit
1. Check the upper surface of the cylinder head, take
care not to damage it. Clean the upper surface of the
cylinder head and remove the oil.
2. Apply silica gel (Dia.: 4mm) to the seam of the timing
chain upper cover plate and the camshaft cover.

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Engine Engine Mechanical

Camshaft - Intake or Exhaust

Remove
1. Disconnect the battery negative.
2. Remove the timing chain.
Timing Chain Remove
3. Remove the timing chain tensioner, and discard the
sealing washer.

7. Loosen 19 bolts on the camshaft bearing cap in

sequence shown until the valve spring does not apply
any pressure to the camshaft.

4. Remove the upper guide rail.

8. Loosen the bolts fixing the camshaft bearing cover,

identify the position of each camshaft bearing cover,
and remove the camshaft bearing covers.

5. Remove and discard the intake & exhaust phase

modulator bolts.
6. Remove the intake phase modulator and exhaust phase
modulator, and hang the chain on the upper guide rail
mounting boss.

9. Identify the position of each camshaft, and remove the

camshafts.

Caution: The intake/exhaust camshaft and signal

wheel shall be removed as an assembly, without
removing the signal wheel.

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Engine Mechanical Engine

Refit 5. Put the camshaft into the bearing seat, fit the camshaft
1. Clean the camshaft. bearing cap and camshaft bolt (do not tighten). Rotate
the camshaft with the timing hole up, and lock the
2. Clean the upper cylinder head plane, top of the
camshaft phase with the TEN00004.
mechanical tappet and camshaft bearing cap.
3. Apply engine oil to the camshaft journal, bearing seat
and top tappet evenly.
4. Put the camshaft into the bearing seat, fit the camshaft
bearing cap, fit the camshaft bolt (do not tighten),
rotate the camshaft and measure the valve clearance.
Intake side clearance of the model to be repaired
is 0.17-0.23mm and the exhaust side clearance is
0.27-0.33mm, calculate the valve clearance and acquire
a proper mechanical tappet.

Caution: The intake/exhaust camshaft and signal

wheel shall be fitted as an assembly, without
removing the signal wheel.

6. Tighten the camshaft bearing cap in sequence shown

with tightening torque of 7-11Nm.

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Engine Engine Mechanical

tighten to 18-22Nm+(22-28°).

7. Rotate the flywheel until the flywheel pin hole is aligned

with the pin hole of the engine body. 12. Secure the intake and exhaust phase modulators to the
8. Insert the TEN00002 into the engine body timing pin camshaft, tighten the bolt to 70-80Nm.
hole and flywheel pin hole to lock the flywheel.

13. Fit the timing chain.

9. Position the phase modulators assembled on the intake
Timing Chain Refit
and exhaust camshafts to the appropriate camshaft,
mount the chains into both modulators, and pre-tighten 14. Connect the battery negative cable.
the bolts.
10. Fit the upper guide rail to the front bearing cap of the
camshaft, fix with two bolts, the tightening torque is
8-12Nm.

11. Fit a new timing hydraulic tensioner washer, screw the

timing hydraulic tensioner into the cylinder head, and

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Engine Mechanical Engine
Mechanical Tappet Q 10187107 T=3.414
Remove
R 10187108 T=3.438
1. Disconnect the battery negative.
S 10187109 T=3.465
2. Remove the camshaft - intake or exhaust.
T 10187110 T=3.495
Camshaft - Intake or Exhaust Remove
U 10187111 T=3.525
3. With a viscous magnet, take away the mechanical tappet
carefully, and put it aside. V 10187112 T=3.555
W 10187113 T=3.585

4. Fit the camshaft - intake or exhaust.

Camshaft - Intake or Exhaust Refit

5. Connect the battery negative cable.

Refit
1. Clean the tappet hole.
2. Lubricate the standard tappet (H group) and fit it into
the tappet hole. Fit the camshaft, select correct tappet
group according to valve clearance.
3. Fit the selected tappet group.
The list of mechanical valve tappet series is as follows:

Group Part No. Tappet Thickness

A 10187088 T=3.000
B 10187090 T=3.030
C 10187091 T=3.060
D 10187092 T=3.090
E 10187093 T=3.120
F 10187094 T=3.150
G 10187096 T=3.174
H 10187097 T=3.198
I 10187098 T=3.222
J 10187099 T=3.246
K 10187100 T=3.270
L 10187101 T=3.294
M 10187103 T=3.318
N 10187104 T=3.342
O 10187105 T=3.366
P 10187106 T=3.390

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Engine Engine Mechanical

Valve Refit
Remove 1. Remove the carbon deposits and other foreign
1. Disconnect the battery negative. objects from the valve duct, valve, valve seat ring and
2. Remove the cylinder head assembly. combustion surface.
2. Check the diameter of the existing valve stem. Check
Cylinder Head Assembly Remove
the valve guide clearance with new valves.
3. Compress the valve spring with the T10005.
3. Check the conditions of the valve seat and valve before
another use.
4. Check the matching height of the valve stem.
5. Check the condition of the valve spring.
6. Ensure that the mechanical tappet, valve, valve spring,
spring cap and lock clamp are clean.
7. Lubricate the valve and valve stem oil seal.
8. Fit the valve stem oil seal to the valve guide with the
TEN00014.

4. Remove the valve lock clamp and release the valve

spring.
5. Remove the T10005.
6. Remove the valve spring, valve spring seat and valve.

9. Fit the valve, spring and spring cap, compress the valve
spring with the T10005, and mount the lock clamps.

7. Remove the valve oil seal with the T10006.

10. Loosen the valve spring, and remove the T10005.

11. Fit the cylinder head assembly.

Cylinder Head Assembly Refit

12. Connect the battery negative cable.

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Engine Mechanical Engine
Cylinder Head Assembly
Remove
1. Disconnect the battery negative.
2. Drain the engine oil.
Engine Oil Filter Remove
3. Drain the engine coolant.

Coolant Drain
4. Remove the alternator.

Alternator Remove
5. Remove the intake manifold and discard the intake
manifold gasket.
Refit
Intake Manifold Remove
1. Clean the sealing area of the cylinder head and upper
6. Remove the exhaust manifold and discard the exhaust cover plate of the timing chain. Clean the camshaft
manifold gasket. cover and joint face between the intake and exhaust
Exhaust Manifold Remove manifolds with foam remover and plastic scraper.

7. Unscrew the bolt fixing the thermostat assembly to the Caution: Don’t use scraper to deal with sealed surface.
cylinder head and remove the thermostat assembly. 2. Blow the oil passage and coolant passage dry.
3. Fit a new cylinder gasket.

8. Remove the contaminants in the spark plug gap.

9. Remove the spark plug. 4. Place the cylinder head to the engine body, put in 10
cylinder head bolts and 3 chain locker bolts carefully,
Spark Plug Remove then pre-tighten with bolts.
10. Remove the mechanical tappet. Warning: The cylinder head bolts cannot be lubricated by
Mechanical Tappet Remove lubricants.
11. Remove the cylinder head assembly, and discard the
cylinder head gaskets.

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Engine Engine Mechanical

10. Fit the intake manifold and fit a new intake manifold
gasket.

Intake Manifold Refit

11. Fit the alternator.

Alternator Refit
12. Fill the engine coolant.

Coolant Refill
13. Fill the engine oil.

Lubricating Fluid Refill

14. Connect the battery negative.

5. Tighten 10 cylinder head bolts with special sleeve in

sequence shown (torque: 30Nm（ （90°+60°)), then
tighten three bolts near the chain locker (torque:
8-12Nm).

6. Fit the mechanical tappet.

Mechanical Tappet Refit
7. Fit the spark plug.
Spark Plug Refit
8. Fit the thermostat housing, and tighten to 8-12Nm.

9. Fit the exhaust manifold and fit a new exhaust manifold

gasket.
Exhaust Manifold Refit

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Engine Mechanical Engine
Cylinder Head Check
Remove
1. Disconnect the battery negative.
2. Drain the engine oil.
Engine Oil Filter Remove
3. Drain the engine coolant.

Coolant Drain
4. Remove the alternator.

Alternator Remove
5. Remove the intake manifold and discard the intake
manifold gasket.
13. Remove the upper guide rail.
Intake Manifold Remove
6. Remove the exhaust manifold and discard the exhaust
manifold gasket.

Exhaust Manifold Remove

7. Unscrew the bolt fixing the thermostat assembly to the
cylinder head and remove the thermostat assembly.

14. Remove the oil control valve.

Oil Control Valve Remove

8. Remove the contaminants in the spark plug gap.

9. Remove the spark plug.

Spark Plug Remove

10. Remove the upper cover plate of the timing chain.

Timing Chain Upper Cover Plate Remove

11. Remove the lower cover plate of the timing chain.

Timing Chain Lower Cover Plate Remove

12. Remove the timing chain tensioner, and discard the 15. Remove and discard the intake & exhaust phase
sealing washer. modulator bolts.
16. Remove the intake phase modulator and exhaust phase
modulator, and hang the chain on the upper guide rail
mounting boss.

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Engine Engine Mechanical

17. Check the end offset of the camshaft with a dial gauge. 22. Identify the position of each camshaft, and remove the
18. If the end offset exceeds the tolerance, replace with a camshafts.
new camshaft and recheck, if the end offset still exceeds Caution: The intake/exhaust camshaft and signal
the tolerance, replace the cylinder head assembly. wheel shall be removed as an assembly, without
Camshaft axial clearance: 0.06-0.19mm removing the signal wheel.

Service Limit 0.30mm

19. Gradually release the cylinder head bolts, remove the

cylinder head assembly, put the cylinder head on a
wooden shelf, take care to protect the combustion
surface from scratch.
20. Remove and discard the cylinder head gaskets.

23. Remove 16 mechanical tappets from the cylinder head,

put them in sequence to avoid confusion.

21. Loosen the bolts fixing the camshaft bearing cover,

identify the position of each camshaft bearing cover,
and remove the camshaft bearing covers.

24. Measure the outer diameter of each mechanical

tappet (outer diameter of mechanical tappet:
29.964mm-29.980mm).
25. Clean the camshaft, camshaft bearing cover and cylinder
head bearing base.

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Engine Mechanical Engine
26. Inspect the camshaft and replace if it is scratched, pitted
or excessively worn.
27. Fix the camshaft to the cylinder head, put a plastic
gauge on each journal, then refit the camshaft bearing
cover, do not rotate the camshaft.
28. Slowly unscrew the camshaft bearing cover bolts, and
remove the camshaft bearing cover.

33. Remove the valve oil seal with the T10006.

29. Measure the widest portion of the plastic gauge on each

journal, if the clearance exceeds the tolerance, replace
with a new camshaft and recheck. If the clearance still
exceeds the tolerance, replace with a new cylinder
head assembly.
Bearing clearance Service Clearance
34. Clean each mating face of the cylinder head.
Previous gear 0.025-0.066mm 0.1mm
35. Check the cylinder head for damage, and especially the
Next 4 gears 0.03-0.07mm 0.1mm combustion surface of cylinder head.
30. Support the exhaust manifold side of the cylinder head 36. Check the combustion surface of cylinder head for
with a wooden block, remove the intake valve in this scratches according to the illustrated method, crossed
position. or diagonally.
31. Compress the valve spring with the T10005, remove
2 clips from the valve, release the valve spring and
remove the tool.

37. Check the cylinder head height.

Cylinder head height:

32. Remove remaining valve spring retainer, valve spring New 118.95－119.05mm
and valve, put them aside in original refit sequence. 38. Remove carbon deposits from the valve, valve duct,
valve seat and combustion chamber surface.

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Engine Engine Mechanical

Valve Seat Width

Intake Valve 1.1mm-1.3mm

Exhaust valve 1.369mm-1.828mm

Valve Seat Surface Angle Intake 150°, 90°, 65°

- Intake Valves & Exhaust
Exhaust 90°, 60°
Valves
Valve surface angle B:

Intake 45°

Exhaust 45°

42. Push the valve onto the seat with even abrasive.
39. Check the diameter of the existing valve stem and
43. Apply Prussian-blue to the valve seat, put it into the
check the valve guide clearance with new valves.
valve and press it in place without rotation, remove it
Valve stem diameter: and check the evenness and central alignment with the
Intake valve f4.967-f4.981mm valve seat, the position of valve seat shown in blue must
be in the central of the valve surface.
Exhaust valve f4.957-f4.971mm
44. Apply the color to the valve seat and recheck.
Clearance between Valve
45. Check the matching height of the valve stem.
Stem and Valve Guide:
0.019-0.053mm New intake valve 50.033-50.893mm
Intake Valve
0.029-0.063mm New exhaust valve 49.948-50.808mm
Exhaust Valve
Service Limit 0.26mm
Replace with a new valve as necessary, if the valve guide is to
46. If it still exceeds the limit, you need to replace the
be replaced, replace the cylinder head assembly.
cylinder head assembly.
40. If the cylinder head is to be reused, please check the
47. Check the valve spring:
valve seat and valve conditions.
Free length 40.2mm
Mounting length Intake 33.6mm; exhaust
33.1mm
Load - Valve Closed Intake 115±9.2Nm; exhaust
125±10Nm
Load - Intake Valve Open 297±14.8Nm
Load - Exhaust Valve Open 291±14.6Nm

Refit
1. Clean the sealing area of the cylinder head and upper
cover plate of the timing chain. Clean the camshaft
cover and joint face between the intake and exhaust
41. Machine the valve surface angle and valve seat to the manifolds with foam remover and plastic scraper.
following standards: Caution: Don’t use scraper to deal with sealed surface.

2. Blow the oil passage and coolant passage dry.

3. Fit the valves.
Valve Refit
4. Fit the cylinder head assembly.
Cylinder Head Refit
5. Fit the mechanical tappet.
Mechanical Tappet Refit

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Engine Mechanical Engine
6. Lubricate the camshaft bearing surface, and position the
camshaft on the cylinder head. Then close the camshaft
bearing cap properly, and pre-tighten with bolts.

Caution: The intake/exhaust camshaft and signal

wheel shall be fitted as an assembly, without
removing the signal wheel.

12. Fit the exhaust manifold and fit a new exhaust manifold
gasket.

Exhaust Manifold Refit

13. Fit the intake manifold and fit a new intake manifold
gasket.

Intake Manifold Refit

7. Measure the clearance of each mechanical tappet,
14. Fit the alternator.
methods: rotate the camshaft, make the base circle
above the mechanical tappet, measure the clearance Alternator Refit
between the camshaft and the mechanical tappet and 15. Fill the engine coolant.
record the clearance. Repeat the operation on each
mechanical tappet. Calculate the clearance, select Coolant Refill
appropriate mechanical tappet so that correct clearance 16. Fill the engine oil.
can be achieved. Intake side clearance: 0.17-0.23mm, Lubricating Fluid Refill
exhaust side clearance: 0.27-0.33mm.
17. Connect the battery negative.

8. Remove the camshaft, fit the mechanical tappet of

correct size into the corresponding mechanical tappet.
9. Fit the camshaft - intake or exhaust.

Camshaft - Intake or Exhaust Refit

10. Fit the spark plug.

Spark Plug Refit

11. Fit the thermostat housing, and tighten to 8-12Nm.

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Engine Engine Mechanical

Cylinder Gasket Cylinder Head Assembly Refit

Remove 9. Refill coolant.
1. Disconnect the battery negative.
Coolant Refill
2. Drain the engine oil.
10. Fill the engine oil.
Engine Oil Filter Remove
Lubricating Fluid
3. Drain the coolant.
11. Connect the battery negative.
Coolant Drain
4. Remove the cylinder head assembly.
Cylinder Head Assembly Remove
5. Remove the cylinder head gasket from the cylinder
block and discard it.

Refit
1. Clean the mating surface of the cylinder head and
cylinder block.
2. Check the surface of the cylinder head for scratch.
3. Check the cylinder head height.
4. Clean the passages of the engine oil and the coolant.
5. Clean the cylinder head bolts and wipe them, check the
thread for any sign of damage.
6. Apply a thin oil film on the cylinder head bolt.
7. Fit a new and clean cylinder head gasket to the cylinder
block.

8. Fit the cylinder head assembly.

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Engine Mechanical Engine
Lower Crankcase
Remove
1. Disconnect the battery negative.
2. Raise the front part of the vehicle.
Warning: Do not work on or under a vehicle supported
only by a jack.Always support the vehicle on safety stands.
3. Remove the powertrain.

Powertrain - AT Remove

Powertrain - MT Remove
4. Remove the upper cover plate of the timing chain.

Timing Chain Upper Cover Plate Remove 10. Remove the lower crankcase.
5. Remove the lower cover plate of the timing chain. Refit
Timing Chain Lower Cover Plate Remove 1. Ensure the junction surface of the lower crankcase and
6. Remove the timing chain tensioner, and discard the the engine block is clean.
seal washer. 2. Please apply the sealant recommended by the
manufacturer for the junction surface of the lower
crankcase.

7. Remove the oil pump belt, and remove the crankshaft

sprocket (oil pump drive).
Caution: When fitting the lower crankcase, try to make
the lower crankcase close to the flywheel end as near
as possible to avoid creating a gap when connecting the
lower crankcase and the transmission case.

3. Tighten the lower crankcase bolts to 27-33Nm in the

sequence as shown.

8. Remove the rear crankshaft oil seal.

Rear Crankshaft Oil Seal Remove

9. Unscrew all bolts fixing the lower crankcase to the
engine block.

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Engine Engine Mechanical

4. Fit the rear crankshaft oil seal. Connecting Rod Bearing Shell Check
Rear Crankshaft Oil Seal Refit
Remove
1. Disconnect the battery negative.
5. Fit the crankshaft pulley (oil pump drive) to the front
end of the crankshaft, and fit the oil pump belt. 2. Remove the cylinder head assembly.

Caution: At the foot of the crankshaft sprocket-oil pump Cylinder Head Remove
teeth side is a dent mark that is used to distinguish it with 3. Remove the lower crankcase assembly.
the crankshaft sprocket-timing chain. Lower Crankcase Remove
6. Fit the oil pump belt to the oil pump sprocket. 4. Mark the cylinder order on the connecting rod big end.
Caution: Keep bearing caps, bearings and bolts in their
fitted order.

5. Rotate the crankshaft to allow the connecting rod bolts

to respectively be located at a easy removal position.
6. Unscrew the connecting rod bolt, remove the
connecting rod lower end cap (connecting rod big end
cap).

7. Fit the lower cover plate of the timing chain.

Timing Chain Lower Cover Plate Refit

8. Fit the upper cover plate of the timing chain.

Timing Chain Upper Cover Plate Refit

9. Refit the powertrain.

Powertrain - AT Refit

Powertrain - MT Refit 7. Remove the connecting rod shell on the connecting rod
lower end cap (connecting rod big end cap).
10. Lower the vehicle.
8. Push the piston connecting rod assembly out of the
11. Connect the battery negative.
cylinder bore through the combustion surface with
a plastic bar or a stick, and remove the remaining
connecting rod shell.
Caution: When fitting the piston, DO NOT scratch the
cylinder liner with the connecting rod fracture.
9. Fit the connecting rod big end cap into the connecting
rod, and lightly tighten the connecting rod bolt.
Refit
1. Clean the mating surface between the cylinder block
and bearing base.
2. Clean the pin and the pin hole.
3. Clean the connecting rod and the retaining position of
the bearing shell on the connecting rod cap.
4. Clean the crankshaft and check for damage.
5. Align two connecting rod shells with the shell groove
and press them into the big end bore of the connecting
rod respectively, make sure the end face of the bearing

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Engine Mechanical Engine
shell is in the same plane as the fracture surface of the Piston Check
connecting rod big end bore. Remove
Caution: The connecting rod bearings are not grouped. 1. Remove the piston connecting rod assembly.

Caution: Record the main bearing mark number on the Connecting Rod Bearing Shell Remove
front of the crankshaft. 2. Remove the used piston ring with an expander (tool)
and discard it.
6. Fit the piston connecting rod assembly into the
TEN00003 from top to bottom, and align the guide Refit
tooling with the cylinder bore, note that the arrow "-" 1. Clean the piston ring groove and purge the oil passage.
on the top surface of the piston shall point to the front 2. Position the new piston ring 20 mm from the top
end of the engine. surface of the cylinder bore and measure the clearance.

3. Check the pistons for deformation and crack.

4. Measure the piston diameter at vertical angles to the
piston pin, 11 mm from the bottom of the skirt, refer
to "Parameter" for details.

Caution: Piston and connecting rods are only supplied as

an assembly. Connecting rods refitted must be the same
weight group.

5. Fit the oil ring spring.

6. With the "TOP" mark facing the top of the piston, fit it
with the expander in sequence: oil ring scraper, second
compression ring, top compression ring.

7. Push the piston hard into the cylinder bore. 7. Ensure the piston ring can rotate freely, separate the
gap A and B of two compression rings at an angle of
Tip: It is recommended to replace the piston connecting 120° and away from the thrust side of the piston.
rod assembly as a set.
8. Scraper gap C and spring gap D shall be located 30°apart
8. Fit the connecting rod big end cover, tighten the from each other at both sides of the piston pin.
connecting rod bolt to (13-17)Nm+（ （77-83） ）°.
9. Fit the lower crankcase assembly.

Lower Crankcase Refit

10. Fit the cylinder head assembly.

Cylinder Head Assembly Refit

11. Connect the battery negative.

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Engine Engine Mechanical

Crankshaft Check
Remove
1. Remove the piston connecting rod assembly.
Connecting Rod Bearing Shell Remove
2. Unscrew the main bearing cap bolt, remove the main
bearing cap and remove the main bearing shell from
the bearing seat.
3. Remove the crankshaft.

9. Check the gap between the new piston ring and the
ring groove, refer to "Parameter" for details.

4. Remove 2 thrust washers from the 4th main bearing.

5. Remove the other half of bearing shell from the
removed main bearing cap.
6. Remove 4 bolts fixing 4 piston cooling nozzles to the
cylinder block.

10. Fit the connecting rod assembly. Refit

1. Clean the mating surface between the cylinder block
Connecting Rod Bearing Shell Refit
and bearing base.
2. Clean the pin and the pin hole.
3. Clean the retaining position of the bearing shell and
thrust plate in the cylinder block.
4. Clean the retaining position of the bearing shell on the
bearing seat.
5. Clean the retaining position of the bearing shell on the
connecting rod and the cap (refer to EPC for the group
of piston connecting rod assembly).

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Engine Mechanical Engine
Caution: The weight groupings of the piston connecting "Parameter" for details.
rod assemblies on the same engine should be same, fit
Caution: The bearings with oil grooves and oil holes are
them correctly. If the piston connecting rod assembly
fitted in the main bearing holes of the cylinder block, and
in the same group cannot be selected and fitted when
bearings without oil grooves and oil holes are fitted in the
servicing, replace all the piston connecting rod assemblies
main bearing caps.
to ensure the piston connecting rod assembly weight is in
the same group. 12. The matching principle of the main bearing shell: the
upper part shall be grouped according to the engine
6. Clean the crankshaft and check for damage.
dimension (A: blue, B: red).
7. Align two connecting rod shells with the shell groove
GRADE DIAMETER
and press them into the big end bore of the connecting
rod respectively, make sure the end face of the bearing
A 53.690＜f≤53.700
shell is in the same plane as the fracture surface of the
connecting rod big end bore. B 53.680≤f≤53.690

Caution: The connecting rod bearings are not grouped.

Caution: Record the main bearing mark number on the
front of the crankshaft.

8. Fix 4 piston cooling nozzles to the cylinder block, fit 4

bolts, tighten to 22-28Nm and check the torque.
9. Record the main bearing shell mark no. on the flange
face at the rear part of the crankshaft, the grouping 13. The lower part shall be grouped according to the
rule is as follows: crankshaft dimension (1: blue, 0: red).
JOURNAL DIA. GRADE 14. Use a piece of cloth without rough edges and
appropriate solvents to clean the sealing surface of the
f50.000-f49.993 0
cylinder block and bearing seat.
f49.992-f49.984 1
Tip: Please use SAIC MOTOR recommended solvent.
15. Fit the selected crankshaft main bearing shell and fit it
to the cylinder block and bearing seat.
16. Clean the new thrust washer and fit it to both sides of
the 4th gear of the cylinder block main bearing.

Tip: The oil groove surface of the thrust washer is the

surface contacting with the crankshaft thrust surface,
and never fit it reversely.
17. Place the crankshaft, apply appropriate lubricating oil
to the main journal, and then fit the main bearing cap.
Torque:(20±2)Nm+（ （90°+45°） ）±5°
18. Fit the connecting rod assembly.

Connecting Rod Bearing Shell Refit

10. Check the diameter of main crankshaft journal, refer

to "Parameter" for details.
11. Determine proper main bearing shells to be fitted
according to the size and model selected, refer to

1.0 93
Engine Engine Mechanical

Rear Crankshaft Oil Seal

Remove
1. Disconnect the battery negative.
2. Remove the transmission assembly.
Automatic Transmission Remove

Manual Transmission Remove

3. Remove the torque converter drive plate.

Torque Converter Drive Plate Remove

4. Unscrew 5 bolts around the rear crankshaft oil seal.
5. Remove the oil seal and discard it.

4. Push the oil seal into the locating pin of the oil seal
slowly along the special tool TEN00013 and drive it
into the pin hole of the engine block.

6. In case of oil passage plug leakage, please remove and

replace the oil passage plug with TEN00118, and the 5. Press and hold the oil seal flange, and pull out the
torque for replacement is 35-45 Nm. special tool slowly.
6. Fit all bolts, and tighten them to 8-12Nm.
7. Fit the torque converter drive plate.

Torque Converter Drive Plate Refit

8. Fit the transmission assembly.

Automatic Transmission Assembly Refit

Manual Transmission Assembly Refit

9. Connect the battery negative.

Refit
1. Clean the mating area of the crankshaft flange neck and
the oil seal, and ensure there is no stain on it.
2. Fit the TEN00013 to the rear end of the crankshaft.
3. Apply clean oil to the oil seal lip.

Caution: Take care to avoid damaging the oil seal lip,

while fitting it.

1.0 94
Engine Mechanical Engine
Oil Strainer
Remove
1. Disconnect the battery negative.
2. Drain the engine oil.
Engine Oil Filter Remove
3. Remove the lower crankcase.

Lower Crankcase Remove

4. Unscrew all bolts fixing the oil baffle to the lower
crankcase, and remove the oil baffle.

Refit
1. Clean the oil strainer and the mating face.
2. Lubricate the new O-ring with engine oil and fit it to the
oil strainer. Insert the oil strainer into the new oil pump
from the opposite direction shown in the figure above.
3. Secure the oil pump and oil strainer to the lower
crankcase, fit the bolt, tighten to 8-12Nm.
4. Fit the oil baffle, and tighten to 8-12Nm.
5. Fit the lower crankcase.

Lower Crankcase Refit

5. Remove the oil pump and oil strainer to the lower
crankcase. 6. Fit the oil filter.

Engine Oil Filter Refit

7. Connect the battery negative.

6. Separate the oil pump and the oil strainer according

to the direction shown, take out the seal ring of the
oil strainer and discard it.

1.0 95
Engine Engine Mechanical

Oil Pump
Remove
1. Disconnect the battery negative.
2. Remove the powertrain.
Powertrain - AT Remove

Powertrain - MT Remove
3. Remove the lower crankcase.

Lower Crankcase Remove

4. Unscrew all bolts fixing the oil baffle to the lower
crankcase, and remove the oil baffle.

Refit
1. Clean the oil strainer and the connecting surface.
2. Lubricate the new O-ring with engine oil and fit the oil
strainer. Insert the oil strainer into the new oil pump in
the opposite direction shown in the figure above.
3. Fit the oil pump mounting bolt and the oil strainer
mounting bolt, and tighten them to 8-12Nm.
4. Fit the oil baffle, and tighten to 8-12Nm.
5. Fit the lower crankcase.

Lower Crankcase Refit

6. Fit the powertrain.
5. Remove the bolts fixing the oil pump and the oil
strainer to the lower crankcase. Powertrain - AT Refit

Powertrain - MT Refit
7. Connect the battery negative.

6. Disengage the oil pump and the oil strainer in the

direction shown, remove and discard the seal ring of
the oil strainer.

1.0 96
Engine Mechanical Engine
Oil Control Valve
Remove
1. Disconnect the battery negative.
2. Disconnect the oil control valve connector.

3. Fit the camshaft cover.

Camshaft Cover Refit

4. Connect the oil control valve connector.
5. Connect the battery negative.
3. Remove the camshaft cover.

Camshaft Cover Remove

4. Loosen the bolt fixing the oil control valve, and remove
the oil control valve.

Refit
1. Refit a new oil control valve onto the front bearing cap,
fix it with bolts, and the tightening torque is 5-7Nm.
2. Check the oil seal of oil control valve, if any leakage or
aging appearance and crack occur, renew the oil seal of
the oil control valve. Fit the oil seal of the oil control
valve to the camshaft cover.

1.0 97
Engine Engine Mechanical

Engine Oil Filter

Remove
1. Raise the vehicle with a lift.
2. Remove the bottom deflector.
Bottom Deflector Remove
3. Place a suitable container under the oil drain plug of
the engine oil pan, unscrew the plug and discard the
sealing washer. Drain the oil.

Warning: Observe due care when draining engine oil as

the oil can be very hot.

Warning: Avoid excessive skin contact with used engine

oil. Used engine oil contains potentially harmful 2. Lubricate the filter seal ring with clean engine oil.
contaminants which may cause skin cancer or other 3. Fit a new filter and tighten to 16-20Nm.
serious skin disorders.

4. Clean the oil drain plug and fit a new sealing washer.
5. Fit the oil drain plug and tighten to 35-40Nm.
6. Take away the engine oil filler cap and fill the engine
oil to a correct level.
Lubricating Fluid Refill
7. Fit the bottom deflector.

Bottom Deflector Refit

8. Fit the oil filler cap.
9. Lower the vehicle.
10. Start and run the engine until the oil pressure warning
lamp goes out.
4. Clean the area around the filter head, and place 11. Stop the engine, recheck the engine oil level.
a suitable container under the filter to collect the 12. Check for any signs of leakage.
possible spillage.
5. Remove the engine oil filter counterclockwise and
discard it.
Refit
1. Clean the mating surface of the oil filter head.

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Engine Mechanical Engine
Engine Oil Pressure Check Intake Manifold Gasket
Check Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Remove the bottom deflector. 2. Remove the intake pipe assembly.
Bottom Deflector Remove Intake Pipe Assembly Remove
3. Disconnect the connector of oil pressure switch. 3. Loosen the clamps and disconnect the canister solenoid
hose from the intake manifold.
4. Remove the oil pressure switch.

4. Pull out the C clip mounted on the intake manifold,

5. Remove the seal ring from the oil pressure switch, and loosen the clamps and disconnect the part load
fit it to the connector of the oil pressure gauge. breather pipe clips from the intake manifold.
6. Refit and tighten the connector of the oil pressure
gauge to the original oil pressure switch position.
7. Connect the oil pressure gauge T10001 and T10002
and tighten the connector.
8. Fit the bottom deflector.

Bottom Deflector Refit

9. Check the engine oil, and refill if necessary.
10. Start and run the engine until the normal operating
temperature is reached.
11. Note the readings indicated on the oil pressure gauge
when the engine runs at 3500 rev/min. Refer to the
section “Parameter”.
5. Disconnect the connector from the electronic throttle
12. Turn off the engine, unscrew the pressure gauge sensor.
connector and remove the gauge.
13. Unscrew the connector.
14. Wipe off the spilled oil.
15. Refit the oil pressure switch.
16. Connect the oil pressure switch connector.
17. Connect the battery negative.

6. Depress the plastic collars, disconnect the brake

1.0 99
Engine Engine Mechanical

booster tube from the intake manifold.

9. Fix an absorbent cloth under the fuel rail.

7. Pull out the harness clip A from the oil rail bracket, 10. Release the fuel inlet pipe from the fuel rail.
disconnect the fuel injector connector B and canister
solenoid connector C.

Caution: Always fit plugs to open connections to prevent

contamination.

11. Remove bolt A connecting the intake manifold to the

engine body first, and then remove 5 nuts fixing the
intake manifold to the cylinder head in sequence shown.

8. Disconnect the connector from the intake manifold

absolute pressure/temperature sensor.

12. Remove the intake manifold, remove and discard 4

sealing washers.

1.0 100
Engine Mechanical Engine
Intake Pipe Assembly Refit
13. Connect the battery negative.

Refit
1. Ensure that the mating surface is clean, and the metal
insert has been fitted into the intake manifold bolt and
bolt hole.
2. Refit a new washer onto the intake manifold.
Tip: Be careful of the error proofing design on the washer.
3. Tighten 5 nuts in the sequence shown, and then fix the
mounting bolt A of the intake manifold and the engine
block, tighten to 22-28Nm and check the torque.

4. Remove the plug from the fuel hose and fuel rail.
5. Fix the fuel inlet pipe to the fuel rail.
6. Connect theTMAP sensor connector.
7. Connect the fuel injector connector, fit the harness clip
into the fuel rail bracket hole, and connect the canister
solenoid connector.
8. Insert the brake booster tube into the quick connector
of the intake manifold.
9. Connect the electronic throttle sensor connector.
10. Connect the part load breather pipe to the intake
manifold and secure it with clamps, insert the C-shape
pipe clip into the intake manifold mounting hole.
11. Connect the canister solenoid hose to the intake
manifold and secure it with clamps.
12. Fit the intake pipe assembly.

1.0 101
Engine Engine Mechanical

Exhaust Manifold Gasket

Remove
1. Disconnect the battery negative.
2. Remove the bolt fixing the exhaust manifold shell.

4. Fit 8 bolts fixing the upper manifold to the engine in

the following sequence below, tighten to 22-28Nm
and check the torque.

3. Remove 8 nuts fixing the exhaust manifold assembly to

the engine.
4. Remove the 8 stubs fixing the exhaust manifold to the
engine with special tool TEN00001 and discard it.

5. Fit the bold fixing the exhaust manifold shell, tighten to

7-10Nm and check the torque.

5. Remove the exhaust manifold gasket from the mating

face of the cylinder head and the exhaust manifold, and
discard it.
Refit
1. Clean the mating surface of the cylinder head and the
exhaust manifold, ensure it is clean and smooth without
any debris.
2. Refit the stud on to the cylinder block with special tool
TEN00001, tighten to 8-12Nm and check the torque.
3. Fit the exhaust manifold gasket to the stud of cylinder
head correctly subject to its error prevention design.

1.0 102
Engine Mechanical Engine
Cylinder Pressure Test will increase substantially. Refill engine oil (about
Test 15ml) through the spark plug hole, and retest the
1. Run the engine until it reaches normal operating cylinder pressure.
temperature. The battery must be fully charged or c. If the low compression pressure is caused by valves,
almost fully charged. low compression pressure will be measured in the
2. Stop the engine. 1st stroke, and it will not increase even when the
3. Disable the fuel system (e.g, pull out the harness oil is refilled.
connector of the fuel pump). d. The same consequence can be resulted from leaking
4. Start the engine again until it stops so as to consume cylinder head gasket and worn valves, but for the
the fuel remaining in the fuel rail. crankcase, the problem may be due to engine
5. Disable the ignition system (e.g, disengage the ignition coolant. In addition, a leaking cylinder head gasket
coil for each cylinder and engine harness connector). will result in low compression pressure readings of
the cylinders in pairs.
6. Remove the ignition coil for each cylinder.
7. Remove the spark plug for all cylinders. 12. Resume the ignition system.

8. Measure the compression pressure of the engine with 13. Resume the fuel system.
the following procedures:
a. Fit the adapter of the spark plug hole into the spark
plug hole.
b. Fit the compression pressure gauge into the adapter
of the spark plug hole.
c. Fully depress the accelerator pedal.
d. With assistance, turn the key to start the starter
until no increased pressure is indicated by the
compression pressure gauge.
Note: Do not keep the starter motor running for 5s at a
time, and the interval for next start shall not be less than 10s.
e. Check and record the readings on the pressure gauge.
f. Remove the compression pressure gauge from the
adapter of the spark plug hole.
g. Remove the adapter of the spark plug hole from the
spark plug hole.
9. Repeat step 8 to test the pressure of other cylinders.
The lower limit value for the engine cylinder (under
normal pressure/temperature) is 7 Bar.
10. Difference between each cylinder pressure and average
pressure for each cylinder: for gasoline engines, it shall
not be greater than 8%.
11. Here are some examples of measurement:
a. When the compression pressure is normal, the
compression pressure of each cylinder will increase
quickly and evenly to the specified value.
b. If the low compression pressure is caused by piston
rings, the compression pressure will drop in the
1st stroke and gradually increase in the subsequent
strokes, however, it will never reach the normal
value. After oil refilling, the compression pressure

1.0 103
Engine Engine Mechanical

Special Tools Tool Description Picture

Tool Description Picture Number
Number

Retainer belt
TEN00009
Engine lift wheel
T10007
bracket

Retainer oil
TEN00006
pump gear
TEN00070 Engine support

Valve spring
T10005
Holding pin compressor
TEN00002
flywheel timing

Remover valve
Retainer T10006
stem seal
TEN00008 crankshaft belt
wheel

Replacer valve
TEN00014
Camshaft timing stem seal
TEN00004
locking

1.0 104
Engine Mechanical Engine
Tool Description Picture Tool Description Picture
Number Number

Piston ring Adaptor engine

TEN00003 T10002
guider oil pressure test

Remover and
Plug remove
TEN00118 TEN00001 replacer M8
tool
stud

Protector
sleeve
TEN00013
crankshaft rear
oil seal

Engine oil
T10001 pressure test
equipment

1.0 105
Engine Engine Cooling System

Engine Cooling System

Specifications
Torque
Description Value
Bolt-Expansion Tank to Body 7–10Nm
Bolt-Condenser to Radiator 5–7Nm
Bolt-Thermostat to Engine（1.5L） 8-12Nm
Bolt-Water Pump to Engine（1.5L） 8-12Nm
Bolt-Water Pump Pully to Water Pump（1.5L） 23-27Nm
Nut-Oil-cooled Pipe to Automatic Transmission 33-37Nm
Bolt-Oil-cooled Pipe Bracket to Automatic Transmission 7-10Nm

1.0 106
Engine Cooling System Engine
Parameter
Model Temperature-controlled, pressure overflow backflow type cooling
system with forced circulation of water and OAT mixture solution
Cooling fan: 8 Vanes, Temperature-controlled Electric Axial Flow Type

Coolant capacity: 5.6L

Cooling fan switch - for A/C system

High speed:

• ON 17.7Mpa
• OFF 13.7Mpa
Cooling fan switch - for cooling during normal engine
operation

ON:
100 ℃
• Low speed
112 ℃
• High speed

OFF:
94 ℃
• Low speed
106 ℃
• High speed
Cooling fan switch - for cooling after engine stop

ON:

• Low speed 110 ℃

• High speed 104 ℃
OFF:

• Low speed 106 ℃

• High speed
100 ℃
Duration
No more than 30s
Radiator Longitudinal-flow Type
Coolant pump Mechanical, radial flow impeller
Drive ratio of coolant pump 1: 1
Dual-thermostat Wax-type component
Primary thermostat:

• Initial activation 80 ± 2 ℃
• Fully Open 94 ℃
• OFF
≤ 80 ± 2 ℃
Secondary Thermostat:

• Initial activation
88 ± 2 ℃
• Fully Open
102 ℃
• OFF
≤ 88 ± 2 ℃
Relief valve of radiator pressure cover

• High pressure ON 93 - 123KPa

• Low pressure ON 0 - 9.8KPa

1.0 107
Engine Engine Cooling System

Description and Operation

System Layout
Engine Cooling System

1. Cooling System Radiator 9. Radiator Upper Shock Pad

2. Radiator Drain Valve 10. Cooling System Wind Scooper Assembly
3. Condenser Assembly 11. Cooling System Wind Scooper Assembly
4. Engine Cooling Fan Assembly 12. Staple Bolt - Radiator Airflow Side Deflector
5. Screw - Cooling Fan Speed Control Resistor 13. Screw - Cooling Fan Relay
6. Cooling Fan Speed Control Resistor 14. Bolt - Radiator Lower Bracket
7. Cooling Fan Relay 15. Exhaust Bolt
8. Radiator Lower Shock Pad

1.0 108
Engine Cooling System Engine
Cooling System Pipeline

1. Radiator Expansion Tank Assembly 12. Clamp - Engine Expansion Tank Overflow Pipe
2. Washer - Engine to Radiator Pipeline 13. Clip - Engine Expansion Tank Overflow Pipe
3. Radiator Expansion Tank Cap 14. Clamp - Heater to Engine Pipeline
4. Screw - Radiator Expansion Tank 15. Clamp - Cooling System Pipeline
5. Radiator Expansion Tank Bracket 16. Pipeline Assembly - Heater to Engine
6. Bolt - Radiator Expansion Tank Bracket 17. Clamp - Radiator Expansion Tank Overflow Pipe
7. Pipeline Assembly - Engine to Radiator 18. Pipeline Assembly - Engine to Heater
8. Clamp - Cooling System Pipeline 19. Clamp - Heater to Engine Pipeline
9. Clip - Engine to Radiator Pipeline 20. Clamp - Heater to Engine Pipeline
10. Pipeline Assembly - Radiator to Engine 21. Clip - Engine Expansion Tank Overflow Pipe
11. Clamp - Radiator to Engine Pipeline 22. Engine Overflow Pipe

1.0 109
Engine Engine Cooling System

Description Thermostat
Overview This thermostat is a wax-type component with pressure relief
The cooling system circulates the engine coolant in the loop characteristics. It is located in the sealing housing on engine
of engine and heater core. The coolant is the mixture of 50% pipe.
water and 50% organic acid technique (OAT), which helps to When starting a cold engine, the coolant temperature is low,
maintain the optimum operating temperature of the engine the wax-type component of the thermostat is in solid state,
when the environment and engine working conditions are and the thermostat valve switches off under the action of the
different. spring. At this point, the cooling system is in a small circulation
Caution: Engine coolant will damage paint finished status, namely, the coolant cannot enter into the radiator for
surfaces. If spilled, immediately rinse area with plenty of circulation. But, it can circulate between the bypass circuit
water. and heater core. When the coolant temperature rises, the
wax-type component starts melting into liquid state gradually
The coolant shall be replaced regularly to keep its optimum
followed by the increase of volume, then the thermostat valve
efficiency and corrosion resistance performance.
will open gradually under the action of the push rod, at this
Components of Cooling System point, the cooling system is in a big circulation status. The
Coolant Pump coolant will flow into the cylinder block through the bottom
hose of the radiator, allow the hot coolant to flow through
The coolant circulates through the rotor type pump on the
the radiator from the top hose to balance heat flow and keeps
rear upper part of the engine crankcase drive, which is sealed
the temperature at the optimal for engine operation. When
to the cylinder block by an O-ring and driven by the crankshaft
the thermostat is fully open, the coolant flows through the
timing belt.
radiator.
Coolant Hose
Radiator and Cooling Fan
The rubber coolant hose delivers coolant among all
The radiator is of aluminum longitudinal-flow type with
components. The coolant hose is fixed to each component
injection moulding water tanks on both ends (for automatic
by spring clamps. The heater core completes the fluid inlet
transmission model, automatic transmission oil cooler is
by connecting the outlet elbow of the engine to the inlet pipe
locate in the water chamber below the radiator. The cooling
of the inlet hard pipe of heater core passing through the dash
hose linked with transmission is connected to the bushing of
panel, then goes to oil cooler water inlet pipe through the
the transmission oil cooler with nuts). The radiator supports
water outlet pipe of heater core and flows back to the engine
the cooling fan assembly, air conditioning (A/C) condenser.
cylinder block through the oil cooler.
The top of the radiator is located in the rubber bushing
Radiator Pressure Seal Cap
supported by the upper radiator beam bracket. The bottom
Radiator pressure cap is mounted on the top of the radiator,
of the radiator is located in the rubber bushing supported
which is equipped with a relief valve and vacuum valve. When
by the bracket fixed on the front longitudinal beam. Sponge
the system pressure is within 0.93 - 1.23 bar, relief valve opens
sealing strips fitted on both sides of the radiator are used to
to release system pressure; when the system pressure is within
guide the airflow through the radiator. The condenser fixed
0 - 0.098 bar, vacuum valve opens, and fluid is replenished to
by bolts is fitted on the front end of the radiator.
the system from outside, so that the cooling system can run
within a certain pressure range. The cooling fan and motor assembly is fitted on the fan shroud
at the rear of the radiator. The "Suction" type fan draws out air
Expansion Tank through the radiator. Besides, the fan shroud is equipped with
The coolant expansion tank is fitted on the left side of the additional vent holes allowing more air flow through radiator
cooling module cooling fan, one overflow/return pipe is when driving at high speed together with cooling fan. Low
connected to the pressure cover at the top of the radiator speed resistance of the cooling fan is fitted at the left side of
through the bottom part of the expansion tank. When the the radiator.
coolant is expanded during warm-up, additional coolant in the
Engine Coolant Temperature (ECT) Sensor
cooling system will flow back to the expansion tank through
the overflow/return pipe; when the coolant in the cooling ECTThe engine coolant temperature sensor is fitted on the
system is insufficient, coolant in the expansion tank will flow engine cylinder block with a packaged negative temperature
back to the cooling system through the overflow/return pipe. coefficient (NTC) thermistor contacting with the engine
coolant, which is part of the bleeder circuit. The circuit is
composed of a 5V rated power supply, an engine control

1.0 110
Engine Cooling System Engine
module (ECM) internal resistance and a variable resistor
related to temperature (ECT sensor).

1.0 111
Engine Engine Cooling System

Operation
Coolant Flow
1.5 DVCT Engine

The cooling system utilizes the heat conduction principle, air in the coolant. The radiator pressure seal cap with relief
conducting heat from the engine components to the coolant. valve and vacuum valve isolates the cooling system from the
When the engine is at low temperature, the coolant pump will ambient atmosphere, the coolant expands as the temperature
circulate the coolant among the engine block, cylinder head rises, and the pressure of the cooling system will increase
and passenger compartment heater core. The thermostat will accordingly. The increased pressure raises the boiling point
be kept closed to prevent the coolant from flowing through of the coolant, allowing the engine to run at a higher, more
the radiator, however, a small amount of coolant may pass efficient operating temperature without the risk of coolant
through the bypass, this helps to prevent the accumulated boiling. The pressurization of the cooling system is limited, so
pressure from getting too high. When the engine reaches a pressure relief valve is provided on the expansion tank cap.
the normal operating temperature, the thermostat opens, By this way, when the max. operating pressure is reached, the
the cool coolant enters into the cylinder block through the excess pressure in the cooling system can be released.
hose at the bottom of the radiator, and the hot coolant will Cooling Fan Control Policy
flow into the radiator through the hose at the top of the
The cooling fan will operate at high or low speed, and the
radiator, so that the cool and hot coolant may be balanced
control is achieved by the ECM and relay unit. ECM The ECM
to maintain the engine at the best temperature. When the
utilizes the information provided by the ECT sensor, BCM
thermostat is fully open, all coolant flow through the radiator.
and A/C pressure switch to control the fan speed and engine
The excess coolant produced by thermal expansion returns
coolant temperature.
to the expansion tank through the overflow pipe at the top of
the radiator. Meanwhile, the expansion tank will remove the

1.0 112
Engine Cooling System Engine
During the normal operation, the cooling fan will operate at winding. The cooling fan relay is powered by a 12 V power
the following coolant temperatures: supply through Fuse 13 of the engine compartment fuse box.
Cooling Fan Status Low speed High speed When the cooling fan runs at low speed, the low-speed relay
provides the power supply; when the cooling fan runs at high
ON 100 ℃ 112 ℃
speed, the high-speed relay provides the power supply.
OFF 94 ℃ 106 ℃
The cooling fan relay may have faults under the following
When the A/C system is working, the cooling fan will operate conditions:
under the following pressure conditions: • High-speed relay coil is open.
Cooling Fan Status High speed • High-speed relay coil is short-circuited.
ON 17.7 Mpa • High-speed relay contact has a high resistance.
OFF 13.7 Mpa • High-speed relay contact is open.
• Low-speed relay coil is open.
The cooling fan control policy includes the engine idle speed
• Low-speed relay coil is short-circuited.
adjustment, which can compensate the additional load after the
fan is on. After the ignition key is removed: • Low-speed relay contact has a high resistance.
• External wire is open.
Cooling Fan Low speed High speed
Status • External wire is short to the 12V power supply.
ON 104 ℃ 110 ℃ • External wire is short to the ground.
OFF 100 ℃ 106 ℃ • External wire has a high resistance.

The cooling fan will operate for 30s to provide additional Warning: Keep clear of the cooling fan. The fan may start
cooling for the engine at high temperature. In case of ECT automatically without warning, even after the engine is
failure, the fan will operate at low speed. turned off.

Cooling Fan Relay Unit

The cooling fan relay unit is connected to the ECM by 2
wires, and one wire provides the ground for the internal relay

1.0 113
Engine Engine Cooling System

Service Procedures
Coolant - Drain and Refill
Drain
1. Remove the coolant expansion tank cap.

Warning: Since injury such as scalding could be caused by

escaping steam or coolant, do not remove the filler cap
from the coolant expansion tank while the system is hot.
2. Secure a proper container to collect the coolant.
3. Remove the bottom deflector.

Bottom Deflector Remove

4. Open the drain valve at the bottom of the engine
cooling system radiator. 5. Ensure that the A/C is turned off.
6. Start the engine and allow it to operate at the speed of
1500 - 2500 RPM. Fill the expansion tank as required
to keep the level just below the neck of the expansion
tank. When the coolant level reaches the neck of
the expansion tank due to thermal expansion, fit the
expansion tank cap.
7. Continuously run the engine at the speed of 1500 -
2500 RPM until the cooling fan operates, and then run
the engine at idle speed until the cooling fan stops.
8. Turn off the engine and cool it down for 30 minutes.
9. Check the cooling system for leak.
10. Check whether the coolant level is between MIN and
5. Drain the engine cooling system. MAX. If not, open the expansion tank cap and top up
Refill the tank with coolant or drain it to be between MIN
and MAX as required.
1. Close the coolant drain valve at the bottom of the
radiator.
2. Prepare the coolant of specified concentration.

Fluid
3. Open the expansion tank cap. Fill coolant to the
expansion tank until the coolant level reaches the neck
of the expansion tank and keeps still.
4. When filling coolant to the vehicle with 1.5 DVCT
engine, unscrew the bleeder bolt on the radiator.
When founding that the coolant is about to spill, screw
up the bolt.

1.0 114
Engine Cooling System Engine
System Pressure Test
Check
1. Visually check the expansion tank cap for signs of
leakage.
2. Check the hose for signs of rupture and distortion and
the attachment strength of pipeline connection.
3. Open the coolant expansion tank cap.

Warning: Since injury such as scalding could be caused by

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

8. Remove the T14001 pressure hose from the

TEN00010.
9. Remove the expansion tank cap from the TEN00010
and fit it to the expansion tank.

5. Connect the T14001 pressure hose to the

TEN00010.

6. Pressurize the expansion tank cap slowly to the

specified pressure, then check the pressure; if the
pressure range is maintained within 140 - 160KPa, the
expansion tank cap is normal.
7. Release pressure through the relief valve on the
pressurizer.

1.0 115
Engine Engine Cooling System

Pressure Seal Cap - Pressure Test Coolant Expansion Tank

Check Remove
1. Check the hose for signs of rupture and distortion and 1. Drain the coolant.
the attachment strength of pipeline connection.
Coolant Drain
2. Open the coolant expansion tank cap.
2. Remove 2 bolts (1) fixing the coolant expansion tank
Warning: Since injury such as scalding could be caused by to the body.
escaping steam or coolant, do not remove the filler cap 3. Remove the clamp (2) fixing the engine overflow pipe
from the coolant expansion tank while the system is hot. to the coolant expansion tank.
3. Fit the TEN00015 to the expansion tank. 4. Remove the clamp (3) fixing the water outlet pipe of
4. Connect the T14001 pressure hose to the the heater to the coolant expansion tank.
TEN00015.
5. Pressurize the system to the pressure of 140 - 160KPa
slowly and check it for leakage.

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

cooling system will be damaged.

5. Remove the coolant expansion tank.

Refit
1. Fit the clamp fixing the water outlet pipe of the heater
to the coolant expansion tank.
2. Fit the clamp fixing the engine overflow pipe to the
6. Visually check the engine and cooling system for signs coolant expansion tank.
of coolant leakage. 3. Fit 2 bolts fixing the coolant expansion tank to the
7. Release pressure through the relief valve on the body, tighten to 7–10Nm, and check the torque.
T14001. 4. Fill the coolant.

Coolant Refill

8. Disconnect the T14001 hose from the TEN00015.

9. Remove the TEN00015 from the expansion tank and
fit the expansion tank cap.

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Engine Cooling System Engine
Cooling Fan Cooling Fan Low Speed Resistor
Remove Remove
1. Remove the cooling fan low speed resistor. 1. Disconnect the battery negative.

Cooling Fan Low Speed Resistor Remove 2. Disconnect the harness connector of the cooling fan
low speed resistor.
2. Remove the bottom deflector.
3. Remove 1 screw fixing the cooling fan low speed
Bottom Deflector Remove
resistor to the cooling fan.
3. Disconnect 4 clips fixing the cooling fan to the radiator.

4. Measure about 5cm lead at resistor end and cut the

4. Pull out the cooling fan. resistor off the lead.
Refit 5. After cutting off the resistor, remove about 7mm
1. Fix the cooling fan to the radiator. insulation respectively from both ends of the remaining
lead.
2. Fit the bottom deflector.
Refit
Bottom Deflector Refit
1. Take a resistance to be fitted and cover the heat-shrink
3. Fit the cooling fan low speed resistor. tubes on the leads of resistance.
Cooling Fan Low Speed Resistor Refit

2. Insert the metal part of the lead whose insulation

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

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Engine Engine Cooling System

and tighten the screw, and fix the lead well with Radiator
tapes to ensure no displacement of the lead and the Remove
serpentuator sleeve, otherwise, it will or may interfere 1. Drain the coolant.
the blade.
Coolant Drain
5. Connect the harness connector of the cooling fan.
2. Remove the cooling fan.
6. After replacement, connect the battery negative and
start the engine to check the fan operation. If there is Cooling Fan Remove
no high humming when the fan is running, resume the 3. Disconnect the clamp (1) fixing the engine overflow
low speed operating condition. pipe to the radiator.
4. Disconnect the clamp (2) fixing the radiator water inlet
pipe to the radiator.

5. Disconnect the clamp fixing the radiator water outlet

pipe to the radiator.

6. Disconnect the automatic transmission oil

cooler/inlet/outlet pipes fixed to the radiator.

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Engine Cooling System Engine
7. Fit the clamp fixing the radiator water outlet pipe to
the radiator.
8. Fit the clamp fixing the radiator water inlet pipe to the
radiator.
9. Fit the clamp fixing the engine overflow pipe to the
radiator.
10. Fit the cooling fan.
Cooling Fan Refit
11. Fill the coolant.

Coolant Refill

7. Remove the front-end module.

Front-end Module Remove
8. Remove 2 bolts (1) fixing the condenser to the radiator.
9. Unscrew the clip (2) fixing the condenser to the
radiator.

10. Remove the radiator.

11. Remove the radiator upper shock pad.
Radiator Upper Shock Pad Remove
12. Remove the radiator lower shock pad.
Radiator Lower Shock Pad Remove
Refit
1. Fit the radiator lower shock pad.
Radiator Lower Shock Pad Refit
2. Fit the radiator upper shock pad.
Radiator Upper Shock Pad Refit
3. Fit the clip fixing the condenser to the radiator.
4. Fit 2 bolts fixing the condenser to the radiator, tighten
to 5–7Nm, and check the torque.
5. Fit the front-end module.
Front-end Module Refit
6. Fit the automatic transmission oil cooler/inlet/outlet
pipes fixed to the radiator.

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Engine Engine Cooling System

Radiator Water Inlet Hose Radiator Water Outlet Hose

Remove Remove
1. Drain the coolant. 1. Drain the coolant.

Coolant Drain Coolant Drain

2. Disconnect the clamp fixing the radiator water inlet 2. Disconnect the clamp (1) fixing the radiator water
hose to the radiator. outlet hose to the radiator.
3. Disconnect the clamp (2) fixing the radiator water
outlet hose to the water pump pipeline.

3. Disconnect the clamp fixing the radiator water inlet

hose to the thermostat.
4. Remove the radiator water outlet hose.
Refit
1. Fit the clamp fixing the radiator water outlet hose to
the water pump pipeline.
2. Fit the clamp fixing the radiator water outlet hose to
the radiator.
3. Fill the coolant.

Coolant Refill

4. Remove the radiator water inlet hose.

Refit
1. Fit the clamp fixing the radiator water inlet hose to
the thermostat.
2. Fit the clamp fixing the radiator water inlet hose to
the radiator.
3. Fill the coolant.

Coolant Refill

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Engine Cooling System Engine
Heater Water Inlet Hose Heater Water Outlet Hose
Remove Remove
1. Drain the coolant. 1. Drain the coolant.

Coolant Drain Coolant Drain

2. Remove the air filter assembly. 2. Remove the air filter assembly.
Air Filter Assembly Remove
Air Filter Assembly Remove
3. Disconnect the clamp (1) fixing the water outlet hose
3. Disconnect the clamp (1) fixing the water inlet hose of
of the heater to the heater core.
the heater to the heater core.
4. Disconnect the clamp (2) fixing the water outlet hose
4. Disconnect the clamp (2) fixing the water inlet hose of
of the heater to the tee fitting.
the heater to the engine.

5. Disconnect the clamp fixing the water outlet hose of

5. Remove the water inlet hose of the heater. the heater to the coolant expansion tank.
Refit
1. Fit the clamp fixing the water inlet hose of the heater
to the engine.
2. Fit the clamp fixing the water inlet hose of the heater
to the heater core.
3. Fit the air filter assembly.

Air Filter Assembly Refit

4. Fill the coolant.

Coolant Refill

6. Remove the water outlet hose of the heater.

Refit
1. Fit the clamp fixing the water outlet hose of the heater
to the coolant expansion tank.
2. Fit the clamp fixing the water outlet hose of the heater
to the tee fitting.
3. Fit the clamp fixing the water outlet hose of the heater
to the heater core.
4. Fit the air filter assembly.
Air Filter Assembly Refit
5. Fill the coolant.
Coolant Refill

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Engine Overflow Pipe - 1.5L Radiator Drain Valve

Remove Remove
1. Drain the coolant. 1. Drain the coolant.

Coolant Drain Coolant Drain

2. Disconnect the clamp fixing the engine overflow pipe 2. Unscrew the radiator drain valve from the radiator.
to the thermostat.

Refit
3. Disconnect the clamp fixing the engine overflow pipe 1. Fix the radiator drain valve to the radiator and tighten
to the coolant expansion tank. it up.
2. Fill the coolant.

Coolant Refill

4. Remove the engine overflow pipe.

Refit
1. Fit the clamp fixing the engine overflow pipe to the
coolant expansion tank.
2. Fit the clamp fixing the engine overflow pipe to the
thermostat.
3. Fill the coolant.

Coolant Refill

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Engine Cooling System Engine
Radiator Upper Shock Pad Radiator Lower Shock Pad
Remove Remove
1. Remove the front-end module. 1. Remove the front-end module.

Front-end Module Remove Front-end Module Remove

2. Pull out the radiator upper shock pad. 2. Pull out the radiator lower shock pad.

Refit Refit
1. Press the radiator upper shock pad. 1. Press the radiator lower shock pad.
2. Fit the front-end module. 2. Fit the front-end module.

Front-end Module Refit Front-end Module Refit

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Engine Engine Cooling System

Wind Scooper - Left Wind Scooper - Right

Remove Remove
1. Remove the front bumper. 1. Remove the front bumper.

Front Bumper Remove Front Bumper Remove

2. Remove 4 plastic clips fixing the left wind scooper to 2. Remove 4 plastic clips fixing the right wind scooper to
the upper radiator beam. the upper radiator beam.

Refit Refit
1. Fit 4 plastic clips fixing the left wind scooper to the 1. Fit 4 plastic clips fixing the right wind scooper to the
upper radiator beam. upper radiator beam.
2. Fit the front bumper. 2. Fit the front bumper.

Front Bumper Refit Front Bumper Refit

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Engine Cooling System Engine
Thermostat - 1.5L Refit
Remove 1. Fit 6 bolts fixing the thermostat to the engine, tighten
1. Drain the coolant. to 8-12Nm, and check the torque.

Coolant Drain 2. Fit the clamp fixing the water inlet hose of the heater
to the thermostat.
2. Disconnect the clamp fixing the radiator water inlet
hose to the thermostat. 3. Fit the clamp fixing the engine overflow pipe to the
thermostat.
4. Fit the clamp fixing the radiator water inlet hose to
the thermostat.
5. Fill the coolant.

Coolant Refill

3. Disconnect the clamp (1) fixing the engine overflow

pipe to the thermostat.
4. Disconnect the clamp (2) fixing the water inlet hose of
the heater to the thermostat.

5. Remove 6 bolts fixing the thermostat to the engine.

6. Remove the thermostat.

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Engine Engine Cooling System

Water Pump Transmission Oil Cooler Inlet Pipe Assembly -

Remove 4AT
1. Drain the coolant.
Remove
1. Drain the automatic transmission fluid.
Coolant Drain
2. Remove the auxiliary drive belt. Automatic Transmission Fluid Drain
2. Remove 1 bolt (1) fixing the bracket of the inlet
Auxiliary Drive Belt Remove
pipe of the transmission oil cooler to the automatic
3. Remove 3 bolts fixing the water pump pulley to the transmission.
water pump.
3. Remove 1 nut (2) fixing the inlet pipe of the transmission
oil cooler to the automatic transmission.

4. Remove 3 bolts fixing the water pump to the engine.

4. Disconnect the inlet pipe of the transmission oil cooler
from the radiator.

5. Remove the water pump.

Refit
1. Fit 3 bolts fixing the water pump to the engine, tighten 5. Remove the inlet pipe of the transmission oil cooler.
to 8-12Nm, and check the torque. Refit
2. Fit 3 bolts fixing the water pump pulley to the water 1. Fix the inlet pipe of the transmission oil cooler to the
pump, tighten to 23-27Nm, and check the torque. radiator.
3. Fit the auxiliary drive belt. 2. Fit 1 nut fixing the inlet pipe of the transmission
oil cooler to the automatic transmission, tighten to
Auxiliary Drive Belt Refit
33-37Nm, and check the torque.
4. Fill the coolant.
3. Fit 1 bolt fixing the bracket of the inlet pipe of the
Coolant Refill transmission oil cooler to the automatic transmission,
tighten to 7-10Nm, and check the torque.
4. Fill the automatic transmission fluid.

Automatic Transmission Fluid Refill

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Engine Cooling System Engine
Transmission Oil Cooler Outlet Pipe Assembly
- 4AT
Remove
1. Drain the automatic transmission fluid.

Automatic Transmission Fluid Drain

2. Remove 1 bolt (1) fixing the bracket of the outlet
pipe of the transmission oil cooler to the automatic
transmission.
3. Remove 1 nut (2) fixing the outlet pipe of the
transmission oil cooler to the automatic transmission.

4. Disconnect the outlet pipe of the transmission oil

cooler from the radiator.

5. Remove the outlet pipe of the transmission oil cooler.

Refit
1. Fix the outlet pipe of the transmission oil cooler to
the radiator.
2. Fit 1 nut fixing the outlet pipe of the transmission
oil cooler to the automatic transmission, tighten to
33-37Nm, and check the torque.
3. Fit 1 bolt fixing the bracket of the outlet pipe of the
transmission oil cooler to the automatic transmission,
tighten to 7-10Nm, and check the torque.
4. Fill the automatic transmission fluid.

Automatic Transmission Fluid Refill

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Engine Engine Cooling System

Special Tools
Tool Description Picture
Number

Pressure test
TEN00010
connector, cap

Cooling system
T14001
pressure test kit

Pressure test
TEN00015 connector,
cooling system

Harness repair
T84001
kit

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Engine Fuel & Management
Specifications
Torque
Description Value
Spark plugs 22-28Nm
Bolt - ignition coil 8-12Nm
Bolt-ECM to Battery Bracket 7-10Nm
Oil temperature sensor 14-18Nm
Bolt - crank sensor 8-12Nm
Bolt - camshaft.sensor 8-12Nm
Bolt - chain guide rail upper to cylinder head front cam 8-12Nm
bearing
Bolt - timing chain tensioner to cyclinder head 18-22Nm+(22-28°)
Bolt - VCT unit to camshaft 70-80Nm
Oil pressure sensor 14-18Nm
Bolt - knock sensor 15-25Nm
Bolt - rail fuel to inlet manifold 8-12Nm
Bolt-Oxygen sensor 40-60Nm
Bolt - TMAP sensor to inlet manifold 4-5Nm
Bolt - fuel filter to filter support bracket 7–10Nm
Fuel tank unit locking ring 75–85Nm
Bolt - fuel tank strap 22–28Nm
Bolt - fuel filler to body 5–7Nm
Bolt - fuel filler neck to body 5–7Nm

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Engine Engine Fuel & Management

Parameter
Engine Management System

Manufacturer/Model Bosch UAESME 17

Emission Standard (EU V)

Spark plug: K6RTC

TORCH 0.8 - 0.9mm

Clearance
Ignition Coil:

Manufacturer UAES (Bosch)

Model 1x1 single ignition coil, top mounted, one ignition coil for one cylinder

Primary resistance (typical) 0.530Ω (±12%)

Secondary resistance (typical) 9.5kΩX (±12%)

Fuel injection system:

Model Fuel returnless system, MFI system, electronically controlled by ECM.

ECM Engine management system of Bosch contactless, electronic, whole control

chart type
Nozzle:
4 × EV6
Operating pressure
0.38 MPa
Static flow rate of nozzle
154.2 g/min

Sensor

Crankshaft position sensor:

Manufacturer/Model UAES BOSCH, Hall sensor which obtains signal from the side of the signal wheel
Camshaft position sensor:

Manufacturer/Model UAES BOSCH, Hall sensor which obtains signal from the side of the camshaft
signal wheel
Oxygen sensor:

Manufacturer/Model UAES BOSCH LSF4.2

Heating element power (nominal value) 7W

Sensor voltage - high ≈ 800mv

Sensor voltage - low ≈ 50mv

Electronic throttle:

Manufacturer UAES BOSCH

Total rail resistance 1.25KΩ ± 30%

Engine coolant temperature sensor:

Manufacturer/Model TEMB / NTC

TMAP sensor:

Manufacturer UAES BOSCH

Sensor supply voltage 5V ± 4%

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Engine Fuel & Management Engine
Description and Operation
System Layout
Control System - 1.5L

1. Oil Temperature Sensor 10. Screw - Camshaft Position Sensor

2. Oil Temperature Sensor Liner 11. Front Oxygen Sensor Assembly
3. Intake Air Temperature/Pressure Sensor 12. Crankshaft Sensor Assembly
4. Bolt - Intake Air Temperature/Pressure Sensor 13. O-ring - Crankshaft Sensor
5. Knock Sensor 14. Screw - Crankshaft Sensor
6. Screw - Knock Sensor 15. Front Oxygen Sensor Bracket
7. Oil Pressure Switch 16. Rear Oxygen Sensor Assembly
8. Oil Pressure Switch Liner 17. Clip - Oxygen Sensor
9. Camshaft Position Sensor

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Engine Engine Fuel & Management

System Control Diagram

Engine Control System Control Diagram

A = Hard Wire; B = CAN Bus

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Engine Fuel & Management Engine

A = CAN Bus

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Engine Engine Fuel & Management

Description 1M Brake Vacuum Sensor

Overview 1N -
The engine management system (ECM) is applied to control 1O -
each aspect of the engine operation. The system receives 1P Non-continuous Power
inputs from various sensors, and then utilizes them to Supply
determine outputs, including the fuel volume delivered to the 1Q Non-continuous Power
combustion chamber, ignition time, air supply control, etc. Supply
Engine uses BOSCH ME 1.7.8.8 ECM which is a continuous 2A CANBus 1 Low
multi-point fuel injection system controlled by ECM and
2B -
adopts the speed/density principle combined with electronic
throttle control. The control intentions of the engine 2C Brake Vacuum Sensor
management system are to: enhance power performance, 2D Continuity Power Supply
reduce fuel consumption and exhaust pollution. 2E -
Engine Control Module (ECM) 2F -
The engine control module is the control centre of the fuel 2G Brake Switch
injection system. It monitors continuously the information 2H -
from various sensors, controls various systems influencing 2J Brake Lamp
the vehicle performance. It also executes system diagnosis
2K -
function. It is able to identify the operation fault, remind the
driver with malfunction indicator lamp (MIL) and store the 2L A/C Medium Pressure
Switch
DTC at indication fault position to facilitate the repair of the
service personnel. 2M A/C High/Low Pressure
Switch
ECMEnd View and Pin Information of Connector - 1.5L (1) 2N -
2O Accelerator Pedal Sensor 2
2P Fan Speed Control 2
2Q Anti-theft Input
3A -
3B -
3C Ignition Switch
3D Accelerator Pedal 2.5V
Power Supply
3E Accelerator Pedal 1.5V
Power Supply
3F -
3G -
Pin No. Description 3H -
1A HS CAN Bus 1 High 3J Fuel Pump Relay
1B -
3K A/C Compressor Relay
1C - -
3L
1D - -
3M
1E Main Relay 3N Accelerator Pedal Sensor 1
1F Clutch Top Switch 3O -
1G Accelerator Pedal 1 Ground 3P Sensor Ground
1H - -
3Q
1J - -
4A
1K - -
4B
1L -

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Engine Fuel & Management Engine
4C - 13 Throttle Position Sensor 1
- Signal
4D
- 14 Throttle Position Sensor 2
4E
Signal
4F Electronic Vacuum Pump
15 Downstream Oxygen
Relay (AT only)
Sensor
4G -
16 Upstream Oxygen Sensor
4H Fan Speed Control 1 Ground
4J - 17 -
4K - 18 -
4L Accelerator Pedal 2 Ground 19 -
4M - 20 Speed/Exhaust Phase Sensor
Ground
4N -
21 Coolant/Oil Temperature
4O -
Sensor Ground
4P ECM Ground 2 22 Throttle Ground
4Q ECM Ground 1 23 Throttle Actuator

ECM End View and Pin Information of Connector - 1.5L (2) 24 Ignition Coil 4 Cylinder 1

25 Knock Sensor B
26 Knock Sensor A
27 Main Load Sensor
28 -
29 Phase Position Sensor
(intake)
30 Canister Valve
31 Downstream Oxygen/Intake
Phase Position Sensor
Ground
32 Engine Speed Sensor Input
33 -

Pin No. Description 34 Phase Position 5V Power

Supply
1 - 35 Ignition Coil 2 Cylinder 4
2 - 36 Ignition Coil 1 Cylinder 3
3 Fuel Injector 4 (Cylinder 1) 37 Engine Coolant Temperature
4 Fuel Injector 1 (Cylinder 3) Sensor Signal
5 Variable Camshaft Timing 38 Intake Air Temperature
(exhaust) Sensor
6 - 39 Oil Temperature Sensor
Signal
7 Variable Camshaft Timing
(intake) 40 Upstream Oxygen Sensor
Signal
8 Fuel Injector 2 (Cylinder 4)
41 Phase Position Sensor
9 Upstream Oxygen Sensor (exhaust)
Heater
42 Alternator Feedback Signal
10 Fuel Injector 3 (Cylinder 2) (for non stop/start)
11 Throttle Actuator 43 Throttle 5V Power Supply
12 Ignition Coil 3 Cylinder 2 44 Speed/Exhaust Phase
Position 5V Power Supply

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Engine Engine Fuel & Management

45 Intake Air Failure

Pressure/Temperature
5V Power Supply The main relay may have failures occurred under the following
conditions:
46 Downstream Oxygen
Sensor Heater • Relay winding short-circuited
47 ECM Ground 4 • Relay winding open-circuit
48 ECM Ground 3 • Relay winding high resistance
• Relay contact normally open
The engine management system is composed of the following
6 components • Relay contact normally closed
• Relay contact high resistance
according to control principle:
• Relay harness open-circuit
• External Control
• Relay harness high resistance
• Engine Air Supply Control System
• Relay harness connected to the 12V power supply is
• Engine Ignition Control System short-circuited
• Engine Fuel Supply Control System • Relay harness short to ground
• Auxiliary 1 (heat management) • ECMFailure to provide ground access
• Auxiliary 2 (external assistance)
In order to determine whether the main relay works normally,
External Control the following checks may be carried out:
The external control of the engine mainly includes:
• Sound check - place the ignition key in "ON" position to
• Main relay check whether the fuel pump will work for 2s.
• Ignition switch • Whether the fuel injector or ignition coil is supported by
• Battery power (apply multimeter to check the voltage of battery)

• CANCommunication If the above are verified, it indicates that the main relay works
• Immobiliser power supply normally.
CANCommunication
The external control mainly refers to the power supply and
communication. One line of power supply of the engine The engine management system applies CAN communication
control module (ECM) is directly connected to the power network for the communications between ECM and ABS,
supply through fuse to ensure ECM is in powered state. BCM and TCM, and diagnoses outputs through diagnostic
When the ignition switch is in "ON" or "IGN" position, the interface.
engine control module can control the opening of the main Immobiliser Power Supply
relay or connect to ignition power supply.
When the ignition switch is turned to Gear 2, the engine
The engine control can communicate with controllers of control module (ECM) and body control module (BCM)
other nodes on the network through CAN to ensure each communicate through CAN bus for mutual information
performance of the system. It can also be connected with verification, after verification, BCM will control the operation
the data link connector (DLC) to facilitate the diagnostic of starter motor, ECM will control ignition, fuel injection, and
operation of the service personnel. the engine will be started.
Main Relay Engine Air Supply Control System
The main relay is in the engine compartment fuse box. It is The engine air supply control system mainly includes:
a 4-pin relay adopting the DIN pin layout. The relay doesn't
• Electronic throttle body
contain the reverse electrode protection diodes, this function
is performed by the ECM. • Accelerator pedal module
• Intake air pressure/temperature sensor
When the engine control module (ECM) detects that the
ignition switch is in "IGN" position, it will output a low level • Camshaft position sensor
signal, control the relay to engage, and the UBR pin of ECM is • Variable camshaft timing valve
connected to the power supply voltage so as to meet the start
conditions.

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Engine Fuel & Management Engine
If the ratio of the air to fuel mass is 14.7:1, the fuel can be burnt the throttle form a part of whole electronic throttle control
sufficiently, and the engine is at the best working state for this system monitoring function, which can provide the redundancy
moment. protection expected by system control.
As for air supply portion, the optimal fuel air ratio is achieved Intake Air Pressure/Temperature Sensor (TMAP)
mainly by the control of air inflow and the master stroke of oil The intake air pressure/temperature sensor measures intake
cylinder. air manifold absolute pressure and intake air temperature and
Electronic Throttle provides engine load and intake air temperature information.
The electronic throttle is composed of throttle, throttle The intake air pressure portion is measured by a piezoelectric
actuator (DC motor) and throttle position sensor, etc. type sensor which can provide the "Load Signal" to the
controller in accordance with the pressure difference
ECM gives instructions to make the DC motor act and affect
between atmosphere and intake manifold; the controller
the throttle opening through the drive mechanism. There are
provides a 5V voltage and feedbacks a 0 - 5V voltage to the
two potentiometers acting as position sensors, which are fit
controller depending on the intake air pressure. The intake
in reverse phase. When the position of the throttle changes,
air temperature portion is measured by a NTC (Negative
the two resistances vary linearly, one increases and the other
Temperature Coefficient) type sensor, whose resistance
decreases. When a +5V voltage is added, the pedal position
changes with the intake air temperature and which transfers
will be transformed into the voltage output corresponding to
a voltage showing the change of the intake air temperature
the changes of the resistance value.
to the controller. The pressure (P) is proportional to output
These two potentiometers along with two potentiometers on voltage and the temperature is inversely proportional to
the accelerator pedal module used for monitoring the stroke of output resistance.
the accelerator pedal form a part of whole electronic throttle
Camshaft Position (CMP) Sensor
control system monitoring function, which can provide the
redundancy protection expected by the system control. The camshaft position sensor is applied to cooperate with
the rotational speed sensor in the circumstances without
Throttle Position Sensor
electricity distributor, to provide the ECM with the camshaft
The throttle position sensor is used to provide throttle angle phase information, namely, identify the compression top dead
information for the ECM. ECM can obtain the engine load centre and exhaust top dead centre of the cylinder 1.
information and operating conditions (such as start, idle
The camshaft position sensor is composed of a hall sensor and
speed, motored condition, part load, full load), acceleration
a rotor made of steel plate. The hall sensor is fixed, and the
and deceleration information according to this information.
rotor with a 36° arc boss is fitted on the camshaft. The inner
Actually, the throttle sensor is an angle potentiometer magnetic field of the hall sensor will change when the boss
characterized by linear output. The potentiometer rotor arm passes it, which leads to the change of output signal voltage. In
and throttle are fitted coaxially. When the throttle rotates, this way, the two top dead centres are identified.
the potentiometer rotor arm will be driven to slide into a
Failure
certain position and the potentiometer output a voltage signal
proportional to the throttle position. CMPThe sensor or magnetic ring may have failures or provide
incorrect signals due to the following conditions:
Accelerator Pedal Module
• CMPSensor gap fails to comply with the specifications.
There are two potentiometers in the accelerator pedal
module acting as sensors, their resistance value will vary • CMPSensor is contaminated by metallic debris.
with the position changes of the electronic accelerator pedal, • CMPSensor hall-effect semiconductor is damaged.
while the ECM can response precisely to the movement • CMPSensor magnetic field is too weak.
of the accelerator pedal, therefore, the movements of the
• CMPSensor harness is open-circuit.
accelerator pedal may be monitored.
• CMPSensor harness is short-circuited.
Because both potentiometers are fitted in the same phase,
• CMPSensor harness has a high resistance.
when the accelerator pedal position changes, their resistances
• Magnetic ring is contaminated by metallic debris.
will increase or decrease linearly. When a +5V voltage is
added, the pedal position will be transformed into the voltage • The precision of magnetic ring is low due to mechanical
output corresponding to the changes of the resistance value. damage.
These two potentiometers and two potentiometers fitted on • Exhaust camshaft timing is incorrect.
the electronic throttle used for monitoring the position of • Intake camshaft timing is incorrect.

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Engine Engine Fuel & Management

Engine Oil Temperature Sensor Failure

The engine oil temperature sensor (EOT) is applied to The ignition coil may have failures under the following
monitor the engine oil temperature and control variable conditions:
camshaft timing valve (i.e. VCT valve). The variable camshaft
• Primary winding open-circuit
timing valve is adjusted at different temperatures to obtain
optimal intake air. • Primary winding short-circuited
• Resistance of primary winding out of tolerance
Failure
• Secondary winding open-circuit
The EOT sensor may have failures or provide incorrect signals
due to the following conditions: • Secondary winding short-circuited
• The circuit connecting secondary winding with primary
• System lack of oil
winding is short
• External harness open-circuit
• Resistance of secondary winding out of tolerance
• External harness short to ground
• Coil top insulation mechanically damaged
• External harness connected to the 5V power supply is
Crankshaft Position (CKP) Sensor
short-circuited
CKPThe crankshaft position sensor is applied to provide
• External harness high resistance
information of the engine speed and crankshaft top dead
• ECMFailure to provide ground access
centre in the ignition system without electricity distributor. It
• EOTSensor thermistor damaged is a hall-effect sensor matched with pulse wheel in application.
Variable Camshaft Timing (VCT) Valve The pulse wheel is a teeth plate, with 58 small teeth separated
by 6°and a 2-teeth gap on magnetic ring. The pulse wheel
The engine control module outputs pulse width modulation
is fitted on the crankshaft, and rotates with the crankshaft.
(PWM) signal to drive the solenoid. Change in duty ratio may
When the tooth tips pass by sensor ends, the pulse wheel
adjust the opening of the solenoid.
made of steel magnetic materials cuts the magnetic force
The VCT system can, under the condition of low speed, line of the permanent magnets in the sensor to produce the
reduce the fuel consumption and improve the performance of induced voltage in the coil, which acts as the rotational speed
engine in the process of exhaust emission, especially torque output signal.
performance.
Failure
ECMIt receives signals from the CKP sensor and CMP
CKPThe sensor or magnetic ring may have failures or provide
sensor. With these signals, the valve timing can be determined
incorrect signals due to the following conditions:
by ECM by consulting control chart. Then ECM operates the
VCT engine oil control valve installed on one side of cylinder • CKPSensor gap fails to comply with the specifications.
head. These solenoid valves control the oil to flow into phase • CKPSensor is contaminated by dust.
modulator and change the relative position to the camshaft of • CKPSensor hall-effect semiconductor is damaged.
the phase modulator so as to adjust the valve timing.
• CKPSensor magnetic field is too weak.
Engine Ignition Control System
• CKPSensor harness is open-circuit.
The engine ignition control system mainly includes: • CKPSensor harness is short-circuited.
• Ignition coil 1、2、3、4 • CKPSensor harness has a high resistance.
• Engine speed sensor • Magnetic ring is contaminated by dust.
• Knock sensor • The precision of magnetic ring is low due to erosion or
• Ignition sequence mechanical damage.
Ignition Coil • The CKP sensor signal is distorted due to out-of-round
flywheel or drive disc.
The ignition coil turns the DC low voltage of battery to high
voltage and ignites the air mixture in cylinder through the spark • The CKP sensor signal is changed due to crankshaft
generated by the discharge of spark plug. Each ignition coil radial movement.
consists of a pair of coil windings around laminated iron core. In order to check the ECM for receiving the signal from CKP
There are four ignition coils fitted on the camshaft cover of sensor, following operations may be conducted:
the engine, and each cylinder has an independent ignition coil
connected with the spark plug.

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• Check the operation of the fuel pump in the engine • HO2SWhen the output voltage changes, the increased
starting process; if the fuel pump supplies fuel when the temperature of HO2S is sufficient for normal operation.
ignition is on but not operating, it indicates that ECM • ECTThe temperature of the sensor is higher than the
does not receive CKP sensor signal. specified temperature.
Knock Sensor • The engine has started for a specified period of time.
The knock sensor is used to provide electronic controller With respect to above conditions, different engines have their
ECM with the engine knock information to carry out knock specific values which are stored in an electronic erasable
control. programmable read only memory (EEPROM). After these
The knock sensor is a vibration acceleration sensor. It is values are met, the system begins closed-loop operation.
fitted on the engine cylinder block. The sensitive element During the closed-loop running, the control module calculates
of the sensor is a piezoelectric crystal. The vibration of the the air fuel ratio and opening time of the injectors according to
engine cylinder block is transferred to the piezoelectric crystal the signals from various sensors, especially the heated oxygen
through the mass block in the sensor. Due to the pressure senor, so that the air fuel ratio is always close to 14.7:1.
generated from the vibration of mass block, the piezoelectric Oxygen Sensor
crystal produces voltage on both pole surfaces to transform
The oxygen sensor measures the oxygen content in the
the vibration signal into voltage signal to output.
engine exhaust to determine if the gasoline and air are
Failure burnt completely. The electronic controller implements the
The knock sensor may have failures or provide incorrect signals closed-loop control aiming at excessive air coefficient l =
due to the following conditions: 1 according to the information to ensure that three-way
catalytic converters have the highest conversion efficiency in
• Sensor open-circuit
such three kinds of pollutant as HC, CO and NOx in the
• Sensor to ground short-circuited exhaust.
• Sensor circuit intermittently open
Its sensing element is a ceramic tube, the inner surface and
• Incorrect knock sensor refit outer surface of which are contacted with exhaust gas and
In case of knock sensor signal failure, the following symptoms ambient air respectively. When the sensing ceramic tube
may occur: temperature reaches 350℃, it will have the property of solid
electrolyte. With this property, the concentration difference
• Store the failure code of oxygen is turned to electric potential difference so as
• ECMFailure to inspect engine combustion knock to form electric signal output. If the mixture is rich, the
• ECMRestore default settings concentration difference of oxygen inside and outside the
Engine Fuel Supply Control System ceramic tube is high, the electric potential difference is high,
a large amount of oxygen ions move from inside to outside
The engine fuel supply control system mainly includes: and the output voltage is high (approximate to 900mV); if the
• Upstream oxygen sensor mixture is thin, the concentration difference of oxygen inside
• Downstream oxygen sensor and outside the ceramic tube is low, the electric potential
difference is low, only a few of oxygen ions move from inside
• Fuel injectors 1 - 4
to outside and the output voltage is low (approximate to
• Canister valve 100mV).
• Fuel pump relay
The oxygen sensor consists of the front oxygen sensor and
The engine fuel supply control system is mainly applied to rear oxygen sensor. The former is used to measure the
control the fuel supply for the engine under different working oxygen content in the engine exhaust to implement the closed
conditions. loop control, and the latter is used to monitor the conversion
function of the three-way catalyst.
When the engine starts for the first time and engine speed
is higher than the preset speed, the system begins open loop Failure
operation. The control module ignores the signals from the HO2SIt may have failures or provide incorrect signals due to
heated oxygen sensor (HO2S). The control module calculates the following conditions:
the air fuel ratio according to the input signal from the ECT,
TMAP and TP sensors. The system stays in open loop state • Contaminated by leaded fuel
until the following conditions are met: • Contaminated by carbon or silicon deposits
• Impact damage/mechanical impact

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• External harness open-circuit At the time of start

• External harness connected to the 12V power supply is • If the fuel system pressure falls to zero, the engine will
short-circuited fail to ignite.
• External harness short to ground • If the fuel system pressure is lower than normal operating
• External harness high resistance pressure (0.38MPa), the engine may try to ignite, but fails
• Heating device open-circuit to work normally.
• Heating device short-circuited • If the fuel system pressure is normal, the engine will ignite
to operate, but will flame out finally with decrease in fuel
• ECMFailure to provide ground access for heating device
pressure, and fails to restart.
• Harness shielding not connected to the ground
During driving
Fuel Injector
If the fuel pump relay fails during driving, the engine will lose
The fuel injector, according to the commands of the ECM,
power and finally shuts down due to shortage of fuel.
injects fuel within the specified time to supply the engine
with fuel and have it atomized. ECMThe ECM energizes the The fuel pump relay may have failures under the following
injector coil to form magnetic force. When the magnetic conditions:
force is strong enough to overcome the resultant force of
• Relay coil short-circuited
the return spring pressure, needle valve gravity and friction,
the needle valve begins to rise, and the fuel injection process • Relay coil open-circuit
starts. When fuel injection pulse ends, the pressure of return • Relay coil high resistance
spring makes the needle valve close again. • Relay contact normally open
Failure • Relay contact normally closed
The fuel injector may fails under the following conditions: • Relay contact high resistance

• Nozzle is contaminated by dust or wax (flow is reduced) • Relay harness open-circuit

• Nozzle offset (injection positioned incorrectly) • Relay harness high resistance

• Fuel filter blockage • Relay harness connected to the 12V power supply is
short-circuited
• Winding open-circuit
• Relay harness short to ground
• Winding short to ground
• ECMFailure to provide ground access
• Winding connected to the 12V power supply is
short-circuited Carry out the following checks and check the fuel pump relay
• Winding resistance out of tolerance for normal operation:

• External harness open-circuit • Sound check - place the ignition key in "ON" position to
• External harness short to ground check whether the fuel pump will work for 2s.

• External harness connected to the 12V power supply is Check the ECM for providing an access to ground for the fuel
short-circuited pump relay when the ignition switch is in "ON" position (for 2s)
Electric Fuel Pump and during the starting. Remove the fuel pump relay, connect
a multimeter between the 12V power supplied by the vehicle
The electric fuel pump transfers the fuel from the fuel tank to
and the fuse box pin connected with fuel pump pin 85, check
the engine and provides sufficient fuel pressure and rich fuel.
the output according to the circuit diagram after the ignition
It is a DC motor driven vane pump, which is fitted in the fuel is on.
tank and immersed in the fuel. It applies fuel for heat dissipation
As the ECM internal drive circuit consumes voltage, the
and lubrication. The battery supplies power to the electric fuel
measured voltage may be lower than the battery voltage.
pump via fuel pump relay, which allows the electric fuel pump
Canister Control Valve
circuit to be closed only when the relay starts and the engine
operates. When the engine stops running due to accident, the The canister control valve is applied to control the
fuel pump will stop operating automatically regeneration air flow of the fuel evaporation control system.
Failure The canister in the fuel evaporation control system absorbs
If the fuel pump relay fails, the following symptoms will occur: fuel steam from fuel tank till it cannot absorb any more.
ECMIt controls the canister control valve to open and allows

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fresh air and saturated fuel steam in the canister to form Failure
regeneration air flow, then sends it to the engine air inlet pipe.
ECTThe sensor may have failures or provide incorrect signals
The electronic controller, based on the different working
due to the following conditions:
conditions of engine, changes the duty ratio of the pulse signal
transmitted to the canister control valve electromagnetic coil • The system is lack of coolant due to leakage
to control the regeneration air flow. Moreover, the flow is • External harness open-circuit
also influenced by the pressure difference on both ends. • External harness short to ground
Failure • External harness connected to the 5V power supply is
The canister control valve may have failures occurred under short-circuited
the following conditions: • External harness high resistance
• Electromagnetic winding open-circuit • ECM Failure to provide ground access
• Electromagnetic winding short-circuited • ECT Thermistor damaged
• External harness connected to the 12V power supply is Cooling Fan Relay Unit
short-circuited The cooling fan relay unit is fitted on the left side of the
• External harness short to ground radiator, which is equipped with two relays.
• External harness high resistance The cooling fan is controlled by the ECM, and is manipulated
• ECMFailure to provide PWM signal through the relay unit. ECM It uses the information provided
• Mechanical problems occur in the valve by the ECT sensor, BCM and A/C pressure sensor to limit
the cooling temperature of the engine.
Auxiliary 1 (Heat Management)
Auxiliary 2 (External Assistance)
The heat management portion mainly includes:
The external assistance portion mainly includes:
• A/C compressor relay
• Alternator control input
• A/C request (On/Off)
• Clutch switch
• Engine coolant temperature sensor
• Brake pedal switch
• Cooling fan relay (low speed, high speed)
• Brake lamp
• A/C pressure sensor
Alternator Control Input
The engine adjusts the opening or closing of the high/low speed
cooling fan relay according to the coolant temperature. The alternator control input is used by the ECM to control the
alternator for the battery charge while the engine operates.
After the driver presses the A/C request (ON/OFF) on
Brake Switch
the instrument panel, ECM monitors the status of the A/C
pressure sensor signal and decides whether to turn on the The brake switch is located on the pedal box in the cab. ECMIt
A/C according to the current engine coolant temperature monitors the switch status and transfers the data to the TCM
sensor signals and engine speed signals. via the CAN bus, and the TCM controls the gearbox clutch
Engine Coolant Temperature Sensor to open. When the brake pedal is operated, the brake switch
is activated.
The coolant temperature sensor is used to provide the engine
Clutch Switch (MT only)
coolant temperature information. Whereby, the controller
can correct the fuel injection and ignition. It is a negative The clutch sensor is fitted on the master cylinder of the
temperature coefficient (NTC) thermistor, whose resistance clutch and is powered by the ECM. When the clutch pedal
value is reduced as the temperature rises, but it is not a linear is depressed, the ECM will receive the clutch release signal;
relationship. The thermistor is mounted inside a copper heat when the clutch pedal is reset, the ECM will receive the clutch
sleeve. engagement signal.

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Service Procedures Ignition Coil

Spark Plug Remove
Remove 1. Disconnect the battery negative.
1. Disconnect the battery negative. 2. Remove the air filter assembly.
2. Remove the ignition coil. Air Filter Assembly Remove
Ignition Coil Remove 3. Disconnect the harness connector and the bolt.
3. Clean the area around the spark plug. Remove the dust
around the spark plug with high pressure gas.
4. Remove 4 spark plugs with the spark plug socket.

4. Hold the end of the ignition coil rubber bush, and pull
out the ignition coil from the spark plug (if difficult to
pull out, you can rotate the ignition coil right and left
to loosen it).
Refit
Refit
1. Identify the model of the original spark plug before
fitting a new one. Spark plug of the same model shall 1. Fit the ignition coil onto the spark plug, and connect
be selected for replacement. the harness connector.

2. Adjust the initial gap of each new spark plug to 2. Tighten the bolts fixing the ignition coil to8-12Nm
0.80-0.90mm. 3. Connect the high voltage wire to the spark plug.
3. Fit the spark plug and tighten it to 22-28Nm. 4. Fit the air filter assembly.
4. Fit the ignition coil. Air Filter Assembly Refit
Ignition Coil Refit 5. Connect the battery negative.
5. Connect the battery negative.

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Engine Control Module (ECM) Engine Coolant Temperature Sensor (ECT)
Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Remove 4 bolts (1) fixing the ECM to the battery 2. Remove the coolant expansion tank cap to release the
bracket. pressure of the cooling system, and then refit the cap.
3. Disconnect the harness connector (2) from the ECM. Warning: Since injury such as scalding could be caused by
Caution: ECMWhen disconnecting the connector, escaping steam or coolant, do not remove the filler cap
avoid shaking the connector all round; avoid from the coolant expansion tank while the system is hot.
applying force on one side only; avoid damaging 3. Disconnect the harness connector.
the connector structure. 4. Drain the coolant.

Coolant Drain
5. Remove the circlip fixing the engine coolant
temperature sensor.
6. Remove the engine coolant temperature sensor.

4. Remove the ECM.

Refit
1. Fit 4 bolts of the battery bracket, tighten to 7-10Nm,
and check the torque.
2. Connect the harness connector to the ECM.
Refit
Caution: ECMWhen connecting the connector, make
1. Clean the thread of the coolant temperature sensor.
sure to align the connector, and insert it with
2. Fit a new sealing washer onto the coolant temperature
even force applied on both ends. Attempt of tilting
sensor.
assembly or assembly with great effort on one side
shall be not allowed. If the connector is damaged, 3. Fit the engine coolant temperature sensor and tighten
replace the engine harness. to 14-18Nm.
4. Connect the engine coolant temperature sensor
3. Connect the battery negative.
harness connector.
4. Programme and encode the ECM.
5. Connect the battery negative.
5. Perform self-learning for the electronic throttle.
6. Refill coolant.
Electronic Throttle Self-learning - UMC System
Coolant Refill
6. Place the ignition switch in "ON" position, and perform
"Engine Module Reset Self-learning Value" with VDS.
7. Wait for 2 - 5 seconds, turn off the ignition switch and
restart the vehicle.

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Engine Oil Temperature Sensor Crankshaft Position Sensor

Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Disconnect the harness connector from the oil 2. Remove the bottom deflector.
temperature sensor.
Bottom Deflector Remove
3. Place the oil sink under the switch to collect the spilled
3. Disconnect the harness connector from the crankshaft
oil.
position sensor.
4. Remove the oil temperature sensor.
4. Remove the bolt fixing the crankshaft position sensor
to the cylinder block.
5. Remove the crankshaft position sensor.

Refit
1. Clean the thread of the oil temperature sensor.
2. Fit a new sealing washer to the oil temperature sensor Refit
and tighten the switch to 14-18Nm.
1. Clean the mating surface of the crankshaft position
3. Connect the temperature sensor connector. sensor and the cylinder block.
4. Remove the oil sink. 2. Locate the crankshaft position sensor, fit the retaining
5. Connect the battery negative. bolt and tighten it to 8-12Nm.
6. Check the engine oil level, and refill if necessary. 3. Connect the crankshaft position sensor harness
connector.
4. Fit the bottom deflector.

Bottom Deflector Refit

5. Connect the battery negative.

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Camshaft Position Sensor Camshaft Phase Modulator
Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Disconnect the harness connector from the camshaft 2. Drain the engine oil.
position sensor.
Engine Oil Filter Remove
3. Remove the bolt fixing the camshaft position sensor,
3. Remove the upper cover plate of the timing chain.
remove the camshaft position sensor and discard the
O-ring. Timing Chain Upper Cover Plate Remove
4. Remove the lower cover plate of the timing chain.

Timing Chain Lower Cover Plate Remove

5. Remove the timing chain tensioner, and discard the
sealing washer.

Refit
1. Clean the camshaft position sensor and mating surface,
and fit an O-ring to the camshaft position sensor.
2. Fit the camshaft position sensor to the cylinder head
and tighten the bolts to 8-12Nm. 6. Remove the upper guide rail.
3. Connect the camshaft position sensor harness
connector.
4. Connect the battery negative.

7. Remove the oil control valve.

Oil Control Valve Remove

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8. Remove and discard the intake & exhaust phase

modulator bolts.
9. Remove the intake phase modulator and exhaust phase
modulator, and hang the chain on the upper guide rail
mounting boss.

4. Position the phase modulators assembled on the intake

and exhaust camshafts to the appropriate camshaft,
mount the chains into both modulators, and pretighten
the bolts.
5. Fit the oil control valve.
Refit Oil Control Valve Refit
1. Rotate the flywheel until the flywheel pin hole is aligned 6. Fit the upper guide rail to the front bearing cap of the
with the pin hole of the engine body. camshaft, fix with two bolts, the tightening torque is
2. Insert the TEN00002 into the engine body timing pin 8-12Nm.
hole and flywheel pin hole to lock the flywheel.

7. Fit a new timing hydraulic tensioner washer, screw the

3. Rotate the camshaft with the timing hole up, and fix the timing hydraulic tensioner into the cylinder head, and
intake/exhaust camshaft with the TEN00004. tighten to 18-22Nm+(22-28°).

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Oil Pressure Switch
Remove
1. Disconnect the battery negative.
2. Remove the bottom deflector.
Bottom Deflector Remove
3. Disconnect the harness connector from the oil
pressure switch.
4. Place the oil sink under the switch to collect the spilled
oil.
5. Remove the oil pressure switch.

8. Secure the intake and exhaust phase modulators to the

camshaft, tighten the bolt to 70-80Nm.

Refit
1. Clean the thread of the oil pressure switch.
2. Fit a new sealing washer to the oil pressure switch and
9. Fit the lower cover plate of the timing chain. tighten the switch to 14-18Nm.
Timing Chain Lower Cover Plate Refit 3. Connect the oil pressure switch harness connector.
10. Fit the upper cover plate of the timing chain. 4. Remove the oil sink.
5. Fit the bottom deflector.
Timing Chain Upper Cover Plate Refit
11. Fill the engine oil. Bottom Deflector Refit
6. Connect the battery negative.
Engine Oil Filter Refit
7. Check the engine oil level, and refill if necessary.
12. Connect the battery negative.

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Knock Sensor Fuel Rail

Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Disconnect the knock sensor harness connector. 2. Release the pressure of the fuel system.
3. Remove the bolt fixing the knock sensor onto the Warning: Fuel vapour is highly flammable and in confined
cylinder block, and take away the sensor. spaces is also explosive and toxic. Always have a fire
extinguisher containing foam, CO2, gas or powder close
3. Disconnect the harness connector from the fuel rail
assembly.

Refit
1. Clean the mating surface of the knock sensor and the
cylinder block.
2. Fit the knock sensor, ensure that the harness is properly 4. Release the fuel inlet pipe from the fuel rail.
placed, and tighten the bolts to 15-25Nm.
Caution: Always fit plugs to open connections to prevent
3. Connect the knock sensor harness connector. contamination.
4. Connect the battery negative.
5. Remove 2 bolts fixing the fuel rail to the intake manifold.

6. Remove the fuel rail assembly.

Refit
1. Clean the fuel injector and the intake manifold groove.
2. Locate the fuel rail assembly on the intake manifold, and
push each fuel injector into the corresponding hole of
the intake manifold.
3. Fix the fuel rail assembly to the intake manifold with 2
bolts, and tighten the bolts to 8-12Nm.
4. Connect the fuel inlet pipe to the fuel rail.
5. Connect the fuel injector harness connector.

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Engine Fuel & Management Engine
6. Connect the battery negative. Fuel Injector
Remove
1. Disconnect the battery negative.
2. Disconnect the fuel injector harness connector.
3. Remove the fuel rail assembly.

Fuel Rail Assembly Remove

4. Release the spring clamp fixing the fuel injector to the
fuel rail, and remove the fuel injector.
5. Remove 2 O-rings from each fuel injector, and discard
them.
6. Fit the end cap to the end of each fuel injector.

Refit
1. Remove the end cap from each fuel injector.
2. Clean the groove of the fuel injector and fuel rail.
3. Lubricate new O-rings with oil, and fit them to both
ends of each fuel injector.
4. Fit the fuel injector to the fuel rail.
5. Fix the fuel injector to the fuel rail with spring clamps.
6. Fit the fuel rail assembly.

Fuel Rail Assembly Refit

7. Connect the fuel injector harness connector.
8. Connect the battery negative.

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Oxygen Sensor Downstream Oxygen Sensor

Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Disconnect the upstream oxygen sensor harness 2. Remove the bottom deflector.
connector (1).
Bottom Deflector Remove
3. Use the special tool for the oxygen sensor TEN00011
3. Disconnect the downstream oxygen sensor connector
to remove the upstream oxygen sensor (2).
(1).
4. Use the special tool TEN00011 for the oxygen sensor
to remove the downstream oxygen sensor (2).

Refit
1. Fit the oxygen sensor with TEN00011, and tighten to
40-60Nm, check the torque.
Refit
Caution: Before the old part is refitted, apply the 1. Fit the oxygen sensor with TEN00011, tighten to
high temperature antiwelding agent onto the thread. 40-60Nm and check the torque.
2. Connect the upstream oxygen sensor harness Caution: Before the old part is refitted, apply the
connector. high temperature antiwelding agent onto the thread.
3. Connect the battery negative.
2. Connect the upstream oxygen sensor harness
connector.
3. Fit the upper bottom deflector.

Bottom Deflector Refit

4. Connect the battery negative.

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Manifold Absolute Pressure/Temperature Sensor Charcoal Canister
Remove Remove
1. Disconnect the battery negative. 1. Raise vehicle on suitable hoist.
2. Remove the starter motor. 2. Raise canister to release from retaining clip.
Starter Motor Remove
3. Disconnect the manifold absolute pressure/temperature
sensor harness connector.
4. Remove the bolts fixing the manifold absolute
pressure/temperature sensor to the intake manifold,
and remove the sensor.

3. Lower canister to access pipes.

4. Disconnect vent pipe, canister to fuel tank and canister
to engine pipes.
5. Remove canister.

Caution: Always fit plugs to open connections to prevent

contamination.
Refit Refit
1. Clean the mating surface of the manifold absolute 1. Position canister to vehicle.
pressure/temperature sensor and the intake manifold.
2. Refit pipes to canister.
2. Fit the manifold absolute pressure/temperature sensor,
3. Position canister in bracket, secure.
and tighten the bolts to 4-5Nm.
4. Lower hoist.
3. Connect the manifold absolute pressure/temperature
sensor harness connector.
4. Fit the starter motor.

Starter Motor Refit

5. Connect the battery negative.

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Carbon Canister Control Valve Pipe Assembly - Body Underfloor Fuel Lines
Remove Remove
1. Disconnect battery earth lead. 1. Disconnect battery earth lead.
2. Disconnect purge valve electrical connector. Warning: Fuel vapour is highly flammable and in confined
3. Disconnect vacuum hose from purge valve spaces is also explosive and toxic. Always have a fire
extinguisher containing foam, CO2, gas or powder close
4. Disconnect fuel ventilating hose from purge valve
2. Depressurise fuel system.
5. Remove purge valve from retaining bracket.
Fuel System - Depressurise
Before disconnecting any part of the fuel system, it
is imperative that all dust, dirt and debris is removed
from around components to prevent ingress of foreign
matter into fuel system.
3. Drain fuel tank.
Drain and Refill
4. Disconnect carbon canister pipe at purge valve.

Refit
1. Connect under-floor pipe to valve of carbon canister.
2. Connect vacuum pipes to valve of carbon canister.
3. Connect the connector of carbon canister valve.
4. Fit carbon canister valve to bracket.
5. Connect battery earth lead.

5. Disconnect fuel supply pipe at fuel rail.

6. Raise vehicle on suitable hoist.
7. Disconnect pipes from carbon canister.
Charcoal Canister
8. Disconnect pipes from fuel filter.
Fuel filter
9. Release 11 clips securing underfloor pipes to body
(one is on the fuel tank, 10 are on the underbody and
engine bay).

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Refit Fuel filter
1. Position pipe assembly to vehicle. Remove
2. Secure pipe retention clips. 1. Disconnect battery earth lead.
3. Reconnect pipe at fuel filter. 2. Depressurise fuel system.

Fuel filter Fuel System - Depressurise

4. Reconnect pipe at charcoal canister. Caution: Always fit plugs to open connections to prevent
contamination.
Charcoal Canister
5. Lower the vehicle. Warning: Depressurise the system before disconnecting
any components. Fuel pressure will be present in the
6. Reconnect pipe at purge vale.
system even if the ignition has been switched off for some
7. Reconnect pipe at fuel rail.
time.
8. Refill fuel tank..
3. Raise vehicle on suitable hoist.
9. Reconnect battery earth lead.
4. Position a suitable container to catch any spillage.
5. Disconnect earth lead.
6. Disconnect pipes/hoses from filter, note original fitted
position.
7. Remove clamp screw.

8. Remove filter.
Refit
1. Position fuel filter in clamp, secure screw, tighten
to7–10Nm
2. Refit pipes to filter.
3. Reconnect earth lead.
4. Lower hoist.
5. Reconnect battery earth lead.

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Engine Engine Fuel & Management

Tank - Fuel
Remove
1. Disconnect battery earth lead.

Warning: Fuel vapour is highly flammable and in confined

spaces is also explosive and toxic. Always have a fire
extinguisher containing foam, CO2, gas or powder close
2. Depressurise fuel system.
Fuel System - Depressurise

Warning: Fuel vapour is highly flammable and in confined

spaces is also explosive and toxic. Always have a fire
extinguisher containing foam, CO2, gas or powder close
3. Drain the fuel system. 10. Lower fuel tank to access top of tank.
11. Disconnect feed and return pipes to fuel pump.
Drain and Refill
12. Disconnect the connector of fuel pump.
Caution: Before disconnecting any part of the fuel
system, it is imperative that all dust, dirt and debris is
removed from around components to prevent ingress of
foreign matter into fuel system.

4. Remove carbon canister.

Carbon Canister Remove

5. Remove fuel filter.

Fuel Filter Remove

6. Remove fuel tank heat shield.
Fuel Tank Heat shield
7. Remove clips securing fuel filler and breather pipes to
tank, remove pipes. 13. Remove tank, use T18007remove the lock ring of fuel
pump.
Refit
1. Position the new pump seal to fuel tank, fit the fuel
pump, do not damage the pump seal.
2. UseT18007fit lock ring of fuel pump to fuel tank, and
tighten to75–85Nm.
3. With assistance position fuel tank on jacking equipment,
position to vehicle.
4. Connect the connector to fuel pump. Connect fuel
feed and return pipes to fuel pump.
5. Raise fuel tank, align straps.
Caution: Take care not to trap any pipes or cables when
Warning: The spilling of fuel is unavoidable during this fitting fuel tank.
operation. Ensure that all necessary precautions are
6. Raise the fuel tank assembly to under-floor, Fit strap
taken to prevent fire and explosion.
bolts and tighten to 22–28Nm.
8. Use a suitable jacking device to support fuel tank.
7. Reconnect fuel filler pipes to fuel tank, secure clips.
9. Release 4 bolts securing retaining straps to body,
8. Refit fuel filter.
remove straps.
Fuel Filter Refit
9. Refit charcoal canister.
Carbon Canister Refit

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10. Refit fuel tank heatshield. Fuel pump
Fuel Tank Heat shield
Remove
1. Disconnect battery earth lead
11. Lower the vehicle.
2. Depressurise fuel system.
12. Refill fuel tank.
13. Reconnect battery earth lead. Fuel System - Depressurise
Warning: Fuel vapour is highly flammable and in confined
spaces is also explosive and toxic. Always have a fire
extinguisher containing foam, CO2, gas or powder close
Warning: The spilling of fuel is unavoidable during this
operation. Ensure that all necessary precautions are
taken to prevent fire and explosion.
3. Remove rear seat cushion
Rear Seat Cushion Assembly Remove
4. Pull back sound insulation and carpet (where applicable).
5. Using a suitable lever, remove fuel pump unit access
cover.

6. Cover surrounding area to protect against fuel spillage.

7. Disconnect electrical connector from fuel pump.
8. Release fuel feed and fuel return pipes from the fuel
pump.

Caution: Before disconnecting any part of the fuel

system, it is imperative that all dust, dirt and debris is
removed from around components to prevent ingress of
foreign matter into fuel system.

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Warning: The spilling of fuel is unavoidable during this Fuel System - Pressure Relief - 1.5L
operation. Ensure that all necessary precautions are Check
taken to prevent fire and explosion. 1. Release the fuel filler cap to release the steam pressure
9. Using T18007 to release and remove fuel pump locking in the fuel tank.
ring.
Warning: Fuel vapour is highly flammable and in confined
10. Carefully release fuel pump assembly. spaces is also explosive and toxic. Always have a fire
11. Remove seal, discard. extinguisher containing foam, CO2, gas or powder close
Refit 2. Remove the fuel pump fuse from the engine
1. Fit new seal to fuel tank. compartment fuse box.
2. Fit fuel pump, taking care not to dislodge the seal. 3. Place the ignition switch in "ON" position and keep the
3. UsingT18007 to fit the fuel pump locking ring and engine idle until it stops.
tighten to 75–85Nm. 4. Place the ignition switch in "OFF" position, restart the
engine with the ignition key and keep for 10s to confirm
Caution: Verify that the triangle mark on fuel pump is
that the engine has no fuel.
aligned with the mark (three parallel line segments) on
fuel tank, and that the outer two line segments are not 5. Fix the fuel filler cap.
exceeded.

4. Connect fuel feed and fuel return pipes to fuel pump.

5. Connect electrical connector to fuel pump.
6. Apply glue, refit access cover.
7. Position sound insulation and carpet.
8. Fit rear seat cushions.

Rear Seat Cushion Assembly Refit

9. Connect battery earth lead.

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Fuel System - Pressure Test - 1.5L fuel pump for normal operation.
Check 7. Respectively disconnect the high-pressure fuel pump
1. Place a piece of absorbent cloth around the joint of the low-pressure fuel pipe and the fuel supply pipe from
high-pressure fuel pump low-pressure fuel pipe and the TCH00106.
underfloor fuel pipeline to collect the spilled fuel. 8. Drain the fuel remaining in the tool to the container.
Warning: Fuel vapour is highly flammable and in confined 9. Connect the high-pressure fuel pump low-pressure fuel
spaces is also explosive and toxic. Always have a fire pipe to the fuel supply pipe.
extinguisher containing foam, CO2, gas or powder close
Warning: The spilling of fuel is unavoidable during this
operation. Ensure that all necessary precautions are
taken to prevent fire and explosion.
2. Disconnect the high-pressure fuel pump low-pressure
fuel pipe from the fuel supply pipe.

3. Respectively connect the joints of the high-pressure

fuel pump low-pressure fuel pipe and the underfloor
fuel pipe to the quick joints of the TCH00106.
4. Fix the TCH00106 to the fuel pressure gauge T18002.

5. Start the engine to allow the fuel pump to work,

observe the readings on the fuel pressure gauge within
a minute; if the readings are in the range of 3.5 - 3.9 bar,
the fuel system is normal.
6. Shut down the engine to stop the fuel pump; if the
system pressure drops below 2 bar after 20 minutes,
there may be something wrong with system pressure
maintaining. Check the pressure regulating valve of the

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Tank-Drain & Refill Filler Neck

Drain and Refill Remove
Warning: Fuel vapour is highly flammable and in confined 1. Disconnect battery earth lead.
spaces is also explosive and toxic. Always have a fire
Warning: Fuel vapour is highly flammable and in confined
extinguisher containing foam, CO2, gas or powder close
spaces is also explosive and toxic. Always have a fire
1. Release fuel filler cap from the filler neck. extinguisher containing foam, CO2, gas or powder close
2. Using a fuel recovery appliance, drain fuel from the tank 2. Drain fuel tank.
into a sealed container.
Drain fuel tank
3. Remove Wheelhouse Lining Board

Wheelhouse Lining Board-Remove

4. Remove clips securing fuel filler and breather pipes to
tank, remove pipes.

3. Follow manufacturer's instructions for connection and

safe use of appliance.

Warning: The capacity of containers must be more than

adequate for the amount of fuel to be extracted or
drained. The container should be clearly marked with its
contents and placed in a safe storage area which meets 5. Remove fuel filler cap.
the requirements of local authority regulation. 6. Remove bolts securing upper filler neck to body.
4. Refill fuel tank.

7. Remove bolts securing filler neck and cover to body .

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Electronic Throttle Self-learning - UMC System
1. Confirm if the vehicle speed is 0 km/h, engine speed is 0
r/min, battery voltage is higher than 10V, opening of the
accelerator pedal is 0, coolant temperature is within 5℃
- 100℃ and the intake air temperature is higher than 5℃.
2. Check if the harness is properly connected and shows no
other faults, mainly including throttle fault.
3. Place the ignition switch in "ON" position, wait for 30s,
at this interval, do not do any other operations.
4. The self-learning is then completed.

8. Remove filler neck assembly.

Refit
1. Position fuel filler neck in vehicle.
2. Refit upper filler neck retaining bolts, tighten to
5–7Nm.
3. Refit filler neck and cover retaining bolts, tighten to
5–7Nm.
4. Fit filler and breather pipes to fuel tank, secure clips.
5. Refit Wheelhouse Lining Board

Wheelhouse Lining Board-Refit

6. Refill fuel tank.
7. Refit filler cap.
8. Reconnect battery earth lead.

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Special Tools Tool Description Picture

Tool Description Picture Number
Number

Three-way pipe
TCH00106 of fuel pressure
Holding pin gauge
TEN00002
flywheel timing

Fuel pressure
T18002
Camshaft timing test equipment
TEN00004
locking

Wrench O2
TEN00011
sensor

Wrench fuel
T18007
tank lock ring

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Engine Manifold & Exhaust System
Specifications
Torque
Description Value
Bolt-Metal-hose Clamps 3-4Nm
Screw-Air Cleaner Body 1.4-1.8Nm
Bolt-Inflow Pipe to Water Beam 5-7Nm
Bolt-Electronic Throttle to Intake Manifold 8-12Nm
Nut-Exhaust Front Tube to Exhaust Back Tube 19-25Nm
Bolt-Exhaust Front Tube to Engine 19-25Nm
Nut-Exhaust Front Tube to Three-way Catalyst 19-25Nm
Bolt-Exhaust Channel Insulation to Body 4-6Nm

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Description and Operation

System Layout

1. Air Filter Assembly 7. Bolt - Air Filter Inlet Pipe

2. Air Filter Element 8. Air Filter Outlet Pipe Assembly
3. Air Filter Liner 9. Air Filter Outlet Pipe Bushing
4. Bolt - Air Filter 10. Air Filter Outlet Pipe Bushing
5. Bolt - Air Filter 11. Clamp - Air Outlet Pipe
6. Air Filter Inlet Pipe Assembly 12. Resonator

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1. Exhaust Tail Pipe 7. Front Exhaust Pipe Assembly

2. Middle Exhaust Pipe Rear Lug 8. Front Exhaust Pipe Lug
3. Exhaust Pipe Rear Mounting Bracket 9. Bolt - Front Exhaust Pipe
4. Bolt - Exhaust Pipe Rear Hook Bracket 10. Nut - Exhaust Manifold
5. Exhaust Tail Pipe Liner 11. Sealing Gasket - Exhaust Manifold
6. Nut - Exhaust Tail Pipe

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Description the exhaust system is located on the front exhaust pipe. The
Air Filter tail pipe is designed with an one-piece pipe with single hole,
which is treated by the stainless steel polishing technology. The
The air filter outlet pipe is fitted between the air filter and the
exhaust system is connected with the vehicle body through 4
throttle body, which is fixed by the worm drive clamp. The air
rubber lugs. The rubber lugs can decrease the vibration of
filter assembly is fixed to the upper part of the engine with 4
the exhaust pipe during driving. Two thermal baffles are fitted
air filter mounting pins.
respectively on the upper part of the exhaust muffler and on
Exhaust System the outer surface of the fuel tank, this can decrease the thermal
The exhaust system consists of the front exhaust pipe and rear radiation from the exhaust pipe to protect the shift device and
exhaust pipe which are connected by nuts. The muffler of fuel system.

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Operation Three-Way Catalytic Converter (TWC)
Air Filter Warning: TWCs operate at very high temperatures;
Air enters into the air filter through the air filter inlet pipe therefore, extreme caution is necessary when handling
located at the front end cooling module. The impurities in the this component.
air are filtered by the air filter element and kept in the air filter
Caution: For the TWC to work efficiently and to prevent
lower housing.
premature failure do not run on leaded fuel and do not
Air from the air filter is transferred to the throttle body via allow unburnt fuel to pass through the exhaust system.
the air filter outlet pipe.
The primary combustion happens in the combustion chamber
Exhaust Manifold and Exhaust System and the exhaust gas enters into the TWC through the exhaust
The high temperature/pressure gas generated during the manifold. TWCIt operates effectively only when its minimum
operation of the engine will enter into the exhaust manifold working temperature is achieved. The exhaust gas enters into
through each exhaust port. The manifold branches integrally an integral structure coated with Pt and Rh (catalyst), and
enter into a flange and transport the gas into the exhaust two procedures (reduction and oxidation) are performed here.
system via the three-way catalytic converter, and finally The nitrogen oxide (NOx) is restored to nitrogen, from which
discharge it through the exhaust tail pipe. With the exhaust the oxide is combined with carbon monoxide (CO) to form
system mufflers, flow noise of the gas can be greatly reduced carbon dioxide. The hydrocarbon (HC) and CO will continue
to meet relevant noise regulations at last. to conduct combustion in the three-way catalytic converter
with the oxygen in the air, which forms water and CO2.

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Service Procedures Air Filter Element

Air Filter Assembly Remove
Remove 1. Remove 1 bolt securing the metal clamp of the air filter
1. Disconnect the battery negative. outlet pipe.
2. Remove 1 bolt securing the metal clamp of the air filter 2. Remove 5 screws fixing the upper housing of the air
outlet pipe. filter to the lower housing of the air filter.

3. Pluck off the air filter inlet pipe from the air filter 3. Remove the air filter element.
assembly. Refit
4. Pull to remove the air filter assembly directly. 1. Fit the air filter element.
Refit 2. Fit 5 screws fixing the upper housing of the air filter
1. Fix the air filter assembly to the engine. to the lower housing of the air filter, tighten to
2. Fit 1 bolt securing the metal clamp of the air filter 1.4-1.8Nm, and check the torque.
outlet pipe, tighten to 3-4Nm, and check the torque. 3. Fit 1 bolt securing the metal clamp of the air filter
3. Fix the air filter inlet pipe to the air filter assembly. outlet pipe, tighten to 3-4Nm, and check the torque.

4. Connect the battery negative.

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Air Inlet Pipe Assembly Electronic Throttle
Remove Remove
1. Remove 2 bolts fixing the air inlet pipe assembly to the 1. Disconnect the battery negative.
upper radiator beam. 2. Remove the intake manifold assembly.
Intake Manifold Liner Remove
3. Fit 3 bolts fixing the electronic throttle to the intake
manifold assembly.

2. Remove 1 bolt of the metal clamp fixing the air inlet

pipe assembly to the resonator.

4. Disconnect the electronic throttle from the intake

manifold assembly, and remove the O-ring.
Refit
1. Clean the junction surface of the throttle and the
intake manifold assembly, and ensure there is no foreign
material.
2. Fit the new O-ring.
3. Fit 3 bolts fixing the electronic throttle to the intake
manifold assembly, tighten to 8-12Nm, and check the
torque.
4. Fit the intake manifold assembly.
3. Remove the air inlet pipe assembly.
Refit Intake Manifold Liner Refit

1. Fit the air inlet pipe assembly. 5. Connect the battery negative.

2. Fit 1 bolt of the metal clamp fixing the air inlet pipe 6. Perform self-learning for the electronic throttle.
assembly to the resonator, tighten to 3-4Nm, and Electronic Throttle Self-learning - UMC System
check the torque.
3. Fit 2 bolts fixing the air inlet pipe assembly to the
upper radiator beam, tighten to 5-7Nm, and check
the torque.

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Front Exhaust Pipe Assembly

Remove
Warning: Exhaust components get extremely hot during
operation. Ensure exhaust components are sufficiently
cooled before handling.
1. Remove the bottom deflector.
Bottom Deflector Remove
2. Remove 2 bolts (1) fixing the front exhaust pipe
assembly to the three-way catalytic converter.
3. Remove 1 bolt (2) fixing the front exhaust pipe
assembly to the engine.

6. Remove the front exhaust pipe assembly.

Refit
1. Fit 2 nuts fixing the front exhaust pipe assembly to the
rear exhaust pipe assembly, tighten to 19-25Nm, and
check the torque.
2. Fit the rubber lug securing the front exhaust pipe
assembly.
3. Fit 1 bolt fixing the front exhaust pipe assembly to the
engine, tighten to 19-25Nm, and check the torque.
4. Fit 2 nuts fixing the front exhaust pipe assembly to the
three-way catalytic converter, tighten to 19-25Nm,
and check the torque.
4. Remove the rubber lug securing the front exhaust pipe
5. Fit the bottom deflector.
assembly.
Bottom Deflector Refit

5. Remove 2 nuts fixing the front exhaust pipe assembly

to the rear exhaust pipe assembly.

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Engine Manifold & Exhaust System Engine
Rear Exhaust Pipe Assembly 2. Fit 2 nuts fixing the rear exhaust pipe assembly to the
Remove front exhaust pipe assembly, tighten to 19-25Nm, and
Warning: Exhaust components get extremely hot during check the torque.
operation. Ensure exhaust components are sufficiently 3. Lower the vehicle on a lift.
cooled before handling.
1. Raise the vehicle on a lift.
2. Remove 2 nuts fixing the rear exhaust pipe assembly to
the front exhaust pipe assembly.

3. Remove the rubber lug securing the rear exhaust pipe

assembly.

Refit
1. Fit the rubber lug securing the rear exhaust pipe
assembly.

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Exhaust Passage Heat Shield Fuel Tank Heat Shield

Remove Remove
1. Remove the front exhaust pipe assembly. 1. Remove the rear exhaust pipe assembly.

Front Exhaust Pipe Assembly Remove Rear Exhaust Pipe Assembly Remove
2. Remove 6 metal retainers fixing the heat shield of the 2. Remove 5 metal retainers fixing the heat shield of the
exhaust passage to the body. fuel tank to the fuel tank.

3. Remove the heat shield of the exhaust passage. 3. Remove the fuel tank heat shield assembly.
Refit Refit
1. Fit 6 metal retainers fixing the heat shield of the exhaust 1. Fit 5 metal retainers fixing the heat shield of the fuel
passage to the body, tighten to 4-6Nm, and check the tank to the fuel tank, tighten to 4-6Nm, and check
torque. the torque.
2. Fit the front exhaust pipe assembly. 2. Fit the rear exhaust pipe assembly.

Front Exhaust Pipe Assembly Refit Rear Exhaust Pipe Assembly Refit

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Engine Electrical System
Specifications
Torque
Description Value
Bolt-Accessory Drive Belt Tensioner to Engine 62-68Nm
Bolt-Accessory Drive Belt Tensioner to Engine 45-55Nm
Bolt-Start Motor to Engine 19-25Nm
Nut-Battery positive cable to start motor 11–15Nm
Bolt-Battery positive cable to transmassion 7–10Nm
Bolt-Battery positive cable to fuse block 6–9Nm
Nut-Battery positive cable to battery positive clamp 4–6Nm
Bolt-Battery negative cable to transmission case 15–20Nm
Bolt-Battery negative cable bracket to the left side rail 19–25Nm
Nut-Engine harness to Battery negative cable 7–10Nm
Nut-Battery negative cable to clamp 4–6Nm
Bolt-Battery clip to battery 19–25Nm
Bolt-Battery bracket to battery tray 19–25Nm
Bolt-Battery tray to engine fuse box 6–8Nm
Bolt-Battery tray to battery tray bracket 19–25Nm
Bolt-Battery tray front of bracket to transmission mount 19–25Nm
Bolt-Battery tray rear of bracket to body 19–25Nm
Bolt-Battery tray rear of bracket to the left side rail 19–25Nm
Idler -Idler to Engine 45-55Nm

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Engine Engine Electrical System

Description and Operation

System layout
Starting and Charging System Layout

1. Starter Motor 2. Generator

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Description Transistors of the regulator can adjust the output voltage
Alternator through the quick switch of the internal induced voltage. The
regulator has an output terminal of the charging indicator
The alternator is fitted on the right front of the engine. The
which can control the operation of the indicator. When the
drive pulley is fitted on one end of the rotor, which is driven
output voltage of the alternator is lower than the battery
by the multislot V-shaped belt of the crankshaft. The location
voltage, the indicator illuminates. The alternator load signal
of the alternator is fixed, and the belt tension is maintained by
output is also provided by the regulator, and the output data
the automatic tension pulley of the wheel train.
is provided to ECM, and ECM adapts to a variety of electrical
The alternators are similar in structure, including a stator, a loads by adjusting the idle speed.
rotor, a rectifier and a regulator. The one-way output terminal
The ignition system provides excitation current to the rotor
is connected to the battery positive with a thick cable via 150A
through the collector ring on the alternator rotor shaft
fuse. The alternator is connected to the ground through its
when the alternator is at low speed. When the speed of the
bracket. A three-pin connector is the load signal connecting
alternator increases, the alternator becomes self-excited.
terminal of charging warning lamp output, ignition signal input
and alternator output. Starter Motor

The rotor consists of an exciting winding, which is wound on The starter motor is located at the left rear side of the engine,
the iron core and fitted on the shaft. Both ends of the iron core it is fixed to the mounting hole on the transmission housing
extend, forming the north and south poles of the magnetic line with 2 flange bolts.
in the coil. The rotor is located in the stator, which is fitted The starter motors are of the pre-engaged type, which
on the bearing so as to guarantee stable rotation and enable it includes a solenoid, a one-way clutch and a motor body. When
to support the high load in the drive belt tension application. the ignition switch is in "START" position and the engine is
The stator includes a stator core and a stator coil which requested for start, the body control module integrated with
has brackets supporting at both ends. The stator is made of anti-theft function will output signals to switch on the starter
the thin and soft iron sheet, its slot fits with the stator coil, relay after passing anti-theft verification.
and is fixed on the alternator housing. The stator has three Battery
sets of coils which are made of copper wires with insulating Battery Instruction
paint. These 3 coil windings are connected in a "triangle
connection" scheme, thus the tail end of each winding is All vehicles have a 12V maintenance-free lead-acid battery
connected together. The output current is provided from the equipped at the left side of the engine compartment, which is
other end of each winding. The stator coil allows the magnetic fitted on the pressed steel bracket fixed on the transmission
flux from the rotor magnetic pole to flow through the stator mount, fastened by the battery retaining strap, and covered
coil. Rotation of the rotor makes the coil generate AC. by the battery heat shield. The battery electrodes are of
chuck-connected pole type.
The rectifier is located at the rear side of the alternator,
converts the AC generated by the stator coil to DC required Warning: Battery fluid (electrolyte) contains sulphuric
for the vehicle electrical system. The rectifier includes 8 acid. It may cause severe burns if it gets on your skin or
semiconductor diodes which are mounted on a heat sink for in your eyes. Wear protective clothing and a face shield.
heat dispersion. Three diodes are mounted on the front, If electrolyte gets on your skin or clothes, immediately
three on the opposite side, and the other two in the middle. rinse it off with water. If electrolyte gets in your eyes,
When the output voltage of the alternator is lower than the immediately flush eyes with water for at least 15 minutes
battery voltage, the rectifier also prevents the current from and seek medical help.
flowing from the battery to the alternator. The battery has three main functions. Firstly, it provides
The integrated circuit regulator is also located at the rear power for starting the engine. Secondly, it is used as a voltage
side of the alternator, controls the output voltage of the regulator of the electrical system. Lastly, it can provide energy
alternator to avoid battery overcharging and protect the in a certain amount of time when the electrical demand
vehicle electrical system. The regulator optimizes the battery exceeds the engine output.
charging according to relevant temperatures, sets a rated Compared with the conventional battery, the packaging
output voltage of 14.5V and changes the output voltage battery have following advantages:
according to the battery load and required load for the vehicle
• There is no need to add water during the entire life cycle
electrical system.
of the battery.

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Engine Engine Electrical System

• It adopts the overcharge protective measures. If the Battery Charging Operation:

voltage applied to the battery is too high, it will not
• Connect two positive poles between charger and battery,
receive the excess current as the conventional battery
and connect two negative poles between charger and
will. For the conventional battery, if the battery
battery as well. If the battery is not removed from the
continues to be charged when the voltage is too high, air
vehicle, PLEASE connect the negative cable of the charger
leakage will occur, causing fluid loss.
negative pole to the body ground well.
• Compared with the conventional battery, self discharge
• Ensure the poles are clean, and the charging circuit loop
does not tend to occur for this kind of battery. This is
is all right.
especially important when the battery is not used for a
long time. • During charging process, if the battery temperature is
higher than 40℃, MUST stop charging, and after he
• For the cigar lighter and smaller electrical equipment, the
battery temperature falling to environment temperature,
electric quantity supplied is more reliable.
the battery can be charged again.
Battery Charging • DO NOT charge the battery under 0℃.
When the engine is not running, by the reasons of electric For the battery whose voltage value is under 11.0V, at the
equipments opening for long time, vehicle creepage and first of charging it may appear the phenomena that the battery
longtime parking, or some malfunction in the alternator, the cannot be charged. Because badly discharging, the inverse
battery might not be charged and will be flat, the vehicle even proportion of vitriol in battery is too small, the liquid is close
not can be started. On this condition, the battery need to be to pure water, battery’s inner resistance value is too high.
charged. With the charging going on, the inverse proportion of vitriol in
Caution: When charging or Emergency Starting, the battery will rise up, the charging process could become breath
negative cable should be connected to the body earth again.
well, while not the negative pole. Battery Measure
Battery Appearance Checking Before Charging: Battery can be measured by familiar equipment on the after
• If the shell is broken or there is a leak, DO NOT charge sales market, such as Midtronics series instruments. If the
the battery and replace it after finding the reason. equipment is not type-suited, the measured data can not be
used to judge the battery’s status.
• If the pole is broken, DO NOT charge the battery and
replace it after finding the reason. Battery Replacement
• The bulge battery for over discharging or over charging, Caution: When removing the battery, ensure that the
CAN NOT be charged. The battery should be replaced. alarm is disarmed and that the ignition is switched off.
• Before charging, clean the poles, rub off rust. And smear Always disconnect the negative terminal first and then
some butter to avoid electricity corroding. the positive terminal. When refitting the battery, always
fit the positive terminal first followed by the negative
Charging Announcements:
terminal.
• PLEASE pull on the security glass.
Refer to "Battery - Remove/Refit" when replacing the battery.
• Keep ventilation and normal temperature when charging.
• DO NOT smoke when charging, and avoid kindling in.
• Before charging, connect the positive cable at first. After
charging, disconnect the negative cable at first.

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Engine Electrical System Engine
Operation lamp will go out. At this moment, the alternator can generate
Alternator sufficient self-excited current via the diode in the magnetic
field and begin to charge the battery. If the charging warning
Alternator uses the self-excited system, where many diodes
lamp remains on, the charging system fails and a check must
supply part of the current generated by the alternator for the
be performed, otherwise, the battery will be damaged.
rotors. Alternator can not supply the initial current required
for start-up of the charging procedure. Initial current is Starter Motor
supplied by the battery power supply through ignition switch When the ignition switch is in "START" position, the coil will
to activate the exciting winding to start up the charging supply power to connect the pinion and the flywheel gear ring.
procedure. When the ignition switch is turned on, the battery The pinion moves spirally around the motor reel, thus the
voltage is also supplied through the charging warning lamp motor reel can achieve the connection through the gear ring.
and grounds via the field winding of the alternator, so that the On the starter motor, the motor drives the pinion through the
LED warning lamp illuminates. transmission instead of the motor reel directly.
When starting the engine, the rotor is rotating in the stator, When starting the engine, the one-way clutch prevents motor
generating the 3-phase alternating current (AC). When the armature overspeed. The driver should not remove the key
rotor speed increases, the output voltage will rise quickly, from the "START" position so that the motor can keep running.
and the potential difference of the diode output end of
After start-up of the engine, when the ignition switch is
the magnetic field will raise. When the voltage increases,
released, the solenoid coil will release energy to pull out the
the charging warning lamp will darken gradually. When the
pinion from the gear ring.
alternator output voltage is equal to the battery voltage, the

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Engine Engine Electrical System

Service Procedures 5. Connect the battery negative wire.

Alternator 6. Put down the vehicle.
Remove
1. Raise the front of the vehicle.

Warning: Do not work on or under a vehicle supported

only by a jack.Always support the vehicle on safety stands.
2. Disconnect the battery negative wire.
3. Remove the connector of the alternator and the engine
harness.

4. Remove the auxiliary drive belt.

Auxiliary Drive Belt Removal

5. Remove 3 bolts connecting the alternator to the
cylinder head and cylinder block.

6. Remove the alternator.

Refit
1. Clean the mating surface of the alternator, cylinder
head and cylinder block.
2. Refit 3 bolts connecting the alternator to the cylinder
head and cylinder block.
3. Refit the auxiliary drive belt.
Auxiliary Drive Belt Refit
4. Refit the connector of the alternator and the engine
harness.

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Engine Electrical System Engine
Auxiliary Drive Belt
Remove
1. Raise the vehicle to a suitable height for operation.

Warning: Do not work on or under a vehicle supported

only by a jack.Always support the vehicle on safety stands.
2. Disconnect the battery negative wire.
3. Insert the mounting tool into the square in the tensioner,
wrench the torque spanner counterclockwise, and the
torque shall be not more than 82Nm. Disconnect the
tensioner from the pulley.

3. Release the tensioner slowly, make sure the pulley is

located in the centre of the tensioner after refit, a 2mm
margin shall be kept on both sides of the tensioner.
4. Take out the tool.
5. Connect the battery negative cable.
6. Put down the vehicle.

4. Take out the pulley.

5. Allow the tensioner return slowly, and take out the

tool.
Refit
1. Insert the mounting tool into the square in the tensioner,
wrench the torque spanner counterclockwise, and the
torque shall be not more than 82Nm.
2. In the sequence shown, refit the auxiliary drive belt
into each pulley groove, tensioner and idler pulley.

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Engine Engine Electrical System

Auxiliary Drive Belt Tensioner Starter Motor

Remove Remove
1. Remove the auxiliary drive belt. 1. Disconnect the battery negative.

Auxiliary Drive Belt Remove 2. Remove the bottom deflector.

2. Remove 1 bolt fixing the auxiliary drive belt tensioner Bottom Deflector Remove
to the engine. 3. Disconnect the harness connector (1) from the starter
motor.
4. Remove 2 bolts (2) fixing the starter motor to the
engine.
5. Remove 1 bolt (3) fixing the battery negative cable to
the starter motor.

3. Remove the auxiliary drive belt tensioner.

Refit
1. Fit 1 bolt fixing the auxiliary drive belt tensioner to the
engine, tighten to 62-68Nm, and check the torque.
(1.5DVCT)
2. Fit 1 bolt fixing the auxiliary drive belt tensioner to the 6. Remove the starter motor.
engine, tighten to 45-55Nm, and check the torque. Refit
(1.3L) 1. Fit 2 bolts fixing the starter motor to the engine,
3. Fit the auxiliary drive belt. tighten to 19-25Nm, and check the torque.
Auxiliary Drive Belt Refit 2. Fit and tighten 1 nut fixing the battery negative cable
to the starter motor.
3. Connect the harness connector to the starter motor.
4. Fit the bottom deflector.

Bottom Deflector Refit

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Engine Electrical System Engine
Battery Positive Cable
Remove
1. Disconnect the battery negative.
2. Unscrew 1 nut fixing the battery positive cable to the
positive battery post, and remove the cable
3. Remove the upper cover of the engine compartment
fuse box.
4. Remove 1 bolt fixing the battery positive cable to the
engine compartment fuse box, and remove the cable.

8. Loosen the harness clip, and remove the battery

positive cable.
Refit
1. Arrange the battery positive cable in the engine
compartment, ensure correct route, and secure with
clips.
2. Fix the battery positive cable to the starter motor, fit 1
nut, tighten to 11–15Nm, and check the torque.
3. Fix the bracket of the battery positive cable to the
transmission housing, fit 1 bolt, tighten to 7–10Nm,
5. Raise the vehicle on a lift.
and check the torque (4AT only).
Warning: Do not work on or under a vehicle supported
4. Lower the vehicle on a lift.
only by a jack.Always support the vehicle on safety stands.
5. Fix the battery positive cable to the engine
6. Remove 1 bolt fixing the bracket of the battery positive
compartment fuse box, fit 1 bolt, tighten to 6–9Nm,
cable to the transmission housing (4AT only).
and check the torque.
6. Fix the battery positive cable to the battery positive
terminal, fit 1 nut, tighten to 4–6Nm, and check the
torque.
7. Connect the battery negative.

7. Remove 1 nut fixing the battery positive cable to the

starter motor, and remove the cable.

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Engine Engine Electrical System

Battery Negative Cable longitudinal beam, fit 1 nut, tighten to 19–25Nm and
Remove check the torque.
1. Loosen 1 nut fixing the battery negative cable to the 4. Fit the battery.
negative terminal, and remove the cable. Battery Refit
2. Remove 1 nut fixing the engine harness to the battery
5. Fit the engine compartment fuse box.
negative cable, and remove the harness.
Engine Compartment Fuse Box Refit
6. Fix the engine harness to the battery negative cable, fit
1 nut, tighten to 7–10Nm, and check the torque.
7. Fix the battery positive cable to the terminal, fit 1 nut,
tighten to 4–6Nm, and check the torque.

3. Remove the engine compartment fuse box.

Engine Compartment Fuse Box Remove
4. Remove the battery.
Battery Remove
5. Remove 1 bolt fixing the battery negative cable to the
left front longitudinal beam.
6. Remove 1 bolt fixing the battery negative cable to the
transmission housing.

7. Loosen the harness clip, and remove the battery

negative cable.
Refit
1. Arrange the battery negative cable in the engine
compartment, ensure correct route, and secure with
clips.
2. Fix the battery negative cable to the transmission
housing, fit 1 bolt, tighten to 15–20Nm, and check
the torque.
3. Fix the battery negative cable to the left front

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Engine Electrical System Engine
Battery Battery Tray
Remove Remove
1. Loosen 1 nut (1) fixing the battery sensor to the 1. Remove the battery assembly.
negative terminal, and remove the cable.
Battery Assembly Remove
2. Loosen 1 nut (2) fixing the battery positive cable to the
2. Remove the engine control module.
positive terminal, and remove the cable.
Engine Control Module Remove
3. Remove the battery sleeve.
4. Remove 1 bolt (3) fixing the battery fascia to the 3. Remove 4 bolts (1) fixing the battery tray to the
battery tray, and remove the battery fascia. front/rear brackets of the battery tray.

5. Remove 1 bolt (4) fixing the battery block to the 4. Remove 2 bolts (2) fixing the battery tray to the engine
battery tray, and remove the block. compartment fuse box, and remove the battery tray.

6. Remove the battery assembly.

Refit

Refit 1. Fix the battery tray to the engine compartment fuse

box, fit 2 bolts, tighten to 6–8Nm, and check the
1. Secure the battery on the tray.
torque.
2. Secure the battery with blocks, fit 1 bolt, tighten to
2. Fix the battery tray to the bracket tray bracket, fit 4
19–25Nm, and check the torque.
bolts, tighten to 19–25Nm, and check the torque.
3. Secure the battery with battery fascia, fix the fascia
3. Fit the engine control module.
bracket to the battery tray, fit 1 bolt, tighten to
19–25Nm, and check the torque. Engine Control Module Mounting Refit
4. Fit the battery sleeve. 4. Fit the battery assembly.
5. Fix the battery positive cable to the positive terminal Battery Assembly Refit
and tighten the nut firmly.
6. Fix the battery sensor to the negative terminal and
tighten the nut firmly.

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Engine Engine Electrical System

Battery Tray Front Bracket Battery Tray Rear Bracket

Remove Remove
1. Remove the battery tray. 1. Remove the battery tray.

Battery Tray Remove Battery Tray Remove

2. Remove the engine compartment fuse box. 2. Remove the harness clip from the rear bracket of the
battery tray.
Engine Compartment Fuse Box Remove
3. Remove 1 bolt fixing the rear bracket of the battery
3. Remove 3 bolts fixing the front bracket of the battery
tray to the left front longitudinal beam.
tray to the transmission mount.
4. Remove 1 bolt fixing the rear bracket of the battery
tray to the body.

4. Remove the front bracket of the battery tray.

Refit
5. Remove the rear bracket of the battery tray.
1. Fix the front bracket of the battery tray to the
Refit
transmission mount, fit 3 bolts, tighten to 19–25Nm,
and check the torque. 1. Fix the rear bracket of the battery tray to the body, fit
1 bolt, tighten to 19–25Nm, and check the torque.
2. Fit the engine compartment fuse box.
2. Fix the rear bracket of the battery tray to the left front
Engine Compartment Fuse Box Refit longitudinal beam, fit 1 bolt, tighten to 19–25Nm, and
3. Fit the battery tray. check the torque.
Battery Tray Refit 3. Fix the harness clip to the rear bracket of the battery
tray.
4. Fit the battery tray.

Battery Tray Refit

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Engine Electrical System Engine
Accessory Belt Idle Pulley
Remove
1. Remove the accessory belt.

Accessory Belt Remove

2. Remove the bolt dust cover.
3. Remove the idler pulley fixing bolt.

4. Remove idle pulley

Refit
1. Confirm the cleanliness of all mating surfaces of the
idle pulley.
2. Place the idle pulley in the fitting place.
3. Fit the idle pulley bolts, the tightening torque is
45-55Nm.
4. Fit the bolt dust cover.
5. Fit the accessory drive belt.

Accessory Belt Refit

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1.0 184
Shift Lock Control-NEW 4AT Transmission
Shift Lock Control-NEW 4AT
Specifications
Torque
Description Value
Nut-Shift Cable to Floor 7-10Nm
Nut-CONTROL-A/TRNS to Floor 7-10Nm
Bolt-Resonator to The Left Side Rail 7-10Nm
Screw-Block a Display Panel to Console 1.0-1.4Nm

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Transmission Shift Lock Control-NEW 4AT

Description and Operation

System Layout

1. Automatic Transmission Gear Shift Mechanism Knob 8. Nut - Transmission Gear Shift Mechanism
Assembly 9. Automatic Transmission Gear Shift Jumper Cable Bracket
2. Clip Assembly
3. Shift Panel 10. Bolt - Transmission Gear Shift Jumper Cable Bracket
4. Transmission Gear Display Module 11. Automatic Transmission Shift Lever Assembly
5. Screw - Panel 12. Nut - Transmission Shift Lever Sleeve
6. Nut - Transmission Gear Shift Mechanism 13. Striker - Transmission Shift Lever Cable
7. Automatic Transmission Gear Shift Mechanism Assembly 14. Clip - Transmission Shift Lever Cable

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Shift Lock Control-NEW 4AT Transmission
Description manual shift controlling. Move the shift lever forward (+) to
Gear Shift Control Mechanism finish upshift, and move the shift lever backward (-) to finish
downshift. To exit Tiptronic mode, return the shift lever to
The gear shift control mechanism mainly consists of a shift
"D" position.
lever, a base, a gear shift lock-up solenoid valve, a gear shift
cable, etc. The gear shift control mechanism base is fixed to Gear Shift Lock-up Solenoid Valve
the body central passage with 4 screws. The inner latch of the The transmission is equipped with a gear shift lock-up solenoid
shift lever is engaged with the inner groove of the base. valve located at the bottom of the shift lever. The operation of
the solenoid valve is determined by the BCM-controlled gear
shift lock-up relay in the passenger compartment fuse box.

When the shift lever is in "P" position, with the ignition switch
on and the brake pedal not applied, the lock-up solenoid valve
is not activated at the time. The lock tongue of "P" position
lock block contacts with the corresponding groove at the shift
lever bottom so as to prevent the accidental movement of shift
lever. The lock-up solenoid valve is activated only when the
brake pedal is depressed. Enable the solenoid valve to make
the solenoid valve push rod move towards front part of the
vehicle, so as to push the lock tongue of "P" position lock block
away from the corresponding groove at the shift lever bottom.
Simultaneously, press the lock button on the shift lever knob
1. Shift Lever to allow the shift lever freely change to other positions from
2. P Gear Unlock Lever "P" position.
The shift lever position operation is as follows: Shift Lever Moving out of P Position in Emergency
With the ignition on and brake pedal depressed, when the shift
lever cannot be moved out from P gear, turn off the ignition
switch, pull out the ignition key and apply the parking cable,
depress the brake pedal, pry up the upper trim panel of the
centre console with a proper tool, press the P gear emergency
unlock button located at the left upper corner of the gear shift
mechanism, move the shift lever to N position simultaneously,
start the engine and shift to the required gear.

• P: Lock the transmission to prevent the wheel glides.

• R: Choose it only when the vehicle is still and the engine
is idling.
• N: No torque passes to wheel.
• D: All 4 forward gears can be used while in this position.
This is the default choosing position of normal driving.
• S: Sport mode.
• +/-: Tiptronic. Gear Shift Cable
Tiptronic Shift The gear shift cable connects the shift lever to the shift rocker
If the shift lever moves from "D" position to the right side, the arm on the transmission. The outer cable is fixed to the shift
system will automatically enter into sport mode with different lever assembly end with a C-clip and fixed to the body and
shifting parameters. Then move the shift lever to separate transmission end by two bolts respectively. The inner cable
the Tiptronic mode and sport mode, offering completely at the shift control mechanism end is connected with the shift

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Transmission Shift Lock Control-NEW 4AT

lever, and the inner cable at the transmission end is buckled to

the transmission shift rocker arm via a cable ball joint.

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Shift Lock Control-NEW 4AT Transmission
Service Procedures
Shift Lever Knob - Automatic
Remove
1. Remove the gear panel.

Gear Panel Remove

2. Pull up the sleeve. Loosen and discard the metal clamp
on the knob.

4. If unable to avoid or mistake let the lock button in the

shift lever knob, please do the following:

a. Remove the red limit lever of the "new" shift lever

knob.

b. Insert the limit lever into the very bottom of the shift
lever knob.

3. Pull up the shift lever knob with care, and remove the
knob and sleeve assembly from the shift lever. Note
that do not touch the lock button by hands.

Caution: Do not press the lock button to the shift

lever knob when removing the knob.

c. Pull out the limit lever, and the lock button of the
shift lever knob can restore to the normal state.

5. Insert the knob assembly into the second slot of the

shift lever.
6. Press the lock button and check if it can retract freely. If
it does, the knob and the shift lever are correctly fitted.
Refit 7. Clamp the bulge of the clip with a caliper. Ensure that
1. Place the shift lever in "P" position. the knob can't be pulled.
2. Locate a new metal clip to the knob. 8. Fit the gear panel.
3. Make sure the lock button of the shift lever knob is in Gear Panel Refit
the correct position.

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Transmission Shift Lock Control-NEW 4AT

Shift Lever Assembly - Automatic

Remove
1. Place the shift lever in "P" position.
2. Remove the battery tray.
Battery Tray Remove
3. Remove 2 bolts fixing the resonator to the left
longitudinal beam, and remove the resonator.

8. Remove 2 nuts fixing the gear cable to the body.

4. Loosen the cable ball joint from the gear selection/shift

rocker arm, and loosen the clip fixing the gear
selection/shift cable to the cable bracket.

9. Remove the shift lever assembly.

Refit
1. Fix the shift lever assembly to the central passage.
2. Fit 2 nuts fixing the shift cable to the underbody, tighten
to 7-10Nm, and check the torque.
3. Fit 4 screws fixing the shift lever assembly to the body,
tighten to 7-10Nm, and check the torque.
4. Connect the connector of the gear shift control
mechanism.
5. Remove the shift lever knob. 5. Straighten out the cable route. Clamp the cable clip
on the gear shift jumper cable bracket assembly of the
Shift Lever Knob Remove
automatic transmission (press the cable mounting seat
6. Remove the heat shield of the exhaust passage. till it clicks, ensure the two ends of the clip are inserted
Exhaust Passage Heat Shield Remove into the bracket). Then insert the cable sleeve into the
7. Remove 4 screws fixing the shift lever assembly to the thermostat bracket (in the driver's perspective, the
body. front end of the sleeve is inside the thermostat bracket).
6. Shift the gear shift control mechanism to the N gear.
7. Press the cable joint clip into the automatic transmission
shift lever knob (before the connection, ensure that the
automatic transmission shift lever is in "N" position -
the raised point aligns with the TCM bolt), then press
the cable adjusting striker to fasten the cable (when it
clicks, it is fastened).

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Shift Lock Control-NEW 4AT Transmission
Gear Panel
Remove
1. Disconnect the battery negative.
2. Place the shift lever in "P" position.
3. Pry up the upper trim panel assembly with care.
4. Disconnect the connector of the gear panel.
5. Remove 4 screws fixing the gear panel to the upper
trim panel assembly, and remove the upper trim panel
assembly.

8. After completion of the system refit, pull out the N

gear striker (if equipped). Pull out the shift lever sleeve
(if equipped) before the knob refit. Then, shift the shift
lever between PRNDSS+S- gears, check if the gears are
clear and shifting force moderate, otherwise, release
the cable adjusting striker in the N gear to re-adjust
and then fasten it.

Caution: The cable clip is worn easily, if shifter is

reassembly, clip should be checked & if it is worn, it
should be replaced by new one.
6. Remove the gear panel from the knob and sleeve
Caution: Shift the lever to p position after assembling the
assembly.
knob for safe.
Refit
9. Fit 2 bolts fixing the resonator to the left longitudinal
1. Fit the gear panel to the knob and sleeve assembly.
beam, tighten to 7-10Nm, and check the torque.
2. Fit 4 screws fixing the gear panel to the upper trim
10. Remove the heat shield of the exhaust passage.
panel assembly, tighten to 1.0-1.4Nm, and check the
Exhaust Passage Heat Shield Refit torque.
11. Remove the shift lever knob. 3. Connect the conncetor of the gear panel.
Shift Lever Knob Refit 4. Fit the upper trim panel assembly with care.
12. Fit the battery tray. 5. Connect the battery negative.

Battery Tray Refit

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Transmission Shift Lock Control-MT

Shift Lock Control-MT

Specifications
Torque
Description Value
Bolt - gear change mechanism to floor 7–10Nm

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Shift Lock Control-MT Transmission
Service Procedures Gear Shift Mechanism Assembly - Manual
Shift Lever Knob and Sleeve - Manual Remove
Remove 1. Remove the shift lever knob and sleeve.
1. Place the shift lever in "N" position. Shift Lever Knob and Sleeve - Manual Remove
2. Remove the centre console upper trim panel assembly. 2. Pay attention to the mounting position, and loosen the
Centre Console Upper Trim Panel Assembly cable ball joint from the gear selection/shift rocker arm
Remove of the manual transmission.
3. Remove and discard the metal clip fixing the knob and
sleeve assembly to the shift lever.

Caution: The clip should be replace when it disassembly.

3. Loosen the clip fixing the gear selection/shift cable to

the bracket.

4. Disconnect the clip fixing the knob and sleeve to the

centre console upper trim panel.

4. Remove the cable from the cable bracket.

5. Remove the heat shield of the exhaust passage.

Exhaust Passage Heat Shield Remove

5. Pull up the knob and sleeve assembly with care, loosen 6. Remove 4 screws fixing the gear shift mechanism
and remove the assembly from the shift lever. assembly to the body.
Refit
1. Fix the shift lever sleeve assembly to the centre console
upper trim panel, and press the clip.
2. Fix the knob and sleeve assembly to the shift lever, and
clamp with new metal clamps.
3. Fit the centre console upper trim panel assembly.

Centre Console Upper Trim Panel Assembly Refit

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Transmission Shift Lock Control-MT

7. Remove the gear shift mechanism assembly.

Refit
1. Embed the clip nut into 2 holes of the central passage.
2. Locate the gear shift mechanism assembly to the central
passage, fit the bolt and tighten to 7–10Nm.
3. Fit the shift lever knob and sleeve.

Shift Lever Knob and Sleeve Refit

4. Fix the gear selection cable to the cable bracket.
5. Fit the exhaust passage heat shield.

Exhaust Passage Heat Shield Refit

6. Fix the gear selection/shift cable to the bracket with
clips.
7. Pay attention to the mounting position, and connect the
cable ball joint to the gear selection/shift rocker arm.
8. Adjust the gear selection/shift cable to a proper length.

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Transmission-AT Transmission
Transmission-AT
Specifications
Torque
Description Value
Bolt-Automatic Transmission to Engine 75-90Nm
Bolt-Automatic Transmission Mount Bracket to Automatic (45-55)Nm+(85-95)deg
Transmission
Bolt-Under The Tie-bar Bracket to Automatic Transmission (45-55)Nm+(85-95)deg
Nut-Oil-cooled Pipe to Automatic Transmission 33-37Nm
Bolt-Oil-cooled Pipe Bracket to Automatic Transmission 7-10Nm
Nut-Cable Arm to Automatic Transmission 14-20Nm
Bolt-Cable Bracket to Automatic Transmission 15-23Nm
Oil Drain Plug 14.7-19.6Nm
Oil Over Flow Plug 23-25Nm
Oil Filler Plug 35-44Nm
Nut-Transmission Control Module to Bracket 7-10Nm
Bolt-Neutral Start Switch to Automatic Transmission 4.3-6.5Nm
Nut-Shift Rocker Arm to Neutral Start Switch 14-20Nm
Bolt-Input Speed Sensor to Transmission 3.9-6.9Nm
Bolt-Output Speed Sensor to Transmission 3.9-6.9Nm
Bolt-Valve Body Cover 6-7.9Nm
Bolt-Valve Body Assy to Automatic Transmission 9.8-11.8Nm
Bolt-Oil Temperature Sensor to Valve Body Assy 5.8-7.8Nm
Union 19.6–29.4Nm

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Transmission Transmission-AT

Parameter
Automatic Transmission
Model AISIN TS-41SN new 4-speed gear automatic transmission
Stall Speed 2631 ± 150rpm
Speed Ratio

·1st gear 2.875

·2nd gear 1.568

·3rd gear 1.000

·4th gear 0.697

·R gear 2.300

·Countershaft 1.023

·Main Reduction 4.277

Clutch:

C1 Flange: 1; clutch plate: 4; clutch disc: 4

C2 Flange: 1; clutch plate: 2; clutch disc: 2

C3 Flange: 1; clutch plate: 2; clutch disc: 2; shock absorber: 1

Brake:

B1 Flange: 2; clutch plate: 2; clutch disc: 2

B3 Flange: 1; clutch plate: 4; clutch disc: 4

One-way clutch:

F2 Roller type
Solenoid valve

·Switch solenoid 1: S1

·Linear solenoid 5: SLC1, SLC2, SLB1, SLU, EMOP

ATFModel AW-1
Oil level adjustment Overflow port type
Main oil circuit pressure

Idle:

·D 0.625 - 0.775 Mpa

·R 0.499 - 0.539 Mpa

Stall:

·D 1.450 - 1.630 Mpa

·R 1.725 - 2.085 Mpa

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Transmission-AT Transmission
High: 12 - 16 mA
Output/input speed sensor
Low: 4 - 8 mA
ATFOil temperature sensor (OT)

-40℃ 161 kΩ (MAX)

-30℃ 36.3 - 52.1 kΩ

10℃ 5.626 - 7.303 kΩ

25℃ 3.5 kΩ (reference value)

110℃ 0.224 - 0.271 kΩ

145℃ 0.102 - 0.121 kΩ

150℃ 0.087 kΩ（MIN）

Clearance
Note Clearance
Automatic transmission housing - hydraulic torque converter 17.3mm
Oil seal - oil pump assembly -0.3 - 0.3mm
Oil seal - automatic transmission housing end 2.6 - 3.6mm
Oil seal - torque converter housing end 1.7 - 2.7mm
Manual shift lever oil seal - automatic transmission housing end 0.75 - 1.25mm

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Transmission Transmission-AT

Description and Operation

System Layout
Automatic Transmission Components Layout

1. Automatic Transmission 3. Shift Lever Assembly

2. Body Control Module (BCM) 4. Ignition Switch

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Transmission-AT Transmission
5. Automatic Transmission Fluid (ATF) Cooler (integrated 7. Neutral Start Switch (NSW)
in the radiator) 8. Data Link Connector
6. Brake Pedal Switch 9. Automatic Transmission Control Module (TCM)

Automatic Transmission Accessories Layout

1. Output Speed Sensor 4. Automatic Transmission Vent Pipe Assembly

2. Bolt and Gasket - Speed Sensor 5. Automatic Transmission Vent Pipe
3. Input Speed Sensor 6. O-ring - Breather Plug

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Transmission Transmission-AT

7. Automatic Transmission Vent Plug 27. Bolt and Washer - Oil Pan
8. O-ring - Automatic Transmission Oil Cooler Pipe 28. Bolt and Washer - Internal Harness Connector
Connector 29. Automatic Transmission Internal Harness Assembly
9. Automatic Transmission Oil Cooler Pipe Connector 30. O-ring - Internal Harness Connector
10. Automatic Transmission Overflow Plug 31. Clip - Temperature Sensor
11. O-ring - Automatic Transmission Oil Drain Plug 32. Bolt - Temperature Sensor
12. Overflow Pipe - Automatic Transmission Oil Pan 33. Washer - Housing and Valve Body Assembly
13. Automatic Transmission Oil Drain Plug 34. Compression Spring
14. Hydraulic Torque Converter Assembly 35. O-ring - C3 Accumulator Piston
15. Oil Seal - T Type - Right - Differential 36. C3 Accumulator Piston
16. Oil Seal - T Type - Left - Differential 37. O-ring - C3 Accumulator Piston
17. Oil Seal - T Type - Input Shaft 38. Compression Spring
18. Manual Shift Shaft Oil Seal 39. Bolt - Valve Body Assembly
19. Shift Control Switch 40. Bolt - Valve Body Assembly
20. Bolt and Washer - Shift Control Switch 41. Automatic Transmission Valve Body Assembly
21. O-ring - Filter Assembly 42. Automatic Transmission Oil Hole Screw
22. Filter Assembly 43. O-ring - Automatic Transmission Oil Hole Screw
23. Magnet 44. Washer - Automatic Transmission Fluid Filler Plug
24. Washer - Oil Pan 45. Automatic Transmission Fluid Filler Hole Plug
25. Automatic Transmission Oil Pan
26. Bolt and Washer - Oil Pan

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Transmission-AT Transmission
Automatic Transmission Section View

1. Hydraulic Torque Converter Assembly 6. C1 Clutch

2. C2 Clutch 7. F2 Single Direction Clutch
3. B3 Brake 8. Countershaft Driving Gear
4. C3 Clutch 9. Countershaft Driven Gear
5. B1 Brake 10. Differential Assembly

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Transmission Transmission-AT

Solenoid Valve Assembly

1. Shift Solenoid Valve (S1) 4. Shift Control Solenoid Valve (SLC2)

2. Lock-up Clutch Control Solenoid Valve (SLU) 5. Shift Control Solenoid Valve (SLC1)
3. Shift Control Solenoid Valve (SLB1) 6. *Electromagnetic Oil Pump (EMOP) (Start/Stop)

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Transmission-AT Transmission
System Control Diagram
Automatic Transmission Control Diagram

A = Hard Wire

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Transmission Transmission-AT

A = HS CAN Bus

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Transmission-AT Transmission
Hydraulic Control System

A: Hard Wire; B: Low-pressure Automatic Transmission Fluid (ATF); C: High-pressure Automatic Transmission Fluid (ATF);

1. Automatic Transmission Control Module (TCM) 8. Oil Operating Pressure

2. TCMOutput Signal 9. Clutch, Brake
3. Valve Body Assembly 10. Lubrication
4. Switch Solenoid 11. Output Automatic Transmission Fluid (ATF)
5. Linear Solenoid 12. Oil Circuit
6. Regulating Valve 1 13. Planetary Gear Mechanism
7. Regulating Valve 2 14. Oil Pump

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Transmission Transmission-AT

15. Oil Cooler Assembly 17. Hydraulic Torque Converter Assembly

16. Oil Pump Pressure

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Transmission-AT Transmission
Description
Overview
This model is equipped with an AISIN AW TS-41SN
electronically controlled 4-speed automatic transmission. This
transmission is applicable to front-engine front-drive vehicles,
with maximum input torque of 150 Nm.

TCMIt controls the system in a way similar to that used by

otherECUequipped on the vehicle. It receives information
from the sensor or otherECU, calculates according to the
pulse spectrum information stored in theTCMmemory and
then outputs signals to the actuators or otherECU. The signal
exchange with otherECUis mainly conducted through the
controller area network (CAN) bus.
The RAVIGNEAVX planetary gear has 2 pairs of sun gears,
The diagnostic test can be conducted through the data link pinions in the same planetary gear unit have different sizes, so
connector. When the transmission has some failures,TCMwill it have more transmission ratios compared with the traditional
store related diagnostic trouble code (DTC), which can be planetary gear unit.
retrieved with the scan tool. See "Diagnosis" for more details.
All gear ratios are obtained through the planetary gear set
Diagnosis in the transmission housing. The single component in the
planetary gear set is driven or locked by 3 clutches, 2 brakes
The gear selection is conducted through the shift lever on
and 1 one way clutch. The clutch, brake and one way clutch
the centre console. The shift lever supplies the driver with 5
control the engagement and rotation direction of these
selectable gears, including P (Park), R (Reserve), N (Neutral),
elements in the planetary gear set, so as to generate the
D (Drive) and S (Sport mode).
selection of "P" gear and "N" gear, 4 drive gear ratios and 1
TCMThe shift mode is controlled according to one of the reserve gear ratio. The P.T.O (power take off) of the drive
preprogramming parameter sets that grouped to different system will be transmitted to the differential through the main
driving modes. reduction gear.
Available Modes: Transmission Gear Ratio
• Economy Mode Gear Speed Ratio
• Sport Mode (the sport mode can activate the Tiptronic 1st Gear 2.875
mode and supply manual control) 2nd Gear 1.568
The current driving mode can be displayed on the instrument 3rd Gear 1.000
pack after the vehicle is started. 4th Gear 0.697
• It will not be displayed if the economy mode is selected. Reverse Gear 2.300
• When selecting the Tiptronic mode, the information of Main Reduction Gear 4.277
the selected gear will be displayed on the instrument
Countershaft 1.023
pack.
Transmission assembly Hydraulic Control System

TS-41SN adopts lightweight and compact RAVIGNEAVX Based on the hydraulic pressure generated by the oil
planetary gears, compared with traditional automatic pump,TCMsends signals to each solenoid valve. These signals
transmissions needing 2 planet gear sets to realize upshift will control the pressure applied to the hydraulic torque
and downshift, TS-41SN can realize the gear shift with converter, planetary gear set, clutch and brake according to
1 RAVIGNEAVX planetary gear set. It makes the drive vehicle driving conditions.
mechanism simpler and lighter. Valve Body Assembly
The transmission uses 6 solenoid valves on the valve body.
The solenoid valves are activated or deactivated by theTCM,
and controls theATFflow (shift sequence) supplied to the
clutch and the brake, hydraulic torque converter, lubrication
and cooling. The solenoid valve may be divided into linear

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Transmission Transmission-AT

control solenoid valves and switch solenoid valves according

to their operations.
• Switch Solenoid Valve: S1
• Linear Control Solenoid Valves: SLC1, SLC2, SLB1, SLU,
EMOP

Each solenoid valve is provided with one inner coil and one
needle valve. The needle valve is activated by the voltage that
passes through the solenoid coil, and it opens or closes the
hydraulic circuit. The shift solenoid valve closes the hydraulic
circuit to accommodate to the current liquid flow. The linear
control solenoid valve can control the hydraulic circuit with a
better linearity.

All solenoid valves are powered byTCM, the grounding of the Shift Control Solenoid Valves (SLC1, SLC2 and
SLB1)
shift solenoid valves (SLC1, SLC2 and SLB1), lock-up clutch
control solenoid valve (SLU) and electromagnetic oil pump
(EMOP) is provided by theTCMand the grounding of the shift
solenoid valve (S1) is provided by the valve housing.
Solenoid Valve
Shift Solenoid Valve (S1)

1. Shift Control Solenoid Valve SLC1

2. Shift Control Solenoid Valve SLC2
3. Shift Control Solenoid Valve SLB1

The shift control solenoid valves (SLC1, SLC2, SLB1) are fitted
on the valve body,TCMcontrols the solenoid valves (SLC1,
SLC2 and SLB1), and the shift control solenoid valve linearly
The shift solenoid valve S1 is fitted on the valve
controls the oil pressure to the clutches (C1, C2 and C3) and
body,TCMcontrols the on/off of the shift solenoid valve S1.
the brakes (B1 and B3) to realize smooth shift. According to
It switches the oil passage according to the on/off state of
the combination of different states of the shift control solenoid
shift solenoid valve S1 to realize the fuel economy. As a
valves, the transmission realizes the gear shift (from 1st gear to
failure protection function, when any shift solenoid valve is
4th gear or from 4th gear to 1st gear). As a failure protection
abnormal,TCMcan cut off the current to the solenoid valve.
function, when any shift solenoid valve is abnormal,TCMcan
Shift solenoid valve S1 is normally closed.
cut off the current to the solenoid valve.

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Lock-up Clutch Control Solenoid Valve (SLU)

The lock-up clutch control solenoid valve SLU is fitted on

the valve body, and it linearly controls the operating pressure
of the lock-up clutch in the hydraulic torque converter
based on the engine speed, throttle opening, input speed
sensor (NC2) signal and output speed sensor (SP) signal so
as to realize the lock-up control. As a failure protection
function, when any lock-up clutch control solenoid valve SLU
is abnormal,TCMcan cut off the current to the solenoid valve.

1. Inlet
2. Outlet
3. Discharge

The shift solenoid valves (SLC1 and SLC2) are normally open,
and the oil pressure decreases with the increase of the current.

The shift control solenoid valve (SLB1) is normally closed, and

the oil pressure increases with the increase of the current.

1. Inlet
2. Outlet
3. Discharge

The lock-up clutch control solenoid valve is normally closed,

and the oil pressure increases with the increase of current.

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1. Inlet
2. Outlet
Valve Body Solenoid Valve Transmission End
Harness Assembly

Electromagnetic Oil Pump (EMOP)

Valve Body Harness Connector

1. Electromagnetic Oil Pump (EMOP)

EMOP is fitted on the front of the valve body. EMOP is of

the same structure as the linear solenoid valve with its piston
moving based on the ON/OFF signal sent byTCMto generate
hydraulic pressure. The hydraulic pressure generated by
Pin No. Description
the EMOP is only used for controlling C1 clutch under the
stop state of Stop/Start to enable the smooth transition of 1 Oil temperature sensor (OT) (+)
the engine to start state. If any abnormality is detected, the 2 Electromagnetic oil pump
operation of EMOP is not permitted under the stop state of (EMOP) (+)
Stop/Start for failure protection. Meanwhile, the current of 3 Lock-up clutch control solenoid
EMOP will be cut off. valve (SLU) (+)
4 Pressure control solenoid
valve (SLB1) (+)
5 Pressure control solenoid
valve (SLC2) (+)
6 Pressure control solenoid
valve (SLC1) (+)
7 Oil temperature sensor (OT) (-)
8 Electromagnetic oil pump
(EMOP) (-)
9 Lock-up clutch control solenoid
valve (SLU) (-)
10 Shift solenoid valve (S1)

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Pin No. Description is on the one way clutch between the pump impeller and the
11 Pressure control solenoid turbine.
valve (SLB1) (-) The pump impeller obtains oil and swings it into the turbine,
12 Pressure control solenoid making the turbine rotate and transmit power. The guide
valve (SLC2) (-) wheel makes the liquid flow returning from the turbine change
13 Pressure control solenoid direction and enter the pump impeller again in the rotation
valve (SLC1) (-) direction same with that of the pump impeller and at the
optimal angle of highest power transmission efficiency.
The valve body solenoid valve harness combines the harnesses
of the shift solenoid valve (S1), the lock-up clutch control The one way clutch prevents the guide wheel from moving
solenoid valve (SLU), the shift control solenoid valves (SLC1, backwards, so as to obtain accurate liquid change direction.
SLC2 and SLB1), the EMOP andATFthe oil temperature When the engine is idling, the pump impeller transmits
sensor (OT) into a connector, and mounts it in an automatic extremely little liquid flow and the turbine remains no rotation,
transmission. and therefore, no power is transmitted to the transmission.
Hydraulic Torque Converter When the engine speed increases, the pump impeller swings
more liquid flow to make the turbine rotate. With the increase
of the engine speed, the turbine speed begins to increase. The
turbine speed becomes faster and faster, more and more liquid
flow is swung to the back of the guide wheel, causing the guide
wheel to rotate in the same direction with the turbine. When
the turbine speed is close to the pump impeller speed, the
centrifugal forces of both are almost equal, and all the three
components rotate roughly in the same speed. This is called
"coupling point".

The torque increases by times or the transmission rate

remains changing until reaching to the 1:1 coupling point. For
obtaining the required power to climb mountain road, the
driver steps down the accelerator pedal, and the hydraulic
1. Hydraulic Torque Converter Assembly torque converter will promote the torque increment as
2. Hydraulic Torque Converter Housing response. When driving on the flat road at the cruise speed,
3. Lock-up Clutch the required power is not big. Therefore, the hydraulic torque
converter remains the speed ratio of 1:1.
4. Turbine
5. Guide Wheel Transmission Control Module (TCM)

6. Pump Impeller
7. Oil Pump
8. Input Shaft

The hydraulic torque converter is in its housing in the right

transmission housing.

The hydraulic torque converter functions to combine the

engine and the transmission. The power output by the engine
is transmitted to the transmission through the hydraulic force
and mechanism (through the lock-up clutch of the hydraulic
torque converter under certain gears and working conditions).
The hydraulic torque converter is connected with the engine
through the drive plate.
TCMis located on the dash panel at the driver side. It is
The hydraulic torque converter comprises the pump impeller, connected with the automatic transmission harness through
guide wheel and turbine. The engine drives the pump impeller, two connectors. The connector A has 24 pins, and the
while the turbine drives the transmission. The guide wheel connector B has 26 pins.

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TCMUse the electrically erasable programmable read TCMadjusts the operation of the transmission through the
only memory (EEPROM). Therefore, the new or following actuators:
replacedTCMcan be used to conduct the external • Shift solenoid valve (S1)
configuration.EEPROMcan alsoTCMupdate the new
• Lock-up clutch control solenoid valve of the hydraulic
information and market-specific data. To input new
torque converter (SLU)
information, theTCMmust be configured with a scan
• Shift control solenoid valve (SLC1, SLC2, SLB1)
tool.EEPROMcanTCMbe reconfigured for many times as
required, so as to meet the constantly changing parameters • Electromagnetic oil pump (EMOP)
and regulations. TCMIt also connects with the following units through
TCMstores the signal values of the transmission sensor theCANbus:
and the actuator. These stored signals guarantee that the • ECM
transmission can always obtain the optimal performance. If • BCM
the battery voltage is too low, such as battery discharges, the
• Instrument Pack
information will be lost. When the engine starts for the first
time after the battery is discharged or disconnected,TCMwill • Data Link Connector
resume to the default value.TCMinside theEEPROMallows TCMreceives the input signals such as the throttle opening
the stored values to be rapidly accessed again. fromECM, engine coolant temperature, engine speed, engine
Input and Output torque, brake switch, etc.;TCMalso receives the input signals
such as the contact positions of the neutral start switch
The sensor signal enablesTCMto monitor the transmission
and input and output speed,ATFoil temperature, valve
state.TCMprocesses the signals and compares them with
body solenoid valve state, mode switch, etc. In addition,
the data stored in the memory. If these signals are not in
theTCMoutputs the torque decrease request, shift gear
theTCMrange of parameters stored,TCMwill adjust the
information and failure warning information toECMand
operation of the transmission through the actuator to provide
outputs execution signal, etc. to the valve body solenoid valve.
the optimal driveability and other performances.

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Wiring Terminal of Automatic Transmission Pin No. Description
Control Module (TCM)
22 Pressure control solenoid
TCMEnd View and Pin Information of Connector valve (SLC1) (+)
GB006 and GB007 23 Ground (-)
24 Ignition switch voltage

Pin No. Description

1 Ground (-)
Pin No. Pin Functions
2 Pressure control solenoid
valve (SLU) (-) 1 "R" signal (NSW)
3 Lock-up clutch control solenoid 2 -
valve (SLU) (-) 3 -
4 Pressure control solenoid 4 -
valve (SLU) (+)
5 Output speed sensor (SP) (-)
5 Lock-up clutch control solenoid
valve (SLU) (+) 6 Input speed sensor (NC2) (-)
6 Supply voltage (+) 7 "D" signal (NSW)
7 CANCommunication signal (low) 8 "N" Signal (NSW)
8 - 9 Manual gearshift mode switch
9 Pressure control solenoid 10 -
valve (SLC) (-) 11 -
10 Electromagnetic oil pump 12 -
(EMOP) (-)
13 -
11 Oil temperature sensor (OT) (+)
14 Output speed sensor (SP) (+)
12 Oil temperature sensor (OT) (-)
13 - 15 -
14 - 16 Input speed sensor (NC2) (+)
17 -
15 CAN high
18 -
16 Shift solenoid valve (S)
19 -
17 CANCommunication signal (high)
20 "P" signal (NSW)
18 -
21 Manual gearshift switch (upshift)
19 Pressure control solenoid
valve (SLC2) (-) 22 Manual gearshift switch
- (downshift)
20
23 -
21 Pressure control solenoid
valve (SLC2) (+) 24 -

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Pin No. Pin Functions

25 -
26 -

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Neutral Start Switch (NSW) • Input speed
• Output speed
• Vehicle speed

The transmission speed sensor is the Hall type and generates

square wave signal which is converted into speed byTCM.
TCMThe vehicleCANspeed signal generated by
theABScontrol module is collected through the bus.

Based on these signals,TCMcontrols the engine torque, shift

time and lock-up.

The neutral start switch is located on the manual

valve gear selection shaft at the front end of the
transmission.TCMreceives the voltage output provided
by the neutral start switch to determine the gear of the
automatic transmission.

1. Input speed sensor

2. Clutch hub
3. Output speed sensor
4. Countershaft drive gear

Input Speed Sensor (NC2)

The input speed sensor is on the transmission housing for

measuring the speed of the transmission input shaft. The
magnetic resistance distribution ring on the hub of clutch C2
TCMdetermines the position of the shift lever by monitoring
will rotate when the hydraulic torque converter drives the
the 5 groups of gear contacts on the neutral start switch.
input shaft. When passing through the input speed sensor, each
Each group of contacts correspond to 1 shift lever position
gear will generate a signal and send it toTCM.
respectively, and only one group of contacts always provide
battery voltage for TCM,TCMmonitors this switch output. Output Speed Sensor (SP)
The electric input of the neutral start switch is supplied by the The output speed sensor is on the transmission housing for
fuse in the passenger compartment fuse box. measuring the speed of transmission output shaft. The output
speed sensor operates in the same manner as the input speed
Only when the shift lever is in N or P gear can the contact
sensor, but its signals are generated when the gear teeth pass
ST close the loop. In this case, the starter motor relay will be
through the magnetic resistance distribution ring on the park
controlled byBCMto engage and the vehicle will be started.
gear.
Speed Sensor
TCMUse the input of the following three speed signals to set
the correct shift sequence:

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Oil Temperature Sensor Brake Pedal Switch

1. Oil Temperature Sensor The brake pedal switch is located on the pedal box in the
cab.TCMUse this switch to monitor the state of the brake
The oil temperature sensor is integrated with the transmission
pedal.ECMmonitors the switch state and transmits the data
internal harness and mounted on the valve body. It directly
viaCANbus toTCM.
detects the temperature of the oil in the hydraulic control
circuit, and sends the oil temperature signal toTCM.TCMuses If signal error of the brake pedal switch occurs,
oil temperature sensor to monitor the oil temperature in the • the shift lever can not shift to other gears from P or N
transmission to accommodate the oil temperature change, and gear.
realize smooth gear shift in a wide temperature range. The
• No additional engine braking will be generated.
oil temperature sensor has an electric output and grounds
viaTCM. Transmission Oil Cooler

The fluid temperature sensor is a negative temperature The transmission oil cooler is located in the collector of the
coefficient sensor. When the temperature rises, the sensor radiator. The oil cooler pipe connects the transmission and
resistance lowers; when the temperature decreases, the the oil cooler.
sensor resistance increases. The resistance change is inversely Controller Area Network (CAN) Bus
proportional to the transmission oil temperature. calculates TCMcommunicates viaCANbus with otherECUand controls
the transmission oil temperatureTCMthrough the sensor the followings:
resistance.
• Shift Torque
• Engine Coolant Temperature
• Engine Torque And Speed
• Vehicle Speed
• Selected Gear
• Shift Information
• Reduction Of Engine Torque
• Engine Braking

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Transmission-AT Transmission
Operation
Power Flow
The following data shows the power flow of each forward gear
and reverse gear in the transmission.

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Data Notes
Clutch, Brake and Planetary Gear Set Operation
Connect the intermediate shaft
C1 Clutch C1
with the front sun gear
Connect the input shaft with the
C2 Clutch C2
planetary carrier
Connect the intermediate shaft
C3 Clutch C3
with the rear sun gear
B1 Brake B1 Lock the rear sun gear
B3 Brake B3 Lock the planetary carrier
Lock the planetary carrier to prevent
F2 One-way Clutch F2
counterclockwise rotation

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Transmission-AT Transmission
Operating Components

One-way
Solenoid Valve Clutch Brake
Clutch
Gear
SLC1 SLC2 SLB1 SLU S1
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C

P × × × × × × × ×
V≤9 × × × × × ×
R
V ＞ 11 × × × × × ×
N × × × × × × × ×
1st × × *1 × × × ×
1st E/B × × × ×
2nd ⊙ *1 × × × ×
N cont. × × × ×
D
2nd - 3rd ® ®× ⊙ × ×® × ®× × ×

3rd × ⊙ × × × × ×
3rd - 4th ×® ⊙ × ®× × ×® × ×
4th ⊙ × × × × ×
ON (N/O: OFF，N/C: ON)
× OFF(N/O: ON，N/C: OFF)
Remarks Lock ON
⊙
Lock OFF
controled (linear oil circuit pressure)

Lock range: 2nd - 4th gear *1: （V≤13km/h)/×(V﹥13 km/h)

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D - 1st Gear

One-way
Solenoid Valve Clutch Brake
Clutch
Gear
SLC1 SLC2 SLB1 SLU S1
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C

D 1st × × *1 × × × ×

*1: （V≤13km/h)/×(V﹥13km/h)

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Transmission-AT Transmission
D - 1st Gear

Functional element: C1, F2 (lock counterclockwise rotation)

Input Locking Output
Planetary Gear Set
Sun Gear Planetary Carrier Gear Ring

1. Input shaft rotates clockwise. 7. Planetary gear ring rotates clockwise.

2. Clutch C1 rotates clockwise. 8. Countershaft drive gear rotates clockwise.
3. Front sun gear rotates clockwise. 9. Countershaft driven gear rotates counterclockwise.
4. Short planetary gear rotates counterclockwise. 10. Differential gear rotates clockwise.
5. Long planetary gear rotates clockwise.
6. One-way clutch F2 operates to prevent counterclockwise
rotation of planetary carrier.

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D - 1st Gear (Engine Brake)

One-way
Solenoid Valve Clutch Brake
Clutch
Gear
SLC1 SLC2 SLB1 SLU S1
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C

D 1stE/B × × × ×

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D - 1st Gear (Engine Brake) locked by one-way clutch F2, it tries to rotate clockwise during
engine braking, but brake B3 locks its rotation after it is on, and
Functional element: C1, F2 (lock counterclockwise rotation),
the driving force is transmitted to the engine from wheels.
B3 (open during engine braking)

The wheel provides drive force when the engine brake works.
Because the counterclockwise rotation of planetary carrier is

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D - 2nd Gear

One-way
Solenoid Valve Clutch Brake
Clutch
Gear
SLC1 SLC2 SLB1 SLU S1
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C

D 2nd ⊙ *1 × × × ×

*1: （V≤13 km/h)/×(V﹥13km/h)

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Transmission-AT Transmission
D - 2nd Gear

Functional element: C1, B1 (lock the front sun gear rotation)

Planetary Gear Set Input Locking Output
Sun Gear Rear Sun Gear Gear Ring

1. Input shaft rotates clockwise. 7. Planetary carrier rotates clockwise.

2. Clutch C1 rotates clockwise. 8. Planetary gear ring rotates clockwise.
3. Front sun gear rotates clockwise. 9. Countershaft drive gear rotates clockwise.
4. Short planetary gear rotates counterclockwise. 10. Countershaft driven gear rotates counterclockwise.
5. Long planetary gear rotates clockwise. 11. Differential gear rotates clockwise.
6. Brake B1 operates to prevent the rotation of front sun
gear.

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Transmission Transmission-AT

D - 3rd Gear

One-way
Solenoid Valve Clutch Brake
Clutch
Gear
SLC1 SLC2 SLB1 SLU S1
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C

D 3rd × ⊙ × × × × ×

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Transmission-AT Transmission
D - 3rd Gear

Functional element: C1, C2

Planetary Gear Set Input Locking Output
Front Sun Gear and - Gear Ring
Planetary Carrier

1. Input shaft rotates clockwise. 5. Countershaft drive gear rotates clockwise.

2. Clutch C1 rotates clockwise. 6. Countershaft driven gear rotates counterclockwise.
3. Clutch C2 rotates clockwise. 7. Differential gear rotates clockwise.
4. Planetary carrier rotates clockwise.

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D - 4th Gear

One-way
Solenoid Valve Clutch Brake
Clutch
Gear
SLC1 SLC2 SLB1 SLU S1
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C

D 4th 4 ⊙ × × × × ×

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D - 4th Gear

Functional element: C2, B1

Planetary Gear Set Input Locking Output
Planetary Carrier Front Sun Gear Gear Ring

1. Input shaft rotates clockwise. 7. Front sun gear rotates clockwise.

2. Clutch C2 rotates clockwise. 8. Planetary gear ring rotates clockwise.
3. Planetary carrier rotates clockwise. 9. Countershaft drive gear rotates clockwise.
4. Brake B1 operates to prevent the rotation of front sun 10. Countershaft driven gear rotates counterclockwise.
gear. 11. Differential gear rotates clockwise.
5. Long planetary gear rotates clockwise.
6. Short planetary gear rotates counterclockwise.

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R Gear

One-way
Solenoid Valve Clutch Brake
Clutch
Gear
SLC1 SLC2 SLB1 SLU S1
C1 C2 C3 B1 B3 F2
N/O N/O N/C N/C N/C

V≤9 km/h × × × × × ×
R
V﹥11 km/h × × × × × ×

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Transmission-AT Transmission
R Gear

Functional element: C3, B3

Planetary Gear Set Input Locking Output
Sun Gear Planetary Carrier Gear Ring

1. Input shaft rotates clockwise. 6. Front sun gear rotates counterclockwise.

2. Clutch C3 rotates clockwise. 7. Planetary gear ring rotates counterclockwise.
3. Brake B3 operates to prevent the rotation of planetary 8. Countershaft drive gear rotates counterclockwise.
carrier. 9. Countershaft driven gear rotates clockwise.
4. Long planetary gear rotates counterclockwise. 10. Differential gear rotates counterclockwise.
5. Short planetary gear rotates clockwise.

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Overview Lock-up Clutch Control of Hydraulic Torque

Converter
TCMIt controls the following functions:

• Gear Shift Control

• Oil Circuit Pressure Control
• Reduction of Engine Torque
• Adaptive Rule
• Lock-up Clutch Control of Hydraulic Torque Converter
• Use of Driving Mode
• Uphill Mode
• Downhill Mode
• Heating Mode
• Gear Display
• Driving Mode Display 1. Pump Impeller
• Malfunction Condition 2. Turbine
• DTC Storage 3. Lock-up Clutch Mechanical Device
• Emergency/Failure Protection Program Control 4. Hydraulic Torque Converter Oil Supply (Release)
Automatic Transmission Shift Control 5. Use of Supply Device
TCMAdjust the sequence of the shift according to the 6. Input Shaft
relationship between the vehicle speed and the throttle
position. According to these inputs, the TCM sends electric
signal to the shift solenoid (S1, SLC1, SLC2, SLB1) in the valve
to control the gear shift, the lock-up clutch control solenoid
(SLU) controls the lock-up clutch.
Gear SLC1 SLC2 SLB1 S1
1st × *1

1stE/G ×
brake
2nd *1

3rd × ×
4th × 1. Pump Impeller

Tiptronic Shift Control 2. Turbine

3. Lock-up Clutch Mechanical Device
If the shift lever moves from "D" position to the right side, the
system will automatically enter into sport mode with different 4. Hydraulic Torque Converter Oil Supply (Lock)
shifting parameters. Then move the shift lever to separate 5. Input Shaft
the Tiptronic mode and sport mode, offering completely
The pump impeller and turbine inside the hydraulic torque
manual shift controlling. Move the shift lever forward (+) to
converter may slide somewhat, which can reduce fuel
finish upshift, and move the shift lever backward (-) to finish
economy. This situation can be eliminated by using the lock
downshift. And the TCM can upshift automatically to prevent
device of the hydraulic torque converter, and the lock device
overspeed. If the vehicle speed is low, it downshifts and locks
is connected with the turbine. According to the engine
the control.
speed, throttle opening and vehicle speed information, the
TCM will activate the lock-up clutch solenoid and lock the
clutch solenoid so as to control the lock-up control valve
and guide the liquid flow to lock or release the hydraulic
torque converter. Lock the lock-up supply pipe imposed by
the hydraulic pressure on the hydraulic torque converter

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Transmission-AT Transmission
and force the friction liner of the lock device to locate on Economy Mode
the pump impeller so as to create mechanical connection
Normally, the TCM will consider the economy mode as
and eliminate the sliding between the pump impeller and
the default mode to be started. The economy mode is a
the turbine. Release the release supply pipe imposed by the
compromise between the sport mode and the snow mode,
hydraulic pressure on the hydraulic torque converter and
in this mode, the shift point and the engaging point to be
force the friction liner to leave the pump impeller and return
locked are within a lower speed range, this helps to reduce
to the hydraulic connection between the pump impeller and
engine speed, provide shift sequence for economical driving
the turbine.
and improve fuel economy.
The transmission has the lock function among the 2nd/3rd/4th
When some specified conditions are met, the automatic
gear, the TCM monitors the relationship between the vehicle
transmission will automatically shift to a specific mode even in
speed and throttle position and determines when to lock the
the economy mode.
hydraulic torque converter.
Sport Mode and Tiptronic Mode
In addition, add speed signal input to detect the sliding ratio
and realize slide control. When locking the clutch by sliding In the sport mode, the TCM uses the shift pulse map with the
within the lock-up cancel range, the slide control can expand engine speed in higher gear higher than that in the economy
the lock-up range to the low speed range. This prevents mode, this strategy helps acceleration and vehicle response.
increased engine speed and drive efficiency and improves fuel However, once the shift lever moves forward or backward,
economy. Meanwhile, with the sliding of the lock-up clutch, the transmission enters into the Tiptronic mode. Then gently
the hydraulic torque converter absorbs the engine vibration. push the shift lever to upshift/downshift manually.
(AW-1 automatic transmission fluid shall be used) In the Tiptronic mode, the TCM controls automatic upshift
N-D and N-R Shift Control and the engine speed can be raised to the maximum. But the
TCM allows manual shift to be done only when the engine
N-D and N-R shift control can improve the shift quality from
speed is within the preset value. If the vehicle returns to the
N gear to D/R gear.
parking state, the 1st gear will be selected automatically. In
After engine start, by controlling/adjusting the shift solenoid the Tiptronic mode, all gears can be selected manually, and the
(SLC1, SLC2), the system controls/adjusts the pressure of the current gear can be displayed on the instrument pack at the
oil flowing to the clutch (C1, C2) and applies the optimum oil driver side. In the Tiptronic mode, the vehicle can start in the
pressure to control the shift quality from N gear to D/R gear. 1st/2nd/3rd gear.
Reverse Control Snow Mode

When the vehicle is in D gear and coasts at a speed above In the snow mode, the vehicle starts in the 2nd gear. TCMShift
11km/h, the reverse control is activated and brake B3 is sequence will be changed to help vehicle control under slippery
released. For safety reasons, the TCM will also prohibit the or icy conditions. Shift operations are done at a low engine
transmission to shift to R gear even when the shift lever moves speed.
from N gear to R gear. Reverse control takes priority over
Uphill Mode
the shift control from N gear to R gear.
This mode changes the general shift sequence and helps to
Self-diagnosis and Failure Protection Function
maintain the driving performance on steep slopes. TCMThe
TCMThese functions monitor the communication status of uphill mode is activated by monitoring the engine torque,
each sensor, actuator and control module (including ECM, etc). throttle angle and engine speed. This mode selects high speed
When any failure occurs, the TCM will warn the driver and shift point and avoids frequent shift according to the gradient.
save the failure in the form of DTC. Deletion of the DTC and
Downhill Mode
initialization learning can only be done by the special scan tool.
When the accelerator pedal is fully released, and the vehicle
With the failure protection function, when the automatic
acceleration is still increasing, TCMdetermine if the vehicle is
transmission system fails, the TCM will output control signal
in the downhill mode, in this mode, change the high speed shift
and achieve movement within a short distance. If the shift
point to control engine brake.
solenoid fails, the TCM will cancel the control signal for the
solenoid, and the shift of the automatic transmission is then Heating Mode
controlled by the oil pressure circuit only. When the shift The purpose of the transmission fluid cooling strategy is to
lever is in the R gear, fix it in the reverse gear; when it is in reduce the temperature of the engine and transmission under
the D gear, fix it in the 3rd gear. high load. Under these conditions, the engine and transmission

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can produce excess heat. If the sensor sends the signal that the Warning: Never use the stall method to raise the ATF
ATF temperature is higher than 130℃, the TCM will adopt temperature, adaptive procedure can be performed
the "heating mode" shift strategy. TCMWhen the heating only when the ATF temperature is between 65℃ and
mode is selected, the gear will upshift in advance and the 80℃. Before performing the adaptive procedure,
lock-up clutch will act between the 2nd gear and the 4th gear. check for shift impact or speed change impact.
This can reduce the engine speed or the sliding in the hydraulic
2. N-D and N-R Shift Adaptive Learning
torque converter and lower the possibility of heat generation.
If the ATF temperature is below 125℃, normal shift strategy During static braking, shift to N gear and maintain for 3s.
will be resumed. Then, shift to D gear from N gear and maintain for 3s,
and then return to N gear. Repeat the above procedures
In the heating mode, the warning lamp on the instrument pack
for 5 times.
will not illuminate.
During static braking, shift to N gear and maintain for 3s.
Failure Protection
Then, shift to R gear from N gear and maintain for 3s,
When the automatic transmission is in the failure protection and then return to N gear. Repeat the above procedures
mode, if the current automatic transmission is in the D gear, for 5 times.
shift to the 3rd gear and maintain the gear; if it is in the R gear,
3. Shift Control Adaptive Learning
maintain the gear.
Shift to D gear, and apply a throttle opening of 25-35％
Adaptive Rule
to accelerate to the 4th gear, the vehicle speed shall be
Caution: Adaption data must be cleared after 80km/h or above. Then release the accelerator pedal and
replacement of the automatic transmission or after a allow the vehicle to coast till it stops (within 60s). Repeat
software update. And readaption will then be required. the above procedures for 10 times.
Perform Adaptive Learning 4. Confirm Adaptive Learning Effect
1. Warm-up
Confirm the shift quality (shift impact or speed change
The ATF temperature can be raised between 65℃ and impact, etc) is better than that before the adaptive
80℃ by driving at idle speed or by driving on city roads. operation.
Use the scan tool to confirm the ATF temperature.

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Transmission-AT Transmission
diagnosis Transmission Malfunction State
Overview If the TCM detects any failure in the transmission system, such
Overview as solenoid valve or sensor failure, the TCM will enter into
If the TCM detects any failure, related diagnostic trouble code the failure protection mode. TCMMultiple failure protection
(DTC) will be stored in the TCM memory. The scan tool can modes can be adopted. TCMThe failure protection mode
be used to download these DTCs to identify the failure causes. most acceptable for the driver will be adopted to ensure
TCMThe TCM memory can store up to 8 DTCs and can not minimum damage to the transmission. When any failure is
store any more codes, unless the stored DTCs are cleared. detected, TCM will send CAN information to the IPK, and
the IPK displays "EP" to inform the driver of the automatic
The DLC produced in accordance with ISO 15765 is located
transmission failure.
in the driver's footwell. The DLC is directly connected to
the CAN bus and can regain the diagnostic information and Caution: Not all the DTCs can illuminate the warning
program some functions to be executed. light of the instrument pack.

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Transmission Transmission-AT

Machinery Diagnosis Harness and Connector Diagnosis

Deflection of Drive Disc Check Warning: The following operating instructions
should be followed when checking:
•Do not hale the harness when disconnecting the
connector.

•Place the detector on the harness side instead of the

connector terminal side when checking the harness.

•Make sure the polarity is correct when connecting the

battery. Polarity connection error will damage parts.

•Be careful when handling parts to avoid damage or

impact.

•Do not damage or bend the terminals when it is necessary

to connect the detector directly to the terminals to check
the parts.
Harness and Connector

1. Check if the deflection of the drive disc is within the

standard value.

Standard Value Within 0.2mm

• TCMConnector (Harness Side)
2. If the measured value exceeds the standard value, replace
the drive disc. Ignition Switch Power Supply System

Caution: Take care to fit correct bolt securing torque Step 1

converter to drive plate. If not, the longer bolt will 1. Disconnect the connector from the TCM.
damage the lock-up clutch. 2. Place the ignition switch in "ON" position.
Caution: DO NOT use the mechanical wrench when 3. With the voltage measurement function of a multimeter,
tightening the bolt. measure the voltage between the combined connector
3. If abnormal wear occurs or hydraulic torque converter terminals.
sleeve/oil pump sticks, replace the hydraulic torque Check the voltage according to the instructions in the
converter and automatic transmission. following table:

Standard:
Terminal No. [Name] Voltage [V]
A24 [IG] - A1 [GND] 10 - 14
A24 [IG] - A23 [GND] 10 - 14

Caution: Do not damage the terminal.

Step 2

1. Place the ignition switch in "OFF" position.

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Transmission-AT Transmission
2. With the resistance measurement function of a 1. Disconnect the connector from the TCM.
multimeter, measure the conductivity between the 2. With the voltage measurement function of a multimeter,
combined connector terminals and the body ground. measure the voltage between the combined connector
Check the conductivity according to the instructions in terminals.
the following table: Check the voltage according to the instructions in the
Standard: following table:
Terminal No. [Name] Conductivity Standard:
A24 [IG] - Body GND No Terminal No. [Name] Voltage [V]
A6 [B+] - A1 [GND] 10-14
Caution: Do not damage the terminal.
A6 [B+] - A23 [GND] 10-14
CAN Communication System

Step 1 Caution: Do not damage the terminal.

1. Disconnect the connector from the TCM. Step 2

2. Disconnect the connector from the ECM. 1. With the voltage measurement function of a multimeter,
3. With the resistance measurement function of a measure the voltage between the combined connector
multimeter, measure the conductivity between the terminals.
combined connector terminals. Check the voltage according to the instructions in the
Check the conductivity according to the instructions in following table:
the following table: Standard:
Standard:
Terminal No. [Name] Voltage [V]
TCM Side - ECM Side Conductivity
A6 [B+] - Body GND 10 - 14
Terminal No. [Name]
A7 [CANL] - [ECM Side/ Caution: Do not damage the terminal.
CANL] Step 3
Yes
A17 [CANL] - [ECM 1. With the resistance measurement function of a
Side/ CANL] multimeter, measure the conductivity between the
combined connector terminals and the body ground.
Caution: Do not damage the terminal.
Check the conductivity according to the instructions in
Step 2
the following table:
1. With the resistance measurement function of a
Standard:
multimeter, measure the conductivity between the
combined connector terminals or between the combined Terminal No. [Name] Conductivity
terminals and the body ground. A1 [GND] - Body GND Yes
Check the conductivity according to the instructions in A23 [GND] - Body GND Yes
the following table:
Standard: Caution: Do not damage the terminal.

TCM Side Terminal Conductivity Tip Gear Shift Switch System

No. [Name] Step
A17 [CANL] - A7 [CANL] 1. Disconnect the connector from the TCM.
A7 [CANL] - Body GND No 2. With the resistance measurement function of a
A17 [CANL] - Body GND multimeter, measure the conductivity between the
combined connector terminals and the body ground.
Caution: Do not damage the terminal.
Check the conductivity according to the instructions in
Battery Power Supply System the following table:
Step 1 Standard:

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Transmission Transmission-AT

Tiptronic B9 [MS] - B21 [MS+] - B22 [MS-] - Switch Solenoid Valve S1

Mode Body GND Body GND Body GND Step
Tiptronic
No No No 1. Disconnect the connector from the TCM.
Mode OFF
Tiptronic 2. With the resistance measurement function of a
Yes No No multimeter, measure the resistance between the
Mode ON
combined connector terminals and the body ground.
Upshift Yes Yes No
Check the resistance according to the instructions in the
Downshift Yes No Yes
following table:
Caution: Do not damage the terminal. Standard:

Oil Temperature Sensor System Terminal No. [Name] Resistance [Ω] 20℃

Step 1 A16 [S1] - Body GND 11 - 15

1. Disconnect the connector from the TCM. Caution: Do not damage the terminal.
2. With the resistance measurement function of Linear Solenoid
a multimeter, measure the resistance between
the combined connector terminals at various oil Step 1
temperatures. 1. Disconnect the connector from the TCM.
Check the resistance according to the instructions in the 2. With the resistance measurement function of a
following table: multimeter, measure the resistance between the
Standard: combined connector terminals.

Automatic Check the resistance according to the instructions in the

Terminal No. Transmission following table:
Resistance [KΩ]
[Name] Oil Temperature Standard:
[℃]
Terminal No. [Name] Resistance [Ω] 20℃
-40℃ 161 (MAX)
A22 [SLC1] - A9 [SLC1G] 5.0 - 5.6
-30℃ 36.3 - 52.1
A21 [SLC2] - A19
5.0 - 5.6
10℃ 5.626 - 7.303 [SLC2G]
A11 [OT] - A12
(25℃) (3.5) A4 [SLB1] - A2 [SLB1G] 5.0 - 5.6
[OTG]
110℃ 0.224 - 0.271 A5 [SLU] - A3 [SLUG] 5.0 - 5.6
145℃ 0.102 - 0.121
Caution: Do not damage the terminal.
150℃ 0.087 (MIN)
Step 2
Caution: Do not damage the terminal. 1. With the resistance measurement function of a
Step 2 multimeter, measure the conductivity between the
combined connector terminals and the body ground.
1. With the resistance measurement function of a
multimeter, measure the conductivity between the Check the conductivity according to the instructions in
combined connector terminals and the body ground. the following table:

Check the conductivity according to the instructions in Standard:

the following table: Terminal No. [Name] Conductivity
Standard: A22 [SLC1] - Body GND No
Terminal No. [Name] Conductivity A9 [SLC1G] - Body GND No
A11 [OT] - Body GND No A21 [SLC2] - Body GND No
A12 [OTG] - Body GND No A19 [SLC2G] - Body GND No
A4 [SLB1] - Body GND No
Caution: Do not damage the terminal.

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Transmission-AT Transmission
Terminal No. [Name] Conductivity Step 1

A2 [SLB1G] - Body GND No 1. Disconnect the connector from the TCM.

A5 [SLU] - Body GND No 2. With the resistance measurement function of a

multimeter, measure the resistance between the
A3 [SLUG] - Body GND No combined connector terminals.

Caution: Do not damage the terminal. Check the resistance according to the instructions in the
following table:
Speed Sensor
Standard:
Step
Terminal No. [Name] Resistance [Ω] 20℃
1. Disconnect the connector from the TCM.
2. With the resistance measurement function of a A15 [EMOP+] - A10
5.0 - 5.6
multimeter, measure the conductivity between the [EMOP-]
combined connector terminals.
Caution: Do not damage the terminal.
Check the conductivity according to the instructions in
Step 2
the following table:
1. With the resistance measurement function of a
Standard:
multimeter, measure the conductivity between the
Terminal No. [Name] Conductivity combined connector terminals and the body ground.
B14 [SP+] - B5 [SP-] Yes Check the conductivity according to the instructions in
B16 [NC2+] - B6 [NC2-] Yes the following table:

Standard:
Caution: Do not damage the terminal.
Terminal No. [Name] Conductivity
Neutral Start Switch (NSW)
A15 [EMOP+] - Body
Step No
GND
1. Disconnect the connector from the TCM. A10 [EMOP-] - Body
No
2. With the resistance measurement function of a GND
multimeter, measure the conductivity between the
combined connector terminals. Caution: Do not damage the terminal.

Check the conductivity according to the instructions in

Valve Body Harness Check
the following table:

Standard:
B20 B19
B1 [R] B8 [N] B7 [D]
[P] - [W]
Gear - A24 - A24 - A24
A24 - A24
[IG] [IG] [IG]
[IG] [IG]
P Yes No No No No
R No Yes No No No
N No No Yes No No
D No No No Yes No
W No No No No Yes
• Valve Body Harness Connector
Caution: Do not damage the terminal. Oil Temperature Sensor (OT) System
Electromagnetic Oil Pump (EMOP)

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Transmission Transmission-AT

Caution: Do not damage the terminal.

Gear Shift Solenoid Valve S1

1. Disconnect the connector of the valve body harness and

body harness.
2. With the resistance measurement function of a
multimeter, measure the resistance between the terminal
of valve body harness connector 10 [S1] and the body
ground.

Check the resistance according to the instructions in the

following table:

Standard:
1. Disconnect the connector of the valve body harness and Terminal No. [Name] Resistance [Ω] (at 20℃)
body harness.
10 [S1] - Body GND 11 - 15
2. Heat the automatic transmission oil and immerse the oil
temperature sensor into it. Caution: Do not damage the terminal.
3. Corresponding to the temperature of the automatic
Linear Solenoid
transmission oil, with the resistance measurement
function of a multimeter, measure the resistance between Step 1
terminal 1 [OT] and 7 [OTG] of the valve body harness 1. Disconnect the connector of the valve body harness and
connector. body harness.
Standard: 2. With the resistance measurement function of a
Automatic Transmission multimeter, measure the resistance between the
Resistance [KΩ] terminals of the valve body harness connector.
Oil Temperature [℃]
-40℃ 161 (MAX) Check the resistance according to the instructions in the
following table:
-30℃ 36.3 - 52.1
Standard:
10℃ 5.626 - 7.303
Terminal No. [Name] Resistance [Ω] (at 20℃)
(25℃) (3.5)
6 [SLC1] - 13 [SLC1G] 5.0 - 5.6
110℃ 0.224 - 0.271
5 [SLC2] - 12 [SLC2G] 5.0 - 5.6
145℃ 0.102 - 0.121
4 [SLB1] - 11 [SLB1G] 5.0 - 5.6
150℃ 0.087 (MIN)
3 [SLU] - 9 [SLUG] 5.0 - 5.6
Caution: Do not damage the terminal.
Caution: Do not damage the terminal.
Step 2
Step 2
1. With the resistance measurement function of a
multimeter, measure the conductivity between the 1. With the resistance measurement function of a
combined terminals of the valve body harness connector multimeter, measure the conductivity between the
and the body ground. combined terminals of the valve body harness connector
and the body ground.
Check the conductivity according to the instructions in
the following table: Check the conductivity according to the instructions in
the following table:
Standard:
Standard:
Terminal No. [Name] Conductivity

1 [OT] - Body GND

No
7 [OTG] - Body GND

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Transmission-AT Transmission
2. With the resistance measurement function of a
Terminal No. [Name] Conductivity
multimeter, measure the conductivity between the
6 [SLC1] - Body GND terminals of the output speed sensor (SP).
13 [SLC1G] - Body GND Check the conductivity according to the instructions in
5 [SLC2] - Body GND the following table:
Standard:
12 [SLC2G] - Body GND
No Terminal No. [Name] Conductivity
4 [SLB1] - Body GND
1 [SP-] - 2 [SP+] Yes
11 [SLB1G] - Body GND
3 [SLU] - Body GND Caution: Do not damage the output speed sensor (SP)
9 [SLUG] - Body GND and terminal.
Step 2
Caution: Do not damage the terminal.

Electromagnetic Oil Pump (EMOP)

Step 1

1. Disconnect the connector of the valve body harness and

body harness.
2. With the resistance measurement function of a
multimeter, measure the resistance between the
terminals of the valve body harness connector.
Check the resistance according to the instructions in the
following table:
Standard:
Terminal No. [Name] Resistance [Ω] (at 20℃)
2 [EMOP+] - 8 [EMOP-] 5.0 - 5.6

Caution: Do not damage the terminal.

Step 2

1. With the resistance measurement function of a

1. Release the connector of the output speed sensor,
multimeter, measure the conductivity between the
connect terminal 2 to the battery positive as shown in
combined terminals of the valve body harness connector
the figure, and connect terminal 1 to the battery negative
and the body ground.
via the resistance (100Ω) and ampere meter.
Check the conductivity according to the instructions in
Caution:
the following table:
•Do not mix the polarity.
Standard:
•Do not damage the output speed sensor (SP).
Terminal No. [Name] Conductivity
•Do not damage the terminal.
2 [EMOP+] - Body GND No
2. When waving the metal piece (magnetic object) back and
8 [EMOP-] - Body GND No forth at the end of the output speed sensor (SP) (less
than 5mm), measure the current.
Caution: Do not damage the terminal.
Standard:
Speed Sensor
Signal Current [mA]
Output Speed Sensor (SP)
High 12.0 - 16.0
Step 1
Low 4.0 - 8.0
1. Disconnect the connector of the output speed sensor
(SP) and body harness. Input Speed Sensor (NC2)

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 Transmission Transmission-AT

Step 1 Standard:
1. Disconnect the connector of the input speed sensor Signal Current [mA]
(NC2) and body harness. High 12.0 - 16.0
2. With the resistance measurement function of a
Low 4.0 - 8.0
multimeter, measure the conductivity between the
terminals of the input speed sensor (NC2). Solenoid Valve
Check the conductivity according to the instructions in Gear Shift Solenoid Valve
the following table: Test the resistance of gear shift solenoid valve S1
Standard:
Terminal No. [Name] Conductivity
1 [NC2-] - 2 [NC2+] Yes

Caution: Do not damage the input speed sensor (NC2)

and terminal.
Step 2

Temperature [℃] Resistance [Ω]

20 11 - 15

1. Remove the automatic transmission valve body cover,

and remove the gear shift solenoid valve S1 of the
transmission.

Caution:

•Do not impact the solenoid valve.

•Do not damage the terminal.

2. With a multimeter, measure the resistance between the

solenoid terminal and the solenoid valve body.
Check the operating condition of gear shift solenoid
1. Remove the input speed sensor (NC2). valve S1
2. Release the connector of the input speed sensor, connect 1. Connect the battery positive to the solenoid valve
terminal 2 to the battery positive as shown in the figure, terminal and battery negative to the solenoid valve
and connect terminal 1 to the battery negative via the housing, and check the solenoid valve operation.
resistance (100Ω) and ampere meter. 2. Connect the battery positive to the solenoid valve
terminal and battery negative to the solenoid valve
Caution:
housing, operate the solenoid valve and apply air, then
•Do not mix the polarity. check if air is flowing in the direction as shown in the
•Do not damage the input speed sensor (NIN). figure.

•Do not damage the terminal.

3. When waving a sheet metal (magnetic material) back and

forth at the end of the input speed sensor (NC2) (less
than 5mm), measure the current.

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 Transmission-AT Transmission

Caution: DO NOT damage the strainer when checking the Connect the battery positive to terminal 1 of each solenoid
operation condition of each solenoid valve. valve via 1 bulb (12 - 21 W), when connecting the battery
negative to terminal 2 of the solenoid valve, check the
Check the resistance of the gear shift control solenoid
valve (SLC1, SLC2, SLB1), lock-up control solenoid operation of the solenoid valve.
valve (SLU) or electromagnetic oil pump (EMOP) Check ATF
When the automatic transmission internal failure occurs, the
quality of ATF will change accordingly, therefore the condition
of ATF will be the key element in failure diagnosis.

1. Low fluid level: oil pump will inhale air which can
result in low oil pressure and functional malfunction of
transmission.
2. High fluid level: a large number of bubbles produced by
the stir of the gear set will overflow from the vent pipe.
3. Normal ATF: red, with moderate viscosity. Abnormal
ATF: water (white emulsion) or a mixture of different
ATF will lead to "shift impact" and "rough running",
degrading the performance.
Check ATF Level
Temperature [℃] Resistance [Ω]
20℃ 5.0 - 5.6Ω Automatic Transmission Fluid Refill
Check ATF Quality
1. Remove the automatic transmission valve body cover,
and remove the valve body assembly. 1. Check the quality of ATF (with or without metal
particles, powder of friction plate, burning smell, white
Caution:
emulsion and nigrescence). Excessive metal chips and
•Do not remove the gear shift control solenoid valve or bushing powder could cause the automatic transmission
lock-up control solenoid valve or EMOP from the valve body internal wear.
assembly. 2. Check if the ATF discolors. If yes, it indicates that ATF
•Do not impact the solenoid valve. may be mixed with water, special attention shall be paid
and the cooling system will be inspected.
2. With a multimeter, measure the resistance between
3. If required, replace the automatic transmission assembly
terminal 1 and 2 of each solenoid valve.
(with AT internal failure).
Check the operating condition of each solenoid valve Fluid Leak
Check the following components for fluid leak: junction
surface of the automatic transmission and engine, housing
junction, oil seal and O-ring.

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Transmission Transmission-AT

For the fluid leak from the joint of the automatic transmission • When the ATF temperature is within 50 - 80℃ and the
and engine, check the fluid leak and determine whether it driving condition is normal.
leaks from the engine or the automatic transmission. If it is • A/C, lamps, etc are off.
automatic transmission fluid, it is probably leaked from the fuel
• Cruise control function is off.
pump oil seal or O-ring.
Warning: When performing the road test on common
For the fluid leak from the housing junction: re-apply the
roads, check road safety first.
sealant.

For the fluid leak from the side cover junction: re-apply the Item Step
sealant. Drive under normal
conditions, check the
For the fluid leak from the joint of the oil pan and housing: Gear Shift Function (D
gear shift, 1st to 2nd gear,
Gear)
repair the oil pan sealing washer. 2nd to 3rd gear and 3rd to
4th gear.
Drive under normal
Horizontal Vibration During
conditions, check if the
Driving
upshift is smooth.
Check the kick-down
function of each gear
Kick-down Function
and check for horizontal
vibration.
Check the operating state
Engine Braking of the engine braking in the
1st gear of the sport mode.
With the shift lever at sport
Gear Shift Control Function
mode, check if it can shift to
at Sport Mode
any gear manually.
When driving on level
roads, slightly depress the
Fluid Leaked from the Outside of Oil Seal accelerator pedal within the
Lock-up Control Function
lock-up speed range to see
a. Check if the oil seal is properly fitted. Replace the oil seal if the engine speed changes
and fit it properly if necessary. dramatically.
When the vehicle is parking
b. Check the condition of the contact surface between on the slope (greater than
transmission housing and oil seal, ensure there is no scratch 5% or 3°), place the shift
or dent. Replace the automatic transmission assembly if lever in P gear and release
P Gear Test
the parking brake, the
necessary.
vehicle shall not move under
Fluid Leaked from the Inside of Oil Seal the action of the parking
pawl.
a. Check the drive shaft for any scratch, dent or wear. Replace
After road test, check each
the oil seal and fit it properly if necessary. Fluid Leak
component for fluid leak.
b.Check and ensure there is no foreign material, cutting mark Function Test
or wear on the oil seal lip. Replace the oil seal and fit it properly
if necessary. Carry out the road test under the following conditions:

Caution: When fitting the drive shaft, it should • After engine check and adjustment.
be erectly inserted into the spline hole of the • A/C, lamps, etc are off.
transmission differential. • Cruise control function is off.
Road Test Warning: To prevent accidental start of the vehicle,
Road tests can be used for precise fault symptom diagnosis and ensure the vehicle is locked before function test.
fault symptom check after the handling procedures, ensure that Delay test
road tests are carried out under the following conditions:
Delay refers to the duration of the slight vibration when
• After engine check and adjustment. switching the shift lever from N gear to D/R gear under idle
engine condition.

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Transmission-AT Transmission
Caution: Make 3 measurements and average the value. 1. Block four vehicle wheels with wood wedges and fully
Ensure there is an interval longer than 1min apply the parking brake to lock the vehicle.
for each delay test so that the pressure of the 2. Depress the brake pedal with the left foot heavily, place
clutch/brake can be fully released. the shift lever in D or R gear, and depress the accelerator
1. Block four vehicle wheels with wood wedges and fully pedal with the right foot to measure the max. speed at
apply the parking brake to lock the vehicle. idling or stalling.

2. With the stopwatch, record the duration of the slight Stall Speed Around 2631 ± 150rpm
vibration when switching the shift lever from N gear to
D/R gear. Stall Test Results Failure Cause
Low engine power
N - D gear Less than 1.5s Both values at D and R gear
are below the standard value Hydraulic torque converter
N - R gear Less than 1.5s one-way clutch failure
Low oil circuit pressure (shift
Delay test results Failure Cause
solenoid valve SLC1/primary
Valve body failure (SLC1 pressure regulating valve
or SLC2 hydraulic system) failure)
Only the value at D gear is
Delay from N gear to C1 failure (slip) above the standard value Valve failure (SLC1 hydraulic
D gear is longer than system)
F2 failure
standard value
C1 failure (slip)
Oil pump failure
F2 failure
Oil filter failure (blockage)
Low oil circuit pressure (shift
Valve body failure (SLC1,
solenoid valve SLC2/primary
SLC2 or S1 hydraulic
pressure regulating valve
system)
Delay from N gear to failure)
C3 failure (slip) Only the value at R gear is
R gear is longer than above the standard value Valve failure (SLC2 hydraulic
standard value B3 failure (slip) system)
Oil pump failure C3 failure (slip)
Oil filter failure (blockage) B3 failure (slip)

Stall Test Low oil circuit pressure

(shift solenoid valve SLC1
The stall test applies the stall speed of the D/R gear to check
or SLC2/primary pressure
the overall performance of the automatic transmission and Both values at D and R gear
are above the standard value regulating valve failure)
engine. Prior to test, ensure the ATF temperature is within
50 - 80℃, and the electrical equipment is off such as A/C, Oil pump failure
headlamp, etc. Filter failure (blockage)
Warning: The operation shall not be longer than
5s, or the ATF will become hot. Ensure there is
an interval longer than 1min for each stall test.
Test for at least 3 times and calculate the average
value.

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Transmission Transmission-AT

Service Procedures 6. Fit the special tool T26001 on the D gear testing hole
Hydraulic Pressure Test of the automatic transmission.
Check 7. Start the engine, depress the brake pedal and place the
During hydraulic test, check the working conditions of the shift lever in "D" position. When the vehicle meets the
automatic transmission by measuring the idling and stall oil requirement, switch to the start/stop state.
pressure at D and R gear. 8. When the engine stops under the start/stop state,
check the fluid pressure.
Warning: The operation shall not be longer than 5s,
or the temperature of the ATF will become too high. Description:
Ensure there is a spacing longer than 1 min between
Gear D Gear
every two stall tests.
ATFTemperature 20 - 110°C
1. Block four vehicle wheels with wood wedges and fully
apply the parking brake to lock the vehicle. C1 Oil Pressure 0.154 Mpa or above
2. Fit the special tool T26001 on the D or R gear testing
hole of the automatic transmission.

Caution: Ensure there is no oil leakage after the

pressure gauge refit.

1. D gear testing hole

2. R gear testing hole

3. Depress the brake pedal with the left foot heavily,

place the shift lever in D or R gear, and depress the
accelerator pedal with the right foot to measure the oil
circuit pressure in idle or stall state.
Idle Speed

• D 0.625 - 0.775 Mpa

• R 0.499 - 0.539 Mpa
Stall

• D 1.450 - 1.630 Mpa

• R 1.725 - 2.085 Mpa
Stall Speed 2631 ± 150rpm

4. To fit the automatic transmission assembly with the

start/stop function, oil pressure test can also be
conducted in the start/stop state.
5. The ignition switch is turned off.

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Transmission-AT Transmission
Automatic Transmission Assembly
Remove
1. Fix the vehicle on lift.
2. Remove the front/rear brackets of the battery tray.
Front Bracket of Battery Tray Remove
Rear Bracket of Battery Tray Remove
3. Drain the automatic transmission fluid.
Automatic Transmission Fluid Drain
4. Remove 2 bolts (1) fixing the bracket of the automatic
transmission cable to the automatic transmission.
5. Remove 1 nut (2) fixing the automatic transmission
cable rocker arm to the automatic transmission. 11. Lift the engine with special tools T10007 and
TEN00070.

6. Disconnect the harness connector from the automatic

transmission. 12. Remove and discard 3 bolts fixing the lower tie rod
bracket to the automatic transmission
7. Disconnect the harness connector from the
input/output speed sensor and temperature sensor.

13. Remove and discard 4 bolts fixing the automatic

transmission mount bracket to the automatic
8. Remove the left drive shaft assembly. transmission.
Left Drive Shaft Assembly Remove
9. Remove 1 bolt (1) fixing the bracket of the automatic
transmission oil cooler pipe to the automatic
transmission.
10. Remove the nut (2) fixing the automatic transmission
oil cooler pipe to the oil cooler pipe connector.

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Transmission Transmission-AT

14. Remove 3 bolts fixing the upper part of the automatic 18. Lower the hydraulic jack slowly and carefully, and
transmission to the engine. remove the automatic transmission assembly.
Refit
1. Clean the junction surface of the engine and automatic
transmission.
2. Clean the locating pin and pin hole of the automatic
transmission.
3. Support the engine with a lifting equipment.
4. Fix the automatic transmission on the jack, and raise
the jack to locate it to the vehicle carefully.
5. Align the front end of the hydraulic torque converter
with the engine crankshaft hole, and simultaneously
align the locating pin of the engine with that of
the automatic transmission, then fit the automatic
15. Remove the starter motor. transmission and engine.

Starter Motor Remove 6. Fit 4 bolts fixing the lower part of the automatic
transmission to the engine, tighten to 75-90Nm, and
16. Support the automatic transmission assembly with
check the torque.
hydraulic jack.
7. Fit the starter motor.
17. Remove 4 bolts fixing the lower part of the automatic
transmission to the engine. Starter Motor Refit
8. Fit 3 bolts fixing the upper part of the automatic
transmission to the engine, tighten to 75-90Nm, and
check the torque.
9. Fit 4 new bolts fixing the bracket of the automatic
transmission mount to the automatic transmission,
tighten to (45-55)Nm+(85-95)deg, and check the
torque.

Caution: Yielding technique is applied to this bolt . For

virgin installation, the bolt is allowed to use twice. For
second use of bolt in the same station, the bolt must be
loosened to zero Nm, then tighten it according to specified
technique; when the bolt is used over twice or unknown
times, new bolt must be taken.
10. Fit 3 new bolts fixing the lower tie rod bracket
to the automatic transmission, tighten to
(45-55)Nm+(85-95)deg, and check the torque.

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Transmission-AT Transmission
Caution: Yielding technique is applied to this bolt . For Automatic Transmission Fluid - Drain and Refill
virgin installation, the bolt is allowed to use twice. For Drain
second use of bolt in the same station, the bolt must be Warning: Observe due care when draining gearbox fluid
loosened to zero Nm, then tighten it according to specified as the fluid can be very hot.
technique; when the bolt is used over twice or unknown
times, new bolt must be taken. Caution: The transmission oil can be drained only
when the transmission is at normal operating
11. Clamp the transmission breather pipe clip about temperature.
vertically at the transmission harness without fixed tie,
and keep the breather pipe clip facing up as much as 1. Place a suitable container below the transmission to
possible. collect the ATF.

12. Fit the left drive shaft assembly. 2. Clean the area around the oil drain plug and overflow
plug.
Left Drive Shaft Assembly Refit
3. Remove the overflow plug and discard the seal ring.
13. Fit the nut fixing the automatic transmission oil cooler
pipe to the oil cooler pipe connector, tighten to
33-37Nm, and check the torque.
14. Fit 1 bolt fixing the bracket of the automatic
transmission oil cooler pipe to the automatic
transmission, tighten to 7-10Nm, and check the
torque.
15. Connect the harness connector to the input/output
speed sensor and temperature sensor.
16. Connect the harness connector to the automatic
transmission.
17. Fit 1 nut fixing the automatic transmission cable
rocker arm to the automatic transmission, tighten to
14-20Nm, and check the torque. 1. Overflow Plug

18. Fit 2 bolts fixing the bracket of the automatic 2. Drain Plug
transmission cable to the automatic transmission, 4. Remove the oil drain plug and discard the seal ring.
tighten to 15-23Nm, and check the torque. 5. Drain the oil.
19. Fill the automatic transmission fluid. 6. Record the total amount of drained oil as necessary.
Automatic Transmission Fluid Refill Refill
20. Fit the front/rear brackets of the battery tray. 1. Ensure that the vehicle is on a horizontal level.

Front Bracket of Battery Tray Refit 2. Block four vehicle wheels with wood wedges and fully
apply the parking brake to lock the vehicle.
Rear Bracket of Battery Tray Refit
3. Move the shift lever to P gear.
21. Lower the vehicle on a lift.
4. Clean the oil drain plug and fit the new seal ring.

Caution: Ensure that the washer is fitted in the

correct direction as shown!

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Transmission Transmission-AT

11. Fit the overflow plug, tighten to 23-25Nm, and check

the torque.
12. Clean the area around the oil filler and the oil filler
plug, and fit the new seal ring.
13. Fit the oil filler plug, tighten to 35-44Nm, and check
the torque.
14. Refit the battery tray.
Battery Tray Refit

5. Fit the oil drain plug, tighten to 14.7-19.6Nm, and

check the torque.
6. Remove the battery tray.
Battery Tray Remove
7. Clean the area around the oil filler plug.
8. Remove the oil filler plug and discard the seal ring.

9. Add an appropriate amount of transmission oil through

the oil filler.
Fluid
10. Clean the overflow plug and fit the new seal ring.
Caution: Ensure that the washer is fitted in the
correct direction as shown!

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Transmission-AT Transmission
Automatic Transmission Fluid - Refill Caution: ATFFluid level is different in cold and
Check and Refill hot states, so it needs to test the ATF level in
Important precautions: faults in the automatic transmission are hot state.
always accompanied with ATF deterioration (metal particles, 12. When the engine is in idle state, depress the brake and
powder of friction plate, smell of burning, white emulsion, etc.), so move the shift lever from P gear to all gears, stay at each
ATF testing is critical. gear separately for min. 3 seconds before returning to
Important precautions: Low oil level: oil pump may inhale air, the P gear, and perform the shift process for 2 times.
which can result in low oil pressure and transmission functional 13. Lift the vehicle, remove the overflow plug, and discard
malfunction. High oil level: a large number of bubbles will be the seal ring.
produced by the stir of the gear set and the oil will overflow from 14. Check the state of the ATF dripping from overflow
the breather pipe. hole.
Important precautions: Normal ATF: red, with moderate viscosity. 15. Confirm if the ATF temperature is within 50℃ - 60℃,
Abnormal ATF: water (white emulsion) or a mixture of different and wait until the ATF drips from the overflow hole.
ATF will lead to "shift impact" and "rough running", degrading the 16. Clean the overflow plug, fit the new seal ring, fit the
performance. overflow plug, tighten to 23-25Nm, and check the
1. Ensure that the vehicle is on a horizontal level, block torque.
the four vehicle tyres with wood blocks, and apply the Caution: After tightening the overflow plug,
park brake to lock the vehicle. make sure that the overflowed oil is wiped off
2. Move the shift lever to P gear. completely.
3. Clean the surrounding area of the oil filler plug, remove 17. Lower the vehicle and shut down the engine.
the oil filler plug and discard the seal ring.

Warning: As the exhaust system components may have

a very high temperature, be careful to avoid burns
and other personal injuries.
4. Raise the vehicle on a lift.
5. Clean the surrounding area of the overflow plug,
remove the overflow plug and discard the seal ring.
6. Check if the ATF drips from the overflow hole.
7. If no ATF drips, add specified fluid (AW-1) until the
ATF drips from the overflow hole.

Caution: If the ATF level is too low, there may be

a leak somewhere, check corresponding parts of the
automatic transmission carefully.
Caution: Make sure that only specified ATF is used.

8. If the ATF drips from the overflow hole, it is

unnecessary to add any fluid.
9. Clean the overflow plug, fit the new seal ring, fit the
overflow plug, tighten to 23-25Nm, and check the
torque.
10. Clean the oil filler plug, fit the new seal ring, fit the oil
filler plug, tighten to 35-44Nm, and check the torque.
11. Lower the vehicle, start the engine, and confirm if the
ATF temperature rises to 50℃ with the scan tool.

Caution: Do not make the ATF temperature rise

quickly by a stalling testing method.

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Transmission Transmission-AT

Transmission Control Module (TCM) Automatic Transmission Harness

Remove Remove
Warning: The Transmission Control Module (TCM) is 1. Remove the battery tray.
uniquely coded to this vehicle and therefore will not work
Battery Tray Remove
if fitted to another vehicle.
2. Disconnect the connector of the input speed sensor.
1. Disconnect the battery negative.
3. Disconnect the connector of the output speed sensor.
2. Remove the driver side lower trim panel assembly.
4. Disconnect the connector of the neutral start switch.
Driver Side Lower Trim Panel Assembly Remove
5. Disconnect the harness connector of the transmission.
3. Disconnect the harness connector (1) of the TCM.
6. Disconnect the connector of the TCM.
4. Remove 2 nuts (2) fixing the TCM to the bracket.

7. Disconnect the harness connector from the instrument

5. Remove the TCM. panel.
Refit 8. Loosen 3 clips fixing the harness to the transmission
1. Fit 2 nuts fixing the TCM to the bracket, tighten to and remove the harness.
7-10Nm, and check the torque. Refit
2. Connect the harness connector of the TCM. 1. Fit the harness and secure with clips.
3. Fit the driver side lower trim panel assembly. 2. Connect the harness connector to the instrument
panel.
Driver Side Lower Trim Panel Assembly Refit
3. Connect the connector of the TCM.
4. Connect the battery negative.
4. Connect the harness connector of the transmission.
5. Turn on the ignition switch but do not start the engine,
shift the lever to P gear or N gear, and make sure that 5. Connect the connector of the neutral start switch.
the vehicle is in stationery state. 6. Connect the connector of the input speed sensor.
6. Connect the scan tool to the vehicle and access the 7. Connect the connector of the output speed sensor.
SIPS. 8. Fit the battery tray.
7. Operate as per "Programming and Coding - TCU -
Battery Tray Refit
Replacement" and interface prompts to update the
TCM and perform the self-learning. The procedures
for replacement already include procedures for update
and self-learning. If it prompts "Failed" during the
replacement, please operate as per the interface
prompts.

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Transmission-AT Transmission
Neutral Start Switch seal to the transmission housing.
Remove Caution: Take care not to damage the oil seal.
1. Ensure that the vehicle is in neutral gear.
2. Raise the vehicle on a lift.
3. Release the control rocker arm from the neutral start
switch and put the rocker arm and cable aside.
4. Disconnect the connector from the neutral start switch.

2. Specification: 1 ± 0.25mm (from the bottom of the

automatic transmission housing)
3. Fit the neutral start switch and bolts to the transmission,
but do not tighten fullly.
4. Connect the connector to the switch.
5. Remove 2 bolts fixing the neutral start switch to 5. Adjust the neutral start switch.
automatic transmission, and remove the switch. Check
the removed neutral start switch for any obvious Neutral Start Switch Adjustment
deformation or damage. If yes, refit a new neutral start 6. Fit the retaining bolt of the neutral start switch, tighten
switch. to 4.3-6.5Nm, and check the torque.
6. If it is necessary to remove the manual shift lever oil 7. Locate the control rocker arm to the neutral start
seal, insert the flat-blade screwdriver between the switch and ensure it is fixed correctly. Fit and tighten
transmission housing and oil seal to remove the oil seal. the nut to 14-20Nm, and check the torque.

Caution: Bind tape on the head of the flat-blade 8. Check if the engine can be started at P and N gear but
screwdriver before use. Take care not to damage can not be started at other gears.
the transmission housing and shift shaft.

7. Pry up the oil seal with flat-blade screwdriver.

Caution: Take care not to damage the contact surface
of the housing.
Refit
1. If the manual shift lever oil seal is removed, use the
special tool TPT00164 and hammer to fit the new oil

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Transmission Transmission-AT

Neutral Start Switch - Check and Adjustment switch and ensure it is fixed correctly. Fit and tighten
Check the nut to 14-20Nm, and check the torque.
1. Remove the neutral start switch. 6. Check if the engine can be started at P and N gear but
Neutral Start Switch Remove can not be started at other gears.

2. Test if it can be energized at each gear position

according to the polarity as shown and the connector
end view.

Caution: The current applied shall not exceed 0.1A,

or it will cause contact failure of the neutral
start switch.
3. If any wrong gear position is displayed during the test,
replace the neutral start switch.
4. After the test, fit the neutral start switch.
Neutral Start Switch Refit
Adjustment
1. Ensure that the shift lever is in "N" position.
2. Release the control rocker arm from the neutral start
switch and put the rocker arm and cable aside.
3. Fit the TPT00220 to the manual valve stem. Check
if the scale line on the TPT00220 is aligned with the
baseline on the neutral start switch.

4. Align the scale line on the TPT00220 with the baseline

on the neutral start switch.
5. Locate the control rocker arm to the neutral start

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Transmission-AT Transmission
Input Speed Sensor Output Speed Sensor
Remove Remove
Warning: Switch off ignition switch and wait for 90 Warning: Switch off ignition switch and wait for 90
seconds before starting work. seconds before starting work.

Warning: Position the earth lead carefully and prevent to Warning: Position the earth lead carefully and prevent to
contact the disconnected battery earth lead again. contact the disconnected battery earth lead again.
1. Disconnect the harness connector from the input 1. Disconnect the harness connector from the output
speed sensor. speed sensor.
2. Remove 1 bolt fixing the input speed sensor to the 2. Remove 1 bolt fixing the output speed sensor to the
transmission, and remove the input speed sensor. transmission, and remove the output speed sensor.

Caution: Be careful not to damage the input speed sensor Caution: Be careful not to damage the output speed
and transaxle housing. sensor and transaxle housing.

Refit Refit
1. Fit the new O-ring applied with ATF to the input speed 1. Fit the new O-ring applied with ATF to the output
sensor. speed sensor.
2. Fit 1 bolt fixing the input speed sensor to the 2. Fit 1 bolt fixing the output speed sensor to the
transmission, tighten to 3.9-6.9Nm, and check the transmission, tighten to 3.9-6.9Nm, and check the
torque. torque.

Note: Always use a new seal bolt. Note: Always use a new seal bolt.

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Transmission Transmission-AT

Automatic Transmission Housing End Oil Seal 4. Fill the automatic transmission fluid and check the fluid
Remove level.
1. Drain the automatic transmission fluid. Automatic Transmission Fluid Refill
Automatic Transmission Fluid Drain
2. Remove the left drive shaft assembly.
Left Drive Shaft Assembly Remove
3. Insert the flat-blade screwdriver between the
differential housing and oil seal to remove the oil seal.

Caution: Bind tape on the head of the flat-blade

screwdriver before use. Take care not to damage
the transaxle housing and differential housing.

4. Pry up the oil seal with flat-blade screwdriver.

Caution: Take care not to damage the contact surface

of the housing.
Refit
1. Fit the new oil seal to the transaxle housing with the
special tool TPT00218 and hammer.

Caution: Take care not to damage the oil seal.

2. Specification: 3.1 ± 0.5mm (from the bottom of the

transmission housing).
3. Fit the left drive shaft assembly.

Left Drive Shaft Assembly Refit

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Transmission-AT Transmission
Torque Converter Housing End Oil Seal level.
Remove Automatic Transmission Fluid Refill
1. Drain the automatic transmission fluid.
Automatic Transmission Fluid Drain
2. Remove the right drive shaft assembly.
Right Drive Shaft Assembly Remove
3. Insert the flat-blade screwdriver between the
differential housing and oil seal to remove the oil seal.
Caution: Bind tape on the head of the flat-blade
screwdriver before use. Take care not to damage
the transaxle housing and differential housing.

4. Pry up the oil seal with flat-blade screwdriver.

Caution: Take care not to damage the contact surface
of the housing.
Refit
1. Fit the new oil seal to the transaxle housing with
TPT00219 and hammer.
Caution: Take care not to damage the oil seal.

2. Specification: 2.2 ± 0.5mm (from the bottom of the

torque converter housing end)
3. Fit the right drive shaft assembly.
Right Drive Shaft Assembly Refit
4. Fill the automatic transmission fluid and check the fluid

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Transmission Transmission-AT

Hydraulic Torque Converter Valve Body Cover

Remove Remove
1. Remove the automatic transmission assembly. 1. Raise the vehicle on a lift.
Automatic Transmission Assembly Remove 2. Drain the automatic transmission fluid.
2. Remove the hydraulic torque converter. Automatic Transmission Fluid Drain
Caution: Take care not to damage the oil seal, and 3. Remove 17 bolts securing the valve body cover, remove
do not drop the torque converter assembly. the valve body cover, and discard the valve body cover
washer.
Caution: Be careful not to damage the valve body cover
and transaxle housing.

Refit
1. Fit the torque converter to the automatic transmission.
Caution: Take care not to damage the oil seal, and
do not drop the torque converter assembly. 4. Remove 4 magnets for oil cleaning from the valve body
cover, check and remove the impurities on the valve
2. Measure the dimension from the tail end of the
body cover and magnets.
transaxle housing to the bolt hole surface of the
hydraulic torque converter assembly.

5. Clean the contact surface between the valve body

3. Check if the hydraulic torque converter has been fitted cover and transaxle housing.
correctly. Caution: Take care and ensure there is no impurity
4. Specification : A = 17.3mm (from the tail end of the on the contact surface between the valve body cover
transaxle housing) and transaxle housing.

5. Fit the automatic transmission assembly. Refit

Automatic Transmission Assembly Refit 1. Remove the packaging materials from the contact
surface of the transaxle and the oil from the contact
6. Fit the oil drain plug, tighten to 14.7-19.6Nm, and
surface.
check the torque.
Caution: Ensure that the mating faces are free from oil.
7. Fit the overflow plug, tighten to 23-25Nm, and check
the torque. 2. Fit 4 magnets for oil cleaning to the valve body cover.

1.0 258
Transmission-AT Transmission
3. Fit the new washer to the valve body cover. Valve Body Assembly
4. Fit the valve body cover to the transaxle housing. Remove
5. Fit 17 new bolts, tighten to 6-7.9Nm, and check the 1. Remove the automatic transmission valve body cover.
torque. Valve Body Cover Remove
Note: Always use a new seal bolt. 2. Remove the automatic transmission filter assembly.
6. Fit the oil drain plug, tighten to 14.7-19.6Nm, and Filter Assembly Remove
check the torque. 3. Remove the bolts and clips securing the automatic
7. Fill the ATF and check the fluid level. transmission temperature sensor, and pull the
Automatic Transmission Fluid Refill temperature sensor out of the valve body assembly.

4. Disconnect the connectors of 6 valve body harnesses.

5. Support the valve body assembly, remove 11 bolts
securing the valve body assembly, and remove the valve
body assembly.

6. Remove the valve body assembly oil seal from the

transmission housing.

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Transmission Transmission-AT

housing.
4. Connect the manual valve control rod to the manual
valve operating rod.

7. Remove the C3 accumulator piston and compression

spring with flat-blade screwdriver.

Caution: Bind tape on the head of the flat-blade

screwdriver before use. 5. Fit 11 valve body assembly bolts 1 and 2, tighten to
9.8-11.8Nm, and check the torque.

Caution: When fitting the valve body assembly to

the transmission housing, do not tilt the C3
accumulator, and do not hold the solenoid valve.

8. Remove 2 O-rings from the C3 accumulator piston

with the flat-blade screwdriver and discard them.

6. Connect the connectors of 6 valve body harnesses.

7. Fit the clips and bolts securing the automatic
transmission temperature sensor, tighten to
5.8-7.8Nm, and check the torque.
8. Fit the automatic transmission filter assembly.

Filter Assembly Refit

9. Fit the automatic transmission valve body cover.
Valve Body Cover Refit
10. Turn on the ignition switch but do not start the engine,
Refit shift the lever to P gear or N gear, and make sure that
1. Fit 2 new O-rings applied with ATF to the C3 the vehicle is in stationery state.
accumulator piston. 11. Connect the scan tool to the vehicle and access the
2. Fit the C3 accumulator piston applied with ATF and the SIPS.
compression spring to the valve body assembly. 12. Operate as per "Programming and Coding - TCU -
3. Fit the new oil seal applied with ATF to the transmission Replacement" and interface prompts to update the

1.0 260
Transmission-AT Transmission
TCM and perform the self-learning. The procedures Oil Pump Oil Seal
for replacement already include procedures for update Remove
and self-learning. If it prompts "Failed" during the 1. Remove the hydraulic torque converter.
replacement, please operate as per the interface
prompts. Hydraulic Torque Converter Remove
2. Remove the oil seal at the oil pump with tools.

Caution: Be careful not to damage the oil seal and the

input shaft.

Refit
1. Fit the new oil seal to the oil pump with the special tool
TPT00161 and hammer.

Caution: Be careful not to damage the oil seal and the

input shaft.
2. Specification: 0 ± 0.3mm (from the tail end of the oil
pump).
3. Apply grease to the oil seal lip.
4. Fit the hydraulic torque converter to the automatic
transmission.

Hydraulic Torque Converter Refit

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Transmission Transmission-AT

Filter Assembly Automatic Transmission Oil Cooler Pipe

Remove Connector
1. Remove the automatic transmission valve body cover.
Remove
1. Remove the inlet/outlet pipe of the automatic
Valve Body Cover Remove
transmission oil cooler.
2. Remove the filter assembly from the valve body
assembly. Automatic Transmission Oil Cooler Inlet Pipe
Remove

Automatic Transmission Oil Cooler outlet Pipe

Remove
2. Remove 2 connectors of the automatic transmission oil
cooler pipe and discard the sealing gaskets.

3. Remove and discard the O-ring on the filter assembly.

Refit
1. Clean the oil cooler pipe connector and fit the new
seal ring.
2. Fit the oil cooler pipe connector, tighten to
19.6–29.4Nm, and check the torque.
3. Fit the inlet/outlet pipe of the automatic transmission
oil cooler.

Automatic Transmission Oil Cooler Inlet Pipe

Refit Refit

1. Fit the new O-ring applied with ATF to the filter Automatic Transmission Oil Cooler Outlet Pipe
assembly. Refit
2. Fit the filter assembly to the valve body assembly.
3. Fit the automatic transmission valve body cover.

Valve Body Cover Refit

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Transmission-AT Transmission
Special Tools Tool Description Picture
Tool Description Picture Number
Number

Replacer driven
Transmission TPT00218 shaft oil seal
T26001 pressure test - LH
equipment

Replacer driven
TPT00219 shaft oil seal
Engine lift - RH
T10007
bracket

Replacer, oil
TPT00161
pump seal
TEN00070 Engine support

Replacer,
TPT00164 manual shaft
oil seal

Adjuster ，
TPT00220 neutral start
switch

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Transmission Transmission-MT

Transmission-MT
Specifications
Torque
Description Value
Bolt-Manual Transmission Mount Bracket to Manual （45-55）Nm+（85-95）deg
Transmission
Bolt-Under The Tie-bar Bracket to Under The Tie-bar （81-99）Nm+（85-95）deg
Bolt-Under The Tie-bar Bracket to Manual Transmission （45-55）Nm+（85-95）deg
Bolt- transmission to engine 75–90Nm
Bolt-Slave Cylinder to Manual Transmission 40-50Nm
Bolt-Battery negative cable to transmission case 15–20Nm
Bolt-Reverse Gear Lock 15-22Nm
Bolt-Control Cover to Rear Housing 15-25Nm
Bolt-Gear Selector Lever to Control Cover 15-25Nm
Bolt-Oil Drain plug to Transmission 25-35Nm
Bolt-Oil Filler Plug to Transmission 25-35Nm
Bolt-Switch Reverse Light to Transmission 12-18Nm
Self – locking bolt 15–20Nm
Bolt - reverse gear lever to front housing 22–28Nm
Bolt - front housing to rear housing 22–28Nm
Bolt - selector and shift cable support bracket to front 22–28Nm
housing
Bolt - reverse idler shaft to rear housing 15–22Nm
Bolt - rear bearing baffle to rear housing 13–15Nm
Nut - output shaft 80–100Nm
Screw plug - 5th gear selector fork 5–8Nm
Bolt - control cover to rear housing 15–25Nm
Bolt - rear cover to rear housing 8–13Nm
Bolt - final drive gear to differential housing 110–150Nm

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Transmission-MT Transmission
Parameter
Model SH63Z Manual Transmission (1.5L) Big Ratio
Gear 5 forward gears (engaged by synchronizer), 1 reverse gear
Speed Ratio SH63Z:

·1st gear 3.727

·2nd gear 2.050

·3rd gear 1.323

·4th gear 0.973

·5th gear 0.795

·Reverse gear 3.454

·Main Reduction 4.235

Transmission Centre Distance 63mm
Allowable Maximum Input Torque

SH63Z 135Nm
Maximum Input Speed 6000r/min
Mass (without oil) 30.6kg
Lubricating Oil MTF 94
Transmission standard oil capacity:

·Drain and Refill 1.8L

·Refill in Dry State 2.0L

Maximum Transmission Boundary
Dimension
342mm
·Length
488mm
·Width
391mm
·Height
Lubrication grease:

·Clutch rocker arm bushing inner bore

Lithium based grease
·Release bearing bore and shifting fork
junction surface Lithium based grease

·Inner and outer surfaces of gear Lithium based grease

selection nylon taper block
Plane sealant:

·Connecting surface of front and rear

Tonsan 1596F
housings
Tonsan 1596F
·Rear cover plate - rear housing
Tonsan 1596F
·Control cover - rear housing

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Transmission Transmission-MT

Thread sealant:

·Reverse idler gear shaft bolt - rear

Tonsan 1243C
housing
Tonsan 1243C
·Self-locking bolt - front housing
Tonsan 1243C
·Reverse gear stop bolt - rear housing
Tonsan 1243C
·4 couter-hit bolts of front housing
Clutch rocker arm shaft sleeve

Input shaft oil seal

Differential oil seal

Input shaft rear bearing adjusting gasket

Circlip Ø29

Shaft circlip Ø18.5

Output shaft rear bearing adjusting gasket

Circlip Ø32
Disposable parts:
Output shaft locking nut

Differential rear bearing adjusting gasket

Spring pin

Pin Ø5×28

Pin Ø3×22

Pin Ø5×22

Gear selection/shift shaft oil seal

Gear selection/shift shaft bearing

1.0 266
Transmission-MT Transmission
Description and Operation
System Layout
Transmission Assembly Layout

1.0 267
Transmission Transmission-MT

Transmission Control and Housing Exploded View

1. Dust Shield - Gear Selection/Shift Shaft 17. Pin Ø5×22

2. Oil Seal - Gear Selection/Shift Shaft 18. Gear Shift Locating Camshaft
3. Bearing - Gear Selection/Shift Shaft 19. Gear Selection/Shift Shaft
4. Gear Selection/Shift Rocker Arm Locating Sleeve 20. Combination Spring Pin
5. Control Cover 21. Gear Selection/Shift Taper Head
6. Bolt M8×25 22. Gear Shift Interlock Baffle
7. Pin Ø5×28 23. 5th/Reverse Gear Selection Stop Spring Cushion
8. Gear Shift Rocker Arm 24. 5th/Reverse Gear Selection Stop Circlip
9. Bolt M8×50 25. 5th/Reverse Gear Selection Return Spring
10. Gear Selection Rocker Arm 26. 5th/Reverse Gear Selection Return Spring Cushion
11. Nylon Block 27. Pin Ø3×22
12. Reverse Gear Stop Torsion Spring 28. Circlip
13. Reverse Gear Lock Plate 29. 1st/2nd Gear Selection Return Spring Cushion
14. Oil Baffle 30. 1st/2nd Gear Selection Return Spring
15. Bolt - Oil Baffle 31. 1st/2nd Gear Fork Shaft
16. Reverse Gear Lock Shaft 32. Spring Pin

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Transmission-MT Transmission
33. 1st/2nd Gear Taper Block 55. Clutch Release Rocker Arm Shaft
34. 1st/2nd Gear Fork 56. N/A
35. 3rd/4th Gear Fork Shaft 57. Clutch Release Fork
36. 3rd/4th Gear Taper Block 58. Clutch Rocker Arm Shaft Sleeve
37. 3rd/4th Gear Fork 59. Self-locking Bolt
38. 5th Gear Fork Shaft 60. Self-locking Spring
39. Reverse Gear Fork Shaft 61. Front Housing
40. Steel Ball 8 62. Locating Pin - Rear Housing
41. Locking Spring - Reverse Gear Taper Pin 63. Locating Pin - Front Housing
42. Reverse Gear Taper Pin 64. Magnetic Steel
43. Reverse Gear Taper Block 65. Gear Shift Stop Bolt
44. 5th Gear Fork Screw Plug 66. Harness Bracket
45. 5th Gear Fork 67. Vent Plug Assembly
46. Retaining Circlip 68. Rear Bearing Baffle
47. Bolt - Reverse Gear Rocker Arm Assembly 69. Screw - Rear Bearing Baffle
48. Reverse Gear Rocker Arm Assembly 70. Bolt - Rear Cover Plate
49. Bolt - Housing Connecting Bolt 71. Rear Cover Plate
50. Bolt - Housing Connecting Bolt 72. Aluminum Washer 8
51. Gasket Ø10 - Reverse Gear Lock Shaft 73. Bolt - Reverse Idler Shaft
52. Clutch Rocker Arm Shaft Sleeve 74. Rear Housing
53. Clutch Release Rocker Arm 75. Bolt - Oil Groove
54. Bolt - Release Fork and Rocker Arm 76. Oil Groove

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Gear Drive Mechanism Exploded View

1. Drive Shaft Oil Seal 16. Shaft Circlip Ø18.5

2. Drive Shaft Front Bearing 17. 4th/5th Gear Synchronizer Slider
3. Drive Shaft 18. 5th Gear Synchronizer Assembly
4. Drive 3rd Gear Assembly 19. 1st/2nd Gear Synchronizer Assembly
5. 3rd/4th/5th Gear Needle Bearing 20. 1st/2nd Gear Synchronizer Slider Assembly
6. 4th/5th Gear Synchronizer Ring 21. Circlip Ø32
7. 3rd/4th Gear Synchronizer Assembly 22. 1st/2nd Gear Synchronizer Outer Cone Ring
8. Circlip Ø29 23. 1st/2nd Gear Synchronizer Intermediate Ring
9. Drive 4th Gear Assembly 24. 1st/2nd Gear Synchronizer Inner Cone Ring
10. 4th Gear Space Ring 25. 1st/2nd Gear Driven Gear Needle Bearing
11. Drive Shaft Rear Bearing 26. Driven 2nd Gear
12. Adjusting Gasket - Drive Shaft Rear Bearing 27. Driven 3rd Gear
13. 3rd Gear Synchronizer Ring 28. 3rd/4th Gear Space Ring
14. 5th Gear Bushing 29. Driven 4th Gear
15. Drive 5th Gear Assembly 30. Output Shaft Bearing

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31. Adjusting Gasket - Output Shaft Rear Bearing 35. Driven 1st Gear
32. Driven 5th Gear 36. Reverse Idler Shaft
33. Nut - Driven Shaft Locking 37. Reverse Idler Assembly
34. Driven Shaft 38. Nylon Washer - Reverse Idler

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Differential Assembly Exploded View

1. Oil Seal - Left Differential 7. Differential Washer

2. Differential Rear Bearing Adjusting Gasket 8. Oil Seal - Right Differential
3. Differential Bearing 9. Circlip
4. Bolt - Differential Housing to Main Reduction Driven 10. Planetary Gear
Gear 11. Planetary Gear Shaft
5. Main Reduction Driven Gear 12. Axle Shaft Gear
6. Differential Housing

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Transmission Accessories Layout

1. Reverse Lamp Switch Assembly 6. Oil Filler Plug

2. Gear Shift Cable Bracket 7. Clip - Reverse Lamp Harness
3. Bolt - Gear Selection/Shift Cable Bracket 8. Drain plug
4. Gear Selection Cable Bracket 9. Neutral Sensor
5. Washer - Oil Plug 10. Bolt - Neutral Sensor

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Transmission Section View

1. Reverse Idler 10. 5th Gear Synchronizer Assembly

2. Reverse Idler Shaft 11. Driven Shaft
3. Drive Shaft 12. Driven Shaft Bearing
4. Drive Shaft Front Bearing 13. Driven 1st Gear
5. Drive 3rd Gear 14. 1st/2nd Gear Synchronizer Assembly and Driven Reverse
6. 3rd/4th Gear Synchronizer Assembly Gear
7. Drive 4th Gear 15. Driven 2nd Gear
8. Drive Shaft Rear Bearing 16. Driven 3rd Gear
9. Drive 5th Gear 17. Driven 4th Gear

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18. Driven 5th Gear 21. Main Reduction Driven Gear
19. Driven Shaft Locking Nut 22. Differential
20. Differential Bearing

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Description housing, the fork shaft is connected with the fork, turn an
Overview appropriate synchronizer to shift to the forward gear, or turn
the sliding idler gear to shift to the reverse gear.
This vehicle is equipped with a 5-speed manual transmission.
The shift lever is located at the centre console of the passenger Reverse Gear Protection and Reverse Lamp Switch
compartment, it provides the driver with 6 choices for variable The reverse gear lock mechanism is used to prevent accidental
speed position, namely, 1st gear, 2nd gear, 3rd gear, 4th gear, shift from the 5th gear to the reverse gear directly. Therefore,
5th gear and reverse gear. The forward gears are engaged by you must ensure that the reverse gear can only be shifted to
the synchronizer, and the reverse gear is driven by the sliding from the neutral position. The reverse lamp plunger switch is
idler gear without a synchronizer. The drive shaft is fitted in fitted on the transmission rear housing.
the differential assembly at the rear of the transmission, and it
Differential
is used to transmit the driving force to the wheel.
Differential with traditional design fixes the main reduction
The transmission housing is made of cast aluminum, and
driven gear to the differential housing by bolts, differential
is connected to the engine cylinder block with bolts. The
housing supports the planetary shaft pin, planetary gear and
transmission input shaft and output shaft are supported by
sun gear. The differential assembly is supported by bearings in
bearings.
the transmission housing.
The transmission housing is equipped with an oil filler plug, Neutral Position Sensor (start/stop system)
which is located at the front lower side of the housing,
The neutral position sensor fixed on the transmission main
and there is an oil drain plug at the rear lower side of
housing is a hall-effect sensor, which is used to identify when
the transmission housing, both of them are sealed with an
the transmission is in neutral position.
aluminum washer. The transmission is filled with lubricating
oil so as to lubricate the internal components in a splashing When the neutral position is selected, if the neutral position
manner. The breather plug is fitted at the rear of the control signal block is aligned with the sensor, the ECM will identify this
seat. The stamped steel closing panel seals the opening signal as the neutral position and the areas within 12° range at
between the transmission and engine cylinder block. both left and right sides are considered as the neutral area.
Gear Shift and Gear Selection If the neutral position signal block is not aligned with the sensor,
Gear selection is realized by manipulating the shift lever fitted the ECM will identify this signal as gear-selected.
at the centre console of the passenger compartment. Both The neutral signal is used for the start/stop of the engine,
cables have one end connected to the bottom of the shift please refer to
lever. The other end is connected to the gear selection rocker Engine Fuel and Control System - Description
arm and gear shift rocker arm fitted outside the transmission for details.
through the connector ring assembly. In the transmission

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Operation
Transmission Assembly
Drivetrain changes the speed and direction of rotation through
the engagement between different gears of the drive shaft and
driven shaft, thereby generating 5 forward gears of different
speed ratio and 1 reverse gear. Except the reverse gear, the
gear wheels of all other gears are constantly engaged.

If the 1st gear is selected, the synchronizer gear ring is

pressed by the synchronizer gear bushing so as to contact
with the conical ring of the corresponding gear selected. In
this way, the speeds of both synchronizer hub and gear are
synchronized. Then, the synchronizer gear bushing protrudes
in the gear wheel through the synchronizer slider assembly When the shift lever is moved to reverse gear position, one
and the protrusion tooth of the synchronizer gear bushing. side of the gear selection/shift taper head turns reverse gear
Ensure that the taper head on the gear selection/shift shaft taper block to let the reverse gear fork drive the reverse
can select the gear accurately and the gears are remained in gear rocker arm assembly, slide the reverse idler gear to
the work position. The torque is transmitted from the engine respectively engage it with the drive shaft reverse gear
to the transmission input shaft through the clutch. Then, the and driven shaft reverse gear (driven shaft reverse gear is
torque is transmitted to the output shaft pinion and main integrated in the 1st/2nd gear synchronizer assembly) so as to
reduction driven gear and then to the drive shaft through the change the rotation direction of the driven shaft.
gear selected. Reverse gear protection
The operation of the 2nd, 3rd, 4th and 5th gear is the same
with that of the 1st gear.

When the reverse gear is selected, the reverse gear tooth

(integrated with the drive shaft) is engaged with the driven shaft
reverse gear tooth and reverse idler gear, hence, the rotation
direction of the driven shaft is changed and the reverse gear is
achieved.
Gear Shift and Gear Selection
When the shift lever is moved to the 1st gear position, the
shift lever will control the gear selection/shift rocker arm
through the cable. The gear selection rocker arm rotates
and moves the gear selection/shift shaft through the torque
of the cable, and the gear selection/shift taper head on the 1. Reverse gear lock plate
gear selection/shift shaft moves along with it and locates at 2. 5th/R gear selection return spring cushion
the groove of the 1st/2nd taper block, at this time, the gear 3. Control seat housing
selection/shift taper head shall be completely separated from
4. Reverse gear lock plate return spring
the groove of the 3rd/4th taper head. One end of the interlock
ring will lock the groove of the 3rd/4th gear, 5th/reverse gear When it is shifted to 5th gear, 5th/R gear selection return
taper block, the other end will be completely separated from spring cushion will push against the reverse gear lock plate to
the groove of the 1st/2nd gear taper block. Then the gear move up together, then the gear selection/shift shaft rotates
shift rocker arm rotates the gear selection/shift shaft through to the left until snapping into the groove of the gear shift
the torque of the cable, and the gear selection/shift taper head positioning cam. When it is shifted directly from 5th gear to R
rotates along with the gear selection/shift shaft, one side of the gear, since 5th/R gear selection return spring cushion is blocked
gear selection/shift taper head turns 1st/2nd gear taper block by the reverse gear lock plate whose motion is restricted by
to drive the operation of the 1st/2nd gear synchronizer so as the control seat housing, so it is impossible to shift to the R
to achieve the gear selection/shift function of the 1st gear. gear. When it is shifted from the neutral position between 5th
gear and R gear to R gear, 5th/R gear selection return spring
The operations of other forward gears are the same as that of
cushion will push against the reverse gear lock plate to move
the 1st gear.
up together, then the gear selection/shift shaft rotates to the

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right until snapping into the groove of the gear shift positioning applied to the whole assembly, and the planetary gear does
cam, so the reverse gear can be shifted to. not rotate. The torque is transmitted to the wheels through
Differential the drive shaft.

The differential allows the wheels to rotate at different speeds When the vehicle takes a turn, the inner wheels will pass a
when the output torques are the same. The pinion integrated shorter distance at a lower speed. Thus it drives the planetary
with the driven shaft is engaged with the main reduction driven gear to rotate, and the outer sun gear offers a higher speed for
gear of the differential assembly. When the driven shaft rotates, outer wheels.
and the wheels swivel straight forward, the torque will be

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Service Procedures
Manual Transmission Assembly
Remove
1. Remove the front/rear brackets of the battery tray.

Front Bracket of Battery Tray Remove

Rear Bracket of Battery Tray Remove

2. Disconnect the connector of the reverse lamp switch.
3. Pay attention to the mounting position, and disconnect
2 cable ball joints of the gear selection/shift rocker arm
of the manual transmission.

6. Drain the manual transmission fluid.

Manual Transmission Fluid Drain

7. Remove the left/right drive shaft assembly.

Left Drive Shaft Assembly Remove

Right Drive Shaft Assembly Remove

8. Remove the starter motor.

Starter Motor Remove

9. Remove 2 bolts fixing the slave cylinder to the manual
transmission.
4. Loosen the clips fixing the gear selection/shift cable to Caution: Don’t hang the slave cylinder for a long time ，
the bracket. or the hose of slave cylinder will become deformed.

5. Remove 1 bolt fixing the battery negative cable to the

10. Support the engine with a lifting equipment.
transmission housing.
11. Support the manual transmission with hydraulic jack.
12. Remove and discard 3 bolts fixing the bracket of the
manual transmission mount to the manual transmission.

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13. Remove 3 bolts fixing the upper part of the manual 17. Disconnect the manual transmission from the engine,
transmission to the engine. adjust the height of the jack, and lower the manual
transmission to the floor slowly and carefully.
Refit
1. Clean the junction surface of the engine and
transmission.
2. Clean the locating pin and pin hole of the transmission.
3. Support the engine with a lifting equipment.
4. Fit 3 new bolts fixing the bracket of the manual
transmission mount to the manual transmission, tighten
to （ 45-55） ）Nm+（ （85-95） ）deg, and check the
torque.
Caution: Yielding technique is applied to this bolt . For
virgin installation, the bolt is allowed to use twice. For
14. Remove 4 bolts fixing the lower part of the manual second use of bolt in the same station, the bolt must be
transmission to the engine. loosened to zero Nm, then tighten it according to specified
technique; when the bolt is used over twice or unknown
times, new bolt must be taken.

5. Fit 1 new bolt fixing the lower tie rod bracket to the
lower tie rod, tighten to （ 81-99） ）Nm+（ （85-95） ）
deg, and check the torque.
Caution: Yielding technique is applied to this bolt . For
virgin installation, the bolt is allowed to use twice. For
second use of bolt in the same station, the bolt must be
loosened to zero Nm, then tighten it according to specified
technique; when the bolt is used over twice or unknown
times, new bolt must be taken.

6. Fit 3 new bolts fixing the lower tie rod bracket to

the manual transmission, tighten to （ 45-55） ）Nm+
15. Remove and discard 1 bolt (1) fixing the lower tie rod
（ 85-95） ）deg, and check the torque.
bracket to the lower tie rod.
Caution: Yielding technique is applied to this bolt . For
16. Remove and discard 3 bolts (2) fixing the lower tie rod
virgin installation, the bolt is allowed to use twice. For
bracket to the manual transmission.
second use of bolt in the same station, the bolt must be
loosened to zero Nm, then tighten it according to specified
technique; when the bolt is used over twice or unknown
times, new bolt must be taken.
7. Fit 4 bolts fixing the lower part of the manual

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transmission to the engine, tighten to 75–90Nm, and Gear Selection/Shift Shaft Oil Seal - Manual
check the torque. Remove
8. Fit 3 bolts fixing the upper part of the manual 1. Remove the battery tray.
transmission to the engine, tighten to 75–90Nm, and Battery Tray Remove
check the torque.
2. Ensure that the shift lever is in neutral position.
9. Fit 2 bolts fixing the slave cylinder to the manual
3. Pay attention to the mounting position, and disconnect
transmission, tighten to 40-50Nm, and check the
2 cable ball joints of the gear selection/shift rocker arm
torque.
of the manual transmission.
10. Fit the starter motor.

Starter Motor Refit

11. Fit the left/right drive shaft assembly.

Left Drive Shaft Assembly Refit

Right Drive Shaft Assembly Refit

12. Fill the manual transmission fluid.

Manual Transmission Fluid Refill

13. Fit 1 bolt fixing the battery negative cable to the
transmission housing, tighten to 15–20Nm, and check
the torque.
14. Connect the clips fixing the gear selection/shift cable 4. Remove 2 bolts fixing the shift rocker arm to the
to the bracket. control cover, remove the gear selection rocker arm
15. Connect 2 cable ball joints of the gear selection/shift and collect the nylon block.
rocker arm of the manual transmission.
16. Connect the connector of the reverse lamp switch.
17. Fit the front/rear brackets of the battery tray.

Front Bracket of Battery Tray Refit

Rear Bracket of Battery Tray Refit

5. Knock out and discard the spring pin fixing the shift
rocker arm to the gear selection/shift shaft, and remove
the shift rocker arm.

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6. Remove 3 bolts fixing the control cover to the rear Transmission Fluid - Drain and Refill
housing, and remove the control cover assembly. Drain and Refill
7. Loosen the reverse gear lock shaft, and remove the 1. Lift the vehicle, and place a proper container below
reverse gear lock plate and reverse gear stop torsion the transmission.
spring. 2. Clean the area around the oil filler plug, remove the oil
8. Pull out the gear selection/shift shaft assembly. filler plug (a) and discard the sealing gasket.
9. Remove and discard the gear selection/shift shaft oil 3. Clean the area around the oil drain plug, remove the oil
seal. drain plug (b) and discard the sealing gasket.
Refit
1. Knock the new gear selection/shift shaft oil seal in place
with the special tool TPT00066 and hammer.

4. Drain the transmission fluid.

5. Clean the filler and oil drain plug.
6. Place the new sealing gasket on the oil drain plug, fit
2. Insert the gear selection/shift shaft assembly. and tighten the oil drain plug to 25-35Nm, and check
3. Locate the reverse gear stop torsion spring and reverse the torque.
gear lock plate, tighten the reverse gear lock shaft to 7. Fill the transmission fluid into the transmission through
15-22Nm, and check the torque. the filler with appropriate and clean funnel until
4. Shift the gear selection/shift shaft assembly to "N" reaching the specified value.
position. ·Drain and Refill 1.8L
5. Clean the junction surface of the control cover and
·Refill from Dry State 2.0L
rear housing, and apply sealant evenly.
6. Fit 3 bolts fixing the control cover to the rear housing, 8. Place the new sealing gasket on the oil filler plug, fit
tighten to 15-25Nm, and check the torque. and tighten the oil filler plug to 25-35Nm, and check
the torque.
7. Locate the gear shift rocker arm to the gear
selection/shift shaft, and knock in a new spring pin with 9. Lower the vehicle.
T24026.
8. Apply lubricating grease to the inner and outer surfaces
of the nylon block, locate the nylon block to the gear
selection/shift rocker arm, fit 2 bolts fixing the gear
selection rocker arm to the control cover, tighten to
15-25Nm, and check the torque.
9. Connect the cable ball joint to the gear selection/shift
rocker arm.
10. Check the performance of the gear selection and shift
operation.
11. Fit the battery tray.

Battery Tray Refit

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Reverse Lamp Switch Left Differential Oil Seal
Remove Remove
1. Remove the battery tray. 1. Drain the manual transmission fluid.

Battery Tray Remove Manual Transmission Fluid Drain

2. Disconnect the harness connector from the reverse 2. Remove the left drive shaft assembly.
lamp switch.
Left Drive Shaft Assembly Remove
3. Remove the reverse lamp switch from the manual
3. Carefully remove and discard the oil seal, be careful not
transmission.
to damage the oil seal groove.
Refit
1. Clean the oil seal groove.

Caution: Oil seals are waxed and must not be lubricated

prior to fitting.

2. Fit the new oil seal with TPT00064.

Refit
1. Clean the junction surface of the reverse lamp switch
and manual transmission.
2. Fit the reverse lamp switch, tighten to 12-18Nm, and
check the torque.
3. Connect the harness connector of the reverse lamp
switch. 3. Fit the left drive shaft assembly.
4. Fit the battery tray. Left Drive Shaft Assembly Refit
Battery Tray Refit 4. Fill the manual transmission fluid.

Manual Transmission Fluid Refill

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Right Differential Oil Seal Manual Transmission Disassembling

Remove Remove
1. Drain the manual transmission fluid. 1. Remove the manual transmission assembly.

Manual Transmission Fluid Drain Manual Transmission Assembly Remove

2. Remove the right drive shaft assembly. 2. Remove the reverse lamp switch.
Reverse Lamp Switch Remove
Right Drive Shaft Assembly Remove
3. Remove the clutch release bearing.
3. Carefully remove and discard the oil seal, be careful not
to damage the oil seal groove. Clutch Release Bearing Remove

Refit 4. Remove 8 bolts securing the rear cover plate, and

remove the rear cover plate.
1. Clean the oil seal groove.

Caution: Oil seals are waxed and must not be lubricated

prior to fitting.

2. Fit the new oil seal with TPT00064.

5. Knock out the circlip at the 5th gear synchronizer gear

hub.

3. Fit the right drive shaft assembly.

Right Drive Shaft Assembly Refit

4. Fill the manual transmission fluid.

Manual Transmission Fluid Refill

6. Remove the circlip on the reverse gear fork shaft with a

circlip plier.

7. Shift to N gear, and release the 5th gear fork bolt.

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8. Remove the steel ball with a magnetic screwdriver. 13. Remove and discard the output shaft locking nut.

14. Remove the output shaft 5th gear.

9. Shift to R gear, and knock out the spring pin on the 5th
15. Loosen 8 screws securing the rear bearing baffle.
gear fork shaft with the punch and hammer.
16. Remove the rear bearing baffle and rear bearing
adjusting gasket.
17. Loosen 4 bolts securing the gear selection/shift cable
bracket, and remove the gear selection/shift cable
bracket.
18. Loosen the bolts securing the gear selection rocker
arm, remove the gear selection rocker arm and collect
the nylon block.
19. Remove the spring pin fixing the gear shift rocker arm
to the gear selection/shift shaft, and remove the gear
selection rocker arm.

10. Remove the 5th gear fork together with the 5th gear
synchronizer assembly.
11. Remove the input shaft 5th gear and the needle bearing.
12. Shift to 4th gear, and lock the transmission input shaft
with TPT00068.

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20. Remove the remaining 3 bolts fixing the control cover 24. Remove the bolts connecting the front and rear
assembly to the rear housing. housings.
21. Remove the gear shift stop bolt and washer. 25. Knock the platform at the front housing large end face
gently with a nylon hammer, disconnect and remove
the rear and front housings.
26. Loosen 3 self-locking bolts at the side of the front
housing.
27. Remove 3 self-locking springs and 3 steel balls in the
hole.

22. Shift to N gear, and remove the control cover assembly.

28. Loosen 2 bolts at the reverse gear rocker arm assembly.

23. Unscrew the reverse idler gear shaft bolt and gasket.

29. Remove the reverse gear rocker arm assembly, reverse

idler gear assembly, reverse idler gear shaft and washer
respectively.

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30. Shift to 4th gear, and remove the 5th/R gear fork shaft
assembly upward.
31. Hold the output shaft assembly, input shaft assembly,
1st/2nd gear fork shaft assembly and 3rd/4th gear fork
shaft assembly with both hands and hold them up out
of the front housing. When there is any difficulty, knock
the front housing platform to disengage it with a nylon
hammer.

3. Fit the output shaft front bearing outer ring into the
front housing output shaft bearing bore, and knock it in
place gently with a nylon hammer.
4. Fit the differential assembly into the front housing, and
knock it in place gently with a nylon hammer when it
is difficult to fit.
5. Insert the 1st/2nd gear fork shaft assembly into the
output shaft assembly 1st/2nd gear synchronizer,
32. Remove the differential assembly from the front and 3rd/4th gear fork shaft assembly into input shaft
housing. When there is any difficulty, shake the assembly 3rd/4th gear synchronizer. After the two shaft
differential assembly accordingly and knock the bearing assemblies are engaged, hold them with both hands into
gently to disengage it. the front housing, at the same time, please ensure that
Refit the fork shaft is aligned with the fork shaft bore at the
housing and the two shaft bearings are aligned with the
1. Fit the new input shaft oil seal into the front housing
housing bearing bores.
with TPT00066.
6. Shift up the 3rd/4th gear fork shaft assembly to the 4th
gear position, and fit the 5th gear and reverse gear fork
shaft assemblies into the front housing.
7. Fit the steel ball and self-locking spring respectively
into the 3 self-locking holes at the side of the front
housing. Apply thread sealant to the thread, fit the new
self-locking bolt, and tighten to 15–20Nm.
8. Fit the reverse idler gear assembly, reverse idler gear
nylon washer and reverse gear shaft into the front
housing.
9. Fit the reverse gear rocker arm assembly into the
front housing, fit 2 bolts, and tighten to 22–28Nm.
After fitting the reverse gear rocker arm assembly,
2. Fit the new front housing oil seal with TPT00069.
the reverse idler gear must be able to rotate flexibly,
and the bolt hole of the reverse idler gear shaft
perpendicular to the gear faces outward.
10. Measure the distance between the front housing plane
and differential rear bearing outer ring plane as well as
the depth of the rear housing differential rear bearing
bore with the differential adjusting gasket measuring
tool. Select the adjusting gasket with the principle of a
pretightening force of 0.1mm. Apply an appropriate
amount of lubricating grease to the adjusting gasket,

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and then put it into the rear housing differential rear Output shaft rear bearing adjusting gasket (cont'd.)
bearing bore.
11. Clean the junction surface of the housing, apply plane 0.35
sealant to the front housing plane and cover the rear
0.4
housing. Apply thread sealant to the 4 counter-hit bolts
of the front housing, fit 11 connecting bolts and tighten 0.45
to 22–28Nm. 0.5
12. Fit the gear selection/shift cable bracket, screw the 0.6
retaining bolt and tighten to 22–28Nm.
15. Press down the rear bearing baffle, fit 8 new screws
13. Align the reverse idler gear shaft hanging hole with the
and tighten to 13–15Nm.
hole at the rear housing reverse gear. Apply thread
sealant to the thread of the reverse idler gear shaft 16. Turn the 3rd/4th gear fork shaft to shift the transmission
hanging bolt, fit the bolt and aluminum washer, and gear to the 4th gear, and lock the transmission input
tighten to 15–22Nm. shaft with TPT00068.
14. Measure the altitude difference between the input
shaft rear bearing outer ring plane and rear housing
plane, the altitude difference between the output shaft
rear bearing outer ring plane and rear housing plane
with the input shaft rear bearing and output shaft rear
bearing adjusting gasket measuring tool, then select a
new appropriate adjusting gasket. Apply an appropriate
amount of lubricating grease to the adjusting gasket, and
then put it into the input shaft bearing. The selecting
principle is with an clearance of 0 - 0.05mm. If it is
put into the output shaft rear bearing, the selecting
principle is with a pretightening force of 0.1 - 0.15mm.
Input shaft rear bearing adjusting gasket
17. Fit the output shaft 5th gear into the output shaft, and
Thickness: mm fit the 3rd/4th gear needle bearing into the 5th gear
bushing and then fit the input shaft 5th gear, screw the
0.1 new output shaft locking nut to the output shaft, and fit
0.15 the rubber gasket at the engaged part of the 5th driving
and driven gear, and tighten the nuts to 80–100Nm.
0.2
18. Lock the nut with a punch.
0.25
0.3
0.35
0.4
0.45
0.5

Output shaft rear bearing adjusting gasket

Thickness: mm

0.1

0.15
19. Apply an appropriate amount of gear oil to the inner
0.2 tapered surface of the 3rd/4th/5th gear synchronizer
0.25 gear for lubrication, then fit it into the 5th driving gear
joint gear tapered surface; insert the 5th gear fork into
0.3
the 5th gear synchronizer gear bushing, and fit them

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Transmission-MT Transmission
together into the 5th gear fork shaft assembly. Manual Transmission Assembly Refit
20. Select an appropriate circlip to snap into the 5th gear
synchronizer gear hub.

21. Press the new spring pin into the pin hole of the 5th
gear fork shaft. And put the steel ball into the hole at
the side of the 5th gear fork, fit the 5th gear fork bolt
and tighten to 5–8Nm.
22. Fit and secure the new circlip with circlip plier.
23. Apply plane sealant to the control window plane on the
rear housing. Fit the control cover assembly to the rear
housing, and fit the gear selection rocker arm assembly,
screw 5 connecting bolts and tighten to 15–25Nm.
24. Locate the gear shift rocker arm to the gear
selection/shift shaft, and knock in a new spring pin with
T24026.
25. Fit the new rear housing oil seal with TPT00069.

26. Apply plane sealant to the rear plane of the rear

housing. Fit the rear cover plate assembly, screw 8 rear
cover plate bolts and tighten to 8–13Nm.
27. Fit the clutch release bearing.
Clutch Release Bearing Refit
28. Fit the reverse lamp switch.
Reverse Lamp Switch Refit
29. Fit the manual transmission assembly.

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Drive Shaft Assembly

Remove
1. Remove the input shaft assembly.

Manual Transmission Disassembling

2. Remove the input shaft rear bearing and 5th gear
bushing together with puller and T32001.
3. Remove the input shaft 4th gear, needle bearing and 4th
gear synchronizer gear ring in sequence.

Refit
1. Knock the input shaft front bearing in place with
TPT00065.

4. Remove the 3rd/4th gear synchronizer gear bushing

and slider assembly.
5. Knock out the synchronizer circlip.

2. Lubricate the needle bearing, fit the input shaft needle

bearing and 3rd gear.
3. Fit the 3rd gear synchronizer gear ring and synchronizer
gear hub.
4. Select an appropriate circlip and knock it in place.

6. Remove the 3rd/4th gear synchronizer gear hub.

7. Remove the input shaft 3rd gear synchronizer gear ring,
3rd gear and needle bearing in sequence.
8. Pull out the input shaft front bearing with puller and
T32001.

5. Fit the 3rd/4th gear synchronizer gear bushing and

slider assembly, ensure that the slider assembly is
correctly located at the slider groove of the gear
bushing and synchronizer gear hub.

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Caution: Ensure parts are fitted in correct order and Driven Shaft Assembly
orientation. Remove
6. Lubricate the needle bearing, and fit the input shaft 4th 1. Remove the input shaft assembly.
gear synchronizer gear ring, needle bearing and 4th Manual Transmission Disassembling and Remove
gear in sequence.
2. Remove the input shaft rear bearing and 5th gear
7. Knock the input shaft rear bearing and 5th gear bushing bushing together with puller and T32001.
in place with TPT00065.
3. Remove the input shaft 4th gear, needle bearing and 4th
gear synchronizer gear ring in sequence.

8. Fit the input shaft assembly.

Manual Transmission Disassembling 4. Remove the 3rd/4th gear synchronizer gear bushing
and slider assembly.
5. Knock out the synchronizer circlip.

6. Remove the 3rd/4th gear synchronizer gear hub.

7. Remove the input shaft 3rd gear synchronizer gear ring,
3rd gear and needle bearing in sequence.
8. Pull out the input shaft front bearing with puller and
T32001.

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Transmission Transmission-MT

Refit 6. Knock the output shaft 3rd gear in place with

TPT00066.
1. Knock the driven shaft front bearing inner ring in place
with TPT00065.
2. Lubricate the needle bearing, and then fit the output
shaft needle bearing, 1st gear and 1st/2nd gear
synchronizer gear ring in sequence.
3. Fit the 1st/2nd gear synchronizer gear hub, select an
appropriate circlip and knock it in place.

7. Knock the input shaft rear bearing in place with

TPT00065.

4. Fit the synchronizer gear bushing, slider and

synchronizer gear ring, and ensure that the slider
assembly is correctly located at the slider groove of the
gear bushing and synchronizer gear hub.
Caution: Ensure parts are fitted in correct order and
orientation.

5. Lubricate the needle bearing, and then fit the output

shaft needle bearing, 4th gear and 3rd/4th gear space 8. Fit the driven shaft assembly.
ring in sequence. Manual Transmission Disassembling and Refit

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Transmission-MT Transmission
Differential Assembly
Remove
1. Remove the differential assembly.

Manual Transmission Disassembling and Remove

2. Pull out the bearings at both ends respectively with a
puller and T32001.

Caution: Support bolt of the drawing die (T32001) cannot

be used to support the propeller shaft hole directly, place
a spacer block between them.

6. Remove the planetary gear shaft, and remove the

axle shaft gear, planetary gear and washers from the
differential housing in sequence.

3. Remove 8 bolts fixing the main reduction driven gear

to the differential housing.
4. Knock down the main reduction driven gear from the
differential housing with a nylon hammer.

Refit
1. Check the differential rear bearing adjusting gasket for
wear or scratch, replace it when necessary.
Differential rear bearing adjusting gasket

Thickness (mm)

0.1

0.15
0.2
0.3
5. Knock out the circlips at both ends of the planetary 0.4
gear shaft.
2. Put the differential washer into the differential housing
cavity.

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Transmission Transmission-MT

3. Put the planetary gear and axle shaft gear into the
differential housing cavity in place.
4. Insert the planetary gear shaft and secure the two ends
with circlips.

5. Knock 2 differential bearings in place respectively with

TPT00067.

6. Fit the main reduction driven gear to the differential

housing, and tighten 8 retaining bolts to 110–150Nm.
7. Fit the differential assembly.

Manual Transmission Disassembling and Refit

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Transmission-MT Transmission
Special Tools Tool Description Picture
Tool Description Picture Number
Number

Replacer, oil T32001 Puller universal

seal, input shaft
TPT00066
and control
cover

Replacer, input
TPT00065 and output shaft
Replacer, Ø5 bearing
T24026
spring pin

Replacer,
TPT00067 differential
Replacer, LH oil bearing
TPT00064
seal, differential

Locking plate,
TPT00068
input shaft

Replacer, RH oil
TPT00069
seal, differential

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Transmission Clutch

Clutch
Specifications
Torque
Description Value
Bolt-Clutch Cover to Flywheel 24-26Nm
Bolt - clutch release fork to release shaft 10–15Nm
Bolt - clutch master cylinder to pedal bracket 7–10Nm
Union - clutch master cylinder to pipe 15–19Nm
Bolt - slave cylinder bracket to rear housing 40–50Nm
Union - clutch slave cylinder to pipe 15–19Nm
Bleed plug - clutch slave cylinder 10Nm

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Clutch Transmission
Parameter
Model Dry Single Disc, Diaphragm Spring, Hydraulic Booster Clutch
Diameter of driven plate 200mm
Diameter of pressure plate 200mm
Depth of rivet:
·New 1.2mm (above the rivet head)
·Service limit 0.2mm (above the rivet head)

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Transmission Clutch

Description and Operation

System Layout
Clutch Mechanical System (5MT)

1. Clutch Friction Plate 3. Screw

2. Clutch Cover 4. Clutch Release Bearing

Clutch Master Cylinder and Pipeline Assembly

(5MT)

1. Pin - Clutch Master Cylinder Push Rod 6. Clutch Master Cylinder Low-pressure Hose
2. Clutch Master Cylinder 7. Sleeve - Clutch Master Cylinder Pipeline
3. Clip - Clutch Master Cylinder Push Rod Pin 8. Clutch Master Cylinder Hard Pipe
4. Bolt - Clutch Master Cylinder 9. Clutch Sensor
5. Clutch Master Cylinder Pipeline Assembly 10. Clip - Clutch Hose

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Clutch Transmission
Clutch Slave Cylinder and Pipeline Assembly (5MT)

1. Clutch Slave Cylinder Pipeline Assembly 3. Bolt - Clutch Slave Cylinder

2. Clutch Slave Cylinder

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Transmission Clutch

Description driven plate. There are 3 pull rings on the outer ring of the
Overview pressure plate, which is then connected to the housing through
a spring. The spring is composed of three quenched and
This is a traditional three-piece diaphragm clutch with a
tempered steel sheets. When the clutch pedal is depressed, it
hydraulic clutch release system, which has no need to adjust
will pull the pressure plate away from the driven plate. Clutch
the clutch to compensate clutch wear.
housing is punched by steal plate.
Clutch Hydraulic System
The diaphragm spring is a cast ring with 18 release fingers in
MT model: The master cylinder of the clutch is directly fitted
its inner ring. There are two round support rings fitted on
on the pedal bracket in the passenger compartment, and the
the housing so that the diaphragm spring can rotate between
push rod of the master cylinder piston is fixed to the clutch
them. The diaphragm spring is not directly connected to the
pedal with clips and pins. Two ends of the hydraulic pipeline
pressure plate. When the release bearing applies stress on the
are connected to the master and slave cylinders with threaded
release finger of the diaphragm spring, the diaphragm spring
joints. The clutch salve cylinder fitted on the bracket of the
will rotate around the support ring to leave the pressure plate.
manual transmission housing, release rocker arm, release fork
And meanwhile, the spring of the pressure plate connected to
and release bearing compose a release mechanism, while the
the housing will also be away from the driven plate.
release bearing is supported and fixed by the guide sleeve
Driven Plate
fitted on the transmission input shaft. The clutch pipeline from
the slave cylinder is connected to the pipeline of the master
cylinder through a quick connector. The release fork leans the
release bearing on the diaphragm spring of the clutch during
separation.
Clutch Mechanical System
The clutch cover assembly is fitted on the flywheel and secured
with six bolts.
Clutch Cover Assembly

1. Driven plate body

2. Friction plate
3. Spline hub
4. Torsional shock absorber

The driven plate is fitted between the flywheel and the

pressure plate. Its feature is that the spline hub engages the
spline on the transmission input shaft. The friction plate is
composed of two discs, which are riveted on each side of the
driven plate body. The rivets are fitted in the notches in the
1. Diaphragm spring friction plate as well as that at the other side to protect the
2. Clutch cover pressure plate and flywheel from damage.
3. Pressure plate Clutch Sensor - MT
4. Support ring The clutch sensor is fitted on the master cylinder of the
5. Leaf spring clutch and is powered by the ECM. When the clutch pedal
is depressed, the ECM will receive the clutch release signal;
The clutch cover assembly is composed of the diaphragm
when the clutch pedal is reset, the ECM will receive the clutch
spring, pressure plate and cover. The pressure plate is made
engagement signal.
of cast iron and has a smooth plane machined to connect the

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Clutch Transmission
Operation plate, and the pressure plate will overcome the resistance of
Hydraulic Operation the spring, move towards the flywheel and apply pressure on
the driven plate.
MT model: when the clutch pedal is depressed, the piston is
pushed into the master cylinder. The piston drives the fluid The pressure on the driven plate applied by the pressure plate
in the master cylinder to move along the clutch pipeline. This increases the frictional force between the driven plate and
pressure is applied on the piston of the slave cylinder and the flywheel. When the clutch pedal is released, the frictional
piston will move under the action of hydraulic pressure. When force will increase, the rotational motion of flywheel is
the clutch pedal is released, the force on the release finger of transmitted to the driven plate, and then it is transferred to
the diaphragm spring will drive the release bearing. The release the transmission input shaft.
bearing then pushes the piston back to the slave cylinder by the
When the pedal is fully released, the force on the pressure
release fork and release rocker arm, and further drives the fluid
plate applied by the diaphragm spring will press the driven plate
back to the clutch pipeline and master cylinder.
on the flywheel, making no skidding between them.
Mechanical Operation
Clutch Sensor - MT
When the fluid in the slave cylinder drives the piston to
When the clutch pedal is depressed, the clutch sensor is
move, piston's movement pushes the clutch release bearing
activated. ECM uses the signal from the clutch sensor for the
to the release finger of the diaphragm spring by the release
following functions:
rocker arm and release fork and the diaphragm spring
will rotate around the support ring on the pressure plate • Reduce impact during gear the shift
housing. Following the deformation of the diaphragm spring, Reduce impact to prevent sharp increase of engine speed
its pressure on the pressure plate will disappear. Three leaf during the gear shift The reduction of the impact can improve
springs will pull the pressure plate away from the driven plate. drivability in the following aspects:
Disappearance of the pressure on the driven plate applied by • Smoother gear shift
the pressure plate reduces the frictional force between the
• Better exhaust emission control
driven plate and flywheel. The driven plate will skid on the
flywheel and can not transmit the power of the flywheel to • Fuel consumption improvement
the transmission input shaft. The clutch sensor receives a 12V reference voltage from the
When the clutch pedal is released, the pressure on the slave ECM. When the clutch pedal is in the reset position, the clutch
cylinder piston will disappear. Disappearance of this pressure sensor is connected to the ground. When the clutch pedal is
allows the release finger of the diaphragm spring to push the depressed, ECM will receive a 12V signal.
release bearing to skid along the guide sleeve, so that the In case of failure of the clutch sensor, any following signs may
release fork and release rocker arm are driven to push the occur:
slave cylinder piston back to the slave cylinder.
• Shifting impact reduction is not available
The diaphragm spring rotates around the support ring on the
pressure plate housing, and applies pressure on the pressure

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Transmission Clutch

Service Procedures
Clutch Assembly
Remove
1. Remove the transmission assembly.

Manual Transmission Assembly Remove

2. Lock the flywheel with T10028.

Thickness of driven plate (compressed) A

New driven plate 7.5mm

Service limit 5.9mm

4. Measure the depth of rivets, replace the driven plate if

the depth is less than the service limit.
Depth of rivet B
3. Gradually loosen and remove 6 bolts fixing the clutch
New driven plate 1.2mm
cover assembly to the flywheel.
Service limit 0.2mm

5. Check the pressure plate for any sign of wear or

damage. Check the drive plate for any sign of overheat
(with color from deep yellow to blue). Replace the
pressure plate if necessary.
Caution: Renew a clutch pressure plate which has been
accidentally dropped.

6. Check the surface levelness of the pressure plate at 4

separate points with a square edge gauge and feeler
gauge. Replace the pressure plate if deformation
exceeds the service limit value.

4. Remove the clutch cover assembly and take out the

driven plate.
5. Remove the release bearing.

Clutch Release Bearing Remove

Check
1. Visually check the diaphragm release finger for wear
or irregular height.
2. Check the clutch driven plate for any sign of wear or
oil contamination. Replace the driven plate if necessary.
3. Measure the thickness of the clutch plate, replace the
driven plate if the thickness is less than the service limit. Deformation of pressure plate

Service limit 0.15mm

7. Check the release bearing for any sign of wear or

damage, replace it if necessary.
8. Clean the pressure plate, flywheel, locating pins and

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Clutch Transmission
pin holes. Clutch Release Bearing
9. Check the flywheel for any sign of scratch or other Remove
damages. Replace it if it is scratched or damaged. 1. Remove the transmission assembly.
Refit Manual Transmission Assembly Remove
1. Fit the release bearing. 2. Remove the release fork locating bolt, and remove the
Clutch Release Bearing Refit release fork.
2. Apply molybdenum disulphide grease to the spline of 3. Loosen the clip from the release fork, and remove the
the clutch driven plate. release bearing from the transmission input shaft guide
3. Locate the clutch cover assembly on the flywheel. sleeve.

4. Make sure that the driven plate is aligned with the

centre of the pressure plate.
5. Insert the TEN00040 into the driven plate, and ensure
that the driven plate is aligned with the centre of the
crankshaft hole.

Refit
1. Clean the junction surface of the release bearing and
bearing guide sleeve.
2. Lubricate the bearing movement surface with
molybdenum disulfide grease.
6. Fit 6 bolts fixing the pressure plate to the flywheel and 3. Fit the release bearing to the release fork, and fix it into
tighten manually. the groove of the release fork with clips.
7. Lock the flywheel with T10028, tighten the bolts 4. Fit the clutch release rocker arm shaft of the front
fixing the pressure plate to the flywheel gradually to housing, screw 2 release fork bolts and tighten to
24-26Nm in diagonal sequence, and check the torque. 10–15Nm.
Pay attention to lock the pressure plate with bolts. 5. Fit the transmission assembly.
8. Remove the TEN00040. Manual Transmission Assembly Refit
9. Fit the transmission assembly.

Manual Transmission Assembly Refit

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Transmission Clutch

Clutch Master Cylinder 3. Connect the low pressure hose of the master cylinder
Remove to the master cylinder, and fasten with clips.
1. Drain the brake fluid from the brake fluid reservoir. 4. Connect the front hard pipe of the master cylinder to
the threaded joint of the master cylinder, and tighten
Caution: Brake fluid will damage paint finished surfaces.
to 15–19Nm.
If spilled, immediately remove fluid and clean area with
water. 5. Fit the driver side lower trim panel assembly.

2. Remove the driver side lower trim panel assembly. Driver Side Lower Trim Panel Assembly Refit
6. Fill brake fluid into reservoir up to the MAX mark.
Driver Side Lower Trim Panel Assembly Remove
7. Bleed the clutch pipeline system.
3. Place a piece of absorbent cloth to absorb the spilled
fluid. Clutch Pipeline System Bleeding
4. Disconnect the clip fixing the low pressure hose of the
master cylinder to the master cylinder connector.
5. Release the thread connection of the master cylinder
front hard pipe and master cylinder.

6. Loosen the clip, and pull out the pin of the master
cylinder push rod.
7. Remove 2 bolts fixing the clutch master cylinder to the
pedal bracket.

8. Remove the clutch master cylinder.

Refit
1. Locate the master cylinder to the pedal bracket, fit the
bolt and tighten to 7–10Nm.
2. Insert the pin connecting the clutch pedal and master
cylinder push rod, and secure with clips.

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Clutch Transmission
Clutch Slave Cylinder Clutch Pipeline System Bleeding
Remove Bleeding
1. Drain the brake fluid from the brake fluid reservoir. Bleed the air that enters into the hydraulic system when
disconnecting the pipeline for repair. During the air bleeding,
Caution: Brake fluid will damage paint finished surfaces.
the brake fluid in the brake fluid reservoir must be maintained
If spilled, immediately remove fluid and clean area with
at or above the MIN mark.
water.
Warning: Do not allow brake fluid to come into contact
2. Disconnect the slave cylinder from the rear clutch
with eyes or skin.
pipeline.
3. Loosen 2 bolts fixing the slave cylinder to the manual Caution: Do not reuse the brake fluid drained from the
transmission. clutch pipeline system.

1. Lift the vehicle on the lifting platform.

2. Unscrew the bleed plug dust cover from the cylinder
slave cylinder, and fit the hose to the bleed plug.
Immerse the free end of the hose into the glass
container half-filled with fresh brake fluid.

4. Remove the clutch slave cylinder.

Refit
1. Support the seat hole of the release rocker arm with
the end of the slave cylinder push rod.
2. Fix the slave cylinder to the manual transmission, and
tighten the bolt to 40–50Nm. 3. Press the clutch pedal to the maximum stroke and hold,
so as to ensure the maximum system pressure.
3. Connect the slave cylinder and rear clutch pipeline, and
tighten to 15–19Nm. 4. Loosen the bleed plug, remove the air in the fluid, the
system pressure will drop at this time.
4. Fill brake fluid into reservoir up to the MAX mark.
5. Tighten the bleed plug firstly to avoid the suck-back
5. Bleed the clutch pipeline system.
of the fluid.
Clutch Pipeline System Bleeding
6. At last, release the clutch pedal to the maximum stoke
steadily, allowing the master cylinder piston to return
to its original position without any external force.
Supplement with sufficient brake fluid.
7. Repeat the operation in the above sequence for several
times until the brake fluid without any air flows into the
container, then fix the clutch pedal to the maximum
stroke, tighten the bleed plug to 10Nm.
8. Remove the hose from the bleed plug, and fit the bleed
plug dust cover.
9. Fill brake fluid into reservoir up to the MAX mark.

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Transmission Clutch

Special Tools
Tool Description Picture
Number

Flywheel
T10028
locking tool

Aligner, clutch
TEN00040
plate

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HVAC Structure HVAC System
HVAC Structure
Specifications
Torque
Description Value
Bolt-Air conditioner compressor to engine 19-25Nm
Bolt-Air conditioner pipe to compressor 19-25Nm
Bolt-Air conditioner pipe to condenser 19-25Nm
Nut-evaporator/compressor pipe A to 7-10Nm
evaporator/compressor pipe B
Bolt-Air conditioner pipe to expansion valve 19-25Nm
Bolt-Condenser to Rad 5-7Nm
Nut/Bolt-Air conditioner case assembly to body 7-10Nm
Nut-Air conditioner case assembly to body 5-7Nm
Bolt-Expansion valve to evaporator 5–7Nm
Bolt-IPK duct to IPK 1.4–1.8Nm

Parameter
Parameter - 1.5L

Type of Refrigerant HFC-R134a

Volume of Refrigerant 480 ± 20 g
Compressor:
Displacement: 140 cm³/r
Speed
∙Minimum Speed 600 r/min
∙Maximum Speed 9200 r/min
Lubricating Oil: SP10
Refill Amount (new) 140 ± 10 ml
Evaporator Temperature Sensor:
∙Compressor ON ≥3℃
∙Compressor OFF Off immediately @ ≤1℃
Pressure Protection:
∙High Pressure Protection ON When pressure ≥3.14 Mpa, the switch disconnects.
∙Low Pressure Protection ON When pressure ≤0.196 Mpa, the switch disconnects.

Amount of lubricating oil for replacement of A/C system components - 1.5L (parameters including oil
recovered):

Total amount of lubricating oil 140 ± 10 ml

Compressor replacement Remaining lubricating oil in the original compressor
Condenser replacement 30 ml
Evaporator replacement 40 ml
Replace one or more pipes 30 ml
Note: 1. Large leak, cracked hose, impact or open relief valve can cause sudden loss of the refrigerant. Refrigerant leak
or slow leak will not cause this degree of fluid loss. When replacing components which cause a huge loss of refrigerant,
add an appropriate amount of fluid to specific components. 2. If the lost fluid of the components exceeds the specified
value, add as per the amount of loss.

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HVAC System HVAC Structure

Description and Operation

System Layout
Heating and Ventilation Components

1. Instrument Panel Air Duct - Left 5. Instrument Panel Air Duct - Right
2. Front Window Air Duct - Left 6. Instrument Panel Air Duct - Face
3. Windshield Air Duct 7. Footwell Air Duct
4. Front Window Air Duct - Right

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HVAC Structure HVAC System
A/C Box Assembly

1. Mode Damper Actuator 5. Blower Assembly

2. Temperature Damper Actuator 6. Blower Speed Regulation Resistor
3. Recirculated Damper Actuator 7. Heater Core
4. A/C Filter 8. Evaporator Core

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HVAC System HVAC Structure

A/C Cooling System

1. Evaporator and Thermostatic Expansion Valve (TXV) 5. A/C Pipeline

2. A/C Pressure Switch 6. Condenser
3. Low-pressure Service Connector 7. Compressor
4. High-pressure Service Connector

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HVAC Structure HVAC System
Description the windshield and front side window are integrated in the
Overview instrument panel.

The heating, ventilation and air conditioning system controls 4 air outlet assemblies in the instrument panel allow occupants
the vehicle interior temperature and air distribution. The to control the flow and direction of air distribution to face.
system contains the A/C box assembly (A/C filter, heater
The front seat footwell air outlet is fitted in the port beside
assembly and evaporator box assembly), air duct, refrigerant
the A/C box assembly.
pipe, controller and control panel. The air outlets are
integrated in the luggage compartment. Fresh air flows into A/C Box Assembly
the A/C box assembly through the A/C filter assembly, and The A/C box assembly heats and distributes the fresh air or
flows through the entire system by the blower operation. circulating air according to the mode selected on the control
According to the setting on the control panel, the heated or panel. The A/C box assembly is below the instrument panel.
cooled air is supplied to the air outlets of "face", "footwell" The A/C box includes the blower, A/C air filter, heater core,
and "defrost" via the air distribution duct. evaporator core and control damper. The passage in the A/C
According to models, the vehicle will be provided with one of box assembly introduces air into the A/C box and divides it into
the two air conditioning systems, i.e. MTC or ETC: three parts, air is delivered to the air outlets for the "face",
"footwell" and "defrost". A fresh recirculating air damper is
• In the MTC system, functions such as the air circulation,
mounted on the A/C box assembly housing, which adjusts the
air temperature, air distribution and blower speeds
vehicle interior air or outside air and takes it as the circulating
are selected manually, and the air temperature and air
air. The drain outlet at the bottom of the box body directs
distribution are operated and controlled with cables.
condensed water from the box body to the lower side of the
• In the ETC system, functions such as air recirculation, air
vehicle.
temperature, air distribution and blower speeds, etc. are
selected manually. The damper is in the A/C box, which controls the inlet air,
outlet air temperature and position of the outlet air.
Ventilation Components
Recirculation damper: the damper actuator drives the
Ventilation components: A/C filter, A/C air duct, A/C box
recirculation damper to open and close the fresh and
(housing, damper, damper actuator, blower) and air outlet.
recirculating air inlets so as to control the inlet air.
A/C Air Filter
Temperature damper: the damper actuator or the damper
The A/C air filter is used to improve the quality of the fresh air cable drives the temperature damper to vary the mixing ratio
supplied to the interior of the vehicle and filter fine particles of the cold/warm air so as to control the temperature of the
such as dust and pollen, etc. A/C outlet air.
The A/C air filter is fitted on the A/C box assembly, it shall be Mode damper: the damper actuator or the damper cable
checked on a regular basis, and replace when necessary. drives the mode damper to vary the air passing through the
A/C Air Duct A/C box and air duct so as to meet the user's different needs,
such as, face, footwell, windshield, etc.
Blower

The blower is the power source of the whole ventilation

system. Use the blower to drive interior air circulation or
introduce fresh air into the vehicle.

The blower is in the A/C box assembly. Control of the blower

air volume can be realized by using the button on the control
panel to control the blower speed control resistor of the A/C
box assembly.
Body Relief Valve

The body relief valve allows the warm air and vent air to go
through the passenger compartment freely.
The face air outlet in the instrument panel is fitted with an
individual air distribution duct. Air distribution ducts for The body relief valve is located at both sides of the luggage
compartment, which allows air in the passenger compartment
to be discharged to the covered area between the body and

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HVAC System HVAC Structure

rear bumper. The air vent is an effective check valve and an aluminum unidirectional flat-tube heat exchanger. Two
each vent contains grille covered by soft rubber damper. The aluminum tubes are fitted on the heater core, they extend
damper can open or close automatically according to the through the engine compartment wall and connect the heater
pressure difference between the passenger compartment and core assembly to the engine coolant circulation system. When
the external environment. the engine works, coolant constantly flows through the heater
Heater Components core under the action of coolant pump.

It provides heat for the A/C heating.

Heater Core

The heater core heats the air supplied to each distribution

outlet. The heater core fitted in the A/C box assembly is

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HVAC Structure HVAC System
Cooling System
A/C System Schematic

A = Liquid Refrigerant; B = Gas Refrigerant

1. Evaporator 6. Filter
2. TXV 7. Desiccant
3. A/C Pressure Switch 8. Condenser
4. High-pressure Service Connector 9. A/C Compressor
5. Cooling Fan 10. Low-pressure Service Connector

The cooling system transfers heat from the vehicle to the pressure/temperature mode starts with the TXV, through the
outside atmosphere and provides the heater assembly with evaporator to the compressor, in the TXV, the refrigerant
dehumidified cool air. The system comprises a compressor, a decreases in pressure and temperature, then it changes from
condenser, TXV, A/C pipeline and an evaporator. The system moderate temperature liquid to low temperature vapour in
is a closed loop system which applies R134a refrigerant as the evaporator before absorbing heat from the ambient air of
the heat transfer medium. Add A/C oil to the refrigerant to the evaporator. The high pressure/temperature mode starts
lubricate the internal components of the compressor. with the compressor, through the condenser to the TXV,
the pressure and temperature of the refrigerant increase as
To accomplish the transfer of heat, the refrigerant is
it passes through the compressor, then it releases heat to
circulated around the system where it passes through two
the atmosphere via the condenser and changes from high
pressure/temperature modes. In each pressure/temperature
temperature vapour to moderate-high temperature liquid.
mode, the state of the refrigerant changes. During this process,
the refrigerant absorbs and releases maximum heat. The low

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HVAC System HVAC Structure

Compressor solid impurities from the refrigerant with its drying module
and functions as a reservoir for liquid refrigerant so as to
accommodate changes of heat load in the evaporator.

With the impact effect and/or cooling fan, the air passing
through the heat exchanger absorbs heat from the refrigerant
and changes the refrigerant from a vapour to liquid. The
condenser cools and liquifies the refrigerant before it enters
the modulator. In the modulator, most of the remaining gas in
the refrigerant is separated. The refrigerant uses the desiccant
and filter to remove moisture and particles before entering
into the secondary cooler. The refrigerant is further cooled
as it flows through the secondary cooler, this results in the
refrigerant from the condenser outlet to the evaporator is
almost 100% converted into liquid.
1. Air intake port
Thermostatic Expansion Valve (TXV)
2. Relief valve
TXV TXV and Evaporator
3. Exhaust port
4. Electromagnetic clutch connector

The compressor circulates the refrigerant by compressing the

low pressure/low temperature vapour from the evaporator
and converting it into the high pressure/high temperature
vapour to the condenser.

The compressor under the mounting bracket of the

transmission is driven by a high-pressure motor.

With fixed displacement, the compressor provides the A/C

system with required amount of refrigerant by the change of
high-pressure motor speed.
Condenser
1. Evaporator
2. O-ring
3. TXV
4. Bolt

The TXV regulates the flow of the refrigerant and matches the
refrigerant flow with the heat load of the air passing through
the evaporator core. The TXV is fitted on the inlet and outlet
ports of the evaporator. The valve consists of an aluminum
housing containing inlet and outlet passages. A metering
valve is fitted in the inlet passage and the metering valve is
controlled by a temperature sensitive tube connected to a
diaphragm. The top of the diaphragm is filled with refrigerant
1. Condenser and senses evaporator outlet pressure and the tube senses
2. Air intake port evaporator outlet temperature. By regulating the opening of
the thermostatic expansion valve, the force can be balanced,
3. Liquid outlet port
this keeps a proper degree of superheat for the evaporator
The condenser transfers the refrigerant heat into the ambient outlet and balances the refrigerant flow and the thermal load
air and changes the refrigerant vapour from the compressor of the air.
into liquid. The condenser also removes moisture and

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HVAC Structure HVAC System
Thermostatic Expansion Valve The temperature and pressure of the refrigerant from the
evaporator drive the diaphragm and temperature sensitive
tube to move and regulate the metering valve opening,
thereby controlling the volume of the refrigerant flowing
through the evaporator. The warmer the air flowing through
the evaporator core, the more heat available to evaporate
refrigerant, and this allows more refrigerant to pass through
the metering valve.
Evaporator
The evaporator is in the air inlet of the heater assembly and
absorbs heat from the exterior or recirculated inlet air. Low
pressure and low temperature refrigerant changes from liquid
to vapour in the evaporator, absorbing large quantities of heat
during this process.
1. Membrane
A/C Pipeline
2. Housing
Aluminum A/C pipelines connect the system components
3. Metering valve together with O-rings between the connections to ensure a
4. Inlet passage to evaporator secure seal. To maintain a similar flow velocity in the system,
5. Outlet passage from evaporator the diameter of the refrigerant lines may vary so as to suit
6. Thermo-sensitive tube the two pressure/temperature modes. The pipelines with
larger diameters are fitted in the low pressure/temperature
The liquid coolant flows from the metering valve to the mode and those with smaller diameters are fitted in the high
evaporator. The metering valve reduces the pressure and pressure/temperature mode, and integrate the refrigerant
temperature of the refrigerant, changes the solid stream of refill port into the A/C pipelines so as to facilitate the system
refrigerant into a fine spray and improves the evaporation service.
effect. As the refrigerant passes through the evaporator,
it absorbs heat from the ambient air flowing through the
evaporator core. The increase of the temperature causes the
refrigerant to vaporize and increases its pressure.

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Service Procedures Drain

Refrigerant Recovery and Refill 1. Check if the high-pressure side and low-pressure side
Refrigerant Recovery hoses are connected to the A/C system. Open the
1. Connect the high-pressure side hose with a quick high/low-pressure side valves on the refilling station
disconnection interface to the high-pressure service control panel.
side connector of the A/C system. 2. Open the gas and liquid valves on the refrigerant
Tip: Use refrigerant tank designed only for service reservoir.
station. Overcharging restraint system is designed based Caution: The evacuating procedure must be carried out
on this kind of refrigerant tank. The tank valve is also before recharging process.
designed for the restraint system.
3. Start the vacuum pump and start the drain process.
2. Open the interface valve. In the process of recirculation, non-condensable gases
3. Connect the low-pressure side hose with a quick (mostly air) will be automatically exhausted from the
disconnection interface to the low-pressure service reservoir. A sound of pressure release may be heard.
side connector of the A/C system. 4. Check the system for leak. For information about the
4. Open the interface valve. refilling station, refer to the manufacturer's instructions
5. Check the high-pressure side and low-pressure side for use.
gauges on the refilling station control panel, and ensure A/C System Lubricating Oil Refill
there is pressure in the A/C. If there is no pressure, At this time, the lubricating oil discharged from the A/C system
there is recoverable refrigerant in the system. during recovery must be supplemented.
6. Open the high-pressure side and low-pressure side
Note:
valves.
• Always keep the lubricating oil bottle cap tight to prevent
7. Open the gas and liquid valves on the refrigerant
moisture or contaminants from entering the lubricating
reservoir.
oil.
8. Drain refrigerant in the oil separator.
• This operation requires a vacuum A/C system. It is
9. Close the drain valve. forbidden to open the lubricating oil filling valve when
10. Connect the refilling station to the appropriate power the A/C system is at positive pressure. This will result in
socket. backflow of lubricating oil through the bottle air vent.
11. Connect the main power switch. • An oil level lower than the suction pipe is prohibited
Caution: Reuse the recycled lubrication is prohibited. The when refilling or supplementing lubricating oil; otherwise,
recycled lubrication will damage the equipment. air will enter the A/C system.

Caution: Part of A/C lubrication (PAG) could be recycled 1. Use the special polyether type lubricating oil (contained
together with refrigerant but service station can separate in graduated bottle) for R-134a system.
lubrication from refrigerant to calculate the quantity of 2. For information about the refilling station, refer to the
lubrication. manufacturer's instructions for use. Add an appropriate
amount of lubricating oil to the A/C system.
12. Start the recycle process. For information about the
refilling station, refer to the manufacturer's instructions 3. When the oil refilled reaches the required point, close
for use. the valve.

13. Wait for 5min before checking the low-pressure side Refill
gauge on the control panel. If the A/C system is capable Refrigerant Refill
of keeping vacuum, the recovery is completed. 1. Close the low-pressure side valve on the control panel.
Warning: If warning indicator illuminates, it means the 2. Open the high-pressure side valve on the control panel.
tank is overfull and service station will stop, install a new 3. For information about the refilling station, refer to the
empty tank to continue this process. The different type manufacturer's instructions for use.
of tank is prohibited using.
4. Fill refrigerant of the required amount into the A/C, and
14. If the pressure at the low-pressure side starts to ensure the unit of measurement is correct, for example,
rise from 0, there remains refrigerant in the system. kg or lb.
Recover the residual refrigerant. Repeat this step until
5. Start refill.
the system can keep vacuum for 2 minutes.

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Refrigerant Refill Completion Compressor - 1.5L
Refrigerant Refill Completion Remove
1. Close the high-pressure side valve on the refilling station 1. Recycle the A/C system refrigerant.
control panel. Both valves shall be closed. A/C System Refrigerant Recycle
2. Start the vehicle and A/C system. 2. Disconnect the battery negative.
3. Keep the engine running until the readings on the 3. Remove the bottom deflector.
high-pressure side pressure gauge and the low-pressure
side pressure gauge are stable. Bottom Deflector Remove

4. Compare the readings with the system specifications. 4. Remove the engine auxiliary drive belt.

5. Check the outlet temperature of the evaporator, and Engine Auxiliary Drive Belt Remove
ensure that the A/C system operation conforms to the 5. Disconnect the harness connector (1).
system specifications.
6. Remove 2 bolts (3) fixing the A/C pipeline to the
6. Keep the A/C running. compressor, disconnect the pipeline, and discard the
7. Close the high-pressure side interface valve. seal ring.
8. Disconnect the high-pressure side hose from the vehicle. Caution: Always fit plugs to open connections to prevent
9. Open the low-pressure side valve on the control panel. contamination.
The system will quickly suck in refrigerant from two
7. Remove 4 bolts (2) fixing the A/C compressor to the
hoses through the low-pressure side hose.
engine, and remove the compressor assembly.
10. Close the low-pressure side interface valve.
11. Disconnect the low-pressure side hose from the vehicle.
Refrigerant Refill Failure
Refrigerant Refill Failure
Sometimes, the refrigerant is not completely refilled into the
A/C system. There are two reasons:
1. The pressure of the refrigerant reservoir in the refilling
station is close to that of the A/C system,

• which leads to slow oil delivery.

• For information about the refilling station, refer to the

manufacturer's instructions for use.

2. There is not enough refrigerant in the refrigerant reservoir Refit

of the refilling station.
1. Fix the compressor to the engine, fit 4 bolts, tighten to
• Therefore, part of the refrigerant refilled must be 19-25Nm, and check the torque.
recovered from the vehicle, then drain the A/C system 2. Remove the plug, fit the new seal ring to the A/C
before refilling. pipeline, and apply clean compressor oil.
• For information about the refilling station, refer to the 3. Fix the A/C pipeline to the compressor, fit 2 bolts,
manufacturer's instructions for use. tighten to 19-25Nm, and check the torque.
4. Connect the harness connector of the compressor.
5. Fit the engine auxiliary drive belt.

Engine Auxiliary Drive Belt Refit

6. Fit the bottom deflector.

Bottom Deflector Refit

7. Connect the battery negative.
8. Fill the A/C system refrigerant.

A/C System Refrigerant Refill

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Compressor Breather Hose - 1.5L 3. Remove the plug, fit the new seal ring to the A/C
Remove pipeline, and apply clean compressor oil.
1. Recycle the A/C system refrigerant. 4. Fix the compressor breather hose to the compressor,
A/C System Refrigerant Recycle fit 1 bolt, tighten to TBD, and check the torque.

2. Disconnect the battery negative. 5. Fit the bottom deflector.

3. Remove the bottom deflector. Bottom Deflector Refit

Bottom Deflector Remove 6. Connect the battery negative.
4. Remove 1 bolt fixing the compressor breather hose to 7. Fill the A/C system refrigerant.
the compressor, disconnect the pipeline, and discard A/C System Refrigerant Refill
the seal ring.
Caution: Always fit plugs to open connections to prevent
contamination.

5. Remove the bolt connecting the compressor breather

hose and the A/C hard pipe assembly, disconnect the
pipeline, and discard the seal ring.
Caution: Always fit plugs to open connections to prevent
contamination.

6. Remove the compressor breather hose.

Refit
1. Remove the plug, fit the new seal ring to the A/C
pipeline, and apply clean compressor oil.
2. Connect the compressor breather hose to the A/C
hard pipe assembly, fit 1 bolt, tighten to TBD, and check
the torque.

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Compressor Exhaust Hose - 1.5L 2. Fix the compressor exhaust hose to the condenser, fit
Remove 1 bolt, tighten to 19-25Nm, and check the torque.
1. Recycle the A/C system refrigerant. 3. Remove the plug, fit the new seal ring to the A/C
pipeline, and apply clean compressor oil.
A/C System Refrigerant Recycle
4. Fix the compressor exhaust hose to the compressor, fit
2. Disconnect the battery negative.
1 bolt, tighten to 19-25Nm, and check the torque.
3. Remove the bottom deflector.
5. Fit the front bumper assembly.
Bottom Deflector Remove
Front Bumper Assembly Refit
4. Remove the front bumper assembly.
6. Fit the bottom deflector.
Front Bumper Assembly Remove
Bottom Deflector Refit
5. Remove 1 bolt fixing the compressor exhaust hose to
7. Connect the battery negative.
the compressor, disconnect the pipeline, and discard
the seal ring. 8. Fill the A/C system refrigerant.

Caution: Always fit plugs to open connections to prevent A/C System Refrigerant Refill
contamination.

6. Remove 1 bolt fixing the compressor exhaust hose to

the condenser, disconnect the pipeline, and discard the
seal ring.
Caution: Always fit plugs to open connections to prevent
contamination.

7. Remove the compressor exhaust hose.

Refit
1. Remove the plug, fit the new seal ring to the A/C
pipeline, and apply clean compressor oil.

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A/C Hard Pipe Assembly - 1.5L seal ring.

Remove Caution: Always fit plugs to open connections to prevent
1. Recycle the A/C system refrigerant. contamination.
A/C System Refrigerant Recycle
2. Disconnect the battery negative.
3. Remove the air filter assembly.
Air Filter Assembly Remove
4. Remove 1 nut securing the clamp of the power steering
reservoir, and remove the power steering reservoir
without removing the fluid.
5. Disconnect the harness connector of the A/C pressure
switch.
6. Remove 1 bolt fixing the A/C hard pipe assembly to the
thermostatic expansion valve, disconnect the pipeline,
and discard the seal ring.
9. Loosen the clip securing the A/C hard pipe assembly,
Caution: Always fit plugs to open connections to prevent
and remove the A/C hard pipe assembly.
contamination.
Refit
1. Fix the A/C hard pipe assembly to the body and secure
with clips.
2. Remove the plug, fit the new seal ring to the A/C
pipeline, and apply clean compressor oil.
3. Fix the compressor hard pipe assembly to the
condenser, fit 1 bolt, tighten to 19-25Nm, and check
the torque.
4. Remove the plug, fit the new seal ring to the A/C
pipeline, and apply clean compressor oil.
5. Connect the compressor breather hose to the A/C
hard pipe assembly, fit 1 bolt, tighten to 7-10Nm, and
check the torque.
7. Remove the bolt connecting the compressor breather
hose and the A/C hard pipe assembly, disconnect the 6. Remove the plug, fit the new seal ring to the A/C
pipeline, and discard the seal ring. pipeline, and apply clean compressor oil.
7. Fix the A/C hard pipe assembly to the thermostatic
Caution: Always fit plugs to open connections to prevent
expansion valve, fit 1 bolt, tighten to 19-25Nm, and
contamination.
check the torque.
8. Connect the harness connector of the A/C pressure
switch.
9. Fix the power steering reservoir to the bracket, fit the
nuts securing the clamp of the power steering reservoir
and tighten them up.
10. Fit the front bumper assembly.

Front Bumper Assembly Refit

11. Connect the battery negative.
12. Fill the A/C system refrigerant.

A/C System Refrigerant Refill

8. Remove 1 bolt fixing the A/C hard pipe assembly to

the condenser, disconnect the pipeline, and discard the

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Pressure Switch Condenser
Remove Remove
1. Recycle the A/C system refrigerant. 1. Recycle the A/C system refrigerant.

A/C System Refrigerant Recycle A/C System Refrigerant Recycle

2. Disconnect the battery negative. 2. Disconnect the battery negative.
3. Disconnect the harness connector of the A/C pressure 3. Remove the front-end module assembly.
switch.
Front-end Module Assembly Remove
4. Remove 1 bolt (2) fixing the A/C pipeline to the
condenser, disconnect the pipeline, and discard the
seal ring.

Caution: Always fit plugs to open connections to prevent

contamination.

5. Remove 2 bolts (1) fixing the condenser to the radiator.

6. Loosen the clip (3), and remove the condenser
assembly.

4. Remove the A/C pressure switch from the A/C

high-pressure pipe and discard the O-ring.

Caution: Always fit plugs to open connections to prevent

contamination.
Refit
1. Lubricate the new O-ring with clean A/C lubricating oil.
2. Fit the O-ring to the A/C pressure switch.
3. Fit and secure the A/C pressure switch to the A/C
high-pressure pipe.
Refit
4. Connect the connector of the A/C pressure switch.
1. Fix the condenser to the radiator with clips, fit 2 bolts,
5. Connect the battery negative. tighten to 5-7Nm, and check the torque.
6. Fill the A/C system refrigerant. 2. Remove the plug, fit the new seal ring to the A/C
A/C System Refrigerant Refill pipeline, and apply clean compressor oil.
3. Fix the A/C pipeline to the condenser, fit 1 bolt, tighten
to 19-25Nm, and check the torque.
4. Fit the front-end module assembly.
Front-end Module Assembly Refit
5. Connect the battery negative.
6. Fill the A/C system refrigerant.

A/C System Refrigerant Refill

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A/C Box Assembly 11. Remove 2 bolts (1) and 4 nuts (2) fixing the A/C box
Remove assembly to the body.
1. Disconnect the battery negative.
2. Recycle the A/C system refrigerant.
A/C System Refrigerant Recycle
3. Drain the coolant.
Coolant Drain
4. Remove the air filter assembly.
Air Filter Assembly Remove
5. Remove 1 bolt fixing the A/C hard pipe assembly to the
thermostatic expansion valve, disconnect the pipeline,
and discard the seal ring.
Caution: Always fit plugs to open connections to prevent
contamination. 12. Remove the A/C box assembly.
Refit
1. Fix the A/C box to the body, fit 2 bolts and 4 nuts,
tighten to 7-10Nm, and check the torque.
2. Fit the harness clip, and connect the harness connector.
3. Fit the A/C drain pipe.
4. Fit the instrument panel beam assembly.
Instrument Panel Beam Assembly Refit
5. Fix the A/C box assembly to the front firewall, fit 2
nuts, tighten to 5-7Nm, and check the torque.
6. Fit the water pipe and fasten with clamps.
7. Remove the plug, fit the new seal ring to the A/C
6. Loosen the water pipe clamp and disconnect the water pipeline, and apply clean compressor oil.
pipe. 8. Fix the A/C hard pipe assembly to the thermostatic
7. Remove 2 nuts fixing the A/C box assembly to the expansion valve, fit 1 bolt, tighten to 19-25Nm, and
front firewall. check the torque.
9. Fit the air filter assembly.

Air Filter Assembly Refit

10. Fill the coolant.

Coolant Refill
11. Fill the A/C system refrigerant.

A/C System Refrigerant Refill

12. Connect the battery negative.
13. Perform a self-learning for the A/C servo motor.

a. Connect the scan tool to the vehicle and access the

VDS.

8. Remove the instrument panel beam assembly. b. Select "Fast Channel - Learning Value/Adjustment -
A/C Servo Motor Self-learning", and operate as per
Instrument Panel Beam Assembly Remove
the instructions on the screen.
9. Pull the A/C drain pipe out of the door.
10. Loosen the harness clip and disconnect the harness
connector.

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HVAC Structure HVAC System
Evaporator Core Expansion Valve
Remove Remove
1. Remove the A/C box assembly. 1. Recycle the A/C system refrigerant.

A/C Box Assembly Remove A/C System Refrigerant Recycle

2. Remove the expansion valve. 2. Disconnect the battery negative.

Expansion Valve Remove 3. Remove 1 bolt fixing the A/C hard pipe assembly to the
thermostatic expansion valve, disconnect the pipeline,
3. Remove the heater core.
and discard the seal ring.
Heater Core Remove Caution: Always fit plugs to open connections to prevent
4. Remove the screw and clip fixing the vent box to the contamination.
heater, and remove the vent box.
5. Remove the evaporator temperature sensor.
6. Remove the clip and screw securing the heater cover,
and disassemble the heater box.
7. Remove the evaporator core.
Refit
1. Fit the evaporator to the heater assembly.
2. Secure the heater cover with clips, fit and tighten the
screw.
3. Fit the evaporator temperature sensor.
4. Fix the vent box to the heater box, secure with clips,
fit and tighten the screw.
4. Remove 2 screws fixing the expansion valve to the A/C
5. Fit the heater core.
box, remove the expansion valve, and discard the seal
Heater Core Refit ring.
6. Fit the expansion valve. Caution: Always fit plugs to open connections to prevent
Expansion Valve Refit contamination.

7. Fit the A/C box assembly.

A/C Box Assembly Refit

Refit
1. Remove the plug, fit the new seal ring to the A/C
pipeline, and apply clean compressor oil.
2. Fix the expansion valve to the A/C box, fit 2 screws,
tighten to 5–7Nm, and check the torque.
3. Remove the plug, fit the new seal ring to the A/C
pipeline, and apply clean compressor oil.
4. Fix the A/C hard pipe assembly to the thermostatic
expansion valve, fit 1 bolt, tighten to 19-25Nm, and

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HVAC System HVAC Structure

check the torque. Heater Core

5. Connect the battery negative. Remove
6. Fill the A/C system refrigerant. 1. Remove the A/C box assembly.

A/C System Refrigerant Refill A/C Box Assembly Remove

2. Remove the sealing gasket of the pipeline, remove 2
screws fixing the cover plate of the pipe clamp to the
pipe clamp, and remove the cover plate.
3. Remove 2 screws fixing the water pipe clamp of the
heater core to the A/C box, and remove the pipe clamp.
4. Remove the mode damper actuator (if equipped).

Mode Damper Actuator Remove

5. Remove 3 screws fixing the heater core shroud to the
A/C box, and remove the shroud.

6. Remove the heater core assembly.

Refit
1. Clip the heater core into the A/C box.
2. Fix the heater core shroud to the A/C box, fit and
tighten 3 screws.
3. Fit the mode damper actuator (if equipped).

Mode Damper Actuator Refit

4. Fix the water pipe clamp of the heater core to the A/C
box, fit and tighten 2 screws.
5. Fix the cover plate of the pipe clamp to the pipe clamp,
fit and tighten 2 screws.
6. Fit the sealing gasket of the pipeline.
7. Fit the A/C box assembly.
A/C Box Assembly Refit

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HVAC Structure HVAC System
Blower Motor Assembly Blower Speed Regulation Resistor
Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Disconnect the harness connector of the blower. 2. Disconnect the harness connector (1) of the blower
3. Remove 3 screws fixing the blower assembly to the speed control resistor.
A/C box. 3. Remove 2 screws (2) fixing the blower speed control
resistor to the A/C box.

4. Remove the blower assembly.

Refit 4. Remove the blower speed control resistor.
1. Fix the blower to the A/C box, fit and tighten 3 screws. Refit
2. Connect the harness connector of the blower. 1. Fix the blower speed control resistor to the A/C box,
fit and tighten 2 screws.
3. Connect the battery negative.
2. Connect the harness connector of the blower speed
control resistor.
3. Connect the battery negative.

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HVAC System HVAC Structure

A/C Filter Cover A/C Filter Element

Remove Remove
1. Remove the glove box assembly. 1. Remove the A/C filter cover.

Glove Box Assembly Remove A/C Filter Cover Remove

2. Loosen the clip, and remove the A/C filter cover. 2. Remove the A/C filter element.
Refit
1. Fit the A/C filter element.
2. Fit the A/C filter cover.

A/C Filter Cover Refit

Refit
1. Fit the A/C filter cover and secure with clips.
2. Fit the glove box assembly.

Glove Box Assembly Refit

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HVAC Structure HVAC System
A/C Drain Pipe Instrument Panel Air Duct
Remove Remove
1. Pry off the clip and remove the passenger side heater 1. Remove the instrument panel assembly.
closing plate.
Instrument Panel Assembly Remove
2. Disconnect the pipeline from the body and A/C box.
2. Remove 9 screws fixing the instrument panel air duct
3. Remove the A/C drain pipe. to the instrument panel.
Refit
1. Fix the A/C pipe to the body and A/C box.
2. Fit the A/C drain pipe.
3. Fit the passenger side heater closing plate and secure
with clips.

3. Remove the instrument panel air duct.

Refit
1. Fix the instrument panel air duct to the instrument
panel, fit 9 screws, tighten to 1.4–1.8Nm, and check
the torque.
2. Fit the instrument panel assembly.

Instrument Panel Assembly Refit

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HVAC System HVAC Structure

Body Relief Valve - Left Body Relief Valve - Right

Remove Remove
1. Remove the rear bumper assembly. 1. Remove the rear bumper assembly.

Rear Bumper Assembly Remove Rear Bumper Assembly Remove

2. Pry off the clip, and remove the body relief valve (left). 2. Pry off the clip, and remove the body relief valve (right).

Refit Refit
1. Fit the body relief valve - left. 1. Fit the body relief valve - right.
2. Fit the rear bumper assembly. 2. Fit the rear bumper assembly.

Rear Bumper Assembly Refit Rear Bumper Assembly Refit

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HVAC-ETC HVAC System
HVAC-ETC
Specifications
Torque
Description Value
Bolt-Controller to cross member dash 2-4Nm
Screw-A/C control panel to IPK 2–3Nm
Bolt-Blend flap servo motor to heater case 0.6–1Nm
Bolt-Distribution flap servo motor to heater case 0.6–1Nm
Bolt-Fresh recirculated air flap servo motor to heater case 0.6–1Nm

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HVAC System HVAC-ETC

Description and Operation

System Layout
A/C Control Panel

1. Temperature Control Knob 6. Blower Speed Control Knob

2. Defrost/Defog Button 7. Windshield and Footwell Mode Button
3. AC On/Off Button 8. Footwell Mode Button
4. Circulation Mode Button 9. Face/Footwell Mode Button
5. Heated Rear Window Button 10. Face Mode Button

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HVAC-ETC HVAC System
A/C Control System

1. A/C Pressure Switch 4. Blower Speed Regulation Resistor

2. A/C Control Panel 5. Evaporator Temperature Sensor
3. A/C controller

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HVAC System HVAC-ETC

System Control Diagram

A = HS CAN Bus; B = Hard Wire

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HVAC-ETC HVAC System
Description
Overview To "Face + Footwell". Direct the air to distribute
through the footwell, side and centre air outlets.
Select blower speed, air temperature, air circulation, air
distribution, etc. by operating the A/C control panel. In
the electronic A/C system, functions such as blower speed, To "Footwell". Direct the air to distribute through
air temperature, air circulation, air distribution, etc. are the footwell air outlets.
selected manually. The whole system consists of the following Note: In this mode, a small amount of airflow
components: will be directed to distribute through the side,
• A/C control panel windshield side and windshield air outlets.
• A/C controller
• Evaporator temperature sensor To "Footwell + Windshield". Direct the air to
distribute through the windshield and footwell air outlets.
• Blower
• Damper actuator Heated Rear Window

Control Panel - ETC

Press the Heated Rear Window button to enable
The temperature control knob and blower speed control the heated rear window function, and the indicator on the
knob are incremental rotary switches, and the rest of the button will illuminate. The heated rear window function will
switches on the control panel are not self-locking switches. automatically turn off after operating for 15 minutes. Operate
The functions include: it for a second time within 5 minutes, and automatically turn
System Switch* off after heating for 8 minutes. When the heated rear window
works, press the button again to turn off the heating function,
Press the system switch to start the A/C system, press again then the indicator on the button goes out.
to turn it off.
Note: The heated rear window function works only
Air Volume Adjustment
when the engine is running.
Rotate the air volume adjustment knob Air Circulation
clockwise/anti-clockwise to increase/decrease the air volume.

Note: The air volume adjustment knob is also the Press the air circulation mode button on the control
A/C system switch knob. Adjust the air volume to 0 panel, switch the circulation damper to internal circulation, and
to turn off the A/C system. the indicator on the button illuminates.
Temperature Adjustment When the vehicle receives a reverse signal and a windshield
Rotate the temperature adjustment knob washing signal, internal/external circulation will be
clockwise/anti-clockwise to increase/decrease the air outlet automatically switched, and the automatic switching function
temperature. will be disabled in the defrost/defog mode.

A/C Switch Note: Keeping the circulation damper closed may

result in windshield frosting/fogging. If this
When the A/C switch button is pressed, the A/C system gives happens, rotate the air distribution mode knob to
request to activate the cooling system, meanwhile the indicator Windshield mode, and regulate the air volume to
on the button illuminates, and all functions are restored to the maximum.
state before the system is turned off. Press the button again
to turn off the cooling system. The indicator lamp goes out. Defrost/Defog

Air Distribution Mode

Press the defrost/defog button on the control panel,
Select the corresponding button to regulate the air distribution and the indicator on the button will illuminate. Meanwhile the
mode as required. system will enter into the temperature and air volume set by
the user to brighten windshield and side windows.
To "Face". Direct the air to distribute through the Press the defrost/defog button again to exit the defrost/defog
side and centre air outlets. state. Then the indicator will go off, and the system will return
to the previous state.

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HVAC System HVAC-ETC

If the defrost/defog mode is selected, operate the A/C When the temperature monitored is lower than a certain
switch button to turn on/off the compressor; operate the value, the compressor will be requested to turn off to prevent
air circulation mode button to switch between internal and the evaporator freezing.
external circulation, without quiting the defrost/defog mode
A/C Pressure Switch
in either case; operate other air distribution functions to
switch to corresponding air distribution mode and quit the The A/C pressure sensor signal varies within 0.2 - 4.8V.
defrost/defog mode. When the A/C refrigerant pressure is low, its signal value will
approach to 0V. When the A/C refrigerant pressure is high, its
Sensors
signal value will approach to 5V. The engine control module
Evaporator Temperature Sensor (ECM) converts the A/C pressure sensor voltage signal to a
The evaporator temperature sensor is a negative temperature pressure value. When the pressure is too high or too low, the
coefficient thermistor. The sensor is in the evaporator, which engine control module will stop the A/C compressor.
is used to measure the surface temperature of the evaporator.

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HVAC-ETC HVAC System
Operation Temperature Control
Overview When the request of temperature change is shown on the
The electric A/C controller operates according to the A/C control panel, the A/C controller enables the temperature
followings inputs: actuator to change the damper angle.
• Mode actuator position Mode Control
• Temperature actuator position When the request of mode change is shown on the A/C
• Blower speed control panel, the A/C controller enables the mode actuator
• Evaporator temperature value to drive the damper angle.

• A/C pressure value Compressor Control

The electric A/C controller controls the followings after When refrigeration request is shown on the A/C control
manual settings on the panel: panel, the A/C controller will receive the switch signal and
then transmit to the engine control module via the bus; the
• Blower speed
engine control module will engage the compressor clutch,
• Mode damper actuator position meanwhile the engine accessory belt drives the compressor
• Temperature damper actuator position to operate, thereby driving the refrigerant to circulate.
• Internal/external circulation damper motor position During the operation of compressor, the engine control
Blower Speed Control module may cut off the supply of clutch in the following
situations:
When the request of blower speed change is shown on the
A/C control panel, the A/C controller controls the speed of • The engine control module receives feedback from the
the blower motor by increasing or decreasing the voltage at pressure switch, and the value is higher or lower than
the blower motor ground end with the blower speed control certain threshold;
resistor. • The engine control module receives the temperature
Intake Control value from the A/C evaporator temperature sensor, and
the value is lower than certain threshold;
When the request of intake air source change is shown
on the A/C control panel, the A/C controller enables the • The engine control module receives the request of
internal/external circulation actuator to change the damper acceleration.
angle.

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HVAC System HVAC-ETC

Service Procedures A/C Panel - ETC

A/C Controller Assembly - ETC Remove
Remove 1. Remove the centre console upper trim panel assembly.
1. Disconnect the battery negative. Centre Console Upper Trim Panel Assembly
2. Remove the A/C panel - ETC. Remove
A/C Panel - ETC Remove 2. Remove 4 screws fixing the A/C panel to the instrument
3. Remove 2 bolts fixing the A/C controller to the panel.
instrument panel beam.

3. Disconnet the harness connector, and remove the A/C

4. Disconnect the harness connector, and remove the panel (ETC).
A/C controller assembly. Refit
Refit 1. Connect the harness connector of the A/C panel.
1. Connect the harness connector of the A/C controller. 2. Fix the A/C panel to the instrument panel, fit 4 screws,
2. Fix the A/C controller to the instrument panel beam, tighten to 2–3Nm, and check the torque.
fit 2 bolts, tighten to 2-4Nm, and check the torque. 3. Fit the centre console upper trim panel assembly.
3. Connect the battery negative. Centre Console Upper Trim Panel Assembly Refit
4. After replacing the A/C controller, the following
operations must be carried out:

a. Connect the scan tool to the vehicle and access the

SIPS.

b. Select "Programming and Coding - HVAC -

Replacement" and operate as per the instructions
on the screen.

c. The procedures for replacement already include

procedures for update, configuration and setting
(diagnostic procedures for A/C servo motor
self-learning).

d. If it prompts "Failed" during the replacement, please

operate as per the interface prompts. If it only
prompts that the A/C servo motor self-learning fails,
repeat the diagnostic procedure with VDS.

5. Fit the A/C panel - ETC.

A/C Panel - ETC Refit

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HVAC-ETC HVAC System
Temperature Damper Actuator Mode Damper Actuator
Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Remove the glove box assembly. 2. Disconnect the harness connector of the mode damper
actuator.
Glove Box Assembly Remove
3. Remove 3 screws fixing the mode damper actuator to
3. Disconnect the harness connector (1).
the A/C box.
4. Remove 3 screws (2) fixing the temperature damper
actuator to the A/C box.

4. Disconnect the connection of the motor and mode

damper linkage mechanism.
5. Disconnect the connection of the motor and
5. Remove the mode damper actuator.
temperature damper linkage mechanism.
Refit
6. Remove the temperature damper actuator.
1. Connect the motor and mode damper linkage
Refit
mechanism.
1. Connect the actuator and linkage mechanism of the
2. Fix the mode damper actuator to the A/C box, fit 3
temperature damper.
screws, tighten to 0.6–1Nm, and check the torque.
2. Fix the temperature damper actuator to the A/C
3. Connect the harness connector.
box, fit 3 screws, tighten to 0.6–1Nm, and check the
torque. 4. Connect the battery negative.

3. Connect the connector of the temperature damper 5. Perform a self-learning for the A/C servo motor.
actuator. a. Connect the scan tool to the vehicle and access the
4. Connect the battery negative. VDS.
5. Perform a self-learning for the A/C servo motor. b. Select "Fast Channel - Learning Value/Adjustment -
a. Connect the scan tool to the vehicle and access the A/C Servo Motor Self-learning", and operate as per
VDS. the instructions on the screen.

b. Select "Fast Channel - Learning Value/Adjustment -

A/C Servo Motor Self-learning", and operate as per
the instructions on the screen.
6. Fit the glove box assembly.

Glove Box Assembly Refit

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HVAC System HVAC-ETC

Internal/External Recirculated Damper Actuator Evaporator Core Temperature Sensor

Remove Remove
1. Remove the glove box assembly. 1. Remove the heater core.

Glove Box Assembly Remove Heater Core Remove

2. Disconnect the harness connector (2). 2. Remove the screw and clip fixing the vent box to the
3. Remove 3 screws (1) fixing the recirculated damper heater, and remove the vent box.
actuator to the A/C box. 3. Remove the evaporator core temperature sensor.
Refit
1. Fit the evaporator core temperature sensor to the
evaporator core.
2. Fix the vent box to the heater box, secure with clips,
fit and fasten the screws.
3. Fit the heater core.
Heater Core Refit

4. Disconnect the connection of the motor and

fresh/recirculated air damper linkage mechanism.
5. Remove the recirculated damper actuator.
Refit
1. Connect the motor and fresh/recirculated air damper
linkage mechanism.
2. Fix the servo motor of the recirculated air damper
to the A/C box assembly, fit 3 screws, tighten to
0.6–1Nm, and check the torque.
3. Connect the connector of the recirculated damper.
4. Connect the battery negative.
5. Perform a self-learning for the A/C servo motor.

a. Connect the scan tool to the vehicle and access the

VDS.

b. Select "Fast Channel - Learning Value/Adjustment -

A/C Servo Motor Self-learning", and operate as per
the instructions on the screen.

6. Fit the glove box assembly.

Glove Box Assembly Refit

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HVAC-MTC HVAC System
HVAC-MTC
Specifications
Torque
Description Value
Screw-A/C control panel to IPK 2–3Nm
Bolt-Fresh recirculated air flap servo motor to heater case 0.6–1Nm

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HVAC System HVAC-MTC

Description and Operation

System Layout
A/C Panel

1. Temperature Control Knob 4. Heated Rear Window (if equipped)

2. Air Circulation Mode 5. Air Distribution Mode Knob
3. Blower Speed Control Knob 6. A/C Button

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HVAC-MTC HVAC System
A/C Control System

1. A/C Pressure Switch 3. Blower Speed Regulation Resistor

2. A/C Control Panel 4. Evaporator Temperature Sensor

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HVAC System HVAC-MTC

System Control Diagram

MTC System Control Diagram

A = HS CAN Bus; B = Hard Wire

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HVAC-MTC HVAC System
Description off after heating for 8 minutes. When the heated rear window
Overview works, press the button again to turn off the heating function,
then the indicator on the button goes out.
In manual A/C system, functions such as air temperature, air
distribution and blower speed are selected manually. Note: The heated rear window function works only
when the engine is running.
Manual Air Conditioning System
A/C Switch:
The control system consists of the following components:
• Manual controller Press the A/C switch to switch on the air conditioner. Press
the switch again to switch off the air conditioner.
• Evaporator temperature sensor
• Blower speed regulation resistor Blower Switch:

Manual Controller Rotate the air volume adjustment knob

clockwise/anti-clockwise to increase/decrease the air volume.
Manual controller and BCM are connected by hard wire so as The air volume has a total of 5 gears, which is 0 gear to 4 gear
to control the rear window heater and mode control, etc. arranged from small to large.
Heating and ventilation system control the temperature and Air Circulation Button
distribution of the air inside the vehicle. This system consists of
the following parts: filter cover, heater assembly, distribution When the ignition is switched on, you may change the
duct and controller assembly. internal/external circulation status with the air circulation
control button.
The fresh air or recycled air from the filter cover flows into the
heater assembly is heated or cooled according to the settings Press the air circulation control button, the indicator in the
on the control panel, then the heated air or cooled air is button will illuminate, the circulation damper will be closed and
supplied to the windshield via the distribution pipe. the internal air is separated from the ambient environment,
the system enters into the internal circulation mode. Press
Control Panel
this button again, the indicator in the button will go off, the
The switch on the control panel has the following functions: circulation damper will be opened and the system switches to
Air Distribution Switch: the external circulation mode.
Sensor
When the switch is pressed every time, the air distribution
will change, and the change range is only face, face and Evaporator Temperature Sensor
footwell, only footwell, footwell and windshield/front side The evaporator temperature sensor is a negative temperature
window defrosting, windshield/front side window defrosting, coefficient thermistor. The sensor is in the evaporator, which
only windshield/front side window defrosting. is used to measure the surface temperature of the evaporator.
Temperature Control: When the temperature monitored is lower than a certain
value, the compressor will be required to be turned off to
Rotate the temperature control knob
prevent evaporator freezing.
clockwise/counterclockwise to increase/decrease the
temperature. A/C Pressure Switch

Heated Rear Window * The A/C pressure sensor signal varies within 0.2 - 4.8V.
When the A/C refrigerant pressure is low, its signal value will
Press the Heated Rear Window button to enable approach to 0V. When the A/C refrigerant pressure is high, its
the heated rear window function, and the indicator on the signal value will approach to 5V. The engine control module
button will illuminate. The heated rear window function will (ECM) converts the A/C pressure sensor voltage signal to a
automatically turn off after operating for 15 minutes. Operate pressure value. When the pressure is too high or too low, the
it for a second time within 5 minutes, and automatically turn engine control module will stop the A/C compressor.

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HVAC System HVAC-MTC

Operation Mode Control

Overview Adjust the mode damper cable manually and drive the angle of
Manual A/C controller operates according to the followings the damper.
inputs: Compressor Control
• Blower speed When refrigeration request is shown on the A/C control
• Evaporator temperature value panel, the A/C controller will receive the switch signal and
• A/C pressure value then transmit to the engine control module via the bus; the
engine control module will engage the compressor clutch,
The manual A/C controller controls the followings after
meanwhile the engine accessory belt drives the compressor
manual settings on the panel:
to operate, thereby driving the refrigerant to circulate.
• Blower speed
During the operation of compressor, the engine control
• Internal/external circulation damper motor position
module may cut off the supply of clutch in the following
Blower Speed Control situations:
When the request of blower speed change is shown on the • The engine control module receives feedback from the
A/C control panel, the A/C controller controls the speed of pressure switch, and the value is higher or lower than
the blower motor by increasing or decreasing the voltage at certain threshold;
the blower motor ground end with the blower speed control • The engine control module receives the temperature
resistor. value from the A/C evaporator temperature sensor, and
Intake Control the value is lower than certain threshold;
When the request of intake air source change is shown • The engine control module receives the request of
on the A/C control panel, the A/C controller enables the acceleration.
internal/external circulation actuator to change the damper
angle.
Temperature Control
Adjust the temperature damper cable manually and change the
angle of the damper.

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HVAC-MTC HVAC System
Service Procedures Temperature Damper Cable
A/C Panel - MTC Remove
Remove 1. Remove the A/C panel - MTC.
1. Disconnect the battery negative. A/C Panel - MTC Remove
2. Remove the centre console upper trim panel assembly. 2. Remove the clip fixing the temperature damper cable
Centre Console Upper Trim Panel Assembly to the air plate linkage, and disconnect the connection.
Remove
3. Remove 4 screws fixing the A/C panel to the instrument
panel.

3. Remove the temperature damper cable.

Refit
1. Fix the cable to the temperature damper linkage, and
4. Loosen the clip, and disconnect the mode damper and secure with clips.
temperature damper cables from the A/C panel. 2. Fit the A/C panel - MTC.
5. Disconnect the harness connector, and remove the
A/C Panel - MTC Refit
A/C panel (MTC).
Refit
1. Connect the harness connector of the A/C panel.
2. Fit the mode damper and temperature damper cable.
3. Fix the A/C panel to the instrument panel, fit 4 screws,
tighten to 2–3Nm, and check the torque.
4. Fit the centre console upper trim panel assembly.
Centre Console Upper Trim Panel Assembly Refit
5. Connect the battery negative.

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HVAC System HVAC-MTC

Mode Damper Cable Recirculated Damper Actuator

Remove Remove
1. Remove the A/C panel - MTC. 1. Remove the glove box assembly.

A/C Panel - MTC Remove Glove Box Assembly Remove

2. Remove the clip fixing the mode damper cable to the 2. Disconnect the harness connector (2).
air plate linkage, and disconnect the connection. 3. Remove 3 screws (1) fixing the recirculated damper
actuator to the A/C box.

3. Remove the mode damper cable.

Refit 4. Disconnect the connection of the motor and
fresh/recirculated air damper linkage mechanism.
1. Fix the cable to the mode damper linkage, and tighten
with clips. 5. Remove the recirculated damper actuator.
2. Fit the A/C panel - MTC. Refit
1. Connect the motor and fresh/recirculated air damper
A/C Panel - MTC Refit
linkage mechanism.
2. Fix the servo motor of the recirculated air damper
to the A/C box assembly, fit 3 screws, tighten to
0.6–1Nm, and check the torque.
3. Connect the connector of the recirculated damper.
4. Connect the battery negative.
5. Perform a self-learning for the A/C servo motor.

a. Connect the scan tool to the vehicle and access the

VDS.

b. Select "Fast Channel - Learning Value/Adjustment -

A/C Servo Motor Self-learning", and operate as per
the instructions on the screen.

6. Fit the glove box assembly.

Glove Box Assembly Refit

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Front Wheel Steering Steering System
Front Wheel Steering
Specifications
Torque
Description Value
Bolts-Steering pump to Steering oil pipe 26–30Nm
Nuts-Steering outer tie rod 63–73Nm
Nuts-Steering outer tie rod to steering arm 28–32Nm
-Steering inner tie rod 70-80Nm
Bolts-Steering gear to front subframe 90–110Nm
Bolts-Steering oil pipe bracket to Steering pump 7–10Nm
Bolts-Steering pump to Steering oil pipe 36–40Nm
Bolts-Front subframe to body 90NM+180°
Nuts- anti-roll bar links to anti-roll bar 55–65Nm
Bolts-Steering column intermediate shaft to steering pump 19–25Nm
Bolts-Steering pump to Steering bracket 19–25Nm
Bolts-Steering pulley to Steering pump 19–25Nm
Bolts-Steering oil pipe bracket to Steering pump 7–10Nm
Bolts-Steering oil pipe bracket to Steering pump 7–10Nm
Bolts-Steering pump to the machine into the tubing is fixed 7–10Nm
to the right front longitudinal beam
Bolts-Steering pump to the machine into the tubing is fixed 7–10Nm
on the steering pump
Bolts-Turning machine flowline fixed to the left front 7–10Nm
longitudinal beam
Bolts-Steering oil pipe bracket to Subframe 7–10Nm
Bolts-Steering cooling pipe to Bulkhead 6.5–7.5Nm

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Steering System Front Wheel Steering

Parameter
Model Hydraulic servo-assist type steering gear can reach linear
transmission ratio steering system
Steering Column:

Model Foldaway and compressible with energy absorbing, steering

wheel can be tilted
Diameter of steering wheel 370 mm
Steering wheel turns - from a dead centre at one side to 2.85
another dead centre at the other side

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Front Wheel Steering Steering System
Description and Operation
System Layout
Steering System Component Layout

1. Steering Wheel 5. Steering Reservoir Assembly

2. Steering Column Assembly 6. Steering Oil Inlet Pipe Assembly
3. Steering Gear Assembly 7. Steering Oil Return Pipe Assembly
4. Steering Pump

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Steering System Front Wheel Steering

Power Steering Gear Exploded View

1. Power Steering Gear Subassembly 6. Nut - Steering Gear

2. Nut - Steering Gear Outer Tie Rod 7. Bolt - Steering Gear
3. Steering Gear Outer Tie Rod Assembly 8. Steering Gear Input Shaft Seals
4. Nut - Steering Gear Outer Tie Rod to Knuckle 9. Steering Gear Outer Tie Rod Assembly
5. Steering Gear Boot 10. Steering Gear Inner Tie Rod

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Front Wheel Steering Steering System
Power Steering Hydraulic System Layout

1. Steering Reservoir Assembly 9. Steering Cooling Pipe Assembly

2. Cooler to Reservoir Oil Return Pipe Assembly 10. Bolt - Steering Cooling Pipe
3. Steering Reservoir to Steering Pump Oil Suction Pipe 11. Steering Pump Assembly
Assembly 12. Bolt - Power Steering Pump
4. Clamp - Steering Reservoir to Steering Pump Oil Suction 13. Bolt - Power Steering Pump
Pipe
14. Nut - Power Steering Pump
5. Steering Reservoir Bracket
15. Steering Gear to Cooler Oil Return Pipe Clamp
6. Clamp - Steering Reservoir to Steering Pump Oil Suction
16. Bolt - Steering Pump to Steering Gear Oil Inlet Pipe
Pipe
17. Bolt - Steering Pump to Steering Gear Oil Inlet Pipe
7. Steering Pump to Steering Gear Oil Inlet Pipe Assembly
18. Bolt - Steering Gear to Cooler Oil Return Pipe
8. Steering Gear to Cooler Oil Return Pipe Assembly

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Steering System Front Wheel Steering

Description Warning: Care is required when working on the hydraulic

Overview systems, since the high pressure fluid can be hot and, when
the pump is operating, reach pressures in excess of 10000
The steering system mainly includes: a two-part foldaway
KPa(1450 lbf/in2) causing a risk of personal injury.
steering column, a power steering gear, a power steering fluid
pump, a power steering fluid reservoir, a steering fluid cooler Power Steering Fluid Flow
and steering fluid hard pipe and hose. The fluid pressure from the power steering fluid pump is
Power Steering Gear transferred to the conversion valve via the steering pinion, the
control valve controls the fluid pressure and changes the fluid
The power steering gear is fitted in an appropriate position
flow direction. The fluid is directed to the pressure cylinder
under the rear beam of the front subframe. Since the mounting
on the corresponding side of the steering gear, generating
point of the power steering gear and the suspension pivot are
steering pinion and rack propelling forces. The pressure
determined by the precisely machined rigid front subframe,
fluid returns from the pressure cylinder of the steering gear
it is possible to maintain the relative designed geometric
through a circular channel of the fluid return pipe. Before
dimensions between the steering pinion and rack mechanism
the power fluid returns to the steering fluid reservoir, in this
and the suspension at any time. The power steering gear
circular channel the power steering fluid cools. The steering
is fixed by two bolts and nuts. The power steering gear
fluid reservoir stores the power steering fluid.
shall rotate 2.85 cycles from one locking position to another
and the rubber bellows hood covers the moving area of the Power Steering Fluid Reservoir
steering pinion and rack. One end of the steering outer tie The power steering fluid reservoir consists of the body, lid
rod is fitted on the threaded steering gear and fixed with and filter assembly. On the lid, there is a fluid level gauge of
locking nuts, which can be used to adjust alignment of the steering fluid reservoir integrated with the lid and an O-ring
steering system. The other end of the steering outer tie rod is preventing fluid leakage. The filter assembly is fitted at the
entirely fixed with locking nuts to the steering arm stretching bottom of the steering fluid reservoir. The filter is made of
out from the front wheel hub. fine stainless steel wire mesh molded in the filter bracket. The
Power Steering Pump filter detracts particles in the steering fluid reservoir before
the steering fluid enters into the fluid supply pipeline. The
The pressure of the steering system is supplied by the vane
filter is a maintenance-free component. The basic function of
power steering pump which is driven by the crankshaft through
the steering fluid reservoir is to maintain a certain amount
steering pump belt. When the engine operates, hydraulic oil is
of surplus steering fluid in the hydraulic system to allow the
pumped out of the fluid reservoir by the steering pump. The
expansion and contraction of the steering fluid at different
fluid amount to be transferred and pressure are adjusted by the
temperatures. Ensure that the fluid supply pipe is always
flow control valve in the power steering pump, and the excess
covered by the steering fluid under all operating conditions.
fluid returns to the inlet of the oil pump through internal oil
Any air in the hydraulic system will be discharged from the
passage.
liquid inside the steering fluid reservoir.

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Front Wheel Steering Steering System
Operation through the gear and rack. When the engine and the power
The turning of the steering wheel is transferred to the steering pump operate, the high pressure fluid flow in the
conversion valve on the rack mechanism of steering gear by steering gear offers steering power.
the steering column. The rotational motion of the steering Neutral Position
wheel is transformed to a linear motion of the steering rack

1. Rotor 5. Pressure Oil in Power Steering Pump

2. Torsion Bar 6. Oil Return to Reservoir
3. Slide Valve 7. Reservoir Supply
4. Pressure Oil Flow in the Cylinders of Steering Gear

When the steering wheel is in the driving forward state, the and sensed by pistons on both sides of the power steering
power steering fluid will flow from the power steering pump cylinder. As the power steering cylinder has equal pressure
to the conversion valve. Slots of the outer cylindrical slide on both sides, the steering wheel shall be kept in the middle
valve are in line with the rotor slots, so that the fluid pressure position. Because most fluid has returned to the steering fluid
is over the conversion valve. Some pressures are applied to reservoir, the pressure at each side of the piston is very low.
the fluid inlet and outlet side of the power steering cylinder

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Steering System Front Wheel Steering

Turn Left

1. Rotor 5. Pressure Oil in Power Steering Pump

2. Torsion Bar 6. Oil Return to Reservoir
3. Slide Valve 7. Oil Flow in the Right Cylinder of Steering Gear
4. Pressure Oil Flow in the Left Cylinder of Steering Gear

When the steering wheel is rotated counterclockwise, the power steering cylinder through the aligned slot, so that
rotor and torsion bar rotate in the same direction. The slot the pressure of the left power steering cylinder increases.
position on the rotor moves from the middle aligned position, The return flow port of the right power steering cylinder is
blocking the fluid flow from returning to the steering fluid open, allowing the fluid to flow into the power steering fluid
reservoir. From now on, the fluid pressure from the power reservoir from the right power steering cylinder piston. The
steering pump flows into the slot newly aligned by the rotor pressure difference between left and right power steering
and the outer cylindrical slide valve from the power steering cylinder pistons generates steering power.
pump; the liquid pressure is directed to the left side of the

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Front Wheel Steering Steering System
Turn Right

1. Rotor 5. Pressure Oil in Power Steering Pump

2. Torsion Bar 6. Oil Return to Reservoir
3. Slide Valve 7. Pressure Oil Flow in the Right Cylinder of Steering Gear
4. Oil Flow in the Left Cylinder of Steering Gear

When the steering wheel is rotated clockwise, the rotor and Cumulative Power
torsion bar rotate in the same direction. The slot position
The cumulative power steering depends on the road resistance
on the rotor moves from the middle aligned position, blocking
of the wheels opposite to the rotation direction of the front
the fluid flow from returning to the steering fluid reservoir.
wheels. When the steering wheel is turned left or right, the
From now on, the fluid pressure from the power steering
rotational motion is passed to the rotor shaft through the
pump flows into the slot newly aligned by the rotor and the
steering column, making the rotor shaft rotate in the same
outer cylindrical slide valve from the power steering pump; the
amount of rotation as the steering wheel. The rotational
liquid pressure is directed to the right power steering cylinder
motion is also passed to the torsion bar from the rotor. If
through the aligned slot, so that the pressure of the right power
the wheel resistance is very high (for example in the parking
steering cylinder increases. The return flow port at the left
state), the torsion bar will rotate. The rotation of the torsion
side of the power steering cylinder is open, allowing the fluid to
bar means that the amount of rotation of the pinion and slide
flow into the power steering fluid reservoir from the left power
valve is slightly less than that of the rotor. The rotation of
steering cylinder piston. The pressure difference between left
the torsion bar makes the slots in the rotor and the torsion
and right power steering cylinder pistons generates steering
bar out of the alignment position, the gap between the two
power.
slots becomes bigger. The greater the road resistance of the
wheels to the steering rotation is, the larger the misalignment

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Steering System Front Wheel Steering

of the slots in the rotor and the torsion bar becomes. As the
misalignment increases, the liquid pressure flowing through the
corresponding side of the power steering cylinder increases.
When the road resistance of the wheels or the steering force
applied to the steering wheel decreases, the torque applied
to the rotor decreases, the torsion bar is released, thus the
misalignment of the slots in the rotor and the torsion bar
decreases and the fluid pressure applied to the corresponding
side of the power steering cylinder decreases.
Hydraulic Circuit

1. Steering Oil Reservoir 6. Pressure Area of Power Steering Cylinder

2. Low-pressure Oil Inlet Pipe 7. Rack Mechanism of Steering Gear
3. Power Assisted Steering (PAS) Pump 8. Conversion Valve Unit
4. Oil Outlet 9. Power Steering Oil Cooling Pipe
5. Flow Control/Safety Valve

After the engine start, the power steering pump sucks the fluid pipe, the high-pressure fluid comes to the conversion
power steering fluid from the steering fluid reservoir into valve. If no steering force is applied, the pressures at both
the low-pressure fluid inlet pipe and turns the fluid to the sides of the power steering cylinder piston are equal. The
high-pressure fluid at the fluid outlet. Though a high-pressure remaining fluid returns to the steering fluid reservoir from

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Front Wheel Steering Steering System
the conversion valve through a power steering fluid cooling steering cylinder returns to the steering fluid reservoir from
pipe. If a steering force of turning to any side is applied, the the conversion valve through a power steering fluid cooling
fluid pressure is directed to the corresponding side of the pipe. The power steering fluid cooling pipe reduces the
power steering cylinder piston to offer steering power so temperature of the power steering fluid, extending the service
as to reduce the necessary steering force. The discharged life of the hoses and seals of the system.
power steering fluid due to piston movement in the power

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Steering System Front Wheel Steering

Service Procedures a. Ensure there is no leakage in the steering system and

Power Steering System - Pressure Test the liquid level is at the maximum position at the
Check time of testing.
1. Test Equipment b. Start the engine when the test equipment valve is
open.

c. Slowly rotate the steering wheel and keep it at lock

position when the engine is running at idle speed
and at normal operating temperature.

d. Repeat this pressure test at relative lock positions.

e. The test pressure shall be increased gradually from

5bar to 90bar. And the pressure may rise to 90 bar
according to road conditions when the steering
wheel is at full lock position.

f. Release the steering wheel when the engine is running

at idle speed, and the reading shall be 5bar or less.

a. Fit the pressure gauge T38001 and hoses to the g. If the pressure exceeds the above value, there may
valve assembly T38002, and tighten the connectors. be something wrong.

b. Fit 2 hoses T38003 to the valve assembly T38002, Adjustment

and tighten the connectors. 1. Keep the test valve closed for no more than 5 seconds,
determine if the failure occurs in the steering pump
2. Disconnect the battery negative.
or in the steering gear. If the test valve is off for an
Caution: Care must be taken to ensure that oil or fluid extended time, the pump will be damaged.
does not enter or contaminate the alternator. 2. If the readings on the pressure gauge can not reach
3. Place a container to collect the oil spilled from the 85 - 95bar (maximum pump pressure), there may be
PAS system. something wrong with the pump.
4. Clean the power steering pump, connecting pipe and 3. If the maximum pump pressure is correct, there may be
pipe connectors. something wrong with the steering gear.
5. Remove the connector connecting the oil inlet pipe of 4. Stop the engine after the test.
the steering gear to the power steering pump. 5. Disconnect the battery negative.
6. Fit the connector T38005 and seal washer to the 6. Remove the connector of the test equipment.
power steering pump. 7. Remove the connectors from the power steering pump
7. Fit the connector TCH00094 to the oil inlet pipe of and the oil inlet pipe of the power steering gear.
the steering gear. 8. Fit the new seal washer, fit the oil inlet pipe to the
8. Connect the hoses T38003 to the TCH00094 and power steering pump, and tighten to 26–30Nm.
the T38005. 9. Clean the chassis and its surrounding areas.
9. Ensure all pipes and mounting parts are not in contact 10. Check the liquid level of the power steering system.
with rotating parts.
Capacity
10. Hang the pressure gauge at a safe place below the
Fluid
bonnet.
11. Connect the battery negative.
11. Connect the battery negative.
12. Start the engine and bleed the power steering system.

Power Steering System Bleeding

13. Check the liquid level of the power steering pump and
fill it up.
Capacity
14. Test Procedure:

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Front Wheel Steering Steering System
Steering Gear Outer Tie Rod Steering Gear Boot
Remove Remove
1. Remove the front wheels. 1. Remove the bottom deflector.

Wheels Remove Bottom Deflector Remove

2. Raise the vehicle on a lift. 2. Remove the outer tie rod of the steering gear.

Warning: Do not work on or under a vehicle supported Steering Gear Outer Tie Rod Remove
only by a jack.Always support the vehicle on safety stands. 3. Remove and discard the outer boot clamp of the
3. Remove and discard 1 nut fixing the steering gear outer steering gear.
tie rod to the knuckle. Disconnect the steering gear 4. Remove and discard the inner boot clamp of the
outer tie rod from the knuckle. steering gear.
4. Loosen the locking nut of the steering gear outer tie
rod.

5. Remove the steering gear boot from the steering gear.

Refit
5. Remove the steering gear outer tie rod from the power
1. Fit the steering gear boot to the steering gear. Ensure
steering gear, and mark the position of the locking nut.
the steering gear boot is fitted in the mounting groove
Refit
of the steering gear.
1. Fit the steering gear outer tie rod to the marked
2. Fit and secure the new inner boot clamp of the steering
location of the locking nut, and keep the ball joint
gear to the steering gear boot.
upward.
3. Fit and secure the new outer boot clamp of the steering
2. Tighten the locking nut of the steering gear outer tie
gear to the steering gear boot.
rod to 63–73Nm.
4. Fit the outer tie rod of the steering gear.
3. Connect the steering gear outer tie rod to the knuckle,
fit the new nut and tighten to 28–32Nm. Steering Gear Outer Tie Rod Refit
4. Fit the front wheels. 5. Fit the bottom deflector.

Wheels Refit Bottom Deflector Refit

5. Check the wheel alignment. 6. Check the wheel alignment.

Wheel Alignment Wheel Alignment

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Steering System Front Wheel Steering

Steering Gear Inner Tie Rod Steering Gear Subassembly

Remove Remove
1. Remove the steering gear boot. 1. Remove the front wheels.

Steering Gear Boot Remove Wheels Remove

2. Unscrew the steering gear inner tie rod from the 2. Remove the bottom deflector.
steering gear. Bottom Deflector Remove
3. Remove and discard 1 bolt fixing the intermediate shaft
to the steering gear.

3. Remove the inner tie rod of the steering gear.

Refit
4. Release the universal joint from the steering gear.
1. Fit the steering gear inner tie rod to the steering gear,
and tighten to 70-80Nm. Caution: Before disconnecting any part of the steering
linkage, ensure the road wheels are positioned straight
2. Fit the steering gear boot.
ahead and the steering wheel is prevented from turning.
Steering Gear Boot Refit Unrestricted turning of the steering wheel will damage the
3. Check the wheel alignment. SRS rotary coupler.

Wheel Alignment 5. Remove the outer tie rod of the steering gear.
Steering Gear Outer Tie Rod Remove
6. Remove and discard the nut (2) fixing the front
horizontal stabilizer bar to the connecting rod of the
front horizontal stabilizer bar.

7. Remove the front exhaust pipe assembly.

Front Exhaust Pipe Assembly Remove
8. Support the front subframe assembly with the hydraulic
lifting equipment, remove and discard 6 bolts fixing
the front subframe to the body, and lower the front

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Front Wheel Steering Steering System
subframe.

14. Carefully draw the steering gear subassembly from the

9. Place a container to collect the spilled fluid. vehicle.
10. Remove the pipe connector connecting the steering Refit
gear oil outlet pipe to the steering gear, and discard 1. Fix the steering gear to the subframe, fit 2 new bolts,
the O-ring. tighten to 90–110Nm, and check the torque.
11. Remove the pipe connector connecting the steering 2. Fix the bracket of the steering gear oil inlet pipe to the
gear oil inlet pipe to the steering gear, and discard the steering gear bracket, fit 1 bolt, tighten to 7–10Nm,
O-ring. and check the torque.
Caution: Always fit plugs to open connections to prevent 3. Clean the pipe connector and the mating surface.
contamination. 4. Fit the new O-ring to the steering gear oil outlet pipe,
connect the pipeline, tighten the pipe connector to
12. Remove 1 bolt fixing the bracket of the steering gear
26–30Nm, and check the torque.
oil inlet pipe to the steering gear bracket, and remove
the oil inlet pipe. 5. Fit the new seal washer to the steering gear oil inlet
pipe, connect the pipeline, tighten the pipe connector
to 36–40Nm, and check the torque.
6. Fit 6 new bolts fixing the front subframe to the body,
evenly tighten to 90NM+180°, and ensure the safety
washer is aligned with the subframe bushing.
7. Move the hydraulic lifting equipment away.
8. Fit the front exhaust pipe assembly.
Front Exhaust Pipe Assembly Refit
9. Align the connecting rod of the front horizontal
stabilizer bar, fix it to the front horizontal stabilizer bar,
fit 1 nut, tighten to 55–65Nm, and check the torque.
Caution: Nuts and bolts must be tightened with weight of
13. Remove 2 bolts fixing the steering gear to the subframe. vehicle on suspension.

10. Fit the outer tie rod of the steering gear.

Steering Gear Outer Tie Rod Refit
11. Fix the universal joint to the input shaft of the power
steering gear, fit 1 new bolt and tighten to 19–25Nm.
12. Fit the bottom deflector.
Bottom Deflector Refit
13. Fit the front wheels.
Wheels Refit
14. Bleed the power steering system.

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Steering System Front Wheel Steering

Power Steering System Bleeding Power Steering Pump

15. Check the alignment parameters of the four wheels. Remove
1. Disconnect the battery negative.
Four-wheel Alignment
2. Remove the bottom deflector.
Bottom Deflector Remove
3. Place a container to collect the spilled liquid.
4. Remove 1 bolt fixing the bracket of the oil inlet pipe
(steering pump to steering gear) to the steering pump.

5. Disconnect the steering gear oil inlet pipe from the

power steering pump.

6. Remove the auxiliary drive belt.

Auxiliary Drive Belt Remove

7. Remove 3 bolts connecting the power steering pump
pulley to the power steering pump.

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Front Wheel Steering Steering System
inlet pipe to the power steering pump, and tighten to
26–30Nm.
6. Fix the bracket of the oil inlet pipe (steering pump to
steering gear) to the steering pump, fit 1 bolt, tighten
to 7–10Nm, and check the torque.
7. Fit the bottom deflector.

Bottom Deflector Refit

8. Connect the battery negative.
9. Bleed the power steering system.

Power Steering System Bleeding

8. Remove 3 bolts connecting the power steering pump

to the bracket.

9. Remove the power steering pump.

Refit
1. Clean the power steering pump and the mating surface.
2. Fit 3 bolts connecting the power steering pump to the
bracket, tighten to 19–25Nm, and check the torque.
3. Fit 3 bolts connecting the power steering pump pulley
to the power steering pump, tighten to 19–25Nm, and
check the torque.
4. Fit the auxiliary drive belt.
Auxiliary Drive Belt Refit

5. Clean the connector connecting the steering gear oil

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Steering System Front Wheel Steering

Oil Inlet Pipe (Reservoir to Steering Pump) Oil Inlet Pipe - Steering Pump to Steering Gear
Remove Remove
1. Place a container to collect the spilled liquid. 1. Place a container to collect the spilled liquid.
2. Disconnect the clamp fixing the oil inlet pipe (reservoir 2. Remove 1 bolt fixing the bracket of the oil inlet pipe
to steering pump) to the steering pump, and disconnect (steering pump to steering gear) to the steering pump.
the pipeline.
Caution: Always fit plugs to open connections to prevent
contamination.

3. Disconnect the connector of the oil inlet pipe (steering

pump to steering gear) from the steering pump, and
remove the seal ring.
3. Disconnect the clamp fixing the oil inlet pipe (reservoir Caution: To prevent damage to components, cushion the
to steering pump) to the reservoir, and disconnect the part pad with a block of wood or hard rubber.
pipeline.
Caution: Always fit plugs to open connections to prevent
contamination.

Caution: Always fit plugs to open connections to prevent

contamination. 4. Remove the bottom deflector.
4. Remove the oil inlet pipe (reservoir to steering pump). Bottom Deflector Remove
Refit 5. Remove 2 bolts fixing the oil inlet pipe (steering pump
1. Clean the oil inlet pipe (reservoir to steering pump). to steering gear) to the right front longitudinal beam.
2. Remove the plug, fix the oil inlet pipe (reservoir to
steering pump) to the reservoir and secure with clamps.
3. Remove the plug, fix the oil inlet pipe (reservoir to
steering pump) to the steering pump and secure with
clamps.
4. Bleed the power steering system.

Power Steering System Bleeding

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Front Wheel Steering Steering System
pipe connector (steering pump to steering gear) to the
steering gear, tighten the pipe connector to 36–40Nm,
and check the torque.
2. Fix the bracket of the steering gear oil inlet pipe to the
steering gear bracket, fit 1 bolt, tighten to 7–10Nm,
and check the torque.
3. Fix the oil inlet pipe (steering pump to steering gear)
to the right front longitudinal beam, fit 2 bolts, tighten
to 7–10Nm, and check the torque.
4. Fit the bottom deflector.

Bottom Deflector Refit

5. Remove the plug to fit the new seal ring, fix the oil inlet
6. Remove 1 bolt fixing the bracket of the steering gear
pipe (steering pump to steering gear) to the steering
oil inlet pipe to the steering gear bracket.
pump, tighten the pipe connector to 26–30Nm, and
check the torque.
6. Fix the oil inlet pipe (steering pump to steering gear)
to the steering pump, fit 1 bolt, tighten to 7–10Nm,
and check the torque.
7. Bleed the power steering system.

Power Steering System Bleeding

7. Disconnect the connector of the oil inlet pipe (steering

pump to steering gear) from the steering gear, and
remove the seal ring.
Caution: Always fit plugs to open connections to prevent
contamination.

Caution: To prevent damage to components, cushion the

part pad with a block of wood or hard rubber.

8. Remove the oil inlet pipe (steering pump to steering

gear).
Refit
1. Remove the plug to fit the new seal ring, fix the oil inlet

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Steering System Front Wheel Steering

Steering Gear Oil Outlet Pipe

Remove
1. Remove the air filter assembly.

Air Filter Assembly Remove

2. Remove 1 bolt fixing the bracket of the steering gear
oil outlet pipe to the subframe.

Caution: Always fit plugs to open connections to prevent

contamination.

8. Remove the steering gear oil outlet pipe.

Refit
1. Remove the plug, fix the steering gear oil outlet pipe to
the steering cooling pipe and secure with clamps.
3. Remove the bottom deflector.
2. Fix the bracket of the steering gear oil outlet pipe to
Bottom Deflector Remove the left front longitudinal beam, fit 2 bolts, tighten to
4. Place a container to collect the spilled liquid. 7–10Nm, and check the torque.
5. Disconnect the connector of the steering gear oil outlet 3. Remove the plug to fit the new seal ring, fix the steering
pipe from the steering gear, and remove the seal ring. gear oil outlet pipe to the steering gear, tighten the pipe
connector to 26–30Nm, and check the torque.
Caution: Always fit plugs to open connections to prevent
contamination. 4. Fit the bottom deflector.

Bottom Deflector Refit

5. Fix the bracket of the steering gear oil outlet pipe to
the subframe, fit 1 bolt, tighten to 7–10Nm, and check
the torque.
6. Fit the air filter assembly.

Air Filter Assembly Refit

7. Bleed the power steering system.

Power Steering System Bleeding

6. Remove 2 bolts (1) fixing the bracket of the steering

gear oil outlet pipe to the left front longitudinal beam,
and disconnect the pipeline.
7. Disconnect the clamp (2) fixing the steering gear oil
outlet pipe to the steering cooling pipe, and disconnect
the pipeline.

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Front Wheel Steering Steering System
Steering Cooling Pipe 2. Fix the steering cooling pipe to the radiator beam, fit 2
Remove bolts, tighten to 6.5–7.5Nm, and check the torque.
1. Remove the front bumper assembly. 3. Remove the plug, fix the steering gear oil outlet pipe to
the steering cooling pipe and secure with clamps.
Front Bumper Assembly Remove
4. Fit the bottom deflector.
2. Remove the bottom deflector.
Bottom Deflector Refit
Bottom Deflector Remove
5. Fit the front bumper assembly.
3. Place a container to collect the spilled liquid.
4. Disconnect the clamp (2) fixing the steering gear oil Front Bumper Assembly Refit
outlet pipe to the steering cooling pipe, and disconnect
the pipeline.

Caution: Always fit plugs to open connections to prevent

contamination.
5. Remove 2 bolts (1) fixing the steering cooling pipe to
the radiator beam.
6. Disconnect the clamp (2) fixing the reservoir oil return
pipe to the steering cooling pipe, and disconnect the
pipeline.

Caution: Always fit plugs to open connections to prevent

contamination.
7. Remove the steering cooling pipe.
Refit
1. Remove the plug, fix the reservoir oil return pipe to
the steering cooling pipe and secure with clamps.

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Steering System Front Wheel Steering

Reservoir Oil Return Pipe Assembly Power Assisted Steering (PAS) System Bleeding
Remove Adjustment
1. Remove the front bumper assembly. 1. Clean the area around the steering reservoir filler and
Front Bumper Assembly Remove the fluid level indicator.
2. Place a container to collect the spilled liquid. 2. Unscrew the cap of the steering reservoir, refill the
steering fluid to a level between the minimum scale and
3. Disconnect the clamp (2) fixing the reservoir oil return
the maximum scale of the dipstick.
pipe to the steering cooling pipe, and disconnect the
pipeline. Capacity

Fluid

Caution: Care must be taken to ensure that oil or fluid

does not enter or contaminate the alternator.

3. Start the engine and operate it for 10 seconds at idle

speed, then stop it.
4. Top up the power steering reservoir.
5. Start the engine, turn the steering wheel fully to the left
and right lock points, then stop the engine.
6. Top up the power steering reservoir again.
7. Start the engine and operate it for 2 minutes and turn
the steering wheel fully to the left and right lock points.
Caution: Always fit plugs to open connections to prevent
contamination. Caution: Do not hold steering at full lock for longer than
10 seconds.
4. Disconnect the clamp fixing the reservoir oil return
pipe to the reservoir, and disconnect the pipeline. 8. Stop the engine.
9. Check the steering reservoir; if there is any bubble
discharged from the fluid, wait until no bubble
discharges, then refill the steering fluid to a level
between the minimum scale and the maximum scale.
10. Fit the filler cap of the power steering reservoir.

Caution: Always fit plugs to open connections to prevent

contamination.

5. Remove the reservoir oil return pipe assembly.

Refit
1. Clean the reservoir oil return pipe (reservoir to
steering cooling pipe).
2. Remove the plug, fix the reservoir oil return pipe to
the reservoir and secure with clamps.
3. Remove the plug, fix the reservoir oil return pipe to
the steering cooling pipe and secure with clamps.
4. Fit the front bumper assembly.
Front Bumper Assembly Refit

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Front Wheel Steering Steering System
Special Tools
Tool Description Picture
Number

PAS pressure
T38001
test equipment

Adaptor
T38002 hydraulic
pressure test

Adaptor
hydraulic
T38003
pressure test
hose

Adaptor power
T38005
steering pump

Adaptor
TCH00094 power steering
pressure Test

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Steering System Steering Wheel and Column

Steering Wheel and Column

Specifications
Torque
Description Value
Bolts- Steering wheel to steering column 60–70Nm
Nut-Steering outer tie rod locking 63-73Nm
Bolt - power steering column to instrument panel frame 19–24Nm
Bolts-Steering column intermediate shaft to steering gear 19–25Nm
Bolts-Steering column intermediate shaft to steering pump 19–25Nm
Bolt - steering column lock-steering column 11–14Nm

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Steering Wheel and Column Steering System
Service Procedures Steering Wheel Positioning/Adjustment
Steering Wheel Assembly Check
Remove 1. Ensure correct tyre pressure and maintain the vehicle
1. Disconnect the battery negative. in unladen mass condition.
2. Remove the steering wheel airbag. 2. Shake the vehicle back and forth to release the stress
for steering and suspension.
Steering Wheel Airbag Remove
3. Please apply the four-wheel aligners recommended
3. Put the steering wheel in the centre and allow the
by our company when measuring the front wheel
wheel to be in the front.
alignment parameters.
4. Disconnect the harness connector of the steering
4. Check if the front wheel alignment parameter is within
wheel.
the specified tolerance range.
5. With the steering wheel stopped, loosen the bolt fixing
the steering wheel to the steering column, after the Four-wheel Alignment Check
steering wheel is fully loosened from the splines of the Adjustment
steering column, remove the bolt. 1. If the steering wheel exceeds the alignment value
clockwise:
a. Loosen the right locking nut.

b. Turn the right outer tie rod to the left by a hexagonal

plane.

c. Tighten the right locking nut to 63-73Nm.

d. Loosen the left locking nut.

e. Turn the left outer tie rod to the left by a hexagonal

plane.
f. Tighten the left locking nut to 63-73Nm.

2. If the steering wheel exceeds the alignment value

6. Remove the steering wheel assembly from the steering counterclockwise:
column.
a. Loosen the left locking nut.
7. Stick tape along the edge of the steering column stalk
combination switch to keep it in the correct mounting b. Turn the left outer tie rod to the right by a hexagonal
position. plane.

Refit c. Tighten the left locking nut to 63-73Nm.

1. Remove the tape on the combination switch of the d. Loosen the right locking nut.
steering column stalk.
e. Turn the right outer tie rod to the right by a
2. Ensure that the wheel is in the front, and fit the steering hexagonal plane.
wheel to the steering column according to the mark.
f. Tighten the right locking nut to 63-73Nm.
3. Fix the steering wheel to the steering column, fit 1 bolt,
tighten to 60–70Nm, and check the torque. 3. Repeat 1 or 2 until the wheels face forward, and the
4. Connect the harness connector of the steering wheel. steering wheel is in the centre position.

5. Fit the steering wheel airbag.

Steering Wheel Airbag Refit

6. Connect the battery negative.

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Steering System Steering Wheel and Column

Combination Switch
Remove
1. Disconnect the battery negative.
2. Remove the steering wheel assembly.
Steering Wheel Assembly Remove
3. Fix the clock spring with tapes, ensure it will not
move left and right (relative to the combination switch
bracket) and is always in the centre.
4. Remove the steering column trim cover.

Steering Column Trim Cover Remove

5. Remove 4 screws fixing the lever switch to the steering
column. 3. Fit the clock spring to the steering column and connect
the harness connector.
4. Connect the harness connector of the lever switch
of the direction indicator lamp/high beam and
wiper/washer respectively, and fix it to the combination
switch bracket with 4 screws.
5. When fitting a new combination switch assembly to the
steering column, ensure the front wheels face the front,
place the combination switch assembly right above the
steering column, fit it into the steering column as an
assembly and locate it by turning from side to side.
6. Fit the steering column trim cover.
Steering Column Trim Cover Refit
6. Disconnect the harness connectors of the clock spring, 7. Fit the steering wheel assembly.
wiper/washer and direction indicator lamp/high beam
Steering Wheel Assembly Refit
lever switches.
8. Connect the battery negative.
7. Remove the lever switches of the wiper/washer and
direction indicator lamp/high beam. 9. Perform a self-learning for the angle sensor.

8. Remove the retaining screw to remove the clock spring a. Connect the scan tool to the vehicle and access the
from the steering column, and take care not to damage VDS.
the tape.
b. Select "Fast Track - Learn Value/Adjustment -
Refit SAS Reset Self-learning", and operate as per the
Caution: If the peg on a new rotary coupler is broken, or instructions on the screen.
if you suspect that the rotary coupler has been dropped
c. Select "Fast Track - Learn Value/Adjustment -
or mishandled, discard the coupler.
SAS Zero Self-learning", and operate as per the
1. Before fitting, ensure the red locating pin of the clock instructions on the screen.
spring is not removed or damaged and the front wheels
10. Perform a system check, rotate each lever of the
face the front.
steering switch and check if it can work.
2. Ensure the clock spring to be fitted is in the centre, if
11. Check if the buttons of the entertainment switch on
it is not, gently rotate the rotor counterclockwise to
the steering wheel can work.
the end, then turn it clockwise for about 2.7 circles.
Align the connector clip with the Lock Pin position (this
location is the centre).

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Steering Wheel and Column Steering System
Steering Wheel Entertainment Switch Upper Steering Column
Remove Remove
1. Disconnect the battery negative. 1. Pull out the key from the ignition switch, disconnect the
2. Remove the steering wheel airbag. battery negative cable. After 10s, disconnect the SRS
backup circuit before it works.
Steering Wheel Airbag Remove
2. Remove the combination switch.
3. Pry off the clip gently and remove the steering wheel
entertainment switch. Combination Switch Remove

4. Disconnect the connector of the steering wheel 3. Remove the driver side lower trim panel assembly.
entertainment switch. Driver Side Lower Trim Panel Assembly Remove
Refit 4. Disconnect the clip fixing the harness to the upper
1. Connect the harness connector on the back of the steering column.
steering wheel entertainment switch. 5. Remove and discard 1 bolt fixing the universal joint of
2. Fix the steering wheel entertainment switch to the the upper steering column to the intermediate shaft.
steering wheel.
3. Fit the steering wheel airbag.

Steering Wheel Airbag Refit

4. Connect the battery negative.

6. Release the universal joint from the intermediate shaft.

7. Remove 4 bolts fixing the upper steering column to
the instrument panel beam.

8. Remove the upper steering column assembly.

Refit
1. Fix the upper steering column to the instrument panel
beam, fit 4 bolts, tighten to 19–24Nm, and check the
torque.
2. Locate the universal joint to the intermediate shaft and
ensure correct orientation, fit 1 new bolt, tighten to
19–25Nm, and check the torque.

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Steering System Steering Wheel and Column

3. Fix the harness to the steering column and secure with Intermediate Shaft
clips. Remove
4. Fit the driver side lower trim panel assembly. 1. Keep the wheels face the front and lock the steering
Driver Side Lower Trim Panel Assembly Refit wheel.
2. Remove the driver side lower trim panel assembly.
5. Fit the combination switch.
Driver Side Lower Trim Panel Assembly Remove
Combination Switch Refit
6. Connect the battery negative and the SRS circuit. 3. Remove and discard 1 bolt fixing the upper steering
column to the intermediate shaft.

4. Remove and discard 1 bolt fixing the intermediate shaft

to the steering gear.

5. Remove the intermediate shaft.

Refit
1. Connect the intermediate shaft and the steering gear
with new bolts, and tighten to 19–25Nm.
2. Connect the intermediate shaft and the upper steering
column with new bolts, and tighten to 19–25Nm.
3. Fit the driver side lower trim panel assembly.

Driver Side Lower Trim Panel Assembly Refit

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Steering Wheel and Column Steering System
Steering Column Lower Trim Cover Mechanical Steering Column Lock
Remove Remove
1. Release the steering column to the lowermost position. 1. Remove the upper steering column.
2. With a screwdriver, carefully disconnect the upper trim Upper Steering Column Remove
cover from the lower trim cover, and remove the gap
2. Fix the upper steering column to the drilling machine.
cover strip of the steering column together.
3. Drill a small hole in the retaining screw head of the
3. Remove 3 screws fixing the lower trim cover of the
steering column lock, choose a broken screw extractor
steering column to the steering column.
with an appropriate diameter to rotate the screw out,
and do not damage adjacent parts.
4. Remove the steering column lock.
Refit
1. Put the steering column lock into the upper steering
column.
2. Secure with new mounting screws, tighten them to
11–14Nm, and twist off the screw heads.
3. Fit the upper steering column.

Upper Steering Column Refit

4. Release the steering column adjusting handle, and

remove the lower trim cover of the steering column.
Refit
1. Fix the steering column lower trim cover to the
steering column, fit 3 screws and fasten.
2. Place the upper trim cover of the steering column on
the steering column, and secure it on the lower trim
cover with care.

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1.0 376
Wheel Alignment Suspension System
Wheel Alignment
Specifications
Torque
Description Value
Nuts - steering rod 63–73Nm

Parameter
Front Wheel
Camber Angle -29'±45'

King Pin Caster Angle 3°26'±45'

King Pin Inclination Angle 12°6¢±45¢

Toe-in (Total toe) 8'±15'

Toe-in (one side) 4'±6'

Rear Wheel
Wheel Camber Angle -1°15¢ ± 45¢

Toe-in (Total toe) 26'±20'

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Suspension System Wheel Alignment

Description and Operation Front Wheel Toe-in

Description
The primary goal of mechanical design is to ensure the
safety and reliability of the steering system and suspension
system. Each component shall be strong enough to bear and
absorb extreme impact. The steering system and front/rear
suspension system shall be in a geometrical shape with the
body. The steering system and suspension system require the
front wheels can return automatically, keeping the rolling force
of the front wheel and the road friction within the minimum
value so that the user can control directions easily and
comfortably. A thorough wheel positioning inspection involves
rear wheel toe angle and camber measurement. Four-wheel
positioning can ensure the four wheels to rotate towards the
same direction. Geometric positioning can help the vehicle to The front wheel toe-in is observed from the top, the wheels
realize optimum fuel economy and maximum tyre service life, rotate inwards (or outwards). Normally, the actual value of
and thus improve the steering and performance. the toe-in angle is less than one degree, merely several cents.
The toe-in of the static wheel enables the wheel to roll levelly
under a dynamic state. Large toe-in or the front tensioner
may increase the wheel friction. For the rear-wheel driving
vehicles, a smaller toe angle (the value measured when the
vehicle is stopped) shall be used to compensate the weak
disturbance caused by rolling resistance and brake operation,
this disturbance may cause the wheel open outward.

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Wheel Alignment Suspension System
Service Procedures
Four-wheel Alignment
Inspection
1. Only the recommended equipment by the company can
be used for four-wheel positioning adjustment.
2. The equipment must be calibrated according to the
manufacturer's requirements.
3. Ensure that the vehicle data input into the equipment
is correct.
4. Check the steering rod ball joint, front lower arm ball
joint and wheel bearing for wear or proper running.
Replace or repair it if necessary.
5. Check and adjust the tyre pressure.
6. Raise the vehicle on a four-wheel aligner.
7. Ensure that the vehicle is in unladen mass condition.
8. Ensure that the wheel mounting clamp has been
adjusted to a correct specification and has been fixed
firmly to the vehicle.
9. Ensure that the camera has been fitted and aligned
properly.
10. Align and adjust the wheels according to the
manufacturer's instruction. Lower the vehicle and keep
the vehicle suspension in normal state.
11. Ensure that the steering wheel is positioned in the
centre.
Adjustment
1. Observe the readings indicated on the test equipment,
and adjust the four-wheel positioning dada according
to the requirements.
2. Front Wheel Alignment Adjustment:

• Release the locking nuts of the steering rod.

• Adjust the steering rod and allow the front wheel
positional parameter to achieve the specified value.
• Tighten the locking nuts to 63–73Nm.

• For the other side, repeat the above steps.

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Suspension System Front Suspension

Front Suspension
Specifications
Torque
Description Value
Bolts - front damper to knuckle 90–110Nm
Bolt - lower arm outer ball joint to swivel hub 50–65Nm
Nuts - steering rod outer ball joint 28–32Nm
Screws - front speed wheel sensor 7–10Nm
Screws - front brake disc to knuckle 30–36Nm
Bolts - front brake caliper to knuckle 90–110Nm
Nuts - rear spindle 320–350Nm
Nuts - lower arm outer ball joint （60±5）Nm+60°±5°
Nut - lower arm outer ball joint to swivel hub 50–65Nm
Nut - lower arm rear bush to subframe lock 90Nm+90°
Nut - lower arm front bush to subframe lock 90Nm+90°
Nuts - piston rod top 54–62Nm
Bolts - subframe brace to body 60–80Nm
Nut - anti-roll bar links to damper 50–65Nm
Bolts - anti-roll bar bush and clamp to subframe 22–28Nm
Nuts - anti-roll bar to links 45–55Nm
Bolt - subframe to body 90Nm+180°

Specifications
Front Lower Arm L shaped, steel forged with lightening holes. Ball joints at forward
inner and outer joints
Anti Roll Bar Diameter 20.5mm
Front Spiral Spring Data:
Total Turns 4.8
Active coils 3.8
Wire diameter 11.6mm

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Front Suspension Suspension System
Description and Operation
System Layout
Front Suspension

1. Front Suspension Shock Absorber Assembly 5. Front Wheel Hub Assembly

2. Front Anti Roll Bar Link 6. Front Anti Roll Bar Bush Clamp
3. Front Subframe Assembly 7. Front Lower Arm Assembly
4. Front Anti Roll Bar

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Suspension System Front Suspension

Front Suspension Components

1. Front Shock Absorber Column 9. Front Suspension Knuckle Dust Cover

2. Front Anti Roll Bar Link 10. Front Wheel Hub
3. Front Anti Roll Bar 11. Front Wheel Hub Bearing
4. Front Anti Roll Bar Bush 12. Front Wheel Hub Circlip
5. Front Anti Roll Bar Anchorage Bracket 13. Front Wheel Hub Flange
6. Front Lower Arm Front Bushing 14. Front Drive Shaft Nut
7. Front Lower Arm Assembly 15. Front Shock Absorber Coil Spring
8. Front Lower Arm Rear Bushing

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Front Suspension Suspension System
Front Damper Components

1. Front Shock Absorber Column 7. Front Shock Absorber Bearing Seat

2. Front Suspension Coil Spring 8. Nut
3. Front Shock Absorber Column Dust Cover 9. Front Shock Absorber Upper Spring Cushion
4. Front Shock Absorber Column Auxiliary Spring 10. Front Shock Absorber Rebound Gasket
5. Front Suspension Shock Absorber Column Insulating Pad 11. Nut
6. Front Shock Absorber Lower Spring Cushion

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Suspension System Front Suspension

Description The twin tube construction allows the damper piston to

Front suspension comprises of: operate on an inner tube with an oil/gas cavity between the
inner and outer tubes.
• Front MacPherson Strut Dampers
This minimises oil cavitation and eliminates the effect of
• Front Lower Arms
damage to the outer tube affecting piston operation.
• Anti Roll Bar
The damper is attached at its lower end to a location on the
• Anti Roll Bar Links
swivel hub and is secured with 2 nut/bolts.
• Front Subframe
Correctly orientation is achieved by a machined section of the
• Front Wheel Hub, Bearing and Drive Flange
front hub being inserted in-between 2 steel tangs welded to
The front suspension design features anti-dive and anti-squat the base of the damper, the machined hub and tangs contain
geometry via the anti-roll bar and 1:1 strut movement ratio. holes which allow the fitment of the retaining nut/bolts.
The layout and design of the struts minimizes camber loss due The damper rod is located in steel inserts in rubber bushes,
to side forces, improving handling and steering response. which are integral with the top mounting plate, and are secured
Front Subframe Assembly with a washer and nut.

The front subframe is a fabricated steel construction made up A hexagon is provided in the outer end of the damper rod to
of precise components welded together to form a light weight, restrain the rod from rotating when the nut is tightened.
high structural strength assembly. The damper rod is sealed in the damper with a low friction
Geometric machining of all key positions takes place after seal.
construction to ensure the precise locations of front An angled spring seat is integral with the damper body.
suspension and steering system components.
A welded bracket on the body of the damper provides the
The subframe is attached to the body via 6 solid mounting location point for the anti roll bar link.
points, this helps to increase the stiffness of the front subframe.

The arrangement of the supporting points avoids the

Front Lower Arm Assembly
displacement of the front subframe under high lateral forces
which could affect handling characteristics. The front lower arm connects the front wheel hub to the front
subframe.
MacPherson Strut
Two MacPherson struts control the damping of the front The fabricated steel front lower arm features an outer ball
suspension. joint, a front bush and a rear bush, all components are
serviceable.
Each strut assembly comprises a damper unit, a coil spring and
a top mount assembly. The outer ball joint features a parallel pin with a
circumferentially machined groove that locates into the hub
The coil spring is retained in a compressed condition between assembly and is clamped/secured using a nut and bolt.
the strut spring seat and the top mount assembly. Isolators
at each end of the spring reduce noise transmitted from the
suspension to the body. Anti Roll Bar and Links

A bearing is fitted to the underside of the top mount assembly A solid spring steel ARB is used that operates via ARB links
and allows the spring to rotate as the steering is operated. secured to each damper (dedicated bracket).

A dust cover is fitted between the bump stop and the damper The ARB is attached to the front of the subframe with two
and protects the damper rod from dirt and damage. Polytetrafluoroethylene (PTFE) bushes that are secured with
clamp plates and bolts.
The coil spring axis is offset to the axis of the damper.
The low friction bushes PTFE require no additional greasing
This arrangement provides side load compensation, which and allow the ARB to rotate freely with quiet operation.
reduces friction within the damper.
This allows the bar to respond quickly to roll inputs and allows
Damper
stiffer bushes to be used as there is relatively little compression
Each damper is handed, is gas charged and oil filled, and is of or twisting.
twin tube construction.
Washers are attached to the ARB to locate the outside of each
bush and prevent sideways movement of the bar.

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Front Suspension Suspension System
The ends of the ARB are attached to each strut spring seat via The lower ball joint is mounted at 180° to the axis of the link
an ARB link. and attaches to the ARB and is secured with a locknut.

This arrangement allows the ARB to act on a ratio of The link must be attached to the ARB with the ball joint on
approximately 1:1 with the wheel travel providing maximum the outboard side of the bar and the locknut facing inwards.
roll bar effectiveness.
The ball joints on the ARB links are not serviceable and if
Each ARB link has a ball joint fitting at each end, which improves replacement of either is necessary, a new link will be required.
response and efficiency.

The top ball joint is mounted on the axis of the link and attaches
directly to the damper strut and is secured with a locknut.

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Suspension System Front Suspension

Service Procedures
Front Hub
Remove
1. Raise vehicle on lift.
2. Remove front wheel.

Wheel Remove
3. With an assistant applying brakes, remove and discard
drive shaft hub nut.

12. Remove M10 nut from ball pin and release track rod
ball joint from hub.
13. Remove screw securing ABS speed sensor, release
sensor and position aside.

4. Remove 2 bolts securing brake caliper to hub.

5. Release brake hose and ABS sensor wiring from
damper.

14. Remove nut and bolt securing lower arm to hub.

6. Release caliper from hub and tie aside.

Caution: Do not tie or allow caliper to hang on brake

hose.

7. Remove countersunk screw securing brake disc to

drive flange.
8. Remove brake disc. 15. Remove lower ball pin shield.

9. Remove nut securing track rod to steering arm and 16. Remove 2 nuts/bolts securing damper to hub.
discard nut.
10. Fit an M10 nut to ball pin, flush with end of pin.
11. Using T38008 release track rod ball joint from steering
arm.

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Front Suspension Suspension System
90–110Nm.
19. Position brake hose and ABS sensor harness to
damper, secure.
20. With an assistant applying brakes, fit drive shaft hub nut
and tighten to 320–350Nm.
21. Stake drive shaft hub nut.
22. Fit road wheel.

Wheel
23. Lower the vehicle.
24. Check wheel alignment.

Wheel Alignment
17. Using T32011release hub from lower arm ball joint.
18. Release drive shaft from hub.
19. Remove hub assembly from damper.

Caution: Do not store hub bearings near magnetic fields

or iron filings as damage may occur.

Caution: Do not remove protective cover from bearing

until hub is about to be fitted.
Refit
1. Clean hub to damper mating faces.
2. Clean drive shaft and flange splines.
3. Clean hub to lower arm ball joint mating faces.
4. Fit hub to damper.
5. Position drive shaft into drive flange.
6. Locate lower arm ball joint in hub.
7. Fit nuts/bolts securing damper to hub and tighten to
90–110Nm.
8. Position lower ball pin shield.
9. Fit nut and bolt securing lower arm to hub and tighten
to 50–65Nm.
10. Ensure ball joint is fully engaged in hub and bolt is in
ball joint groove.
11. Clean track rod to steering arm ball joint mating faces.
12. Connect track rod ball joint to steering arm, fit new
nut and tighten to 28–32Nm.
13. Clean wheel ABS sensor to hub mating faces.
14. Lightly lubricate ABS sensor and hub mating faces with
correct grade of grease.

Capacities, Fluids and Lubricants

15. Fit ABS sensor to hub and secure with screw and
tighten to 7–10Nm.
16. Fit brake disc to drive flange, fit countersunk screw and
tighten to 30–36Nm.
17. Release brake caliper and position to brake disc.
18. Fit bolts securing caliper to hub and tighten to

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Suspension System Front Suspension

Front Hub Bearing

Remove
1. Remove hub assembly.
Front Hub Remove
2. Position hub assembly on suitable press.
3. Using TCH00020 to press drive flange from
bearing/hub.

Refit
1. Clean hub and bearing mating faces.
2. Using TCH00019 support hub, use TCH00067 to
press the new bearing into hub.

4. Remove circlip from hub.

3. Fit circlip to hub.

4. Using TCH00019 support the hub bearing, using
TCH00018 press the hub flange into hub bearing.

5. Re-position hub on suitable press using support tools

TCH00021 and TCH00068.

5. Fit hub.

Front Hub Refit

6. If necessary use T32001 and TCH00020 to remove

the inner ring of bearing from drive flange.

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Front Suspension Suspension System
Front Lower Arm
Remove
1. Remove wheel.
Wheel Refit
2. Remove nut/bolt securing lower arm ball joint to hub,
remove ball pin shield.

Refit
1. If necessary position ball pin to lower arm, fit nuts/bolts,
tighten to （60±5） ）Nm+60°±5°.
2. Position lower arm to vehicle, locate front and rear
bushes.
3. Insert bolt in front bush, start nut, do not fully tighten
at this stage.
3. Release ball joint from hub.
4. Insert bolt in rear bush, loosely tighten.
4. Remove bolt from lower arm rear pivot bush.
5. Position lower ball pin shield.
6. Locate lower arm ball pin in hub, fit nut/bolt, tighten
to 50–65Nm.
7. Tighten lower arm rear bush bolt to 90Nm+90°.
8. Tighten lower arm front bush nuts/bolts to 90Nm+90°.
9. Fit wheel.

Wheel Refit
10. Carry out wheel alignment check.

Wheel Alignment

5. Remove nut/bolt from lower arm front bush.

6. Remove lower arm.

7. If necessary remove nuts/bolts X3 securing ball pin to
lower arm.

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Suspension System Front Suspension

Front_Lower_Ball_Pin Front Lower Arm Rear Bush

Remove Remove
1. Remove wheel. 1. Remove front lower arm.

Wheel Remove Front Lower Arm Remove

2. Remove nut/bolt securing lower arm ball joint to hub. 2. Position lower arm on suitable press.
3. Using TCH00069 and TCH00070 press bush from
lower arm.

3. Release ball joint from hub.

4. Remove nuts/bolts X3 securing ball pin to lower arm.

4. Discard bush.
Refit
1. Position new bush to arm on suitable press.
2. Using TCH00069 and TCH00070 press bush into
lower arm.

Reift
1. Position ball pin to lower arm, fit nuts/bolts, tighten to
（ 60±5） ）Nm+60°±5°.
2. Locate lower arm ball pin in hub, fit nut/bolt, tighten
to 50–65Nm.
3. Fit wheel.
3. Refit front lower arm.
Wheels Refit
Front Lower Arm Refit
4. Carry out wheel alignment check.

Wheel Alignment

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Front Suspension Suspension System
Front Lower Arm Front Bush Front Damper
Remove Remove
1. Remove front lower arm. 1. Raise vehicle on lift.

Front Lower Arm Remove 2. Remove road wheel.

2. Position lower arm on suitable press. Wheel Remove
3. Using TCH00071 and TCH00072 press bush from 3. Release ABS sensor harness and brake hose from
lower arm. damper. Release harness and brake hose from clip.

4. Discard bush. 4. Use an open ended spanner on the flats machined on

Refit the anti-roll bar link to prevent ball stud from rotating,
remove nut, release anti roll bar link from damper.
1. Position new bush to arm on suitable press.
2. Using TCH00071 and TCH00072 press bush into
lower arm.

5. Remove bolts securing damper to hub.

3. Refit front lower arm.

Front Lower Arm Refit

6. Release hub from damper.

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Suspension System Front Suspension

7. Lower vehicle. damper. Ensure bump stop and bump stop washer are
8. Remove nut securing damper to body, retrieve washers. correctly located in dust cover.
5. Fit spring to damper.
6. Position spring/damper assembly to spring compressor
T32016 and T32017. Compress spring.
7. Ensuring correct orientation, fit spring mounting plate
and rubber to damper shaft.
8. Fit washer and new nut.
9. Hold shaft with an Allen key, tighten nut to 54–62Nm.
10. Release spring tension, release shoes, remove spring
compressor.
11. Clean damper/spring location on underside of wing.
12. Position damper/spring assembly to body, fit washers,
tighten nut to 60–80Nm.
9. Remove spring and damper assembly.
13. Locate hub to damper, fit nuts/bolts, tighten to
10. Position spring compressor T32016 and T32017 in 90–110Nm.
suitable vice.
14. Clean anti-roll bar link, fit to damper, tighten nut to
11. Position spring and damper assembly to spring 50–65Nm. Use an open ended spanner on the flats
compressor. Compress spring. provided to prevent ball stud rotation.
15. Secure brake hose and ABS sensor harness to
brackets. Secure ABS sensor harness and brake hose
in swivel clip.
16. Fit road wheel.

Wheel Refit
17. Lower the vehicle.
18. Check wheel alignment.

Wheel Alignment

12. Hold shaft with an Allen key, remove piston rod top
nut. Discard nut.
13. Remove washer and mounting turret with bearing.
14. Remove isolator.
15. Remove spring.
16. Remove bump stop washer, bump stop and dust cover.
17. Remove isolator.
18. Release spring tension, release shoes and remove spring
from compressor.
Refit
1. Inspect damper, spring mounting rubbers and bearing
for deterioration and damage.
2. Inspect damper dust cover and bump stops for signs of
deterioration and damage.
3. Wipe damper shaft and bump stop cup.
4. Fit bump stop, bump stop washer and dust cover to

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Front Suspension Suspension System
Anti Roll Bar Anti Roll Bar Bush
Remove Remove
1. Remove front subframe. 1. Raise vehicle on hoist.

Front Subframe Remove 2. Remove bolts securing anti roll bar brackets to
subframe.

2. Remove bolts securing anti roll bar brackets to

subframe. 3. Remove anti roll bar bush brackets, discard bushes.
Refit
1. Position new bushes on anti roll bar.

Caution: Anti roll bar bushes have a special coating and

must not be lubricated.

2. Secure anti roll bar brackets, tighten to 22–28Nm.

3. Lower vehicle.

3. Remove anti roll bar, discard bushes.

Refit
1. Position new bushes on anti roll bar.
2. Position anti roll bar on front subframe.
3. Secure anti roll bar brackets, tighten to 22–28Nm.
4. Refit front subframe.

Front Subframe Refit

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Suspension System Front Suspension

Anti Roll Bar Link Front Subframe Assembly

Remove Remove
1. Remove wheel. 1. Raise the vehicle on a lift.

Wheels Remove 2. Remove the front wheels.

2. Use an open ended spanner on the flats machined on Wheels Remove
the anti-roll bar link to prevent ball stud from rotating, 3. Remove the exhaust pipe.
remove nut, release anti roll bar link from damper.
Exhaust Pipe Remove
4. Remove the lower rear tie rod of the engine.
5. Disconnect the steering tie rod from the steering
knuckle assembly with the tool T38008.

3. Use an open ended spanner on the flats machined on

the anti-roll bar link to prevent ball stud from rotating,
remove nut, release anti roll bar link from anti roll bar.

6. Disconnect the connecting rod of the stabilizer bar

from the horizontal stabilizer bar.

4. Remove anti roll bar link.

Refit
1. Position new link in anti roll bar and damper.
7. Loosen the rear bushing of the front lower swing arm
2. Fit nut to link at anti roll bar, use an open ended spanner from the front subframe.
on the flats machined on the anti-roll bar link to prevent
ball stud from rotating , tighten to 45–55Nm.
3. Fit nut to link at damper, use an open ended spanner on
the flats machined on the anti-roll bar link to prevent
ball stud from rotating , tighten to 50–65Nm.
4. Refit wheel.

Wheel Refit

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Front Suspension Suspension System

8. Loosen the front bushing of the front lower swing arm Refit
from the front subframe. 1. Locate 2 new bolts to the corresponding holes of the
body but do not tighten them.
2. Locate 4 new bolts to the corresponding holes of the
body but do not tighten them.
3. Tighten 2 bolts to 90Nm+180°.
4. Tighten 4 bolts to 90Nm+180°.
5. Connect the rear bushing of the front lower swing
arm to the front subframe, and tighten the bolt to
90Nm+90°.
6. Connect the front bushing of the front lower swing
arm to the front subframe, and tighten the bolt to
90Nm+90°.
7. Connect the connecting rod of the stabilizer bar to
9. Remove and discard 6 bolts fixing the front subframe the horizontal stabilizer bar, and tighten the nut to
to the body in white. 45–55Nm.
8. Fit the exhaust pipe to the vehicle.

Exhaust Pipe Refit

9. Fit the wheels.
Wheels Refit
10. Lower the vehicle.
11. Check the wheel alignment parameters.

Four-wheel Alignment

10. Remove the front subframe assembly from the vehicle.

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Suspension System Front Suspension

Special Tools Tool Description Picture

Tool Description Picture Number
Number

T32001 Puller universal

Remover ball
T38008
joint

Support front
Lever front TCH00019
hub
T32011 lower arm ball
joint

Support front
TCH00067 hub bearing and
Remover front drive flange
TCH00020
hub bearing

Replacer front
TCH00018
Support front hub bearing
TCH00021
hub

Remover and
replacer front
Support front TCH00069
lower arm bush
TCH00068 hub bearing and (big)
drive flange

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Front Suspension Suspension System
Tool Description Picture
Number

Support front
TCH00070 lower arm bush
(big)

Remover and
replacer front
TCH00071
lower arm bush
(small)

Support front
TCH00072 lower arm bush
(small)

Coil spring
T32016
compressor

Adaptor
T32017 coil spring
compressor

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Suspension System Rear Suspension

Rear Suspension
Specifications
Torque
Description Value
Nut - rear damper to body 55–65Nm
Bolts - rear damper to trailing arm 140–170Nm
Nuts - rear spindle 320–350Nm
Bolts - rear subframe to bracket 90–110Nm
Screw - hand brake clip bracket 7–10Nm

Specifications
Rear suspension

Total coils 6.48

Wire diameter 11.3mm

Free Length 302mm

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Rear Suspension Suspension System
Description and Operation
System Component Layout
Rear Suspension Layout

1. Rear Damper Assembly 3. H Frame Member Assembly

2. Rear Suspension Coil Spring Assembly 4. Rear Hub Assembly

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Suspension System Rear Suspension

Rear Suspension Disassembled View

1. Rear Suspension Damper Assembly 4. Rear Suspension Lower Spring Vibration Isolator
2. Rear Suspension Upper Spring Vibration Isolator 5. H Frame Member Mounting Bracket Assembly
3. Rear Suspension Spring 6. H Frame Member Assembly

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Rear Suspension Suspension System
Rear Shock Absorber Disassembled View

1. Rear Damper Assembly 7. Bolt － Rear Brake Caliper Assembly to Trailing Arm
2. Rear Damper Gasket 8. Rear Suspension Limit Disc
3. Bolt 9. Rear Suspension Damper Column Piston Rod Bushing
4. Rear Suspension Damper Column Dust Cover 10. Rear Damper Rebound Gasket
5. Rear Suspension Spring 11. Nut
6. Buffer Gasket - Rear Suspension Shock Absorber

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Suspension System Rear Suspension

Description The lower isolator is positively retained by a location pip on

Rear suspension includes: the lower arm.

• Coil springs A hole in the lower isolator is provided for water drainage
and must be aligned with corresponding hole in the lower arm
• Dampers
when fitted.
• H frame member
Rear Shock Absorber
H Frame Member
The dampers are gas charged and oil filled and are of twin tube
The H frame member consist of a couple of trailing arm, a
construction.
cross beam , a lower coil spring seat , a damper fixing point
and a stub axle. The twin tube construction allows the damper piston to
operate on an inner tube with an oil/ gas cavity between the
The trailing arms are fabricated structure which is attached to
inner and outer tubes.
the body via two fabricate mounting brackets, forward of the
rear wheels. This minimises oil cavitation and eliminates the effect of
damage to the outer tube affecting piston operation.
A fabricated bracket inboard of each stub axle connected to
the trailing arm and cross beam provides the lower coil spring The lower damper mounting is fitted with a non-serviceable
seat. bush that is attached to the trailing arm with a bolt and washer.

The trailing arm, rearward of the stub axle provides the lower This mounting position gives the damper an approximate ratio
damper fixing point. of 1:1, which is beneficial for damping control.

A stub axle is bolted with four bolts to each side of the frame The damper rod is located in a bush in a top mounting and is
and provides location for the rear brakes and road wheels. secured with a rebound plate and a locknut.

The ‘twist beam ’ principle use angled pivot bushes which have The top mounting is attached to the body with two bolts.
a special construction to decrease the vertical vibration of the The rebound plate fitted between the damper rod locknut and
body. the top mounting cushions forces as the damper rod reaches
Coil Spring full extension.
Coil springs, manufactured from chromium steel, are fitted A spring aid plate and a spring aid are fitted over the rod
between the body and the lower arm. and cushion the damper operation if maximum bump travel
is reached.
Each spring is located in upper and lower spring isolators which
reduce noise transmitted to the body from the suspension.
Both isolators are positively retained to the spring.

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Rear Suspension Suspension System
Service Procedures Rear Spring
Rear Damper Assembly Remove
Remove 1. Remove wheel.
1. Remove wheel. Wheel Remove
Wheels Remove 2. Place suitable support under rear lower arm.
2. Place suitable support under rear lower arm. 3. Remove lower damper mounting to subframe bolt.
3. Remove rear damper upper mounting to body fixings.

4. Lower support device/suspension arm, remove spring.

4. Remove lower damper mounting to subframe bolt. 5. Remove isolator pads.
Refit
1. Position spring isolator pads.
2. Position spring.
3. Raise support device/suspension arm to align lower
damper fixing.
4. Fit lower damper to subframe bolt, tighten
to140–170Nm.
5. Remove support.
6. Refit wheel.

Wheel Refit

5. Remove the shock absorber.

Refit
1. lower damper
2. Fit lower damper to subframe bolt, do not fully tighten
at this stage.
3. Fit upper damper mounting to body bolts, tighten to
55–65Nm.
4. Fully tighten lower mounting fixing bolt to
140–170Nm.
5. Remove support.
6. Refit wheel.

Wheel Refit

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Suspension System Rear Suspension

Rear Hub Bearing H Frame Assembly

Remove Remove
1. Remove brake drum. 1. Remove handbrake cables from brake shoes.

Brake Drum Handbrake Cable

2. Remove grease cap. 2. Remove handbrake cable to subframe fixing clips.
3. Knock back lock nut stake, remove nut, discard. 3. Remove rear ABS sensors.
4. Remove rear drive flange/hub bearing, collect washer. ABS Sensor - Rear
4. Disconnect rear brake pipes from rear flexible hoses at
subframe fixing clips.
5. Release rear flexible brake hoses from subframe
brackets.
6. Using suitable jacking equipment support rear subframe.
7. Remove lower damper fixings.

Refit
1. Fit rear drive flange/hub bearing.
2. Position washer.
3. Fit new nut, tighten to 320–350Nm.
4. Using a suitable chisel knock in locking stake.
5. Fit grease cap.
8. Lower subframe, remove rear springs.
6. Refit brake drum.
9. Remove subframe mounting fixings.
Brake Drum

10. Lower subframe, remove from jacking equipment.

Refit
1. Position subframe on suitable jacking equipment.
2. Raise subframe to vehicle, align and loosely fit front
mounting bolts.
3. Ensure correct fitment of spring isolator pad/s
4. Position springs, fit lower damper fixings.
5. Fully tighten front subframe mountings to 90–110Nm.

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Rear Suspension Suspension System
6. Fully tighten lower damper bolts to 140–170Nm.
7. Refit brake flexible hose to subframe, fit brake pipe,
secure clip.
8. Position handbrake cable clips to subframe, tighten
to7–10Nm.
9. Refit ABS sensors.

ABS Sensor - Rear

10. Refit handbrake cable.

Handbrake Cable
11. Bleed brakes.

Brake System Draining

12. Carry out alignment check.

Four-wheel Alignment

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Suspension System Tires and Wheels

Tires and Wheels

Specifications
Torque
Description Value
Bolt - road wheel 105–115Nm
Nut-Tire press sensor locknut 4.5–5.5Nm

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Tires and Wheels Suspension System
Parameter
Wheel Rim Specification 6.0J×15 6.5J×16 5.5J×14
Tyre Specification 185/65 R15 195/55 R16 185/70 R14

Tyre Pressure (no-load) 210kPa/2.1bar/30psi 210kPa/2.1bar/30psi 210kPa/2.1bar/30psi

Category Wheel Wheel Spare Tyre

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Suspension System Tires and Wheels

Service Procedures
Wheel
Warning: Do not use silicone lubricant on the or wheel rim
or tyre edge. Clean tyre edge before removing. Use 50%
non-silicone lubricant and 50% water based lubricant to
these areas prior to refitting.
Remove
1. Remove the wheel trim cover assembly with a
screwdriver.
2. Remove 4 highway type wheel bolts with a circular
ended wrench of the vehicle hand tools.
3. Place the vehicle at the lifting platform and lift to a
certain height. Warning: If there is oil leakage between the wheel and the
4. Remove wheels. brake disc or drum, it will cause the wheel bolts to become
loose and result in injury with the vehicle out of control.
5. Remove the tyre and the wheel valve assembly.
Never use heat to remove a seized wheel. This will shorten
Warning: Use a tyre changer to remove the tyre. Manual the life of the wheel, wheel bolts, hub and bearing. Wheel
tools or prybar could damage the road wheel or tyre. bolts must be tightened in correct sequence and to correct
Caution: Do not place the wheel face down on the ground torque to avoid distortion of wheel, brake drum or disc.
to avoid scratching. 5. Refit the wheel trim cover assembly.
Refit
Caution: Please clean the corrosive on the surface of the
road wheel, drum and brake disc before refitting. If wheel,
disc and drum contact surfaces are not properly cleaned,
the wheel bolts could become loose and may cause the
wheel to fall off while the vehicle is moving. This will cause
the vehicle to go out of control, and could cause injury.

1. Refit the wheel valve assembly.

2. Refit the tyre with a tyre changer and charge the tyre
until the rim is put in place. Ensure that the locating
ring at the outside of the tyre bead is around the wheel
rim flanges. This method can ensure the right position
of tyre bead.
3. Perform the wheel dynamic balance operation again,
refit new and appropriate wheel balance blocks.
4. Refit wheels, tighten 4 steel highway type wheel bolts
to 105–115Nm. For tightening order, please see the
picture below (1 to 4).

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Tires and Wheels Suspension System
Tyre Pressure Monitoring Controller Tyre Pressure Sensor
Remove Remove
1. Disconnect the battery negative. 1. Remove the wheels.
2. Remove the centre console assembly. Wheels Remove
Centre Console Assembly Remove 2. Exhaust the tyres.
3. Disconnect the electrical connector of the tyre 3. Press the tyre at the valve core on the tyre changer
pressure monitoring controller. until the tyre pressure sensor is exposed.
4. Loosen 2 nuts and remove the tyre pressure monitoring 4. Remove the locking nut fixing the tyre pressure sensor
controller. and the valve core assembly to the wheel, and remove
the tyre pressure sensor and the valve core assembly.

Refit
1. Fix the tyre pressure monitoring controller to the Refit
centre console bracket with nuts and tighten the nuts
1. Fit the new tyre pressure sensor and the valve core
up.
base assembly to the wheel hub, fit and tighten the
2. Connect the electrical connector of the tyre pressure locking nut to 4.5–5.5Nm.
monitoring controller.
Keep the tyre from the electronic module during the tyre
3. Fit the centre console assembly.
mounting process.
Centre Console Assembly Refit 2. Inflate the tyres.
4. Connect the battery negative. 3. Fit the wheels.
5. Perform a self-learning for the tyre pressure monitoring
Wheels Refit
system (TPMS).
4. Perform a self-learning for the tyre pressure monitoring
system (TPMS).

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1.0 410
Brake Brake System
Brake
Specifications
Torque
Description Value
Nuts - master cylinder to servo 21–29Nm
Bolt - hose to panel 7–10Nm
Brake pipe unions to master cylinder 15–19Nm
Nuts - servo to pedal box 19–25Nm
Nut - master cylinder to servo 21–29Nm
Bolts - pedal box to body 19–25Nm
Nuts - ped box to body 19–25Nm
Blots - clutch cylinder to pedal box 7–10Nm
Screw - accelerator to body 8Nm
Bolt - brake lamp switch to pedal box 8–12Nm
Bolt - brake caliper 90–110Nm
Front brake hose to caliper housing 16–18Nm
Screw - front brake bleeding 7–9Nm
Screw - front brake disk to hub 7–10Nm
Bolt - front caliper housing to hub 85–105Nm
Screw - cap drum-brake 6–8Nm
Bolt - wheel cylinder to back-plate 7–13Nm
Rear brake hose to rear brake drum connection 15–19Nm
Screw - rear brake drum bleeding 7–10Nm
Bolt - EVP to bracket 7–10Nm

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Brake System Brake

Description and Operation

System Layout
Brake System

1. Front Brake Caliper Assembly 7. Rear Brake Drum

2. Front Ventilated Brake Hole Disc 8. Rear Wheel Speed Sensor
3. ABS Modulator 9. Brake Reservoir
4. Brake Booster Assembly 10. Air Intake Manifold
5. Brake Master Cylinder 11. Vacuum Tube
6. Front Wheel Speed Sensor

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Brake Brake System
Description The tandem master cylinder contains two chambers and
Vacuum Servo Assembly associated pistons.

The vacuum servo/booster assembly provides boost during Each piston/chamber controls a circuit, the rear piston
braking to reduce the pedal force required for braking. produces brake pressure for the primary circuit, this covers
LHF & RHR, the front piston produces brake pressure for the
In a case of the vacuum booster assembly failure, the hydraulic
secondary circuit, and this covers RHF & LHR.
system maintains brake function, but greater pedal braking
force is required due to lack of vacuum assistance. The remote brake fluid reservoir is installed higher than the
master cylinder in order to maintain a gravitational feed.
The vacuum booster assembly is connected to the bulkhead
(LHD)/pedal box (RHD) via 4 studs. The fluid reservoir is partitioned inside to feed fluid to each
brake circuit independently, thus avoiding the condition that
The brake master cylinder assembly is connected via two fixing
both circuits could become devoid of fluid.
bolts at the front end of the vacuum booster assembly.
The brake fluid reservoir utilizes a fluid level switch.
The brake servo assembly consists of a circular housing which
contains two diaphragms, a central plate, a control valve A reed style switch, featuring a permanent magnet and float is
assembly, input and output push rods and a filter. installed in the fluid reservoir which is linked to the fluid level,
handbrake and EBD warning lamp in the instrument pack.
The input push rod is connected to the brake pedal.
Front Brake
The output push rod locates in the primary piston of the
master cylinder. Each front brake consists of a single-piston sliding brake caliper
assembly fitted to the hub and a ventilated brake disc.
A protective gaiter is installed on the control valve assembly
Rear Brake
where it extends from the rear of the housing.
Each rear brake consists of a back plate, a brake drum, brake
A port in the front face of the housing is connected to a vacuum
shoes, a hydraulic wheel cylinder, a self adjusting rod and return
line from the engine.
springs.
A non return valve is incorporated into the vacuum line.
The back plate is installed on the stub axle, retained by the stub
The control valve assembly consists of a valve body containing axle bolts and provides location for brake shoes and hydraulic
a valve, a piston, a valve spring and an input rod spring. wheel cylinder.
The valve controls a vacuum port in the valve body. The brake drum is fitted to the flange of bearing, and rotates
The piston controls an air inlet port between the valve and the with the wheels.
piston. Each rearward brake shoes is fitted with a handbrake cable
A reaction disc and a ratio disc separate the piston from the lever.
output push rod. Brake Pedal and Brake Lamp Switch
A guide tube on the front of the valve body is attached to the The brake pedal is installed on a pivot shaft in the pedal
front diaphragm and supported in a bush in the central plate. mounting bracket on the engine bulkhead.

A return spring locates in the open end of the guide tube. A clevis pin and clip connect the input rod of the brake servo
to the brake pedal.
Brake Master Cylinder Assembly
A tandem brake master cylinder is installed on the brake servo A tang on the end of the brake pedal activates a plunger style
assembly. brake switch in the pedal mounting bracket.

Fluid is supplied via a remote reservoir connected to the The brake switch is adjustable and secured in position using a
master cylinder via two rubber hoses. lock nut.

The master cylinder is fixed to the front of the brake servo via The brake lamp switch provides two brake pedal state outputs,
2 stud fixings. one power, the other ground.

When the brake pedal is pressed, the brake master cylinder This signal is supplied to the ECM and used to illuminate the
assembly produces hydraulic pressure so that the brake stop lamps.
operates.

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Brake System Brake

Service Procedures Master Cylinder and Fluid Reservoir

Low Brake Fluid Level Indicator Switch - RHD Remove
Remove 1. Position absorbent cloth under master cylinder to
1. Disconnect multiplug from brake fluid low level absorb any fluid spillage.
indicator switch. Caution: Brake fluid will damage paint finished surfaces.
If spilled, immediately remove fluid and clean area with
water.

2. Drain master cylinder contents using suitable syringe.

3. Disconnect multiplug from brake fluid low level
indicator switch.

2. Release clip securing brake fluid low level indicator

switch to brake fluid reservoir, remove switch.
Refit
1. Fit brake fluid low level indicator switch to brake fluid
reservoir, secure using clip.
2. Connect multiplug to brake fluid low level indicator 4. Disconnect master cylinder brake pipe connections.
switch.

5. Release clutch fluid supply pipe from reservoir.

6. Remove brake master cylinder to servo fixings, discard.

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Brake Brake System
Brake Servo
Remove
1. remove battery earth lead.
2. Drain fluid from reservoir.
3. Place a suitable absorbent cloth beneath master
cylinder.
Caution: Brake fluid will damage paint finished surfaces.
If spilled, immediately remove fluid and clean area with
water.

4. Disconnect brake fluid level switch electrical connector.

5. Remove both brake pipes from master cylinder –
position aside.
7. Remove brake reservoir to body fixings.
Caution: Before disconnecting or removing components,
ensure the immediate area around joint faces and
connections are clean. Plug open connections to prevent
contamination.

8. Remove master cylinder and fluid reservoir.

Refit
1. Fit master cylinder to servo, fit new nuts, secure to
21–29Nm. 6. Remove brake master cylinder to servo fixings, discard.
2. Fit reservoir to body, secure bolts to 7–10Nm
3. Connect brake pipes to master cylinder, secure to
15–19Nm.
4. Connect clutch pipe to reservoir.
5. Connect multiplug to brake fluid low level indicator
switch.
6. Brake System Bleeding.
Brakes - Bleed

7. Remove brake reservoir to body fixings.

8. Manipulate brake master cylinder away from servo – be
careful to avoid damaging brake pipes, position aside.
9. Disconnect brake servo vacuum pipe.
Caution: The force to remove the hose shouldn’t too
heavy to damage the connector of vacuum hose.Do not
damage the connector and keep the connector away

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Brake System Brake

from water when removing or fixing the hose with vacuum 10. Connect battery earth lead.
sensor. 11. Bleed brakes.

Brake Bleed
12. Run engine, test for vacuum leaks.

10. Remove steering column closing panel base.

11. Remove pedal box/brake servo fixings.

12. Remove brake pedal push rod clip and clevis pin.
13. Remove brake servo.
Refit
1. Position brake servo.
2. Fit pedal box/brake servo fixings, secure to19–25Nm
3. Fit brake pedal clevis pin and clip.
4. Fit steering column closing panel.
5. Fit servo vacuum pipe.

Caution: Keep the dust and foreign matter from vacuum

hose.If having trouble to fix vacuum hose ， please using
grease special for fixing vacuum hose to lubricate ， other
liquid or grease is prohibited.

6. Position brake master cylinder to servo, secure new

fixings21–29Nm.
7. Fit brake fluid reservoir to body fixings, secure
to7–10Nm.
8. Fit brake pipes to master cylinder, tighten unions to
15–19Nm.
9. Connect brake fluid level switch electrical connector.

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Brake Brake System
Brake pedal 17. Remove clutch pedal.
Remove 18. Remove brake pedal.
1. Disconnect battery earth lead.
2. Remove steering column closing panel base.
Steering Column
3. Remove brake pedal push rod clip and clevis pin.
4. Remove clutch master cylinder push rod clip and clevis
pin.
5. Remove clutch master cylinder fixings, manipulate
cylinder to one side.
6. Disconnect brake light switch, clutch pedal switch and
throttle position sensor electrical connectors.
7. Remove pedal box/brake servo fixings X4.

Refit
1. Position brake pedal and spring.
2. Partially insert pedal pivot.
3. Position clutch pedal and spring.
4. Fully insert pivot pin.
5. Fit clutch/brake pedal pivot pin retaining clip.
6. Fit pedal springs.
7. Position clutch pedal switch.
8. Position brake light switch.
9. Position pedal box assembly to brake servo and
bulkhead.
8. Remove bolts securing throttle position sensor to
10. Fit pedal box to body fixings, tighten to19–25Nm
pedal box.
11. Fit pedal box/brake servo fixings, secure to 19–25Nm
9. Remove throttle pedal & sensor.
12. Fit brake pedal clevis pin and clip.
10. Remove bolts securing pedal box to bulkhead panel.
13. Refit clutch master cylinder, tighten fixings to 7–10Nm
11. Remove pedal box assembly.
14. Fit clutch pedal push rod pin and clip.
12. Remove clutch pedal switch.
15. Refit throttle pedal/position sensor, tighten fixings to
13. Remove brake light switch.
8Nm.
16. Refit all electrical connectors.
17. Adjust clutch and brake pedal switches.
18. Fit steering column closing panel.

Steering Column Closing Panel

19. Reconnect battery.

14. Remove clutch/brake pedal pivot pin retaining clip.

15. Release pedal springs.
16. Slide out pivot pin.

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Brake System Brake

Brake lamp switch Brake Caliper – Front

Remove Remove
1. Disconnect the battery negative. Warning: Do not work on or under a vehicle supported
2. Remove the steering column lower cover plate. only by a jack.Always support the vehicle on safety stands.
1. Raise vehicle on lift.
Steering Column Lower Cover Plate Remove
2. Remove front wheel/s.
3. Release the brake lamp switch harness connector.
Wheels
4. Refit the inner nut securing the brake lamp switch to
the pedal bracket with an open spanner, remove the 3. Remove brake pads.
outer nut and the brake lamp switch. Brake Pads - Front
4. Place a container beneath vehicle to collect any fluid
spillage.
5. Clamp brake flexible hose using suitable brake pipe
clamp.
6. Loosen brake hose to caliper union.
Caution: Before disconnecting or removing components,
ensure the immediate area around joint faces and
connections are clean. Plug open connections to prevent
contamination.

7. Remove 2 brake caliper fixing bolts.

Refit
1. Adjust the initial position at the time of brake lamp
switch refit. Release the pedal first and keep it in the
initial position. Then allow the brake lamp switch
contact to contact with the brake pedal, adjust the
stretching length of the brake lamp switch contact
(between the pedal and the outer nut), ensure that the
stretching length is kept within 0.5-1.5mm.
2. Secure the inner nut of the brake lamp switch with
an open spanner, refit the outer nut and tighten to
8–12Nm.
3. Connect the brake switch connector. 8. Remove brake caliper from flexible brake hose.

4. Refit the steering column lower cover plate assembly. Refit

1. Clean components and mating faces.
Steering Column Lower Cover Plate Refit
Warning: Do not use compressed air to clean brake
5. Connect the battery negative.
components. Dust from friction materials can be harmful
if inhaled.
2. Remove any scale and loose corrosion from around
edge of disc.
3. Fit brake caliper to flexible brake hose – do not fully
tighten at this stage.
4. Fit brake pad to caliper housing.
5. Position caliper to hub, fit bolts, tighten to 90–110Nm
6. Fully tighten flexible brake hose to 16–18Nm – ensure
hose is not twisted.
7. Fit brake pads.
Brake Pads - Front

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Brake Brake System
8. Bleed brake system. Brake Pads – Front
Brake Bleed
Remove
Warning: Do not work on or under a vehicle supported
9. Fit wheel/s.
only by a jack.Always support the vehicle on safety stands.
Wheel
Warning: Brake pads must be renewed in axle sets only,
10. Lower the vehicle.
otherwise braking efficiency may be impaired.
1. Raise vehicle on lift.
2. Remove front wheels.
Wheels
3. Remove anti-rattle spring from caliper housing.
4. Remove 2 caps from guide pin dust covers.
5. Remove 2 guide pins from caliper housing.
6. Release caliper housing from caliper carrier and tie
aside.
Caution: Don’t tie brake caliper on brake hose.
7. Remove brake pads from caliper housing.

Refit
1. Remove any scale and loose corrosion from around
edge of disc. Clean caliper housing and caliper carrier
using brake cleaning fluid.
Warning: Do not use compressed air to clean brake
components. Dust from friction materials can be harmful
if inhaled.
2. Inspect caliper and seals for damage.
3. Remove bleed screw cap, connect bleed hose and
bottle to bleed screw. Loosen bleed screw.
4. Press piston into caliper housing then tighten bleed
screw to 7–9Nm.
5. Disconnect bleed hose and remove bottle.
6. Secure bleed screw cap.
7. Fit brake pads to caliper housing.
8. Lubricate guide pins with anti-seize grease.
Caution: If brake pads low warning light was illuminated
on the instrument pack before changing brake pads, the

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Brake System Brake

sensor must be renewed, otherwise the warning light will Brake Disc – Front
still be illuminated. Remove
9. Untie caliper housing and position to caliper carrier Warning: Do not work on or under a vehicle supported
and align. Fit guide pins and tighten.. only by a jack.Always support the vehicle on safety stands.
10. Fit caps to guide pin dust covers. Caution: Brake discs must be renewed in pairs, unless one
11. Fit anti-rattle spring clip to carrier housing. disc requires renewal before 1000 miles (1500 km) from
new.
12. Check and top up brake fluid reservoir.
Caution: Never re-use fluid that has been bled from the 1. Raise vehicle on lift.
brake system. 2. Remove front wheels.

13. Fit wheels. Wheels

3. Remove 2 bolts securing caliper carrier to hub.
Wheels
4. Release caliper carrier from hub and tie aside
14. Lower the vehicle.
15. Operate brake pedal several times to seat brake pads. Caution: Do not tie or allow caliper to hang on brake
hose.
Tip: Pedal travel may be longer than normal during first
brake applications. 5. Remove Torx screw securing brake disc to drive flange.

6. Remove brake disc.

Refit
1. Ensure mating surfaces of disc and drive flange are clean.
2. Fit disc to drive flange, fit countersunk screw and
tighten to 7–10Nm.
3. Check brake disc run-out.

Thickness and Run-out Check

4. Examine brake pads and renew if necessary.
5. Fit caliper assembly to hub, tighten bolts to 85–105Nm.
6. Fit wheel.

Wheel
7. Lower the vehicle.

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Brake Brake System
Thickness and Run-Out Check-Front Brake Disc 85–105Nm.
Check 11. Fit wheel.
1. Raise vehicle on lift.
Wheel
Warning: Do not work on or under a vehicle supported 12. Press brake pedal several times to seat brake pads.
only by a jack.Always support the vehicle on safety stands.
13. Lower the vehicle.
2. Remove front wheels.

Wheel
3. Remove 2 bolts securing caliper carrier to hub, release
caliper carrier from hub and tie aside.

Caution: Do not tie or allow caliper to hang on brake

hose.

4. Using a micrometer, measure the thickness of disc

at 4 equally spaced points around disc, 10 mm from
outer edge of disc. Disc thickness must be 20.0 mm
minimum; Renew disc if outside limit(s).

Caution: Brake discs must be renewed in pairs, unless one

disc requires renewal before 1000 miles (1500 km) from
new.

5. Mount a Dial Test Indicator (DTI) toTCH00022 and

secure to inboard side of hub using caliper assembly
bolt hole.

6. Position DTI probe 5 mm from outside edge of disc.

7. Zero DTI and rotate disc one complete turn to measure
disk runout. Disc runout must not exceed 0.05 mm.
8. If disc runout is outside limits:

• Remove countersunk screw securing brake disc to hub

and remove disc.
• Ensure disc to hub flange mounting faces are clean.
• Fit disc to hub and tighten countersunk screw and tighten
to 7–10Nm.
• Check disc run-out again as detailed.
• If run-out is still outside limits, renew disc and/or hub.
9. Remove DTI and TCH00022 from inboard side of hub.
10. Fit caliper assembly to hub, fit and tighten bolts to

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Brake System Brake

Brake Drum Brake Shoes - Rear

Remove Remove
Warning: Do not work on or under a vehicle supported Warning: Do not work on or under a vehicle supported
only by a jack.Always support the vehicle on safety stands. only by a jack.Always support the vehicle on safety stands.

Warning: Brake pads must be renewed in axle sets only, Warning: Brake pads must be renewed in axle sets only,
otherwise braking efficiency may be impaired. otherwise braking efficiency may be impaired.
1. Raise vehicle on lift. 1. Release handbrake.
2. Remove rear wheels. Handbrake Cable - Adjust
Wheels 2. Raise vehicle on lift.
3. Remove brake drum retaining screw/s. 3. Remove rear brake drums.

Brake Drum
4. Clean brake shoes and components using brake cleaning
fluid.

Warning: Do not use compressed air to clean brake

components. Dust from friction materials can be harmful
if inhaled.
5. Compress clips and rotate to release brake shoe
retaining pins, remove retaining pins.
6. Ease one shoe out of lower retaining groove in
abutment followed by other shoe.
7. Detach shoe abutment return spring from leading shoe
end and remove spring.
4. Withdraw brake drum/s.
Tip: The forward shoe is leading shoe, and the shoe
Refit
connecting with parking brake cable is trailing shoe.
1. Remove any scale and loose corrosion from around
8. Release hand brake cable from brake shoe lever.
edge of drum. Clean brake shoes and components
using brake cleaning fluid. 9. Manoeuvre shoe assembly around wheel cylinder and
remove.
Warning: Do not use compressed air to clean brake
components. Dust from friction materials can be harmful Caution: Ensure edges of brake shoes do not damage
if inhaled. wheel cylinder dust covers.
2. Manually adjust brake shoes. 10. Fit an elastic band around wheel cylinder to retain
3. Fit brake drum/s. pistons.
4. Secure brake drum retaining fixing/s 6–8Nm 11. Manipulate trailing shoe to remove from adjuster
mechanism.
5. Fit wheels.
12. Detach upper spring from shoes.
Wheel
13. Remove adjuster wheel ratchet plate and vertical spring.
6. Lower the vehicle.
14. Screw adjuster mechanism fully in.
7. Operate brake pedal several times to seat brake shoes.

Tip: Pedal travel may be longer than normal during first

brake applications.

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Brake Brake System
Brake Shoes – Manually Adjust
Manually Adjust
Warning: Do not work on or under a vehicle supported
only by a jack.Always support the vehicle on safety stands.
1. Release handbrake.
Handbrake Cable - Adjust
2. Raise vehicle on lift.
3. Remove rear brake drums.

Brake Drum
4. Clean brake shoes and components using brake cleaning
fluid.
Refit
Warning: Do not use compressed air to clean brake
1. Remove any scale and loose corrosion from around components. Dust from friction materials can be harmful
edge of drum. Clean brake shoes and components if inhaled.
using brake cleaning fluid.
5. Use suitable screwdriver to rotate brake shoe adjuster
Warning: Do not use compressed air to clean brake nut 1 notch.
components. Dust from friction materials can be harmful 6. Refit brake drum, ensure no resistance.
if inhaled.
7. Repeat above until light resistance felt.
2. Fit adjuster wheel ratchet plate and vertical spring.
8. Back off adjuster 1 notch.
3. Position adjuster on leading shoe.
9. Fit brake drum/s.
4. Locate upper spring in both brake shoes.
Brake Drum
5. Manipulate brake shoes over adjuster rod.
10. Adjust handbrake cable.
6. Remove elastic band from wheel cylinder.
Handbrake Cable - Adjust
7. Position brake shoes onto brake drum and wheel
cylinder. 11. Lower the vehicle.
8. Locate handbrake cable in lever. 12. Operate brake pedal several times to seat brake shoes.
9. Position lower brake shoe spring in both shoes. Tip: Pedal travel may be longer than normal during first
10. Position shoes on abutment. brake applications.
11. Fit brake shoe retaining pins and clips.
12. Manually adjust brakes.

Brakes - Adjust
13. Fit brake drums.

Brake Drum
14. Adjust handbrake cable.

Handbrake Cable - Adjust

15. Lower the vehicle.
16. Operate brake pedal several times to seat brake shoes.

Tip: Pedal travel may be longer than normal during first

brake applications.

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Brake System Brake

Hydraulic Wheel Cylinder Brake System Bleed

Remove Draining
Warning: Do not work on or under a vehicle supported The following procedure covers bleeding the complete system,
only by a jack.Always support the vehicle on safety stands. but where only the primary or secondary circuit has been
disturbed in isolation it should only be necessary to bleed
Warning: Brake pads must be renewed in axle sets only,
that circuit. Partial bleeding of the hydraulic system is only
otherwise braking efficiency may be impaired.
permissible if a brake pipe or hose has been disconnected with
1. Raise vehicle on lift.
only minor loss of fluid.
2. Remove brake drum/s.
Caution: If brake modulator has been renewed please
Brake Drum follow bleed process outlined within diagnostic equipment
3. Place suitable brake hose clamp on flexible brake hose. section.
4. Remove bleed nipple. Warning: Do not allow brake fluid to come into contact
5. Release brake pipe union, remove pipe from cylinder. with eyes or skin.
6. Remove wheel cylinder to back-plate fixings. Caution: Never re-use fluid that has been bled from the
7. Withdraw wheel cylinder. brake system.
Refit 1. Top-up fluid level in brake reservoir to 'MAX' mark.
1. Clean brake shoes and components using brake cleaning
Caution: During the entire bleeding process, ensure the
fluid.
new brake fluid level in the brake reservoir is between the
Warning: Do not use compressed air to clean brake Min. and Max. position.
components. Dust from friction materials can be harmful
2. Raise the vehicle on a lift.
if inhaled.
3. At LHR brake remove bleed screw dust cap and attach
2. Position hydraulic wheel cylinder.
tube to bleed screw. Submerge free end of tube in clear
Caution: Ensure edges of brake shoes do not damage container containing new brake fluid.
wheel cylinder dust covers. 4. Apply pressure to brake pedal several times, then apply
3. Fit cylinder to back-plate fixings, secure to 7–13Nm. steady pressure.

4. Fit brake pipe union, secure to 15–19Nm. 5. Loosen bleed screw to release brake fluid and air.
Allow pedal to return unassisted.
5. Fit bleed nipple, do not fully tighten at this stage.
6. Repeat procedure until a flow of clean airfree fluid is
6. Manually adjust brake shoes.
purged into the container then, while holding pedal
7. Fit brake drum/s – do not refit wheel/s. at end of downward stroke, tighten bleed screw
Brake Drum to7–10Nm.
8. Remove brake flexible hose clamp. 7. Remove tube from bleed screw and fit bleed screw
9. Bleed brakes. dust cap.
8. Repeat bleed procedure at remaining three brake
Brake Bleed
calipers in the following sequence:
10. Fit wheel/s.
• rear left; front right; front left.
11. Lower the vehicle.
12. Operate brake pedal several times to seat brake shoes. Warning: Braking operation may be seriously impaired if
the incorrect bleed sequence is used.
Tip: Pedal travel may be longer than normal during first
9. Lower the vehicle.
brake applications.
10. Top-up fluid level in brake reservoir to 'MAX' mark.
11. Apply brakes and check for leakage.
12. Road test vehicle. Check brake pedal for firm travel
when brakes are applied.

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Brake Brake System
Electronic Vacuum Pump
Remove
1. Disconnect the battery negative.
2. Disconnect the harness connector of the electronic
vacuum pump.
3. Disconnect the electronic vacuum pump from the
vacuum brake hose.
4. Remove 2 bolts fixing the electronic vacuum pump to
the bracket.

5. Remove the electronic vacuum pump.

Refit
1. Fix the electronic vacuum pump to the bracket, tighten
2 bolts fixing the electronic vacuum pump to the
bracket to 7–10Nm.
2. Connect the vacuum hose assembly to the electronic
vacuum pump.

Caution: Keep the dust and foreign matter from vacuum

hose.If having trouble to fix vacuum hose ， please using
grease special for fixing vacuum hose to lubricate ， other
liquid or grease is prohibited.

3. Connect the harness connector of the electronic

vacuum pump.
4. Connect the battery negative.

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Brake System Brake

Special Tools
Tool Description Picture
Number

Brake disc
TCH00022
runout test kit

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Park Brake Brake System
Park Brake
Specifications
Torque
Description Value
Bolt - brake cable to body 7–10Nm
Bolt - brake cable to rear frame 19–25Nm

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Brake System Park Brake

Description and Operation

System Layout
Hand Brake Layout

1. Nut - Hand Brake Adjustment 3. Hand Brake Cable Tensioner/Compensation Rod

2. Hand Brake Control Assembly 4. Rear Brake Cable Assembly

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Park Brake Brake System
Description A warning switch on the lever operates a warning lamp in the
Parking Brake instrument pack.

The parking brake consists of a transmission tunnel mounted When applying the hand brake, the warning switch connects
lever assembly that features a standard ratchet locking system the instrument pack warning lamp with ground, if the ignition
with a push button release. switch is ON, the warning lamp illuminates.

An adjustable compensator rod connects the lever to twin The instrument pack performs a self-check on the bulb every
cables. ignition cycle.

Each cable is connected to the handbrake lever fitted to the

rearward brake shoe in each drum brake.

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Brake System Park Brake

Service Procedures Handbrake Cable – Equaliser

Handbrake Cable - Adjust Remove
Adjust Warning: Do not work on or under a vehicle supported
Warning: Do not work on or under a vehicle supported only by a jack.Always support the vehicle on safety stands.
only by a jack.Always support the vehicle on safety stands. 1. Release handbrake cable adjustment.
1. Raise rear of vehicle. Handbrake Cable - Adjust
2. Ensure rear brakes are correctly adjusted 2. Remove adjuster nut.
3. Remove consol cover to access handbrake cable 3. Raise vehicle on lift.
adjuster.
4. Remove exhaust heatshield.

Exhaust Heatshield
5. Release handbrake cables from equaliser assembly.
6. Release grommet.
7. Remove equaliser.
Refit
1. Position equaliser through floor.
2. Position floor grommet.
3. Fit cables to equaliser assembly.
4. Fit exhaust heatshield.
Exhaust Heatshield
4. Tighten adjuster nut until: 5. Lower the vehicle.

Notch 1 - rear brake drums turn without resistance, handbrake 6. Fit adjusting nut.
warning lamp in instrument pack on or off. 7. Adjust handbrake cable.

Notch 2 - rear brake drums turn with light resistance, Handbrake Cable - Adjust
handbrake warning lamp in instrument pack on.

Notch 3 and above - rear brake drums locked, handbrake

warning lamp in instrument pack on.

5. Refit console cover.

6. Lower vehicle.

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Park Brake Brake System
Handbrake Cable – Rear
Remove
Warning: Do not work on or under a vehicle supported
only by a jack.Always support the vehicle on safety stands.
1. Release handbrake cable adjustment.
Handbrake Cable - Adjust
2. Raise vehicle on lift.
3. Remove rear brake shoes.
4. Release hand brake cable from back-plate.
5. Remove handbrake cable from floor retaining clips.

9. Remove cable.
Refit
1. APosition cable, fit floor retaining clips 7–10Nm.
2. Secure rear subframe retaining clips 19–25Nm.
3. Fit cable to equaliser assembly.
4. Fit exhaust heatshield.

Exhaust Heatshield
5. Position cable in back-plate.
6. Fit brake shoes.
7. Lower the vehicle.
6. Remove handbrake cable from rear subframe retaining 8. Adjust handbrake cable.
clips.
Handbrake Cable - Adjust

7. Remove exhaust heatshield.

Exhaust Heatshield
8. Release handbrake cable from equaliser assembly.

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Brake System Park Brake

Handbrake Lever
Remove
1. Remove centre console.

Centre Console
2. Remove handbrake adjuster nut.
Handbrake Cable - Adjust
3. Release handbrake switch electrical connector
4. Remove handbrake lever to floor fixings.

5. Remove handbrake lever assembly.

Refit
1. Position handbrake lever to floor.
2. Fit fixings, tighten to 19–25Nm.
3. Fit handbrake adjuster nut.
4. Adjust handbrake cable.

Handbrake Cable - Adjust

5. Fit centre console.

Centre Console

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Brake Module Brake System
Brake Module
Specifications
Torque
Description Value
Screws - front speed wheel sensor 7–10Nm
Screws - rear speed wheel sensor 7–10Nm
Bolt - ABS to bracket 7–10Nm
Rear brake pipes to modulator 16–18Nm

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Brake System Brake Module

Description and Operation

System Layout
Brake System Control Component Layout

1. Brake Fluid Reservoir 5. Brake Modulator

2. Brake Fluid Level Sensor 6. Front Wheel Speed Sensor Assembly
3. Vacuum Booster 7. Rear Wheel Speed Sensor Assembly
4. Brake Master Cylinder

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Brake Module Brake System
System Control Diagram
Brake System Control Chart

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Brake System Brake Module

Description If the wheel locks in emergency, the inlet/outlet valves will be

Anti-lock Brake System (ABS) closed at the same time to keep the brake pressure in the
wheel cylinder so as to exert the best brake performance.
During braking, the function of the ABS prevents wheel lock,
and thus the vehicle can stay stable even in emergency. Electronic Brake Distribution (EBD)

Warning: ABS is an aid to retaining steering control and EBDThe function of the EBD is to optimize the distribution
stability while braking: of the hydraulic pressure between the front and rear axles to
keep the vehicle at a stable state in brake process according to
• ABS cannot defy the natural laws of physics acting
the vehicle load condition and road conditions.
on the vehicle
• ABS will not prevent accidents resulting from With the ABS ECU in the normal brake mode, the vehicle
excessive cornering speeds, following another vehicle deceleration of 0.3g and above (i.e., moderate to high
too closely, aquaplaning, etc. brake pedal load), the EBD function can be automatically
implemented in forward or reverse mode.
• The additional control provided by ABS must never
be exploited in a dangerous or reckless manner which EBDIts operation is similar to the ABS, but the EBD operates
could jeopardise the safety of the driver or other road at lower wheel slip limit, and the EBD is only applicable to the
users rear wheel brake.
• The fitting of ABS does not imply that the vehicle will During braking, if the ABS ECU detects that the rear axle
always stop in a shorter distance. wheel is slower than the front axle wheel, that is, the possibility
Tip: During normal braking the feel of the brake pedal on of wheel slip exists, the ABS ECU will send a signal to the
vehicles equipped with ABS will be the same as that on hydraulic pressure regulator to turn off the fluid inlet solenoid
non ABS vehicles. During anti-lock braking operation, the valve of the rear wheel brake.
driver will experience feedback in the form of a pulsating This prevents further increase of the hydraulic pressure of
brake pedal and solenoid/pump motor noise from the ABS the rear wheel brake but allows the hydraulic pressure of the
modulator. front wheel brake to increase, the whole brake force is thus
In conventional brakes, the ABS does not work. maximized.

Brake fluid directly flows into each wheel cylinder from the If the rear wheel speed returns to the calibration wheel slip
reservoir through hydraulic control unit (HCU) channel to limit range, the ABS ECU will send a signal to turn on the
apply brake to each wheel. fluid inlet valve gradually, which allows progressive increase of
the hydraulic pressure of the rear axle brake.
Once ABS ECU detects that a wheel locking occurs through
the wheel speed sensor, ECU will give an order to close the EBDIts operation can be felt through the following ways: the
inlet valve, and the brake fluid will no longer flow into the movement of the brake pedal is more violent by turning off the
wheel cylinder. fluid inlet solenoid valve and the brake pedal has a slight pulse
as a result of the fluid inlet solenoid valve's turning on.
Meanwhile, the outlet valve is opened to discharge the
hydraulic oil from the wheel cylinder to allow the wheel to When the brake pedal is released, the EBD will stop
rotate. immediately.

If it is detected that a wheel slips normally, the outlet valve will EBDThe wheel slip limit that enables the EBD varies with the
be closed due to low brake pressure and the brake fluid will vehicle speed.
flow into the wheel cylinder from the inlet valve to increase
the brake force.

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Brake Module Brake System
Service Procedures ABS Sensor - Rear
ABS Sensor - Front Remove
Remove Warning: Do not work on or under a vehicle supported
Warning: Do not work on or under a vehicle supported only by a jack.Always support the vehicle on safety stands.
only by a jack.Always support the vehicle on safety stands. 1. Raise vehicle on lift.
1. Raise vehicle on lift 2. Remove ABS sensor to back-plate fixing.
2. Remove wheel/s. 3. Withdraw sensor.
Wheels 4. Locate and disconnect ABS sensor block connector.
3. Remove ABS sensor fixing. 5. Release sensor wiring from retaining clips.
4. Withdraw sensor from hub assembly. Refit
5. Locate and disconnect ABS sensor block connector. 1. Insert ABS sensor into back-plate, secure fixing to
6. Release sensor wiring from retaining clips. 7–10Nm.

Refit 2. Secure ABS sensor harness in retaining clips.

1. Insert ABS sensor into hub assembly, secure fixing to 3. Connect ABS sensor block connector.
7–10Nm 4. Lower the vehicle.
2. Secure ABS sensor harness in retaining clips. 5. Clear any fault codes using diagnostic equipment.
3. Connect ABS sensor block connector
4. Fit wheel/s.

Wheel
5. Lower the vehicle.
6. Clear any fault codes using diagnostic equipment.

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Brake System Brake Module

Brake Modulator instructions.

Remove 10. Progress ‘Routine - Reset Adaptions - iTPMS Reset
1. Disconnect battery earth lead. - Next’，reset iTPMS according to the on-screen
2. Place suitable absorbent material under modulator to instructions.
absorb any fluid spillage. 11. Bleed brakes.
Caution: Brake fluid will damage paint finished surfaces. Brake Bleed
If spilled, immediately remove fluid and clean area with
water.

3. Disconnect electrical multiplug connector.

Caution: Before disconnecting or removing components,
ensure the immediate area around joint faces and
connections are clean. Plug open connections to prevent
contamination.

4. Disconnect 2 fluid brake pipes from master cylinder

to modulator.

5. Note fitted positions of 4 outlet pipes on modulator,

disconnect pipes.
6. Remove modulator/bracket assembly fixings.
7. Lift out modulator/bracket assembly.
8. Remove ABS modulator to lower bracket fixings.
Refit
1. Fit mounting bracket to modulator, tighten fixings to
7–10Nm.
2. Fit modulator/bracket assembly to body, ensure fixing
grommets are correctly engaged.
3. Clean brake pipe unions.
4. Connect inlet and outlet brake pipes to modulator,
ensure pipes are connected to their correct ports.
5. Tighten brake pipe unions to 16–18Nm.
6. Connect multiplug to modulator.
7. Connect battery earth lead.
8. Start the diagnostic tool, progress ‘Diagnostic -
Veh.Scan - Start Scan’ after identify vehicle ID.
9. Progress ‘Programming - Configuration - Read - Save’,
configure ABS module according to the on-screen

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Driveline/Axle Driveline/Axle
Driveline/Axle
Specifications
Torque
Description Value
Bolt - lower arm outer ball joint to swivel hub 50–65Nm
Nuts - steering rod outer ball joint 28–32Nm
Nuts - anti-roll bar to links 45–55Nm
Nut - front drive shaft 350 – 370 Nｍ

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Driveline/Axle Driveline/Axle

Description and Operation

System Layout
Right Drive Shaft Disassembled View

1. Constant Velocity Joint Assembly 7. Clip

2. Constant Velocity Joint Circlip 8. Internal Joint Gaiter
3. Clip 9. Clip
4. Constant Velocity Universal Joint Gaiter 10. Circlip
5. Clip 11. Tripod Joint
6. Power Vibration Damping Ring 12. Circlip

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Driveline/Axle Driveline/Axle
Left Drive Shaft Disassembled View

1. Constant Velocity Joint Assembly 7. Clip

2. Constant Velocity Joint Circlip 8. Internal Joint Gaiter
3. Clip 9. Clip
4. Constant Velocity Universal Joint Gaiter 10. Circlip
5. Clip 11. Tripod Joint
6. Power Vibration Damping Ring 12. Circlip

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Driveline/Axle Driveline/Axle

Description All joints are packed with grease and protected by gaiters.
Each drive shaft comprises of a solid shaft with inner and outer Both drive shafts are fitted with dynamic dampers.
constant velocity joints.
The drive shaft transmits engine torque, via the gearbox, to
The inner joint is of the tripode type with spherical bushing to the front wheels.
reduce sliding resistance.
The dynamic dampers reduce any vibration produced by the
The shaft and joint are one assembly. drive shaft's rotation.
The outer joint is a constant velocity ball and socket type which
is splined to the shaft and secured with a snap ring.

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Driveline/Axle Driveline/Axle
Diagnostic shake may also refer to the swing occurs in the front and the
Diagnosis rear of the vehicle.

Mechanical Check The start shake of the front-wheel drive vehicle may caused by
When rotating, a rattle sound can be heard. the followings:

When the worn or damaged constant velocity universal joint • Internal tee universal joint is worn or damaged.
of the front wheel drive shaft rotates, a rattle sound may be • Internal universal joint is severely worn or ceratoid.
heard. If there's a rattle sound, check the constant velocity
The universal joint shows severe ceratoid angle, which is
universal joint shield of the front wheel drive shaft for crack or
normally caused by the excessive height of the front cocked
damage.
head or the spring. When the power assembly suspension is
A "clunk" sound can be heard during accelerating
damaged or mismatched, following situations may occur:
and sliding.
• Angle of the universal joint is oversize.
If a "click" sound can be heard during rotation, check the
followings: • Start Shake

• Check the external universal joint for wear or damage. During rapid acceleration, high torque of the vehicle power
assembly causes increase of the front suspension. When the
• Check the seal for breakage or damage.
suspension raises, the angle of the internal tee universal joint
Shake or Vibration When Accelerating
will increase accordingly. Start shake may occur when following
Start Shake situations appear:
Start shake refers to the vibration felt on the steering wheel • Universal joint is worn.
and/or the front of the vehicle when the vehicle is shifted from
• Oversize angle exists before acceleration.
static starting to rapid accelerating. During acceleration, start

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Driveline/Axle Driveline/Axle

Service Procedures
RH Shaft & Both Joints
Remove
1. Raise vehicle on lift.
2. Remove wheel.

Wheel Remove
3. Prise locking device from nut. With an assistant pressing
brake pedal, remove and discard drive shaft nut.
4. Remove nut from track rod end, fit an M10 nut to ball
pin, flush with end of pin.
5. Break taper joint using toolT38008and release end
from track rod.
13. Remove and discard drive shaft circlip.
6. Remove nut from ball pin.
Refit
1. Fit new drive shaft circlip.
2. Clean ends of drive shaft and locations in hub and
differential.
3. Fit drive shaft to differential and push fully home.
4. Clean mating face of drive shaft support bracket and
cylinder block.
5. Pull hub outwards, engage drive shaft to hub and fit
hub to lower ball joint.
6. Fit nut and bolt securing hub to lower arm and tighten
to 50–65Nm.
7. Ensure lower ball joint is fully engaged in hub and bolt is
located in ball joint groove.
7. Remove nut securing link to anti roll bar and release
link. 8. Ensure tapers in track rod end and steering arm are
clean and rubber boot is not damaged.
8. Remove nut and bolt securing hub to lower arm.
9. Fit track rod end to steering arm and tighten nut to
9. UsingT32011 release lower arm ball joint.
28–32Nm.
10. Ensure anti-roll bar and link mating faces are clean.
11. Position link to anti roll bar, fit and tighten nut
to45–55Nm.
12. Fit new drive shaft nut and tighten nut to 350 – 370
Nｍ ｍ.
13. Stake the nut to drive shaft.
14. Fit wheel

Wheel Fit
15. Lower the vehicle.

10. Take care not to damage lower ball joint rubber gaiter.
11. Pull hub outward to release drive shaft from hub.
12. Release drive shaft from differential using TCH00001,
remove shaft.

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Driveline/Axle Driveline/Axle
LH Shaft & Both Joints
Remove
1. Raise vehicle on lift.
2. Remove wheel.
Wheel Remove
3. Prise locking device from nut. With an assistant pressing
brake pedal, remove and discard drive shaft nut.
4. Remove nut from track rod end, fit an M10 nut to ball
pin, flush with end of pin.
5. Break taper joint using toolT38008and release end
from track rod.
6. Remove nut from ball pin.
13. Remove and discard drive shaft circlip.
Refit
1. Fit new drive shaft circlip.
2. Clean ends of drive shaft and locations in hub and
differential.
3. Fit drive shaft to differential and push fully home.
4. Clean mating face of drive shaft support bracket and
cylinder block.
5. Pull hub outwards, engage drive shaft to hub and fit
hub to lower ball joint.
6. Fit nut and bolt securing hub to lower arm and tighten
to 50–65Nm.

7. Remove nut securing link to anti roll bar and release 7. Ensure lower ball joint is fully engaged in hub and bolt is
link. located in ball joint groove.

8. Remove nut and bolt securing hub to lower arm. 8. Ensure tapers in track rod end and steering arm are
clean and rubber boot is not damaged.
9. UsingT32011 release lower arm ball joint.
9. Fit track rod end to steering arm and tighten nut to
28–32Nm.
10. Ensure anti-roll bar and link mating faces are clean.
11. Position link to anti roll bar, fit and tighten nut
to45–55Nm.
12. Fit new drive shaft nut and tighten nut to 350 – 370
Nｍ ｍ.
13. Stake the nut to drive shaft.
14. Fit wheel

Wheel Fit
15. Lower the vehicle.

10. Take care not to damage lower ball joint rubber gaiter.
11. Pull hub outward to release drive shaft from hub.
12. Release drive shaft from differential using TCH00001,
remove shaft.

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Driveline/Axle Driveline/Axle

Outer CV Joint Gaiter Inner joint

Remove Remove
1. Remove driveshaft and both joints 1. Remove driveshaft and both joints

Right Drive Shaft Remove Right Drive Shaft Remove

Left Drive Shaft Remove Left Drive Shaft Remove

2. Place driveshaft in suitable vice. 2. Place driveshaft in suitable vice.

3. Release both gaiter clips and discard. 3. Release both gaiter clips and discard.

4. Slide gaiter along drive shaft to gain access to outer

joint. 4. Remove outer section of tripod joint.

5. Using circlip pliers, release circlip, remove joint from 5. Using circlip pliers, release circlip, remove tripod joint
drive shaft and discard. from drive shaft, discard circlip.

6. Remove circlip from drive shaft and discard.

Refit
1. Clean drive shaft and gaiter..
2. Fit new circlip to drive shaft.
3. Position outer joint to drive shaft, using a tool press
circlip into its groove, push joint fully onto drive shaft.
4. Apply grease to the joint.
5. Position gaiter to joint and secure with new clips.

6. Remove tripod section from driveshaft.

7. Slide of gaiter.
Refit
1. Clean drive shaft and gaiter.
2. Position gaiter on shaft.
3. Refit inner tripod joint.
4. Fit new circlip to drive shaft.

6. Refit the drive shaft assembly. 5. Apply grease to the joint.

6. Fit outer section of tripod joint.
Right Drive Shaft Refit
7. Refit the drive shaft assembly.
Left Drive Shaft Refit
Right Drive Shaft Refit

Left Drive Shaft Refit

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Driveline/Axle Driveline/Axle
Inner Joint Gaiter
Remove
1. Remove inner CV joint

Inner Joint Remove

2. Remove inner joint gaiter from drive shaft.

Refit
1. Clean drive shaft.
2. Fit new gaiter to drive shaft.
3. Fit inner joint.

Inner Joint Refit

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Driveline/Axle Driveline/Axle

Special Tools
Tool Description Picture
Number

Remover ball
T38008
joint

Lever front
T32011 lower arm ball
joint

Remover drive
TCH00001
shaft

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Interior Trim and Paneling Interior Fitting
Interior Trim and Paneling
Specifications
Torque
Description Value
Bolt-‘BC’upper post trim to Body 1.5–2.2 Nm
Bolt-front seat belt to body 35–45Nm
Bolt - rear seat belt to lower ‘D’ post 30–35Nm
Bolt-‘D’upper post trim to Body 1.5–2.2 Nm

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Interior Fitting Interior Trim and Paneling

Service Procedures
Front Door Interior Trim Panel and Waterproof
Membrane
Remove
1. Disconnect the battery negative.
2. Pry off the screw hole cap of the power window switch,
and remove 1 screw fixing the power window switch
to the door.
3. Pry off the screw hole cap of the inner handle, and
remove 1 screw fixing the inner door handle to the
door.

6. Pry off 8 clips fixing the door trim panel to the door,
remove and discard the clips.

4. Pry off the screw hole cap, and remove the front
retaining screw of the front door interior trim panel.

7. Disconnect the stay wire of the inner handle cable

assembly and the harness connector.
8. Remove the front door interior trim panel.
9. Pry off to remove the power window switch if
necessary.
10. Remove 2 screws securing the door trim panel
mounting bracket, and remove the door trim panel
mounting bracket. Firstly remove the electrical
connectors from the corresponding positions of the
waterproof membrane.
11. Remove the front door waterproof membrane from
5. Pry off the screw hole cap, and remove the rear the door sheet metal.
retaining screw of the front door interior trim panel. Refit
1. Have the electrical connectors pass through the
corresponding positions of the waterproof membrane,
align the locating hole of the waterproof membrane
with the door trim panel mounting bracket, and the
upper edge is parallel to the upper edge of the door
sheet metal, then fit the door waterproof membrane.
2. Fit and tighten 2 screws securing the door trim panel
mounting bracket.
3. To remove the power window switch, the power
window switch must be located on the door interior

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Interior Trim and Paneling Interior Fitting
trim panel. Front Door Inner Handle
4. Fit the new clip to the door trim panel, fit the stay wire Remove
of the inner handle cable assembly, connect the harness 1. Remove the front door interior trim panel.
connector, align the interior trim panel clip of the front
Front Door Interior Trim Panel Remove
door with the corresponding sheet metal mounting
hole, and fit the front door interior trim panel to the 2. Remove 3 screws fixing the front door inner handle to
door. the back of the door interior trim panel.

5. Fit and tighten 1 screw fixing the power window switch

to the door, and fit the screw hole cap of the power
window switch.
6. Fix the inner handle to the door, fit and tighten 1 screw,
and fit the screw hole cap.
7. Fit and tighten 2 screws (front/rear) fixing the interior
trim panel to the door, and fit the screw hole cap.
8. Connect the battery negative.

3. Pry off the clip and remove the front door inner handle
from the door interior trim panel.
Refit
1. Locate the inner door handle to the front door interior
trim panel, press the clip in place and secure with 3
screws.
2. Fit the front door interior trim panel.

Front Door Interior Trim Panel Refit

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Interior Fitting Interior Trim and Paneling

Rear Door Interior Trim Panel and Waterproof

Membrane
Remove
1. Disconnect the battery negative.
2. Pry off the screw hole cap of the power window switch,
and remove 1 screw fixing the power window switch
to the door.
3. Pry off the screw hole cap of the inner handle, and
remove 1 screw fixing the inner door handle to the
door.

6. Pry off 8 clips fixing the door trim panel to the door,
remove and discard the clips.

4. Pry off the screw hole cap, and remove the front
retaining screw of the rear door interior trim panel.

7. Disconnect the stay wire of the inner handle cable

assembly and the harness connector.
8. Remove the rear door interior trim panel.
9. Pry off to remove the power window switch if
necessary.
10. Remove 2 screws securing the door trim panel
mounting bracket, and remove the door trim panel
mounting bracket. Firstly remove the electrical
connectors from the corresponding positions of the
waterproof membrane.
5. Pry off the screw hole cap, and remove the rear 11. Remove the rear door waterproof membrane from the
retaining screw of the rear door interior trim panel. door sheet metal.
Refit
1. Have the electrical connectors pass through the
corresponding positions of the waterproof membrane,
align the locating hole of the waterproof membrane
with the door trim panel mounting bracket, and the
upper edge is parallel to the upper edge of the door
sheet metal, then fit the door waterproof membrane.
2. Fit and tighten 2 screws securing the door trim panel
mounting bracket.
3. To remove the power window switch, the power
window switch must be located on the door interior

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Interior Trim and Paneling Interior Fitting
trim panel. Rear Door Inner Handle
4. Fit the new clip to the door trim panel, fit the stay wire Remove
of the inner handle cable assembly, connect the harness 1. Remove the rear door interior trim panel.
connector, align the interior trim panel clip with the
Rear Door Interior Trim Panel Remove
corresponding sheet metal mounting hole, and fit the
rear door interior trim panel. 2. Remove 3 screws fixing the rear door inner handle to
the back of the door trim panel.
5. Fit and tighten 1 screw fixing the power window switch
to the door, and fit the screw hole cap of the power
window switch.
6. Fix the inner handle to the door, fit and tighten 1 screw,
and fit the screw hole cap.
7. Fit and tighten 2 screws (front/rear) fixing the interior
trim panel to the door. Fit the screw cap.
8. Connect the battery negative.

3. Pry off the clip, and remove the rear door inner handle
from the door interior trim panel.
Refit
1. Locate the inner door handle to the rear door interior
trim panel, press the clip in place and secure with 3
screws.
2. Fit the rear door interior trim panel.

Rear Door Interior Trim Panel Refit

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Interior Fitting Interior Trim and Paneling

A Pillar Upper Trim Panel A Pillar Lower Trim Panel

Remove Remove
1. Pry off the front door body side weatherstrip outside 1. Pry off the front door body side weatherstrip outside
the A pillar upper trim panel assembly. the A pillar lower trim panel assembly.
2. Pry off the A pillar upper trim panel assembly clip. 2. Remove and discard the release handle of the bonnet.
3. Disconnect the connector of the tweeter and the 3. Pry off the clips of the A pillar lower trim panel
retaining clips of the airbag. assembly, and remove the A pillar lower trim panel
assembly.

4. Remove the A pillar upper trim panel assembly.

Refit
Warning: It is imperative that before any work
is undertaken on the SRS system the appropriate 1. Locate the A pillar lower trim panel assembly to the
information is read thoroughly. vehicle body and press the clip in place.
Refit 2. Fit the new release handle of the bonnet, and ensure
the handle is pressed till the end.
1. Fit the special clips of the side curtain airbag, and
connect the connector of the tweeter. 3. Fit the front door body side weatherstrip of the A pillar
lower trim panel assembly.
Warning: The clip for side air curtain must be changed
when A pillar need refit, otherwise it may cause the side
curtain invalidate.
2. Locate the A pillar upper trim panel assembly to the
body, and press the clip in place.
3. Fit the front door body side weatherstrip of the A pillar
upper trim panel assembly.

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Interior Trim and Paneling Interior Fitting
B/C Pillar Upper Trim Panel B/C Pillar Lower Trim Panel
Remove Remove
1. Pry off the door weatherstrips on both sides of the B 1. Pry off the door weatherstrips on both sides of the B/C
pillar upper trim panel assembly. pillar lower trim panel assembly.
2. Pry off the bolt cap fixed on the B pillar upper trim 2. Pry off the front part of the doorsill trim panel and the
panel and remove 1 screw. rear part of the A pillar lower trim panel.
3. Pry off the clips of the B/C pillar lower trim panel
assembly, and remove the B/C pillar lower trim panel
assembly.

3. Remove 1 bolt fixing the driver seat belt to the

underbody.
4. Pry off the clips of the B pillar upper trim panel, pull
the seat belt out of the hole of the B pillar upper trim Refit
panel, and remove the B pillar upper trim panel. 1. Locate the B/C pillar lower trim panel assembly to the
Refit B/C pillar and press the clip in place.
1. Pass the seat belt through the hole of the B pillar upper 2. Restore the doorsill trim panel and the A pillar lower
trim panel assembly. trim panel.
2. Locate the B pillar upper trim panel assembly to the B 3. Fit the door weatherstrip at the B/C pillar lower trim
pillar and press the clip in place. panel assembly.
3. Fit 1 bolt fixing the B pillar upper trim panel to the
body, tighten to 1.5–2.2 Nm, and check the torque.
4. Fit the screw cap of the B pillar upper trim panel.
5. Fit 1 bolt fixing the driver seat belt to the underbody,
tighten to 35–45Nm, and check the torque.
6. Fit the door weatherstrips on both sides of the B pillar
upper trim panel assembly.

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Interior Fitting Interior Trim and Paneling

D Pillar Upper Trim Panel D Pillar Lower Trim Panel

Remove Remove
1. Pry off the tail gate and the body weatherstrip outside 1. Pry off the body weatherstrip outside the D pillar.
the D pillar. 2. Remove the D pillar upper trim panel.
2. Remove the rear coat rack assembly.
D Pillar Upper Trim Panel Remove
Rear Coat Rack Assembly Remove 3. Pry off the D lower trim panel.
3. Loosen 2 bolts fixing the D pillar upper trim panel to
the body.

Refit
1. Locate the D pillar lower trim panel on the body and
4. Pry off the clip, and remove the D pillar upper trim press the clip in place.
panel.
2. Fit the D pillar upper trim panel.
5. Fold down the rear seat back, remove 1 bolt fixing the
D Pillar Upper Trim Panel Refit
rear seat belt to the body, and draw the seat belt from
the hole of the D pillar upper trim panel assembly. 3. Fit the body weatherstrip outside the D pillar.
Refit
1. Pass the seat belt through the hole of the D pillar upper
trim panel assembly.
2. Fix the lower rear seat belt to the body, fit 1 bolt,
tighten to 30–35Nm, and check the torque.
3. Fix the D pillar upper trim panel assembly to the body,
and press the clip in place.
4. Fit 2 bolts fixing the D pillar upper trim panel to the
body, tighten to 1.5–2.2 Nm, and check the torque.
5. Fit the rear coat rack assembly.

Rear Coat Rack Assembly Refit

6. Fit the tail gate and the body weatherstrip outside the
D pillar.

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Interior Trim and Paneling Interior Fitting
Rear Coat Rack Carpet
Remove Remove
1. Open the tail gate. 1. Open the tail gate.
2. Remove the rope hanging the rear coat rack. 2. Disconnect the battery negative.
3. Remove the rear coat rack assembly. 3. Remove the rear seat cushion assembly.
Refit Rear Seat Cushion Assembly Remove
1. Fit the rear coat rack assembly. 4. Remove the lower trim panel of the left/right A pillars.
2. Fit the rope hanging the rear coat rack. A Pillar Lower Trim Panel Remove
3. Close the tail gate. 5. Remove 2 bolts fixing the left/right front seat belts to
the body.
6. Remove the left/right B/C pillar lower trim panels.
B/C Pillar Lower Trim Panel Remove
7. Remove the doorsill trim panel assembly.
8. Remove the front seat assembly.
Front Seat Assembly Remove
9. Remove 4 clips fixing the carpet to both left and right
sides of the base plate.
10. Remove the centre console heater closing plate
assembly.
Centre Console Heater Closing Plate Assembly
Remove
11. Remove the centre console assembly.
Centre Console Assembly Remove
12. Remove the carpet.

Refit
1. Fit the carpet.
2. Fit 4 clips fixing the carpet to both left and right sides
of the floor.
3. Fit the centre console heater closing plate assembly.
Centre Console Heater Closing Plate Assembly
Refit
4. Fit the centre console assembly.
Centre Console Assembly Refit
5. Press the clip, and fit the door sill trim panel assembly.

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Interior Fitting Interior Trim and Paneling

6. Fit the B/C pillar lower trim panel assembly. Luggage Compartment Side Trim Panel
B/C Pillar Lower Trim Panel Refit
Remove
1. Remove the coat rack.
7. Fit 2 bolts fixing the left/right front seat belts to the
underbody, tighten to 35–45Nm, and check the 2. Remove the D pillar upper trim panel.
torque. D Pillar Upper Trim Panel Remove
8. Fit the A pillar lower trim panel assembly. 3. Remove the carpet of the luggage compartment.
A Pillar Lower Trim Panel Refit 4. Remove the luggage compartment sill trim panel.
9. Fit the front seats. Luggage Compartment Sill Trim Panel Remove
Front Seat Assembly Refit 5. Remove the weatherstrip outside the side trim panel of
10. Fit the rear seat cushion assembly. the luggage compartment.

Rear Seat Cushion Assembly Refit 6. Remove the retaining screw of the trim panel and
remove the luggage compartment side trim panel.
11. Connect the battery negative.
12. Close the tail gate.

Refit
1. Locate the side trim panel of the luggage compartment
to the body, and fit the retaining screw to fix it.
2. Fit the luggage compartment sill trim panel.

Luggage Compartment Sill Trim Panel Refit

3. Fit the weatherstrip outside the side trim panel of the
luggage compartment.
4. Fit the carpet of the luggage compartment.
5. Fit the D pillar upper trim panel.

D Pillar Upper Trim Panel Refit

6. Fit the coat rack.

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Luggage Compartment Sill Trim Panel Tail Gate Interior Trim Panel
Remove Remove
1. Pry off the body weatherstrip outside the luggage 1. Open the tail gate.
compartment sill trim panel. 2. Pry off the screw covers, remove 2 screws fixing the
2. Remove the carpet of the luggage compartment. tail gate interior trim panel to the tail gate, pry off the
3. Remove 4 clips and the upper clip fixing the luggage clip, and remove the tail gate interior trim panel.
compartment sill trim panel to the vehicle body.

Refit
4. Remove the luggage compartment sill trim panel. 1. Fix the tail gate interior trim panel to the tail gate,
Refit ensure the clip is fitted in place, fit and tighten 2 screws,
and fit the screw covers.
1. Fit the luggage compartment sill trim panel, and ensure
the clip is fitted in place. 2. Close the tail gate.

2. Fit the carpet of the luggage compartment.

3. Fit the body weatherstrip outside the luggage
compartment sill trim panel.

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Roof Interior Trim

Remove
1. Open the tail gate.
2. Disconnect the battery negative.
3. Remove the front reading lamp assembly.

Front Reading Lamp Assembly Remove

4. Remove the microphone.

Microphone Remove
5. Remove the sun visor and bracket assembly.

Sun Visor and Bracket Assembly Remove

6. Remove the door weatherstrip at the column, etc.
Refit
7. Remove the inner roof handle.
1. Move the roof interior trim panel into the vehicle to
Inner Roof Handle Remove seat it with the roof panel, while press two rear clips
8. Remove the driver side glasses box. into the roof beam hole.
2. Fit the inner roof handle.
Driver Side Glasses Box Remove
9. Remove the A pillar upper trim panel. Inner Roof Handle Refit
3. Fit the driver side glasses box.
A Pillar Upper Trim Panel Remove
10. Remove the B/C pillar upper trim panel. Driver Side Glasses Box Refit
4. Fit the sun visor and bracket assembly.
B/C Pillar Upper Trim Panel Remove
11. Remove the D pillar upper trim panel. Sun Visor and Bracket Assembly Refit
5. Fit the front reading lamp assembly.
D Pillar Upper Trim Panel Remove
12. Release the clip securing the roof interior trim panel. Front Reading Lamp Assembly Refit

13. Fold down the rear seat, and tilt two front seats. 6. Fit the microphone.

14. Remove the roof interior trim panel from the luggage Microphone Refit
compartment lid carefully. 7. Fit the weatherstrip at the column.
8. Fit the A pillar upper trim panel.

A Pillar Upper Trim Panel Refit

9. Fit the B/C pillar upper trim panel.

B/C Pillar Upper Trim Panel Refit

10. Fit the D pillar upper trim panel.

D Pillar Upper Trim Panel Refit

11. Connect the battery negative.
12. Close the tail gate.

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Sun Visor and Bracket Insulation Pad of Engine Compartment Heat
Remove Shield
1. Open the sun visor downward.
Remove

2. Pry off the screw trim cover of the sun visor, and 1. Remove the engine transmission assembly.
remove 1 screw fixing the sun visor to the roof interior Automatic Transmission Assembly Remove
trim panel. Manual Transmission Assembly Remove
3. Remove the sun visor from the sun visor bracket. 2. Remove the ABS modulator.
ABS Modulator Remove
ABSABS
3. Remove the brake master cylinder and reservoir
assembly.
Brake Master Cylinder and Reservoir Assembly
Remove
4. Remove the vacuum booster assembly.
Vacuum Booster Assembly Remove
5. Disconnect the water inlet/outlet pipes of the A/C
4. Pry off the screw trim cover of the sun visor bracket, heater.
and remove 1 screw fixing the sun visor bracket to the
6. Disconnect the A/C water inlet/outlet pipes from the
roof interior trim panel.
expansion valve.
5. Remove the sun visor bracket.
7. Remove 5 plastic nuts fixing the insulation pad of the
Refit engine compartment heat shield to the front body.
1. Fix the sun visor bracket to the roof interior trim panel,
fit and tighten 1 retaining screw, and fit the screw trim
cover.
2. Fix one end of the sun visor to the sun visor bracket
and the other end to the roof interior trim panel, fit
and tighten 1 retaining screw.
3. Fit the screw trim cover of the sun visor.
4. Reset the sun visor.

8. Remove the insulation pad of the engine compartment

heat shield.
Refit
1. Fit the insulation pad of the engine compartment heat
shield to the front body with 5 plastic nuts.
2. Connect the A/C water inlet/outlet pipes to the
expansion valve.
3. Fit the water inlet/outlet pipes of the A/C heater.
4. Fit the vacuum booster assembly.
Vacuum Booster Assembly Refit
5. Fit the brake master cylinder and reservoir assembly.
Brake Master Cylinder and Reservoir Assembly
Refit
6. Fit the ABS modulator.
ABS Modulator Refit
ABSABS

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7. Fit the engine transmission assembly. Front Insulation Pad

Automatic Transmission Assembly Refit
Remove
Manual Transmission Assembly Refit 1. Remove the instrument panel assembly.

Instrument Panel Assembly Remove

2. Remove the pedal.
Brake Pedal Remove
3. Remove the A/C box assembly.

A/C Box Assembly Remove

4. Remove the front carpet.

Carpet Remove
5. Remove 5 clips fixing the front insulation pad to the
front body.
6. Remove the front insulation pad.

Refit
1. Lay the front insulation pad to the corresponding
position of the body, and put the locating hole over
the locating pin.
2. Fix the front insulation pad to the body with 7 clips.
3. Fit the main carpet.

Carpet Refit
4. Fit the A/C box assembly.
A/C Box Assembly Refit
5. Fit the brake pedal.

Pedal Assembly Refit

6. Fit the instrument panel.

Instrument Panel Refit

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Driver Side Glasses Box Inner Roof Handle
Remove Remove
1. Open the glasses box, and pry off the screw trim cover 1. Open the trim cover to expose the screw of the inner
in it to expose the screw securing the glasses box. roof handle.
2. Loosen 2 screws fixing the glasses box to the roof. 2. Loosen 2 screws fixing the inner roof handle to the
roof.

3. Remove the driver side glasses box.

3. Remove the inner roof handle.
Refit
Refit
1. Locate the driver side glasses box to the roof interior,
fit and tighten 2 screws. 1. Locate the inner roof handle to the roof, fit and tighten
2 screws.
2. Cover the inside screw trim cover and close the glasses
box. 2. Open 2 screw trim covers.

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Interior Fitting Fascia and Console

Fascia and Console

Specifications
Torque
Description Value
Bolt-front passenger airbag to facia bracket 6–8Nm
Bolt-Fasic Main to Fasic Bracket 19–25 Nm
Bolt-Fasic Bracket to Body 19–25 Nm
Bolt-Fuel filler flab release handle to Fasic Bracket 7-10Nm
Bolts- Steering column to facia framework 19-25Nm
Bolt-Floor console switch to floor console upper applique 1.0–1.4Nm
Screw-Block a Display Panel to Console 1.0-1.4Nm
Bolt-Console Main to Console front bracket 1.6–2.0Nm

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Fascia and Console Interior Fitting
Service Procedures Driver Side Lower Trim Panel Assembly
Instrument Panel End Cover Plate Assembly Remove
Remove 1. Remove 2 screws fixing the driver side lower trim panel
1. Pry off the clip fixing the left end cover of the to the instrument panel, pry off the clip of the driver
instrument panel to the instrument panel assembly. side lower trim panel, and disconnect the harness
connector.

2. Pull the left end cover of the instrument panel out of

the door weatherstrip covering the edge of the left 2. Remove 3 screws fixing the card slot to the driver side
end cover of the instrument panel. Take care not to lower trim panel from the back. Remove the card slot
scratch it. and the release handle of the oil filler cap together.

3. Remove the right end cover assembly of the instrument 3. Remove the driver side lower trim panel.
panel in the same way. 4. Remove the headlamp leveling switch as necessary.
Refit Refit
1. Extend the edge of the left end cover of the instrument 1. If the headlamp leveling switch needs to be replaced,
panel to the bottom of the door weatherstrip, fit the insert the switch into the driver side lower trim panel
left end cover of the instrument panel and press the first.
door weatherstrip tightly. 2. Locate the card slot and the release handle of the oil
2. Fit the right end cover assembly of the instrument panel filler cap to the driver side lower trim panel, fit and
in the same way. tighten 3 screws.
3. Connect the harness connector of the headlamp
leveling switch, fix the driver side lower trim panel to
the instrument panel, press the clip in place, fit and
tighten 2 retaining screws.

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Glove Box Assembly Instrument Panel Side Air Outlet Assembly

Remove Remove
1. Open the glove box door to a certain angle. 1. Pry off the clip of the left side air outlet and remove
2. Press the inner wall of the glove box with both hands the left side air outlet.
to make the stopper be out of the instrument panel
body, then release the upper glove box assembly.

2. Pry off the clip along the edge of the instrument panel
upper molding and remove the instrument panel upper
molding.
3. Press and hold the glove box assembly to remove it
from the instrument panel body.
4. Remove the glove box.
Refit
1. Align the glove box to a position of the lower panel
where the glove box could be opened completely.
2. Align two semicircular bushings on the lower part of the
glove box assembly to the instrument panel frame shaft.
3. Gently push the glove box stopper into the instrument
panel and ensure it is fitted in place.

3. Remove 1 screw fixing the right side air outlet to the

instrument panel, pry off the clip, and remove the right
side air outlet.

Refit
1. Locate the left side air outlet to the instrument panel,
and press the clip in place.

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2. Locate the right side air outlet to the instrument panel, Central Instrument Panel Air Outlet Assembly
press the clip in place, fit and tighten 1 retaining screw. Remove
3. Locate the instrument panel upper molding to the 1. Pry off the clip along the edge of the instrument panel
instrument panel, and press the clip in place. upper molding and remove the instrument panel upper
molding.

2. Remove 4 screws fixing the central air outlet assembly

to the instrument panel upper molding from the back,
pry off the clip, and remove the central air outlet
assembly of the instrument panel.

Refit
1. Locate the central air outlet to the central control
panel of the instrument panel, and press the clip. Fit 4
screws and tighten them up.
2. Fix the instrument panel upper molding to the
instrument panel assembly, press the clip, and ensure it
is fitted in place.

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Central Control Panel and Entertainment Switch

of Instrument Panel
Remove
1. Disconnect the battery negative.
2. Pry off the clip fixing the central control panel to the
instrument panel, and remove the central control panel.
(Here's a storage box in vehicles with low configuration,
but the remove method is the same.)

3. Connect the harness connector of the entertainment

control switch.
4. Fit the central control panel of the instrument panel
and press the clip in place. (Here's a storage box in
vehicles with low configuration, but the refit method
is the same.)
5. Connect the battery negative.

3. For vehicles with an independent knob cap, first remove

the knob cap (1) from the front of the entertainment
panel switch separately.
4. Remove 2 screws (3) fixing the entertainment control
switch to the central control panel.
5. Release the clip to remove the entertainment control
switch (2).

Refit
1. Fix the entertainment control switch to the central
control panel of the instrument panel from the back, fit
and tighten 2 screws.
2. For vehicles with knob caps, align any one clip of the
knob caps with any one mounting slope, then fit it to
the knob cap from the front of the central control panel
assembly of the instrument panel until a sound of "click"
is heard, which indicates the knob cap is correctly fitted.

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Instrument Panel IPK Frame Assembly Instrument Panel Assembly
Remove Remove
1. Adjust the steering wheel to the bottom to leave 1. Disconnect the battery negative.
enough space. 2. Pry off the clip fixing the left end cover of the
2. With a screwdriver, gently disconnect the upper trim instrument panel to the instrument panel assembly.
cover from the lower trim cover.
3. Pry off the clip on the IPK frame of the instrument
panel, and remove the instrument panel IPK frame.

3. Pull the left end cover of the instrument panel out of

the door weatherstrip covering the edge of the left
end cover of the instrument panel. Take care not to
Refit scratch it.
1. Fix the IPK frame of the instrument panel to the 4. Remove the right end cover assembly of the instrument
instrument panel IPK, press the clip and fit the IPK panel in the same way.
frame of the instrument panel. 5. Remove 2 screws fixing the driver side lower trim panel
2. Place the steering column upper trim cover on the to the instrument panel, pry off the clip of the driver
steering column, and fix it to the lower trim cover with side lower trim panel, and disconnect the harness
clips. connector.
3. Adjust the steering wheel to the initial position.

6. Remove 3 screws fixing the card slot to the driver side

lower trim panel from the back. Remove the card slot
and the release handle of the oil filler cap together.
7. Remove the driver side lower trim panel.
8. Pry off the clip along the edge of the instrument panel
upper molding and remove the instrument panel upper
molding.

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9. Pry off the clip fixing the central control panel to the 12. Remove the left/right A pillar upper trim panel.
instrument panel, and remove the central control panel. A Pillar Upper Trim Panel Remove
(Here's a storage box in vehicles with low configuration,
13. Remove the display/player.
but the remove method is the same.)
Display Remove
Player Remove
14. Remove the centre console.
Centre Console Remove
15. Remove the A/C controller.
A/C Controller Assembly - ETC Remove
A/C Panel - MTC Remove
16. Open the glove box door to a certain angle.
17. Press the inner wall of the glove box with both hands
to make the stopper be out of the instrument panel,
then release the upper glove box assembly.

10. Pry off the driver side air outlet.

18. Press and hold the glove box assembly to remove it

from the instrument panel.
11. Remove 1 screw, pry off the clip and remove the right 19. Remove the glove box.
air outlet assembly. 20. Remove the steering column trim cover.
Steering Column Trim Cover Remove
21. Remove the steering wheel.
Steering Wheel Remove
22. Remove the instrument pack.
Instrument Pack Remove

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23. Remove 12 bolts fixing the instrument panel assembly pipe to the instrument panel assembly and remove the
to the instrument panel beam assembly and pry off the instrument panel air outlet pipe.
clip. 28. When replacing the instrument panel assembly, take
away the airbag module of the instrument panel.
Instrument Panel Airbag Assembly Remove
Refit
1. Fit the instrument panel airbag to the instrument panel.
Instrument Panel Airbag Assembly Refit
2. Fit and tighten the screw fixing the instrument panel air
outlet pipe to the instrument panel assembly.
3. With assistance, fit the instrument panel assembly into
the vehicle.
4. Connect the connector of the solar/temperature
sensor and secure the harness clip.
5. Fix the passenger airbag module bracket to the
24. Pry off the plug cap near the solar/temperature sensor,
instrument panel frame, fit 2 bolts, tighten to 6–8Nm,
disconnect the connector, move the instrument panel
and check the torque.
assembly, and remove the harness clip of the instrument
panel. 6. Locate the instrument panel assembly to the instrument
panel beam, fit 12 bolts fixing the instrument panel to
the instrument panel beam, tighten to 19–25 Nm, and
check the torque.
7. Align the glove box to a position of the lower panel
where the glove box could be opened completely.
8. Align two semicircular bushings on the lower part of the
glove box assembly to the instrument panel frame shaft.
9. Fit the glove box assembly to the instrument panel with
slight force.
10. Fit the instrument pack.
Instrument Pack Refit
11. Fit the steering column trim cover.
25. Remove 2 bolts of the passenger airbag bracket and Steering Column Trim Cover Refit
disconnect the harness connector of the passenger 12. Fit the steering wheel assembly.
airbag. Steering Wheel Assembly Refit
13. Fit the A/C controller.
A/C Controller Assembly - ETC Refit
A/C Panel - MTC Refit
14. Fit the centre console.
Centre Console Refit
15. Fit the player/display.
Player Assembly Refit
Display Refit
16. Fix the left air outlet to the instrument panel assembly
and press the retaining clip.
17. Locate the right air outlet to the instrument panel and
26. With assistance, remove the instrument panel assembly ensure the clip is fitted in place; fit 1 screw and tighten
from the vehicle. it up.
27. Remove the screw fixing the instrument panel air outlet 18. Fix the instrument panel upper molding to the

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instrument panel assembly, press the clip and ensure it Instrument Panel Beam Assembly
is fitted in place. Remove
19. Fix the central control panel assembly of the instrument 1. Remove the instrument panel assembly.
panel to the instrument panel assembly, press the clip
Instrument Panel Assembly Remove
and ensure it is fitted in place. (Here's a storage box in
2. Remove 4 bolts fixing the steering column to the
vehicles with low configuration, but the refit method
instrument panel beam assembly.
is the same.)
3. Remove 2 bolts fixing the communication module to the
20. Fit the left/right A pillar upper trim panel.
instrument panel beam and remove the communication
A Pillar Upper Trim Panel Refit module.
21. Connect the connector of the airbag module.
22. Extend the edge of the left end cover of the instrument
panel to the bottom of the door weatherstrip, fit the
left end cover of the instrument panel and press the
door weatherstrip tightly.
23. Fit the right end cover assembly of the instrument panel
in the same way.
24. Connect the battery negative.

4. Disconnect the harness clip fixing the electrical harness

assembly of the instrument panel to the instrument
panel beam, and remove the harness.
5. Remove the A/C air inlet grille.
A/C Air Inlet Grille Assembly Remove
6. Remove the windshield wiper linkage mechanism
assembly.
Windshield Wiper Linkage Mechanism Assembly -
With Motor Remove
7. Remove 1 bolt (1) fixing the instrument panel beam to
the front body.
8. Remove 8 bolts fixing the instrument panel frame to
the body.

9. Remove the instrument panel beam assembly from the

vehicle.

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Fascia and Console Interior Fitting
Refit Centre Console Upper Trim Panel Assembly and
1. Fit the instrument panel beam assembly into the vehicle.
Switch Assembly
Remove
2. Locate the instrument panel beam assembly.
1. Disconnect the battery negative.
3. Fit 8 bolts fixing the instrument panel frame to the
body, tighten to 19–25 Nm, and check the torque. 2. Pry off the clips fixing the centre console upper trim
panel to the instrument panel and the center console.
4. Fit the harness clip fixing the electrical harness assembly
of the instrument panel to the instrument panel beam,
and connect the harness.
5. Fit 1 bolt fixing the instrument panel beam to the front
body, tighten to 19–25 Nm, and check the torque.
6. Fit the windshield wiper linkage mechanism assembly.

Windshield Wiper Linkage Mechanism Assembly

- With Motor Refit
7. Fit the A/C air inlet grille.

A/C Air Inlet Grille Assembly Refit

8. Fix the communication module to the instrument panel
beam, fit 2 bolts,, tighten to 7-10Nm, and check the
torque. 3. Disconnect the harness connector, disconnect the shift
9. Fix the upper steering column assembly to the lever sleeve from the clip of the centre console upper
instrument panel beam, fit 4 bolts, tighten to trim panel, remove the centre console upper trim
19-25Nm, and check the torque. panel, remove 4 screws from the back fixing the gear
panel to the upper trim panel assembly, and remove
10. Fit the instrument panel assembly.
the gear panel.
Instrument Panel Assembly Refit 4. Remove 4 screws from the back fixing the A/C control
switch frame to the upper trim panel assembly, and
remove the A/C control switch frame.
5. Remove the 12V power socket from the centre console
upper trim panel.
6. Remove 2 screws fixing the centre console switch to
the centre console upper trim panel, release the clip,
and remove the centre console switch.
Refit
1. Fit the centre console switch from the back to the
centre console upper trim panel assembly, fit 2 screws,
tighten to 1.0–1.4Nm, and check the torque.
2. Fix the 12V power socket to the centre console upper
trim panel.
3. Fit 4 screws fixing the gear panel to the upper trim
panel assembly, tighten to 1.0-1.4Nm, and check the
torque.
4. Fit and tighten 4 screws fixing the A/C control switch
frame to the upper trim panel assembly.
5. Connect the harness connector.
6. Connect the shift lever sleeve with the centre console
upper trim panel with clips, locate the centre console
upper trim panel assembly to the centre console, and
press the clips.
7. Connect the battery negative.

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Centre Console Assembly Centre Console Heater Closing Plate Assembly

Remove Remove
1. Disconnect the battery negative. 1. Pry off the clip of the centre console heater closing
2. Remove the centre console upper trim panel. plate and remove the centre console heater closing
plate.
Centre Console Upper Trim Panel Remove
3. Remove the centre console heater closing plate
assembly.

Centre Console Heater Closing Plate Assembly

Remove
4. Pry off the centre console screw trim cover, and
remove 4 screws fixing the centre console to the
centre console bracket.

2. Repeat the above steps to remove the centre console

heater closing plate on the other side.
Refit
1. Fix the heater closing plates on both sides of the centre
console to the centre console, and ensure the clip is
fitted in place.

5. Pry off the hand brake cover plate and remove the
centre console.
Refit
1. Locate the centre console in the vehicle and fit the
hand brake cover plate.
2. Fit 4 screws securing the centre console, tighten to
1.6–2.0Nm, and check the torque. Fit the centre
console screw trim cover.
3. Fit the centre console upper trim panel.

Centre Console Upper Trim Panel Refit

4. Fit the centre console heater closing plate assembly.
Centre Console Heater Closing Plate Assembly
Refit
5. Connect the battery negative.

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Seats Interior Fitting
Seats
Specifications
Torque
Description Value
Screw - front seat to floor 40–50Nm
Bolt - squab to cushion 40–50Nm
Bolt - striker to body 19–25Nm

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Description and Operation

System Layout
Seat Layout

1. Driver Seat
2. Front Passenger Seat
3. Rear Seat

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Seats Interior Fitting
Description The front seat assembly may have different configurations
Front Seat Assembly according to vehicle configuration and seat exterior, for
Overview example, 4 way manual seat (forward/backward adjustment,
seat back inclination); 6 way power seat (forward/backward
adjustment, seat back inclination and seat height adjustment);
fabric of high quality or PVC and fabric; optional seat side
airbag.
Rear Seat Assembly

1. Seat Headrest
2. Seat Back Assembly
3. Seat Back Cover and Foam
4. Seat Back Frame
5. Seat Cushion Assembly
The rear seat of this model is a 4/6 type seat with reclinable
6. Seat Cushion Cover and Foam seat back. If you want to expand the luggage compartment
7. Seat Cushion Frame space, first fully lower (or remove) all the rear seat headrests,
The common seat mainly consists of headrest, seat back, then pull up the unlock straps (1) on both sides respectively
seat cushion and accessories. Among them, both seat back and fold the seat back forward. When unfolding the rear seat
assembly and seat cushion assembly consist of cover, foam back, pull up the seat back unlock straps, push the seat back
and frame. The seat assembly and the main components until it reaches an appropriate position, and the seat back is
are repaired as fittings according to the vulnerability and locked when it clicks.
maintainability of the components.

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Operation 3. Seat Back Adjusting Handle

Manual Seat The front/rear position of the seat can be adjusted by the
Driver Seat handle in the front of the seat. Lift the handle and pull it to
the desired position. Release the handle to lock the seat to
the selected position. The 2nd adjusting handle is located in
the front of the trim panel outside the seat cushion, which can
adjust the seat height. Lift or press the handle repeatedly to
raise or lower the seat. The 3rd adjusting handle is located in
the rear of the height adjusting handle, which can adjust the
seat back inclination. Lift the handle and pull it to the desired
position. Release the handle to lock the seat to the selected
position.
Front Passenger Seat
The passenger seat is adjusted in the same way as the driver
seat. The front/rear position of the seat can be adjusted by the
1. Seat Longitudinal Position Adjusting Handle handle in the front of the seat. The position of the sear back
can be adjusted by the side handle.
2. Seat Height Adjusting Handle*

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Seats Interior Fitting
Service Procedures Front Seat Squab
Front Seat Remove
Remove 1. Remove the front seat.
1. If the seat is adjustable, raise the seat fully. Front Seat Remove
2. Fully move the seat backward. 2. Release the interior trim panel fixing screw, remove
3. Using a suitable lever, remove fixing trim covers. the inner seat trim panel.
4. Remove 2 bolts fixing front of seat to body, discard.
5. Fully move the seat forward.
6. Using a suitable lever, remove fixing trim covers.
7. Remove 2 bolts fixing front of seat to body, discard.
8. Disconnect all electrical connectors.
9. Remove seat from vehicle.
Refit
1. Place the front seat in the body front seat mounting
position.
2. Connect all electrical connectors.

Warning: Always ensure SRS wiring is routed correctly.

Be careful to avoidtrapping or pinching the SRS wiring. 3. Remove outer seat trim panel.
Do not leave the connectors hanging loose or allow SRS Driver's Seat Exterior Trim Panel Remove
components to hang from their harnesses. Look for
4. Loosen the cables and J-clamps fixing the backrest
possible points of chafing.
upholstery to the seat frame.
3. Fix the seat to the vehicle body, fit 2 new rear bolts and
5. Remove the 4 bolts connecting the cushion assembly
tighten them to 40–50Nm.
with the squab assembly.
4. Refit fixing trim covers.
5. Fully move the seat backward.
6. Fit 2 new front retaining bolts and tighten them to
40–50Nm.
7. Refit fixing trim covers.

6. Carefully separate squab from cushion, release block

connector from seat frame and thread airbag harness
through cushion.
7. Remove seat squab.
Refit
1. Locate the cushion assembly and squab assembly,
refit 4 bolts and tighten to 40–50Nm, thread airbag
wiring through seat cushion.Always ensure SRS wiring
is routed correctly. Be careful to avoidtrapping or
pinching the SRS wiring. Do not leave the connectors
hanging loose or allow SRS components to hang from
their harnesses. Look for possible points of chafing.

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2. Fix the squab upholstery to the seat frame with cables Front Seat Backrest Cover
and J-clamps. Remove
3. Refit the exterior trim panel. 1. Remove the front seat backrest assembly.
Front Seat Outer Trim Panel Refit Front Seat Backrest Remove
4. Locate the interior trim panel, refit the screw and 2. Pull the headrest to the top, loosen the buckle fixing
tighten it. the headrest and remove the headrest.
5. Refit the front seat. 3. Remove 2 guide pipes of the headrest.
Front Seat Refit 4. Release J-clamps of the backrest upholstery under the
seat.
5. Pull the upholstery upward, and open the C-rings
connecting the backrest foam and the interior of the
upholstery, note and mark their exact positions.
6. Remove the upholstery.
Refit
1. Locate the upholstery to the backrest, fix the interior
of the upholstery to the marked position of the back
foam with C-ring.
2. Close J-clamps of the backrest upholstery under the
seat.
3. Fix the backrest upholstery to the frame with J-clamps.
4. Refit 2 headrest guide pipes.
5. Locate and secure the headrest.
6. Refit the front seat backrest assembly.
Front Seat Backrest Refit

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Seats Interior Fitting
Front Seat Cushion Front Seat Cushion Cover
Remove Remove
1. Remove the front seat. 1. Remove the front seat cushion assembly.

Front Seat Remove Front Seat Cushion Assembly Remove

2. Remove seat cubby box (if fitted). 2. Loosen the J-clamp and C-ring fixing the cushion
3. Remove the exterior trim panel. upholstery to the frame.
3. Open the C-rings connecting the cushion foam and the
Driver's Seat Exterior Trim Panel Remove
interior of the upholstery, note and mark their original
4. Loosen the cables and J-clamps fixing the backrest
fitted positions.
upholstery to the seat frame.
4. Remove seat cushion cover.
5. Remove 4 bolts connecting the cushion assembly to
Refit
the backrest assembly.
1. Place front seat cushion cover in position on cushion
6. Remove the cushion assembly.
foam, fix the interior of the upholstery to the marked
Refit position of the cushion foam with C clips.
1. Refit 4 bolts connecting the cushion assembly and the 2. Fix the cushion upholstery to the frame with J-clamps
squab assembly and tighten to 40–50Nm . and C clips.
2. Fix the squab upholstery to the seat frame with cables
3. Refit the front seat cushion assembly.
and C-rings.
Front Seat Cushion Assembly Refit
3. Ensure any SRS wiring follows original route.Always
ensure SRS wiring is routed correctly. Be careful to
avoidtrapping or pinching the SRS wiring. Do not leave
the connectors hanging loose or allow SRS components
to hang from their harnesses. Look for possible points
of chafing.

Always ensure SRS wiring is routed correctly. Be

careful to avoidtrapping or pinching the SRS wiring. Do
not leave the connectors hanging loose or allow SRS
components to hang from their harnesses. Look for
possible points of chafing.

4. Refit the exterior trim panel.

Front Seat Outer Trim Panel Refit

5. Refit the front seat.

Front Seat Refit

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Interior Fitting Seats

Front Seat Outer Trim Panel Rear Seat Cushion

Remove Remove
1. Remove the front seat. 1. Release the seat belt buckle from the belt through-hole.

Remove-Front Seat 2. Pull the front end of the cushion upward until it is
released from the retaining clips.
2. Partially raise recline and seat height handles (where
applicable).
3. Remove screws at front (behind recline handle) and
rear of trim.

3. Slide seat cushion forwards to release from rear

retainers and remove.

4. Release rear clip, push trim toward front of seat to

release front clip.
5. Remove the outer trim panel fixing screw under the
handle.
Refit
1. Place trim in position on seat frame, push rearward
to engage front retainer.
2. Press trim to locate rear clip.
3. Fit retaining screws, front and rear.
4. Position recline and height adjustment handles (where
applicable), push to engage retaining clip.
Refit
5. Fit the front seat。
1. Position rear of seat cushion in aperture, push
Refit-Front Seat rearwards, ensure engagement of retaining clips, take
care to correctly locate seat belts etc.
2. Align seat cushion front clips.
3. Pull the belt buckle out of the cushion belt buckle
through-hole.
4. Push down on cushion to secure.

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Seats Interior Fitting
Rear Seat Squab Hinge Rear Seat Squab
Remove Remove
1. Turn down the rear seat backrest assembly. 1. Remove rear seat cushion.
2. Mark the position of the lower seat backrest hinge Rear Seat Cushion Remove
buckle.
2. Operate seat tilt release button, tilt seat fully forward.
3. Unscrew 2 bolts fixing the hinge to the vehicle body.
3. Holding the squab at the bottom, pull upwards to
partially release from fixing bracket.
4. Using a suitable device, press plastic hinge clip to
release, pull seat squab upwards to fully release fixing.
5. Manipulate seat squab inner hinge from other seat
section and hinge retainer.

Refit
1. Position the hinge to the vehicle body, refit the bolt
and tighten to 19–25Nm.
2. Refit the rear seat backrest assembly.

6. Release squab from centre bracket and remove squab.

Refit
1. Position squab inner hinge/pin onto opposite seat
squab/centre bracket.
2. Tilt seat squab to fully forward position.
3. Insert outer pivot clip into bracket, push fully home,
ensure clip, guide and pivot are fully engaged and secure.
4. Refit rear seat cushion.

Rear Seat Cushion Refit

5. Return squab to upright position, engage in catch.

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1.0 484
Fixed Windows Exterior Fitting
Fixed Windows Rear Door Quarter Window
Service Procedures Remove
Front Door Quarter Window 1. Remove the outer weatherstrip of the door window.
Remove
Door Window Outer Weatherstrip Remove
1. Remove the outer weatherstrip of the door window.
2. Remove the inner guide rail weatherstrip of the rear
Door Window Outer Weatherstrip Remove door window.
2. Remove the inner guide rail weatherstrip of the front 3. Remove the rear door window.
door window.
Rear Door Window Remove
3. Remove the front door window.
4. Remove the rear door separating pillar.
Front Door Window Remove
Rear Door Separating Pillar Remove
4. Remove the front door separating pillar.
5. Remove the rear door quarter window from the
Front Door Separating Pillar Remove vehicle.
5. Remove the front door quarter window from the 6. Remove the weatherstrip of the quarter window.
vehicle. Refit
6. Remove the weatherstrip of the quarter window from 1. Fix the weatherstrip of the rear door quarter window
the quarter window. to the quarter window.
Refit 2. Fit the rear door quarter window.
1. Fix the weatherstrip of the front door quarter window 3. Fit the rear door window chute weatherstrip.
to the quarter window.
4. Fit the rear door separating pillar.
2. Fit the front door quarter window.
Rear Door Separating Pillar Refit
3. Fit the front door separating pillar.
5. Fit the rear door window.
Front Door Separating Pillar Refit
Rear Door Window Refit
4. Fit the front door window.
6. Fit the inner guide rail weatherstrip of the rear door
Front Door Window Refit window.
5. Fit the inner guide rail weatherstrip of the front door 7. Fit the outer weatherstrip of the door window.
window.
Door Window Outer Weatherstrip Refit
6. Fit the outer weatherstrip of the door window.

Door Window Outer Weatherstrip Refit

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Exterior Fitting Fixed Windows

Windshield Rear Window

Remove Remove
1. Remove the A pillar upper trim panel. 1. Disconnect the battery negative.

A Pillar Upper Trim Panel Remove 2. Disconnect the connector of the rear window defogger.
2. Remove the interior rearview mirror. 3. Remove the rear window wiper motor.

Interior Rearview Mirror Assembly Remove Rear Window Wiper Motor Remove

3. Remove the A pillar exterior trim panel. 4. Put 2 suction cups symmetrically on both sides of the
rear window (outer side).
A Pillar Exterior Trim Panel Remove
5. Remove the adhesive on the rear window assembly and
4. Remove the A/C air inlet grille assembly.
the rear window frame with the glass sealant remover.
A/C Air Inlet Grille Assembly Remove 6. Remove the rear window with suction cups on both
5. Put suitable coverings on the vehicle body to protect sides aided by an assistant.
it from scratch. 7. Remove the adhesive on the original rear window and
6. Put 2 suckers symmetrically on both sides of the rear window frame.
windshield (outer side). Refit
7. Remove the adhesive around the windshield assembly 1. Thoroughly clean the mounting position of the rear
with the glass sealant remover. window on the body and the rear window with cleaner.
8. Remove the windshield with suckers on both sides 2. Apply glass primer to the body assembly area of the
aided by an assistant. rear window.
9. Remove the adhesive on the original windshield and 3. Apply adhesive to the rear window assembly, and press
windshield frame. the rear window into the rear window frame with
Refit suction cups.
1. Thoroughly clean the mounting position of the 4. Fix the rear window to the rear window frame with
windshield on the body and the windshield with cleaner. tapes, and allow the adhesive to dry for 24 hours.
2. Apply glass primer to the body assembly area of the 5. Remove the tape.
windshield. 6. Pour the water on the windshield assembly, and check
3. Apply adhesive to the windshield assembly, and press for leak. If any leak is found, dry the windshield
the windshield into the windshield frame with suction assembly and block the leaking location with adhesive.
cups. If it still leaks, remove the windshield assembly and
4. Fix the windshield to the windshield frame with tapes, repeat all service procedures.
and allow the adhesive to dry for 24 hours. 7. Fit the rear window wiper motor.
5. Remove the tape. Rear Window Wiper Motor Refit
6. Pour the water on the windshield assembly, and check 8. Connect the electrical connector of the rear window
for leak. If any leak is found, dry the windshield defogger.
assembly and block the leaking location with adhesive. 9. Connect the battery negative.
If it still leaks, remove the windshield assembly and
repeat all service procedures.
7. Fit the A/C air inlet grille assembly.

A/C Air Inlet Grille Assembly Refit

8. Fit the A pillar exterior trim panel.

A Pillar Exterior Trim Panel Refit

9. Fit the interior rearview mirror.

Interior Rearview Mirror Assembly Refit

10. Fit the A pillar upper trim panel.

A Pillar Upper Trim Panel Refit

1.0 486
Bumpers, Fascias and Grille Exterior Fitting
Bumpers, Fascias and Grille
Specifications
Torque
Description Value
Bolt-From front bumper to fender 2–2.5Nm
Bolt-From rearbumper to wheel casing 2–3Nm
Bolt-From under flow duct to front bumper 4–6Nm
Bolt-From front bumper to fend upper tie bar 3–5Nm
Bolt-From front bumper impact bar to body in white 40–50Nm
Screw-From front bumper impact bar to fend upper tie bar 7–10Nm
Bolt-From rear bumper brackt to bodyside 3–4Nm
Bolt-From rearbumper to wheel casing 3–4Nm
Bolt-From rear bumper to body in white 3–4Nm
Bolt-From rear bumper impact bar to body in white 19–25Nm

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Exterior Fitting Bumpers, Fascias and Grille

Service Procedures
Front Bumper and Bracket
Remove
1. Disconnect the battery negative.
2. Remove 2 screws (1) fixing the front bumper to the
upper part of the left (right) wheelhouse liner, and
remove 1 screw (2) fixing the left (right) side of the
front bumper to the left (right) fender.

5. With assistance, lift both sides of the front bumper

carefully and pull it outward to remove the front
bumper from the brackets on both sides of the body.
6. Disconnect the harness of the ambient temperature
sensor on the air inlet grille under the front bumper,
and remove the front bumper.
7. If necessary, remove 4 screws fixing the mounting
brackets on both sides of the front bumper to the body
to remove the mounting brackets.
3. Remove 4 bolts (1) and 2 clips (2) fixing the front
bumper to the upper radiator beam. Refit
1. If the mounting brackets on the left and right sides of
the front bumper have been removed, fit 4 screws
securing the mounting brackets on both sides at first,
tighten to 2–2.5Nm, and check the torque.
2. Connect the harness of the ambient temperature
sensor on the air inlet grille under the front bumper.
3. With assistance, fit the front bumper assembly to the
body, press both sides into the left and right brackets
of the front bumper, align the upper and lower parts
with the mounting holes in the upper radiator beam
and bottom deflector respectively, and press the clip
in place.
4. Fit 6 screws fixing the front bumper to the bottoms of
4. Remove 6 screws (1) fixing the front bumper to the the left/right wheelhouse liners, tighten to 2–3Nm,
lower part of the left/right wheelhouse liner, and and check the torque.
remove 3 bolts (2) fixing the front bumper to the
5. Fit 3 bolts fixing the front bumper to the bottom
bottom deflector.
deflector, tighten to 4–6Nm, and check the torque.
6. Fit 1 screw fixing the left (right) side of the front
bumper to the left (right) fender, tighten to 2–2.5Nm,
and check the torque.
7. Remove 2 screws fixing the front bumper to the left
(right) wheelhouse liner, tighten to 2–3Nm, and check
the torque.
8. Fit 4 bolts fixing the front bumper to the upper radiator
beam, tighten to 3–5Nm, and check the torque.
9. Connect the battery negative.

1.0 488
Bumpers, Fascias and Grille Exterior Fitting
Front Bumper Beam Rear Bumper and Bracket
Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Remove the front bumper. 2. Open the tail gate.
Front Bumper Remove 3. Remove 2 bolts fixing the rear bumper to the body.
3. Remove the tweeter.
Tweeter Remove
4. Remove the wind scoopers on both sides.
Wind Scooper - Left Remove
Wind Scooper - Right Remove
5. Remove 2 nuts (1) and 6 bolts (2) fixing the left and
right sides of the front bumper beam to the body and 4
bolts (3) to the front-end module.

4. Remove 2 bolts and 2 screws fixing the lower rear

bumper to the body bracket.

6. Remove the front bumper beam.

Refit
1. Locate the front bumper beam to the body, fit 6 bolts
fixing the left and right sides of the front bumper
beam to the body, tighten to 40–50Nm, and check
the torque. 5. Remove 1 screw (1), 1 split pin (2) and 1 clip (3) of the
left (right) side of the rear bumper and the left (right)
2. Locate the front bumper beam to the body, fit 2 nuts
rear wheelhouse liner.
fixing the left and right sides of the front bumper
beam to the body, tighten to 40–50Nm, and check
the torque.
3. Fit 4 bolts fixing the left and right sides of the front
bumper beam to the front-end module, tighten to
7–10Nm, and check the torque.
4. Fit the wind scoopers on both sides.
Wind Scooper - Left Refit
Wind Scooper - Right Refit
5. Fit the tweeter.
Tweeter Refit
6. Fit the front bumper.
6. Carefully disconnect the rear bumper from the body,
Front Bumper Refit disconnect the rear fog lamp connectors on the left and
7. Connect the battery negative. right sides and the harnesses of the rear bumper rear

1.0 489
Exterior Fitting Bumpers, Fascias and Grille

radar sensor, and remove the rear bumper. Rear Bumper Beam
7. If the brackets on both left and right sides of the rear Remove
bumper are required to be removed, remove 6 bolts 1. Remove the rear bumper.
fixing the left/right rear bumper brackets to the rear
Rear Bumper Remove
end panel.
2. Remove 6 bolts (1) and 2 nuts (2) fixing the left and
Refit
right sides of the rear bumper beam to the rear end
1. If the brackets on both left and right sides of the rear of the body.
bumper have been removed, fix 3 screws of the left
(right) bracket of the rear bumper at first, tighten to
3–4Nm, and check the torque.
2. Connect the rear fog lamp connectors on the left and
right sides and 4 connectors of the rear bumper rear
radar sensor.
3. Gently push the rear bumper in place to allow the
bumper on each side to engage with the bumper
bracket.
4. Fit 1 clip, 1 split pin and 1 screw of the lower part of
the left (right) rear bumper and the left (right) rear
wheelhouse liner, tighten to 3–4Nm, and check the
torque.
5. Fit 2 screws and 2 bolts fixing the lower rear bumper 3. Carefully remove the rear bumper beam from the rear
to the body bracket, tighten to 3–4Nm, and check end of the body.
the torque. Refit
6. Fit 2 screws fixing the rear bumper to the body, tighten 1. Locate the rear bumper beam to the body, fit 6 bolts
to 3–4Nm, and check the torque. and 2 nuts fixing the left and right sides of the rear
7. Close the tail gate. bumper beam to the rear end of the body, tighten to
19–25Nm, and check the torque.
8. Connect the battery negative.
2. Fit the rear bumper.

Rear Bumper Refit

1.0 490
Exterior Trim and Paneling Exterior Fitting
Exterior Trim and Paneling
Specifications
Torque
Description Value
Screw-A/C air intake grille to body 1.5–2Nm
Bolt-From under flow duct to front wheel casing 2–3Nm
Bolt-From front wheel casing to front bumper 2–3Nm
Bolt-From front wheel casing to front bumper and sill 2.5–3.5Nm
Bolt-From rear wheel casing to rear bumper 2–3Nm
Nut-From under body shield to body 4-6Nm
Bolt-From under flow duct to former vice frame 4-6Nm
Bolt-From front bumper to under flow duct 3-4Nm

1.0 491
Exterior Fitting Exterior Trim and Paneling

Service Procedures Front Wheelhouse Liner

A/C Air Inlet Grille Assembly Remove
Remove 1. Raise the vehicle on a lift.
1. Open the bonnet. 2. Remove the front wheels.
2. Pry off the clips at the side corners of the A/C air inlet Wheels Remove
grille, and remove the side corners.
3. Remove 5 screws (1) fixing the left front wheelhouse
3. Remove the windshield wiper arm assembly. liner to the left side of the front bumper.
Windshield Wiper Arm Assembly Remove 4. Remove 3 bolts (2) fixing the left front wheelhouse
4. Remove 2 screws (1) and 2 clips (2) fixing the A/C air liner to the body.
inlet grille to the body. 5. Remove 1 hexalobular socket screw (3) fixing the left
front wheelhouse liner to the pedal.
6. Remove 1 plastic nut (4) fixing the left front wheelhouse
liner to the body.
7. Remove 1 bolt (5) fixing the left front wheelhouse liner
to the left side of the bottom deflector.

5. Disconnect the connection of the windshield washer

pump hose and the windshield nozzle hose.
6. Disconnect the windshield nozzle hose from the nozzle
and remove both of them.
Refit
8. Remove the left front wheelhouse liner.
1. Fit the windshield nozzle and nozzle hose.
9. Remove the right front wheelhouse liner according to
2. Connect the windshield washer pump hose and the
the above steps.
windshield nozzle hose.
Refit
3. Locate the A/C air inlet grille to the body, press the
clip, fit 2 screws fixing the middle part of the A/C air 1. Lift the wheelhouse and pre-fasten the wheelhouse to
inlet grille to the body, tighten to 1.5–2Nm, and check the body in white with split pins.
the torque. 2. Remove 1 plastic nut fixing the left front wheelhouse
4. Fit the windshield wiper arm assembly. liner to the body.
3. Fix the left front wheelhouse to the relative position of
Windshield Wiper Arm Assembly Refit
the bottom deflector, fit 1 bolt, tighten to 2–3Nm,
5. Locate the A/C air inlet grille side corner and press it check the torque.
into the clip in place.
4. Fit 3 bolts fixing the left front wheelhouse liner to the
6. Close the bonnet. body, tighten to 2–3Nm, and check the torque.
5. Fit 5 screws fixing the left front wheelhouse liner to
the left side of the front bumper, tighten to 2–3Nm,
and check the torque.
6. Fit 1 screw connecting the left front wheelhouse liner
to the bottom of the front bumper and the pedal,
tighten to 2.5–3.5Nm, and check the torque.
7. Fit the right front wheelhouse according to the above
steps.

1.0 492
Exterior Trim and Paneling Exterior Fitting
8. Fit the front wheels. Rear Wheelhouse Liner
Wheels Refit
Remove
1. Raise the vehicle on a lift.
9. Lower the vehicle.
2. Remove 2 screws (1) fixing the left rear wheelhouse
to the rear bumper.
3. Remove 2 plastic nuts (2) and 1 clip (3) fixing the left
rear wheelhouse to the body.

4. Remove the left rear wheelhouse liner.

5. Refer to the steps for removing the left rear wheelhouse
liner to remove the right rear wheelhouse liner.
Refit
1. Lift the wheelhouse liner, fit and tighten 1 clip and 2
plastic nuts fixing the left wheelhouse liner to the body.
2. Fit 2 screws connecting the left rear wheelhouse liner
to the rear bumper, tighten to 2–3Nm, and check the
torque.
3. Lower the vehicle.

1.0 493
Exterior Fitting Exterior Trim and Paneling

Bottom Deflector
Remove
1. Raise the vehicle on a lift.
2. Follow steps 3 - 4 to remove the bottom deflector with
high configuration; follow steps 5 - 6 to remove the
bottom deflector with low configuration. Follow steps
7 - 8 to remove the bottom deflector on both sides of
the middle part.
3. If it is the bottom deflector with a big head, remove 3
bolts connecting the bottom deflector and the bottom
of the front bumper.
4. Remove 6 bolts fixing the bottom deflector to the front
wheelhouse liner and the front subframe, and remove Refit
the bottom deflector. 1. Follow steps 2 - 3 to fit the central guard plate on both
sides of the middle part; follow steps 4 - 5 to fit the
deflector with low configuration; follow steps 6 - 7 to
fit the bottom deflector with high configuration.
2. Fit 6 clips fixing the central guard plate to the
underbody, and press the clip in place.
3. Fit 6 bolts fixing the central guard plate to the
underbody, tighten to 4-6Nm, and check the torque.
4. Fix the bottom deflector in place, fit 4 bolts fixing the
bottom deflector to the front subframe and the right
front wheelhouse liner, tighten to 4-6Nm, and check
the torque.
5. Fit 1 bolt connecting the bottom deflector and the
5. If it is the bottom deflector with small right side, bottom of the front bumper, tighten to 3-4Nm, and
remove 1 bolt connecting the bottom deflector and the check the torque.
bottom of the front bumper. 6. Insert the bottom deflector into the lower revers of
6. Remove 4 bolts fixing the bottom deflector to the right the front bumper, fit 6 bolts fixing the bottom deflector
front wheelhouse liner and the front subframe, and to the front subframe and the front wheelhouse liner,
remove the bottom deflector. tighten to 3-4Nm, and check the torque.
7. Fit 3 bolts connecting the bottom deflector and the
bottom of the front bumper, tighten to 3-4Nm, and
check the torque.
8. Lower the vehicle.

7. If it is the central guard plate on both sides of the

middle part, remove 6 bolts (1) fixing the left central
guard plate to the underbody.
8. Remove 6 clips (2) fixing the central guard plate to the
underbody, and remove the central guard plate.

1.0 494
Exterior Trim and Paneling Exterior Fitting
A Pillar Exterior Trim Panel
Remove
1. Open the front door.
2. Remove 3 screws fixing the exterior trim panel of the
A pillar to the body.
3. Pry off 4 clips and remove the exterior trim panel of
the A pillar.
Refit
1. Locate the exterior trim panel of the A pillar to the A
pillar, and press the clip in place.
2. Fit and tighten 3 screws fixing the exterior trim panel
of the A pillar to the A pillar.
3. Close the front door.

1.0 495
Exterior Fitting Mirrors

Mirrors
Specifications
Torque
Description Value
Screw - exterior mirror 9–10Nm

1.0 496
Mirrors Exterior Fitting
Description and Operation
System Layout
Exterior Rearview Mirror Layout

1. Left Exterior Rearview Mirror Assembly 2. Right Exterior Rearview Mirror Assembly

1.0 497
Exterior Fitting Mirrors

System Control Diagram

A=Hard Wire

1.0 498
Mirrors Exterior Fitting
Description Headlamp Leveling Switch
Overview
The power exterior rearview mirror assembly is fitted on all
models as a standard configuration. Each exterior rearview
mirror assembly is controlled by the circular control switch of
the headlamp leveling switch.
Exterior Rearview Mirror Assembly
The left and right exterior rearview mirror assemblies shall
be distinguished, but the basic structures are the same. The
housing of the exterior rearview mirror assembly is a plastic
mould which includes the mirror and side direction indicator
lamp. The exterior rearview mirror assembly is fixed on the
front door by 2 bolts which are visible only when the front trim
panel of the exterior rearview mirror cover is removed.
The headlamp leveling switch is located on the lower trim panel
The housing of the exterior rearview mirror assembly is at the driver side.
unrepairable and shall be replaced as an assembly. The
The headlamp leveling switch has a circular control knob which
exterior rearview mirror, the exterior rearview mirror cover,
can operate the vertical and horizontal motors in the exterior
side direction indicator lamp bulb and the seal gasket are
rearview mirror assembly. The circular control knob can be
repairable.
adjusted to 4 directions and rotate. Turn the two LEDs (L & R)
above the circular control knob counterclockwise/clockwise to
select one of the exterior rearview mirrors. When the width
lamp or the headlamp illuminates, the LED flashes.

1.0 499
Exterior Fitting Mirrors

Operation Exterior Rearview Mirror Manual Folding

Exterior Rearview Mirror Fold manually to achieve the folding/expansion of the exterior
The steering gear of the exterior rearview mirror includes rearview mirror.
2 bidirectional motors (vertical motor and horizontal motor) Interior Rearview Mirror
which provide horizontal and vertical motions for the rearview
Manual Anti-dazzle Function
mirror. The vertical motor is responsible for the up-and-down
motion while the horizontal motor is for the left-and-right During driving, the strong light from the interior rearview
motion. mirror may affect the driver. To avoid such visual shock, pull
the lever at the base of the interior rearview mirror and change
The exterior rearview mirror can provide the following
the view to 'dip' the mirror. Push back the lever to return the
functions:
interior rearview mirror to the normal position.
• Exterior rearview mirror manual folding
• Side direction indicator lamp

1.0 500
Mirrors Exterior Fitting
Service Procedures Exterior Rearview Mirror Cover
Exterior Rearview Mirror Assembly Remove
Remove 1. Remove the mirror glass.
1. Remove the front door interior trim panel. 2. Unscrew 2 bolts securing the mirror cover to the
Remove of Front Door Interior Trim Pane exterior rearview mirror assembly.

2. Pry the outside trim shell.

3. Using a suitable lever remove mirror cover.

3. Remove the door trim panel and the waterproof film,

now you can see the plug of the exterior review mirror
connector, disconnect the connector.
4. Remove the 2 bolts securing the exterior review mirror
to the body, and remove the exterior review mirror
assembly.

Refit
1. Refit mirror cover to exterior rearview mirror
assembly.
2. Refit 2 screws securing mirror cover.
3. Refit the mirror glass.

Refit
1. Position the exterior review mirror with the location
pin on it to corresponding location hole on the door,
fit 2 bolts, and tighten to 9–10Nm.
2. Connect the exterior review mirror connector, and fit
the waterproof film.
3. Fit the outside trim shell.
4. Fit the front door interior trim panel.

Refit of Front Door Interior Trim Pane

1.0 501
Exterior Fitting Mirrors

Interior Rearview Mirror

Remove
1. Knock down the interior rearview mirror assembly
with a rubber hammer with care to remove it from
the base.

Refit
1. Locate the interior rearview mirror to the mounting
bracket and push it into the slot with care to fit it in
place.

1.0 502
Wipers and Washer Exterior Fitting
Wipers and Washer
Specifications
Torque
Description Value
Nut - front windscreen wiper arm 14–16Nm
Screw - motor and Linkage 7–10Nm
Screw - washer tank 7–10Nm
Screw - washer filler neck 4–6Nm
Nut-Rear wiper arm to motor shaft 8–10Nm
Nut-Rear wiper motor to tailgate 7–10Nm

1.0 503
Exterior Fitting Wipers and Washer

Description and Operation

System Layout
Wiper and Washer Layout

1. Washer Reservoir and Washer Pump 4. Wiper/Washer Lever Switch

2. Body Control Module (BCM) 5. Windshield Wiper and Motor Assembly
3. Rear Window Wiper and Motor Assembly

1.0 504
Wipers and Washer Exterior Fitting
System Control Diagram

A = HS CAN Bus; B = Hard Wire

1.0 505
Exterior Fitting Wipers and Washer

Description The rear wiper is located at the bottom of the rear window.
Overview Its motor is fitted on a linkage mechanism on the tail gate. The
linkage mechanism can drive the wiper arm and the wiper blade
The wiper and washer system is controlled by the body control
to operate.
module (BCM), which will operate after receiving commands
from the wiper/washer lever switch on the right side of the Washer Exploded View
steering wheel. The washer system includes:
The diagnostic information for the wiper and washer system
can be read with the scan tool.
Wiper Exploded View
The wiper system includes:

1. Washer Reservoir
2. Windshield Washer Pump
3. Windshield Washer Reservoir Hose
4. Windshield Washer Hose Assembly
1. Front Wiper Motor 5. Washer Reservoir Neck
2. Passenger Side Wiper Arm Assembly 6. Washer Reservoir Cap
3. Driver Side Wiper Arm Assembly 7. Washer Reservoir Neck Seal Ring
4. Passenger Side Wiper Blade Assembly 8. Tail Gate Washer Nozzle Hose
5. Driver Side Wiper Blade Assembly 9. Tail Gate Washer Reservoir Hose
6. Shaft Cap 10. Rear Window Washer Nozzle
7. Shaft Cap 11. Windshield Washing Nozzle
8. Rear Wiper Motor The washer reservoir is fitted in the right wheelhouse, with a
9. Rear Window Seal Ring capacity of about 4 liters. The engine compartment is provided
10. Rear Wiper Blade with a filler neck with a seal cap which can be used to refill the
washer reservoir.
11. Rear Wiper Arm
The washer pump is fitted below the washer reservoir. When
The windshield wiper motor is below the air inlet grille
the washer pump is enabled, it will pump the fluid in the washer
at the bottom of the windshield, which is fitted to a
reservoir into the washer nozzle under the action of pressure.
linkage mechanism on the bracket between inner and outer
compartment walls. The linkage mechanism can drive the
wiper arm and the wiper blade to operate.

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Wipers and Washer Exterior Fitting
Operation wipe vary with the vehicle speed level and the setting of wiper
Overview delay potentiometer.

The front/rear wipers and washers are controlled by the BCM. When the switch is in intermittent, low speed or high speed
When the BCM receives an ON signal from the washer/wiper position, the BCM will adjust the interval of intermittent wipe
lever switch connected by the hard wire, it drives the washer according to the vehicle speed. ABS ECU monitors the wheel
pump and wiper motor to work. The bidirectional washer speed signal and transmits it to the BCM through HS CAN
pump provides washer fluid for the front and rear windows, bus.
the front washer pump is indirectly controlled by the BCM,
If the wiper/washer lever switch is in the intermittent wipe,
and the rear washer pump is directly controlled by the rear
the BCM adjusts the selected delay time by comparing vehicle
window washer switch.
speed with the resistance corresponding to the intermittent
Front Wiper/Washer System delay rotary switch.
The front wiper includes the BCM, washer/wiper lever switch Programmed Wash/Wipe
and two relays. One of the relay (1) is used to turn on/off the
When the ignition switch in "ACC" or "ON" position and the
wiper, and the other (2) is used to control the wiper speed.
front wiper switch is enabled, the BCM controls the front
When the BCM receives signals from the washer/wiper lever
wiper to work at low speed, enables the washer pump and
switch, it drives the front wiper to work by closing the two
triggers the internal counter. When the counter value achieves
wiper relays in the engine compartment fuse box.
the set value, the BCM closes the relay, and the front wiper
The switches for single wipe, intermittent wipe and low/high starts to work. When the driver release the washer/wiper
speed wipe form a closed circuit with the BCM through relay lever, the washer pump and front wiper stop.
1 or 2.
Caution: During engine start, the windshield wiper
When the ignition switch is in "ACC" or "ON" position, the and washer function is disabled.
output status of the front wiper is as follows:
Caution: The wiper continues operating for three
Front Wiper
Switch 1 Switch 2 times after the lever switch is released. After
Mode
several seconds, the wiper will wipe once more to
Stop 0 0 eliminate the washer fluid on the windshield.
Single Wipe 1 1 Front Wiper Stop
Auto Wipe 1 0
With the ignition switch ON, turn the wiper switch of
Low Speed Wipe 0 1 the washer/wiper lever to "OFF" position, the wiper relay
High Speed Wipe 1 1 disconnects immediately and the front wiper then stops
0 = Disconnected 1 = Closed promptly.

High Speed Wipe If the ignition switch is turned off when the wiper is working,
the wiper relay will remain closed, even if the washer/wiper
When choosing high speed mode for the front wiper, the BCM
lever is in "OFF" position; when the wiper shifts to the "RESET"
will send a signal to the wiper relay. When relay 2 closes, the
position at low speed, the relay disconnects automatically and
power supply connects the motor directly through the resistor
the wiper stops working.
for deceleration, at this stage, the wiper works at high speed.
Front Wiper Failure Protection
Low Speed Wipe
When choosing low speed wipe mode, the BCM sends a signal When the front wiper is enabled, the BCM monitors the
to the wiper relay. The power supply passes through relay 1 position signal of the front wiper switch. If the ignition switch
before connecting with the motor by a resistor. The resistor is in "OFF" position, but the switch of the front wiper remains
reduces the power, so the wiper works at low speed. in the original status, the relay of the front wiper will also
disconnect automatically.
Auto Wipe-Variable Intermittent Wipe
Rear Wiper/Washer System
The function of variable intermittent wipe: the vehicle is
provided with a wiper delay potentiometer. BCMWhen a valid request from the rear wiper switch is
received, it will control the corresponding relay to work.
When receiving valid wiper interval request, the BCM will
control the wiper at slow speed. The times of intermittent

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Exterior Fitting Wipers and Washer

Intermittent Wipe speed/intermittent mode, if the shift lever is turned to the R

When the ignition switch is in "ACC/ON" position, if the BCM gear, the BCM will apply the rear wiper relay automatically
detects that the rear wiper switch is ON, it controls the rear after several seconds and activate the rear wiper, this does
wiper to work at low speed, enables the washer pump and not affect the front wiper.
triggers the internal counter. When the counter value achieves Rear Window Washer/Wiper Failure
the set value, the BCM closes the relay, and the rear wiper
If the tail gate is open, the wiper/washer of the rear window
starts to work.
will be disabled for any mode.
Programmed Wipe If the BCM detects that the tail gate is open when the rear
When the rear wiper switch is activated, the washer pump is wiper is working, the rear wiper will be disabled immediately.
enabled, and the BCM monitors the status of the rear wiper After the tail gate is closed, the rear wiper returns to normal
switch and counts. If the switch is not released, the BCM will state after appr. 5s, this provides enough time for the user to
activate the rear wiper relay to start the rear wiper. take his hands away from the wash/wipe area.
R Gear Wipe
When the ignition switch is in "ACC/ON" position, and
the front washer/wiper lever switch is in high speed/low

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Wipers and Washer Exterior Fitting
Service Procedures Windshield Wiper Arm Assembly
Windshield Wiper Blade Assembly Remove
Remove 1. Open the engine hood.
1. Raise the wiper blade from the windshield. 2. Remove the wiper arm shaft cover to expose the wiper
arm nuts.

2. Take out the blade from the wiper arm and remove
while pressing the safety clips. 3. Remove the nuts securing the wiper arm to the linkage
Refit mechanism.

1. Engage the wiper blade assembly into safety clips, and 4. Remove the wiper arm assembly.
refit on the wiper arm assembly. Refit
2. Secure the wiper arm to the windshield. 1. Engage the wiper blade assembly into safety clips, and
refit on the wiper arm assembly.
2. Refit the wiper blade and arm assembly to the pivot of
mechanism assembly.
3. Ensure that the adhesive tapes of two wiper blades are
fitted in initial positions properly and align with the dots
on the black printing edge of the glass.
4. Refit the nuts to the pivot of mechanism assembly,
tighten to 14–16Nm.
5. Refit the wiper to the pivot.
6. Close the engine hood.

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Exterior Fitting Wipers and Washer

Windshield Wiper Linkage Mechanism Assembly Washer Reservoir Assembly

- Energized Remove
Remove 1. Remove the front bumper and the bracket.
1. Disconnect the battery negative.
Front Bumper and Bracket Remove
2. Remove the windshield wiper arm assembly.
2. Remove the washer pump assembly.
The Windshield Wiper Arm Assembly Remove
Washer Pump Remove
3. Remove the air intake grille assembly.
3. Loosen 1 bolt securing the washer fluid filler pipe.
4. Remove 3 bolts from windshield wiper linkage
mechanism assembly.

4. Loosen 2 nuts (1) and 1 bolt (2) securing the washer

reservoir.
5. Remove the windshield wiper linkage mechanism
assembly.
Refit
1. Refit the windshield wiper linkage mechanism assembly,
and tighten to 7–10Nm.
2. Refit the air intake grille assembly.
3. Refit the windshield wiper arm assembly.

The Windshield Wiper Arm Assembly Refit

4. Connect the battery negative.

5. Remove the washer reservoir.

Refit
1. Locate the washer reservoir to the body, and fit the lug
nut to the mounting hole of the reservoir neck.
2. Fit 2 nuts securing the washer reservoir, tighten to
7–10Nm, and check the torque.
3. Fit 1 bolt securing the washer reservoir, tighten to
7–10Nm, and check the torque.
4. Fit 1 bolt securing the washer fluid filler pipe, tighten
to 4–6Nm, and check the torque.
5. Fit the washer pump assembly.
Washer Pump Refit
6. Fit the front bumper and the bracket.
Front Bumper and Bracket Refit

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Wipers and Washer Exterior Fitting
Washer Pump Assembly Windshield Washer Pump Hose
Remove Remove
1. Remove the front bumper and the bracket. 1. Remove the front bumper and the bracket.

Front Bumper and Bracket Remove Front Bumper and Bracket Remove
2. Put one container under the washer reservoir. 2. Remove the front wheelhouse liner.
3. Disconnect the connector of the washer pump (1). Front Wheelhouse Liner Remove
4. Remove the washer pump from the washer reservoir. 3. Put one container under the washer reservoir.
5. Disconnect the windshield washer pump hose (2). 4. Disconnect the windshield washer pump hose from the
6. Disconnect the rear window washer pump hose (3). washer pump.

7. Remove the washer pump. 5. Disconnect the connection of the windshield washer
Refit pump hose and the windshield nozzle hose.
1. Fit the washer pump to the washer reservoir. 6. Remove the clip fixing the windshield washer pump
hose to the body, and remove the windshield washer
2. Connect the windshield washer pump hose.
pump hose.
3. Connect the rear window washer pump hose.
Refit
4. Connect the connector of the washer pump.
1. Fit the new hose and connect it to the washer pump.
5. Refill the windshield washer fluid.
2. Route the new hose according to the used one and
6. Fit the front bumper and the bracket.
fit the clip.
Front Bumper and Bracket Refit 3. Connect the windshield washer pump hose and the
nozzle hose.
4. Refill the windshield washer fluid.
5. Fit the front wheelhouse liner.

Front Wheelhouse Liner Refit

6. Fit the front bumper.

Front Bumper Refit

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Exterior Fitting Wipers and Washer

Rear Window Washer Pump Hose 8. Fit the trim panel assembly of right door sill.
Remove 9. Fit the clip to the rear of the roof interior in place.
1. Remove the front bumper and the bracket. 10. Fit the right luggage compartment side trim panel.
Front Bumper and Bracket Remove Luggage Compartment Side Trim Panel Refit
2. Put one container under the washer reservoir. 11. Fit the tail gate interior trim panel.
3. Disconnect the rear window washer pump hose from
Tail Gate Interior Trim Panel Refit
the washer pump.

4. Remove the lower trim panel of the right A pillar.

A Pillar Lower Trim Panel Remove
5. Remove the lower trim panel of the right B pillar.
B Pillar Lower Trim Panel Remove
6. Remove the trim panel assembly of the right door sill.
7. Remove the right luggage compartment side trim panel.
Luggage Compartment Side Trim Panel Remove
8. Pry off the rear part of the roof interior.
9. Remove the interior trim panel of the tail gate.
Tail Gate Interior Trim Panel Remove
10. Disconnect the connection of the rear window washer
pump hose and the rear window nozzle hose.
11. Remove the hose of the rear window washer pump.
Refit
1. Fit the new fluid pipe and connect it to the washer
pump.
2. Route the new pipe according to the used one and
twine it with strips.
3. Connect the rear washer fluid pipe to the check valve.
4. Refill the windshield washer fluid.
5. Fit the front bumper and the bracket.
Front Bumper and Bracket Refit
6. Fit the lower trim panel of the right A pillar.
A Pillar Lower Trim Panel Refit
7. Fit the lower trim panel of the right B pillar.
B Pillar Lower Trim Panel Refit

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Wipers and Washer Exterior Fitting
Rear Window Wiper Arm Assembly Refit
Remove 1. Fix the rear window wiper arm to the wiper motor
Caution: Remove the nozzle to use the special tool, shaft, fit 1 nut, tighten to 8–10Nm, and check the
otherwise the nozzle will be damaged. torque.

1. Remove the mounting shaft cap of the rear wiper arm, 2. Fit the nozzle to the wiper motor shaft in the right
and remove 1 nut fixing the rear window wiper arm direction and tap it to fit in place. Check if the spray
assembly to the rear wiper motor shaft. direction of the washer fluid is correct, if necessary,
insert a needle into the nozzle hole to adjust the nozzle
by prying the needle gently, enabling the washer fluid to
be sprayed directly to the center of the windshield.
3. Fit the mounting shaft cap of the rear wiper arm.
4. Ensure that the blade tape is fitted in the correct
initial position and is aligned with the dot on the black
printing edge of the glass.

2. Gently clip the upper nozzle with a proper tool to

remove the nozzle.
3. Remove the rear window wiper arm assembly with the
special tool TBO00015.

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Exterior Fitting Wipers and Washer

Rear Window Wiper Motor

Remove
1. Disconnect the battery negative.
2. Remove the rear window wiper arm assembly.
Rear Window Wiper Arm Assembly Remove
3. Remove the seal ring of the rear wiper motor from the
wiper motor output shaft.
4. Remove the tail gate trim panel.

Tail Gate Interior Trim Panel Remove

5. Disconnect the electrical connector (1) and the rear
washer fluid pipe (2).
6. Remove 2 nuts (3) and 1 bolt (4) fixing the rear window
wiper motor assembly to the tail gate.

7. Remove the rear window wiper motor assembly.

Refit
1. Fix the rear window wiper motor assembly to the tail
gate, fit 2 nuts, tighten to 7–10Nm, and check the
torque.
2. Fit 1 bolt, tighten to 7–10Nm and check the torque.
3. Connect the electrical connector and the rear washer
fluid pipe.
4. Fit the tail gate trim panel.

Tail Gate Interior Trim Panel Refit

5. Fit the seal ring and the rear window wiper arm
assembly.

Rear Window Wiper Arm Assembly Refit

6. Connect the battery negative.

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Wipers and Washer Exterior Fitting
Special Tools
Tool Description Picture
Number

Remover rear
TBO00015
wiper bar

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1.0 516
Lighting Lighting Systems
Lighting
Specifications
Torque
Description Value
Screw self-tapping - reading lamp 1.5–2Nm

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Lighting Systems Lighting

Description and Operation

System Layout
Interior Lighting Layout

1. Body Control Module (BCM) 3. Luggage Compartment Lamp

2. Front Reading Lamp Assembly

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Lighting Lighting Systems
System Control Diagram
Interior Lighting Control Diagram

A = HS CAN Bus; B = RF Signal; C = Hard Wire

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Lighting Systems Lighting

Description The interior lamp is fitted with a single filament bulb. The
Overview assembly is connected to the body harness.

The interior lighting system is controlled by the body control The lens can be removed to allow for replacement of the bulb.
module ( BCM ) which is located on the passenger side of the Boot Lamp
vehicle, behind the glovebox.
The boot (loadspace) lamp is located in the RH trim panel in
The interior lighting comprises: the load space.
• Front reading lamp The lamp comprises a plastic moulding which incorporates a
• Boot lamp lens and also provides location for a bulb holder.
Front Reading Lamp The boot lamp operates automatically when the boot is
The front interior lamp assembly is located centrally in the head opened, a door is opened.
lining above the windscreen. Bulb Specification
The assembly is retained with two screws which locate in Lamp Bulb Type Voltage Power
brackets attached to the roof panel. Front Reading C10W 12V 10W
Lamp
Spring clips provide retention to the headlining.
Luggage C5W 12V 5W
The interior lamp assembly has one non-latching switch for the Compartment
interior lamp operation. Lamp

The lamp is located in a plastic moulding which also provides

the location for the passenger airbag disabled warning lamp.

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Lighting Lighting Systems
Operation • When pressing the LOCK button on the remote key, or
Overview using the mechanical key to lock the door, the interior
lamps will dim gradually.
Interior Lighting
• When all doors are in the closed state and the ignition
Interior lighting includes:
switch is in "ACC" or "ON" position, the interior lamps
• Front Reading Lamp will dim gradually.
• Luggage Compartment Lamp • If any door is opened, the interior lamps will illuminate
• Interior Backlight and gradually dim in 15min for the energy-saving function
of the battery is on.
BCMIt receives signals of the interior lighting system. When
the BCM receives the reading lamp signal, door switch signal Note: In auto mode PWM control, once the impact
or luggage compartment OPEN signal, it will illuminate the sensor is triggered, the interior lamps will
corresponding lamp inside the vehicle. illuminate immediately, and when the interior
lighting switch is pressed, the interior lamps
PWMInterior Lighting Controlled (by PWM)
will go out at once.
PWMThe interior lamps under control include the front Manual Mode PWM Control
reading lamp and luggage compartment lamp. The interior
door lighting system can be controlled by auto mode or Press the master switch on the front reading lamp assembly to
manual mode. turn on/off the front reading lamp. When the interior lamps
are turned on/off manually, the auto delay function will be
Auto Mode PWM Control
cancelled.
No need to press the switch, the BCM will control the Manual Shift Between Control Modes
working status of the interior lamp according to the signal
received. Press the master switch on the front reading lamp assembly to
activate the auto mode. Press the master switch again to turn
Caution: At the moment of engine start,the interior light off the auto mode.
with turned on will be off,after that it will relight on
automatically. The interior lighting delay power control includes:
• Front Reading Lamp
The interior lamp will illuminate automatically under the
following conditions: BCMIt controls the interior lighting system by the relay.

• When pressing the UNLOCK button on the remote key, Under the following situations, the BCM controls the delay of
or using the mechanical key to unlock the door, the the front reading lamp by disconnecting the delay relay.
front reading lamp illuminate gradually. If the door is • When the ignition switch is in "ACC" or "ON" position
not unlocked within 30s, the front reading lamp will dim
• When the UNLOCK button on the remote key is
gradually.
pressed, and the door is unlocked by the mechanical key
• After the ignition switch is off and the position lamp is
on, the reading lamp will illuminate gradually. If the door The delay function may fail under the following conditions:
is not unlocked within 30s, the reading lamps will dim • 15min since the ignition is OFF
gradually.
• When the LOCK button on the remote key is pressed,
• When the ignition switch is off within 30s after the and the door is locked by the mechanical key
position lamp goes out, the reading lamps will illuminate
• When the vehicle is in anti-theft state
gradually.
• When the vehicle is locked externally
• If any door is opened, the reading lamps will illuminate
• When the ignition switch in "START" position
gradually.
LEDInterior Backlight
• If the interior lamps illuminate, all doors are in the closed
state. When the ignition switch is shifted to "OFF" When the position lamp is enabled, the interior backlight
position from "ACC" or "ON" position, the interior illuminates.
lamps will dim gradually in 30s.

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Lighting Systems Lighting

Service Procedures Rearview Mirror and Lamp Leveling Switch

Interior Lamp Assembly Remove
Remove 1. Disconnect the battery negative.
1. Disconnect the battery negative. 2. Remove the driver side lower trim panel assembly.
2. Remove the glass cover of reading lamp. Driver Side Lower Trim Panel Assembly Remove
3. Disconnect the harness connector.
4. Remove the instrument panel light control switch.
Refit
1. Connect the connector of the light control switch.
2. Insert the instrument panel light control switch into the
driver side lower trim panel.
3. Fit the driver side lower trim panel assembly.

Driver Side Lower Trim Panel Assembly Refit

4. Connect the battery negative.

3. Remove 2 self-tapping screws from reading lamp

bracket.
4. Pry up the clips, remove the reading lamp.

5. Disconnect the electrical connector.

Refit
1. Disconnect the electrical connector.
2. Refit 2 self-tapping screws to the lamp bracket, tighten
to 1.5–2Nm.
3. Refit the glass cover of reading lamp.
4. Connect the battery negative.
5. Reading Lamp Refit.

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Lamps Lighting Systems
Lamps
Specifications
Torque
Description Value
Bolt - headlamp assy 3–5Nm
Bolt - rear lamp assy 3–5Nm

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Lighting Systems Lamps

Description and Operation

System Layout
Exterior Lighting Layout

1. Headlamp 6. Tail Lamp

2. Hazard Warning Lamp Switch 7. Rear Fog Lamp
3. Body Control Module 8. Lamp Lever Switch
4. High-mounted Stop Lamp 9. Side Direction Indicator Lamp
5. Rear License Plate Lamp

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Lamps Lighting Systems
System Control Diagram

A = HS CAN Bus; B = Hard Wire

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Lighting Systems Lamps

Description Headlamp
Overview Headlamp (low configuration)
The exterior lighting system includes all external lamps, which
are controlled by the master light switch and auto lamp control
sensor. Exterior lighting system includes:

• Headlamp
• Side Direction Indicator Lamp
• Tail Lamp
• High-mounted Stop Lamp
• Rear Fog Lamp
• Rear License Plate Lamp
Lamp Lever Switch
1. Front Width Lamp/Daytime Running Lamp (bulb)
2. Front Direction Indicator Lamp (bulb)
3. High/Low Beam (bulb)

The headlamp is fixed on the upper radiator beam with

screws. There are two types of headlamps: high configuration
headlamp and low configuration headlamp.

The headlamp assembly includes the high/low beam, front

width lamp/daytime running lamp and front direction indicator
lamp. The high/low beam of the high configuration headlamp
and the front direction indicator lamp are equipped with
halogen bulbs, the front width lamp/daytime running lamp
are LEDs, while the low configuration front width lamp is
The lamp lever switch is located at the left side of the steering provided with the halogen bulb.
column, which controls the front lamps and rear lamps. Tail Lamp
Headlamp
Headlamp (high configuration)

1. Rear Width Lamp (LED)

1. Front Width Lamp/Daytime Running Lamp (LED) 2. Brake Lamp (bulb)
2. Front Direction Indicator Lamp (bulb) 3. Reverse Lamp (LED)
3. High/Low Beam (bulb) 4. Rear Direction Indicator Lamp (bulb)

The tail lamp is fitted on the body by bolts, which includes the
rear width lamp, brake lamp, reverse lamp and rear direction
indicator lamp.

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Lamps Lighting Systems
Rear Fog Lamp Bulb Specification
Bulb Type Voltage Power
High Beam and HB3 LL 12V 60W
Low Beam
Front Direction PY21W 12V 21W
Indicator Lamp
Front Width LED
Lamp/Daytime
Running
Lamp (high
configuration)
Front Width W5W 12V 5W
Lamp (low
1. Rear Fog Lamp (bulb) configuration)
Side Direction WY5W 12V 5W
Rear fog lamps are on the rear bumper. The bulbs extend from Indicator Lamp
the lens gaps of the lamps and illuminate the area around the High-mounted W5W 12V 5W
lens. Stop Lamp
Rear Fog Lamp P21W 12V 21W
Side Direction Indicator Lamp
Rear Width Lamp LED
The bulb of the side direction signal lamp is integrated in the
Reverse Lamp LED
exterior rearview mirror.
License Plate W5W 12V 5W
Centre High-mounted Stop Lamp (CHMSL) Lamp
The high-mounted stop lamp is above the rear window, which Brake Lamp P21W 12V 21W
is a bulb high-mounted stop lamp fixed with clips to the tail Rear Direction WY16W 12V 16W
gate panel. Indicator Lamp
Rear License Plate Lamp
The two rear license plate lamps are fitted on the rear bumper.

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Lighting Systems Lamps

Operation activated, the triangle mark on the switch will flash. When the
Overview position lamp or headlamp is enabled, the triangle mark dims,
but it will still flash. The hazard warning lamp can be activated
BCMIt controls the following exterior lamps:
manually regardless of current position of the ignition switch.
• Low Beam
Operation Priority of Direction Indicator Lamp and Hazard
• High Beam Warning Lamp
• Rear Fog Lamp
If the direction indicator lamp switch is enabled when the
• Position Lamp/Tail Lamp hazard warning lamp is working, the direction indicator lamp
• Rear License Plate Lamp will cancel the hazard warning lamp. Then, the hazard warning
• Daytime Running Lamp (if equipped) lamp will still flash after the direction indicator lamp switch or
ignition switch is disabled.
BCMIt monitors the following exterior lamps:
If the hazard warning lamp switch is enabled when the direction
• Reverse Lamp
indicator lamp is working, the hazard warning lamp will cancel
BCMIt controls and monitors the following exterior lamps: the direction indicator lamp. The direction indicator lamp will
resume after the hazard warning lamp is disabled.
• Direction Indicator Lamp (excluding side direction
indicator lamp) The hazard warning lamp can be activated automatically under
• Hazard Warning Lamp the following situations:
Brake Lamp In case of impact, when the BCM detects an impact signal, it
When the brake pedal is depressed, the brake lamp illuminates, will activate the hazard warning lamp automatically. Accidental
and the ECM monitors the brake lamp through the hard wire activation of the hazard warning lamp during impact can be
and sends the braking status signal to other ECUs to use cancelled by pressing the hazard warning lamp switch for more
through the CAN bus. than 5s.

Direction Indicator Lamp Low Beam Headlamp

When the ignition switch is in "ON" position and the When the ignition switch is in "ON" position, and the lamp
direction indicator lamp switch is enabled, the BCM flashes lever switch is turned to the low beam, the low beam headlamp
the corresponding direction indicator lamp by identifying illuminates. The low beam headlamp is controlled by the relay
the switch status of the direction indicator lamp. Then the in the BCM.
direction indicator lamp on the instrument pack flashes and High Beam Headlamp
provides the current status of the direction indicator lamp for
When the ignition switch is in "ON" position, the BCM closes
the driver by acoustic warning.
the high beam relay and illuminates the high beam headlamp
Rear Fog Lamp by identifying the status of the lamp lever switch. When the
When the ignition switch is in "ON" position, the low beam high beam is enabled, the indicator of high beam on the IPK
headlamp is enabled, then the activation of the rear fog lamp illuminates.
switch can illuminate the rear fog lamp. The BCM sends the Position Lamp / Tail Lamp & License Plate Lamp
ON/OFF status of the rear fog lamp to the IPK by receiving
The position lamp/tail lamp and license plate lamp are
the activation signal of the rear fog lamp, and the indicator of
controlled by the same output port of the BCM. When
rear fog lamp on the IPK illuminates. When the rear fog lamp
moving the headlamp and width lamp knobs to "WIDTH
switch, low beam headlamp or front fog lamp (if equipped) is
LAMP" position, the BCM can detect the ON signal of the
disabled, the rear fog lamp is cancelled. If the rear fog lamp is
width lamp/tail lamp and license plate lamp and output signals
already activated at the time of engine start, it will remain ON.
to turn on an external relay, so that the width lamp/tail lamp
Hazard Warning Lamp and license plate lamp will illuminate simultaneously.
The hazard warning lamps is comprised of the front/rear Reverse Lamp
direction indicator lamp and side direction indicator lamp.
With the ignition switch in "ON" position, the reverse lamp
The hazard warning lamp switch is marked with a triangle, illuminates when the shift lever is moved to "R" gear.
which is a touch switch. When the hazard warning lamp is

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Lamps Lighting Systems
Note: For vehicles with automatic transmission, to With the Follow Me Home activated, pull the high beam
avoid shifting to "R" gear and illuminating the headlamp lever or shift the ignition switch to disable the
reverse lamp accidentally, when the BCM detects Follow Me Home.
that the shift lever is in "R" gear, it will hold
When enabled ignition switch, alternator failure or battery
it there for more than 1s before illuminating the
overdischarge is detected, the Follow Me Home cannot work
reverse lamp.
properly.
Additional Function
Lamp of Security System
Follow Me Home
If the BCM receives a valid request signal of the outside lock,
When the driver turns off the ignition switch and is about to
and the vehicle is in the security system, locked or completely
leave the vehicle, the Follow Me Home function can control the
in the anti-theft state, it controls the direction indicator lamp
illumination of the low beam headlamp to illuminate the area
to give 3 flashes.
around the vehicle. The following lamps can provide Follow
Me Home function: low beam headlamp. If the anti-theft function of the security system is disabled, the
direction indicator lamp gives 1 flash.
The BCM can identify the status of the Follow Me Home
function according to the activation signal of this function. If the vehicle is not fully locked (bonnet, luggage compartment
lid or door is open), the direction indicator lamp will not flash.
The Follow Me Home function can be set by manual mode as
follows:

After the ignition switch is off, turn the lamp lever switch to the
steering wheel, the system enters into the Follow Me Home
mode.

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Lighting Systems Lamps

Service Procedures Integrated High/Low Beam Bulb

Headlamp Assembly Remove
Remove 1. Disconnect the battery negative.
1. Disconnect the battery negative. 2. Turn the high/low beam bulb cover counterclockwise
2. Remove the front bumper. to an appropriate position, and remove the bulb cover.

Front Bumper Remove 3. Turn the integrated high/low beam bulb

counterclockwise, and disconnect the harness
3. Remove 4 bolts fixing the headlamp to the body.
connector.

4. Disconnect the connector from the headlamp assembly. Refit

5. Remove the headlamp assembly. 1. Connect the harness connector, and fit the integrated
Refit high/low beam to the headlamp assembly.
1. Connect the electrical connector. 2. Fit the high/low beam bulb covers.
2. Fix the headlamp assembly to the body, fit 4 bolts, 3. Connect the battery negative.
tighten to 3–5Nm, and check the torque.
3. Fit the front bumper.

Front Bumper Refit

4. Connect the battery negative.

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Lamps Lighting Systems
Front Position Lamp Front Direction Indicator Lamp
Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Turn the front position lamp bulb cover 2. Turn the front direction indicator lamp bulb cover
counterclockwise to an appropriate position, counterclockwise to an appropriate position, and
and remove the bulb cover. remove the bulb cover.

3. Turn the front position lamp holder counterclockwise 3. Turn the front direction indicator lamp holder
and remove the holder. counterclockwise and remove the holder.
4. Remove the bulb from the lamp holder and discard it. 4. Remove the bulb from the lamp holder and discard it.
Refit Refit
1. Fit the new bulb into the lamp holder. 1. Fit the new bulb into the lamp holder.
2. Fit the bulb holder to the headlamp assembly. 2. Fit the bulb holder to the headlamp assembly.
3. Fit the front position lamp bulb cover. 3. Fit the front direction indicator lamp bulb cover.
4. Connect the battery negative. 4. Connect the battery negative.

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Lighting Systems Lamps

Bulb – Indicator – Side Repeater High-mounted Stop Lamp Assembly

Remove Remove
1. Disconnect battery earth lead. 1. Disconnect the battery negative.
2. Carefully prise off appropriate door mirror glass. 2. Open the tail gate, pry off the trim panel of the
3. Remove bulb holder from mirror base. high-mounted stop lamp with an appropriate tool, and
remove the high-mounted stop lamp assembly.
3. Disconnect the connector of the high-mounted stop
lamp (1).
4. Remove 3 screws (2) fixing the high-mounted stop lamp
to the trim panel of the high-mounted stop lamp, and
remove the lamp to replace the bulb.

4. Remove bulb
Refit
1. Fit bulb to holder.
2. Lightly lubricate bulb rubber holder.
3. Fit bulb holder to mirror.
4. Align mirror glass, press to engage clips. Refit
5. Connect battery earth lead. 1. Connect the harness connector, locate the trim panel of
the high-mounted stop lamp to the mounting position
of the tail gate, press the trim panel gently, and fit the
clip in place.
2. Connect the battery negative.

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Lamps Lighting Systems
Tail Lamp Assembly Tail Lamp Assembly Bulb
Remove Remove
1. Disconnect the battery negative. 1. Remove the tail lamp assembly.
2. Remove 2 bolts fixing the tail lamp assembly to the Tail Lamp Assembly Remove
body.
2. Turn the rear brake lamp holder (1) counterclockwise
to remove it.
3. Turn the direction indicator lamp holder (2)
counterclockwise to remove it.

3. Release the tail lamp assembly and disconnect the

connector.
4. Remove the tail lamp assembly.
Refit 4. Remove the bulb from the lamp holder and discard it.
1. Connect the connector of the tail lamp, fix the tail lamp Refit
assembly to the body, fit 2 bolts, tighten to 3–5Nm, 1. Fit the new bulb into the lamp holder, and fit the holder
and check the torque. into the tail lamp assembly.
2. Connect the battery negative. 2. Fit the tail lamp assembly.

Tail Lamp Assembly Refit

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Lighting Systems Lamps

Rear License Plate Lamp Assembly

Remove
1. Disconnect the battery negative.
2. Remove the rear bumper.
Rear Bumper Remove
3. Loosen the clip securing the rear license plate lamp
from the outside of the bumper, and remove the rear
license plate lamp assembly.

Refit
1. Insert the rear license plate lamp into the rear bumper.
2. Fit the rear bumper.

Rear Bumper Refit

3. Connect the battery negative.

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Door Body Systems
Door
Specifications
Torque
Description Value
Bolt - door hinge to door 22–28Nm
Bolt - striker to door body 25±5Nm
Bolt - door hinge to body 30–36Nm
Bolt - door checker to body 19–25Nm
Bolt - door handle–outer to door panel 3.5–5Nm
Bolt - latch assy to door inner panel 8–10Nm
Bolt - division bar to door 6–8Nm
Bolt - glass to regulator 2–4Nm
Nut - regulator to door 6.5–7.5Nm
Bolt - window regulator guide rail to door 7–10Nm
Bolt - glass holder 7–10Nm
Bolt - glass to window regulator guide rail 7–10Nm

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Body Systems Door

Service Procedures Front Door Assembly and Hinge

Front Door Adjustment Remove
Protect the edges of the door panel from scratch with tapes. 1. Disconnect the battery negative.
An assistant is required to support the door in the adjustment 2. Open the front door.
process.
3. Put the wood block on the jack, and put the jack under
Door Hinge Adjustment the door to support the front door.
1. Put the wood block on the jack, and put the jack under 4. Remove and discard 1 bolt fixing the door check to
the body to support the front door. the body side.
2. Unscrew 4 bolts fixing the upper/lower door hinges to
the front door.

5. Pry off the rubber seal ring, pull out the body harness,
and disconnect the harness connector of the body.
3. Support the door with the jack and adjust it to the 6. With the help of an assistant, hold the door, remove
correct position. and discard 4 bolts (2) fixing the upper/lower hinges to
4. When the required effect is achieved by adjustment, the door side.
tighten the door hinge bolts to the specified torque 7. Remove the front door assembly.
22–28Nm.
8. Remove and discard 2 bolts (1) fixing the upper hinge
Striker Adjustment to the body, and remove the front door upper hinge.
1. Open/close the door to evaluate its close property. 9. Remove and discard 3 bolts (1) fixing the lower hinge
2. Loosen 2 striker screws. to the body, and remove the front door lower hinge.
3. Adjust the striker to an appropriate position.
4. Tighten the striker to the body screw to 25±5Nm.

Refit
1. Fit 2 new bolts fixing the upper hinge to the body,
tighten to 30–36Nm, and check the torque.
2. Fit 3 new bolts fixing the lower hinge to the body,
tighten to 30–36Nm, and check the torque.
3. With the help of an assistant, locate the door to the

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Door Body Systems
body. Driver Side Door Outside Handle and Private
4. Connect the harness connector of the body, and insert Lock
the rubber seal ring into the mounting hole of the body. Remove

5. Fit the new bolts fixing the front door upper/lower 1. Ensure that the window is fully lifted.
hinges to the door side respectively, but do not tighten 2. Disconnect the battery negative.
them. 3. Remove the driver door interior trim panel.
6. Fit the new bolts fixing the door check to the body
Front Door Interior Trim Panel Remove
side, tighten to 19–25Nm, and check the torque.
4. Remove the waterproof membrane.
7. Close the door and check if the door can be properly
5. Release the clips（1）of connecting rod securing the
opened or closed, and make the adjustment. Tighten
outer handle and lock cylinder.
the bolts fixing the upper/lower hinges to the door side
to 22–28Nm, and check the torque. 6. Remove the retaining bolts (2) of outer door handle.
8. Connect the battery negative.

7. Remove the lock inside the door.

8. Remove the outer door handle.
Refit
1. Locate the outer door handle to front door via-hole.
2. Refit the lock to the outer door handle.
3. Engage the connecting rod securing the outer handle
and lock cylinder in corresponding clips.
4. Refit the 2 retaining bolts from the outer handle to the
door, secure them to3.5–5Nm. And check the torque.
5. Refit the waterproof membrane.
6. Refit the driver door interior trim panel.

Driver Door Interior Trim Panel Refit

7. Connect the battery negative.

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Body Systems Door

Driver Door Lock Body Assembly

Remove
1. Ensure that the window is fully lifted.
2. Disconnect the battery negative.
3. Remove the driver door interior trim panel.

Front Door Interior Trim Panel Remove

4. Remove the waterproof membrane.
5. Loosen the clips of 2 connecting rods connecting to the
outer door handle and door lock cylinder.
6. Unscrew 3 bolts securing the door lock.

Refit
1. Connect the inner handle cable to the lock body.
2. Refit the door lock inside the door cavity from the
inside of door carefully and locate it.
3. Refit 3 retaining bolts of the door lock in sequence
from top to bottom, the tightening torque is 8–10Nm.
4. Carefully secure 2 door lock cables connecting to outer
door handle and door lock cylinder with clips by using
a flat blade screwdriver.
5. Connect the electrical connector.
6. Refit the door waterproof membrane.
7. Pull out the lock body from the door cavity to
7. Refit the interior trim panel of the door.
disconnect the electrical connector of the door lock.
Front Door Interior Trim Panel Refit
8. Pull the outer door handle, and check if it is firmly
connected with the door lock cable.
9. Connect the battery negative.

8. Disconnect the inner handle cable from the lock body

to remove the lock body assembly.

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Door Body Systems
Front Passenger Door Outside Handle Rear Door Adjustment
Remove Protect the edges of the door panel from scratch with tapes.
1. Ensure that the window is fully lifted. An assistant is required to support the door in the adjustment
2. Disconnect the battery negative. process.

3. Remove the front passenger door interior trim panel. Door Hinge Adjustment
1. Put the wood block on the jack, and put the jack under
Front Door Interior Trim Panel Remove
the body to support the rear door.
4. Remove the waterproof membrane.
2. Loosen 4 bolts fixing the upper/lower door hinges to
5. Loosen the clip at outer handle connecting rod and the rear door.
outer handle.
6. Remove 2 bolts securing the outer door handle.

3. Adjust the door to an appropriate position.

4. When the required effect is achieved by adjustment,
7. Remove the outer door handle. tighten the hinge bolts to the specified torque
Refit 22–28Nm.
1. Locate the passenger side outer door handle to the Striker Adjustment
via-hole of right front door. 1. Open/close the door to evaluate its close property.
2. Refit the retaining bolts of outer door handle from the 2. Loosen 2 striker screws.
door cavity, the tightening torque is 3.5–5Nm. 3. Adjust the striker to an appropriate position.
3. Engage the connecting rod into the clips of outer 4. After the adjustment, tighten the screws to 25±5Nm.
handle.
4. Refit the waterproof membrane.
5. Refit the driver side door interior trim panel.

The Front Door Interior Trim Panel Refit

6. Connect the battery negative.

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Body Systems Door

Rear Door Assembly and Hinge body.

Remove 4. Connect the harness connector of the body, and insert
1. Disconnect the battery negative. the rubber seal ring into the mounting hole of the body.
2. Open the rear door. 5. Fit the new bolts fixing the rear door upper/lower
3. Put the wood block on the jack, and put the jack under hinges to the door side respectively, but do not tighten
the door to support the rear door. them.

4. Remove and discard 1 bolt fixing the door check to 6. Fit the new bolts fixing the door check to the body
the body side. side, tighten to 19–25Nm, and check the torque.
7. Close the door and check if the door can be properly
opened or closed, and make the adjustment. Tighten
the bolts fixing the upper/lower hinges to the door side
to 22–28Nm, and check the torque.
8. Connect the battery negative.

5. Pry off the rubber seal ring, pull out the body harness,
and disconnect the harness connector of the body.
6. With the help of an assistant, hold the door, remove
and discard 4 bolts (2) fixing the upper/lower hinges to
the door side.
7. Remove the rear door assembly.
8. Remove and discard 2 bolts (1) fixing the upper hinge
to the body, and remove the rear door upper hinge.
9. Remove and discard 3 bolts (1) fixing the lower hinge
to the body, and remove the rear door lower hinge.

Refit
1. Fit 2 new bolts fixing the upper hinge to the body,
tighten to 30–36Nm, and check the torque.
2. Fit 3 new bolts fixing the lower hinge to the body,
tighten to 30–36Nm, and check the torque.
3. With the help of an assistant, locate the door to the

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Door Body Systems
Rear Door Outer Handle Rear Door Catch/CDL Motor
Remove Remove
1. Ensure that the window is fully lifted. 1. Ensure door glass is fully raised.
2. Disconnect the battery negative. 2. Disconnect battery earth lead.
3. Remove the rear door interior trim panel. 3. Remove door trim panel.

The Rear Door Interior Trim Panel Remove Rear Door Trim Panel Remove
4. Remove the waterproof membrane. 4. Remove the waterproof membrane, take care not to
5. Loosen the clip 1 of outer handle connecting rod. damage membrane.

6. Remove 2 bolt 2 securing the outer handle from door 5. Release out handle to catch release rod clip, remove
cavity. rod.
6. Disconnect electrical connector.

7. Remove the outer door handle.

Refit 7. Remove 3 door lock/CDL motor retaining bolts.

1. Locate the outer door handle to the via-hole of rear

door.
2. Engage the lock body connecting rod into the clips of
outer handle.
3. Refit 2 bolts securing the outer handle from the door
cavity, secure to 3.5–5Nm.
4. Refit the waterproof membrane.
5. Refit the rear door interior trim panel.

Rear Door Interior Trim Panel Refit

6. Connect the battery negative.

8. Manipulate catch/motor to remove release cable.

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Body Systems Door

Front Door Upper Molding

Remove
1. Remove door outer weatherstrip.
Outer Weatherstrip Remove
2. Remove front quarter light glass.
Front Quarter Light Glass Remove
3. Release seal at upper door pillar corner, remove torx
screw.

9. Remove catch/motor.
Refit
1. Position door catch/CDL motor in door.
2. Refit release cable.
3. Fit door catch bolts, tighten to8–10Nm.
4. Refit handle release rod to clip, secure clip.
5. Reconnect electrical connector.
6. Refit waterproof membrane.
4. Remove inner door glass weatherstrip (felt trim).
7. Refit door trim panel.
5. Release door glass channel from door.
Rear Door Trim Panel Refit
6. Drill out upper moulding pop rivets, ensure all debris
8. Connect battery earth lead. is retrieved.

7. Remove trim.
Refit
1. Position upper moulding on door.
2. Secure using new pop rivets.
3. Refit torx screw.
4. Refit front quarter light glass.
Front Quarter Light Glass Refit
5. Refit door glass channel to door.
6. Refit inner door glass weatherstrip.
7. Refit outer weatherstrip on door.
Outer Weatherstrip Refit

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Door Body Systems
Rear Door Upper Molding Door Window Outer Weatherstrip
Remove Remove
1. Remove door outer weatherstrip. 1. Using suitable trim tool, prise weatherstrip up from
Outer Weatherstrip Remove door starting at front end.

2. Remove rear quarter light glass. 2. Remove weatherstrip.

Rear Quarter Light Glass Remove Refit

3. Release seal at upper door pillar corner, remove torx 1. Position weatherstrip on door.
screw. 2. Use suitable rubber mallet to locate clips onto door
starting at front.

4. Remove inner door glass weatherstrip (felt trim).

5. Release door glass channel from door.
6. Drill out upper moulding pop rivets, ensure all debris
is retrieved.

7. Remove trim.
Refit
1. MPosition upper moulding on door.
2. Secure using new pop rivets.
3. Refit torx screw.
4. Refit rear quarter light glass.
Rear Quarter Light Glass Refit
5. Refit door glass channel to door.
6. Refit inner door glass weatherstrip.
7. Refit outer weatherstrip on door.
Outer Weatherstrip Refit

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Body Systems Door

Front Door Window Glass Rear Door Window Glass

Remove Remove
1. Open the front door. 1. Open the rear door.
2. Disconnect the battery negative. 2. Disconnect the battery negative.
3. Remove the front door interior trim panel and the 3. Remove the rear door interior trim panel and the
waterproof membrane. waterproof membrane.

Front Door Interior Trim Panel and Waterproof Rear Door Interior Trim Panel and Waterproof
Membrane Remove Membrane Remove

Caution: Before taking down the panel, please raise the Caution: Before taking down the panel, please raise the
glass so that the bolts is just in the mounting holes of the glass so that the bolts is just in the mounting holes of the
door. door.

4. Remove 2 screws fixing the front door window glass 4. Remove 2 screws fixing the rear door window glass
to the window regulator. to the window regulator.

5. Release 2 fasteners of the guide rail of the front door 5. Release 2 fasteners of the guide rail of the rear door
window glass. window glass.
6. Carefully remove the door window glass from the door 6. Carefully remove the door window glass from the door
cavity. cavity.
Refit Refit
1. Fit the glass into the door cavity and then to the guide 1. Fit the glass into the door cavity and then to the guide
rail of the front door window glass. rail of the rear door window glass.
2. Fit the bolt of the guide rail of the front door window 2. Fit the bolt of the guide rail of the rear door window
glass, and tighten to 6–8Nm. glass, and tighten to 6–8Nm.
3. Fit the glass to the window regulator, secure with 2 3. Fit the glass to the window regulator, secure with 2
screws, and tighten to 2–4Nm. screws, and tighten to 2–4Nm.
4. Fit the front door interior trim panel and the 4. Fit the rear door interior trim panel and the waterproof
waterproof membrane. membrane.
Front Door Interior Trim Panel and Waterproof Rear Door Interior Trim Panel and Waterproof
Membrane Refit Membrane Refit
5. Connect the battery negative. 5. Connect the battery negative.

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Door Body Systems
Front Door Window Regulator Rear Door Window Regulator
Remove Remove
1. Remove door glass. 1. Remove door glass.

Front Door Glass Remove Rear Door Glass Remove

2. Disconnect door mirror harness connector, position 2. Remove 7 glass regulator fixings.
aside.
3. Remove 7 glass regulator fixings.

3. Manipulate glass regulator from door.

Refit
4. Manipulate glass regulator from door. 1. Position regulator in door.
Refit 2. Fit 7 fixings, tighten to 6.5–7.5Nm.
1. Position regulator in door. 3. Refit door glass.
2. Fit 7 fixings, tighten to 6.5–7.5Nm.
Rear Door Glass Refit
3. Connect door mirror harness, secure connection to
door.
4. Refit door glass.

Front Door Glass Refit

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Body Systems Door

Front Door Window Regulator Adjustment Rear Door Window Regulator Adjustment
Adjustment Adjustment
1. Open the front door. 1. Open the rear door.
2. Disconnect the battery negative. 2. Disconnect the battery negative.
3. Remove the front door interior trim panel and the 3. Remove the rear door interior trim panel and the
waterproof membrane. waterproof membrane.

Front Door Interior Trim Panel and Waterproof Rear Door Interior Trim Panel and Waterproof
Membrane Remove Membrane Remove

Caution: Before taking down the panel, please raise the Caution: Before taking down the panel, please raise the
glass so that the bolts is just in the mounting holes of the glass so that the bolts is just in the mounting holes of the
door. door.

4. Loosen 2 clamping screws (1) fixing the front door 4. Loosen 2 clamping screws (1) fixing the rear door
window glass to the window regulator. window glass to the window regulator.
5. Loosen 7 mounting nuts (2) securing the window 5. Loosen 7 mounting nuts (2) securing the window
regulator. regulator.

6. Adjust the window so as to make it engage well with the 6. Adjust the window so as to make it engage well with the
seals on both ends and ensure the window works well. seals on both ends and ensure the window works well.
7. Tighten 7 mounting nuts securing the window regulator 7. Tighten 7 mounting nuts securing the window regulator
to 7–10Nm, and check the torque. to 7–10Nm, and check the torque.
8. Tighten 2 clamping screws of the window to 7–10Nm, 8. Tighten 2 clamping screws of the window to 7–10Nm,
and check the torque. and check the torque.
9. Raise and lower the window glass to check the 9. Raise and lower the window glass to check the
operation and positioning. operation and positioning.
10. Fit the front door interior trim panel and the 10. Fit the rear door interior trim panel and the waterproof
waterproof membrane. membrane.

Front Door Interior Trim Panel and Waterproof Rear Door Interior Trim Panel and Waterproof
Membrane Refit Membrane Refit
11. Connect the battery negative. 11. Connect the battery negative.
12. Check if the window glass regulator can work. 12. Check if the window glass regulator can work.

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Door Body Systems
Front Door Glass Channel Rear Door Glass Channel
Remove Remove
1. Remove front door glass. 1. Remove rear door glass.

Front Door Glass Remove Rear Door Glass Remove

2. Release glass channel from division bar, door and rear 2. Release glass channel from division bar, door and front
channel guide. channel guide.
3. Remove rubber channel. 3. Remove rubber channel.
Refit Refit
1. Position rubber channel in door. 1. Position rubber channel in door.
2. Fit channel into rear channel guide, door and division 2. Fit channel into front channel guide, door and division
bar. bar.
3. Refit front door glass. 3. Refit rear door glass.
Front Door Glass Refit Rear Door Glass Refit

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Body Systems Door

Front Door Division Bar Rear Door Division Bar

Remove Remove
1. Remove front door glass. 1. Remove rear door glass.

Front Door Glass Remove Rear Door Glass Remove

2. Release glass channel from division bar. 2. Release glass channel from division bar.
3. Remove 2 fixing screws. 3. Remove 2 fixing screws.

4. Remove division bar. 4. Remove division bar.

Refit Refit
1. Position division bar in door. 1. Position division bar in door.
2. Fit screws, tighten to 6–8Nm. 2. Fit screws, tighten to 6–8Nm.
3. Refit glass channel to division bar. 3. Refit glass channel to division bar.
4. Refit front door glass. 4. Refit rear door glass.
Front Door Glass Refit Rear Door Glass Refit

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Door Body Systems
Power Window Switch - Driver Power Window Switch - Others
Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Pry off the screw trim cover of the power window 2. Pry off the screw trim cover of the power window
switch. switch.
3. Remove 1 screw fixing the power window switch to 3. Remove 1 screw fixing the power window switch to
the door. the door.
4. Remove the power window switch from the door 4. Remove the power window switch from the door
interior trim panel, and disconnect the harness interior trim panel, and disconnect the harness
connector. connector.
Refit Refit
1. Connect the connector of the power window switch. 1. Connect the connector of the power window switch.
2. Fix the power window switch to the door interior trim 2. Fix the power window switch to the door interior trim
panel, fit and tighten 1 screw. panel, fit and tighten 1 screw.
3. Fit the screw trim cover of the power window switch. 3. Fit the screw trim cover of the power window switch.
4. Connect the battery negative. 4. Connect the battery negative.

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Body Systems Door

Central Control Door Lock Switch

Remove
1. Disconnect the battery negative.
2. Remove the driver door interior trim panel.
Front Door Interior Trim Panel Remove
3. Remove the door lock switch from the door interior
trim panel.
Refit
1. Fix the door lock switch to the door interior trim panel.
2. Fit the driver door interior trim panel.

Front Door Interior Trim Panel Refit

3. Connect the battery negative.

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Front Closures Body Systems
Front Closures
Specifications
Torque
Description Value
Nut - fender to body 7–10Nm
Screw - front bumper support bracket 3–4Nm
Bolt - headlamp assy 3–5Nm
Bolt - head lamp bracket to MFE 7–10Nm
Bolt-Expansion Tank stand to Body 7–10Nm
Bolt-intercooler to platform 4–6Nm
Bolt - hood hinge to body 26–34Nm
Nut - hood hinge to hood panel 19–25Nm
Nut - hood hinge to hood 26–34Nm
Bolt - hood latch to platform 7–10Nm

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Body Systems Front Closures

Service Procedures
Fender
Remove
1. Remove the front bumper assembly.

Front Bumper Assembly Remove

2. Loosen 1 bolt above the headlamp.

12. Remove the bolt (4) fixing the middle bracket of the
fender to the fender, and remove the middle bracket.
13. Remove 2 clips (8) connecting the fender to the
acoustic pad, and remove the acoustic pad of the fender.
Refit
1. Locate the acoustic pad of the fender to the fender,
and fit the clip.
3. Remove the A pillar exterior trim panel.
2. Locate and adjust the fender.
A Pillar Exterior Trim Panel Remove 3. Locate the middle bracket to the fender, fit the bolt
4. Remove 4 screws securing the left and right mounting fixing the middle bracket to the fender, tighten to
brackets of the front bumper, and remove the brackets. 7–10Nm, and check the torque.
5. Remove 2 bolts (1) fixing the fender to the front 4. Fix the fender to the body, do not tighten the bolt.
bracket of the fender. 5. Adjust the gap between the fender and adjacent panels
6. Remove 2 bolts (2) fixing the fender to the front upper and ensure uniform gap. Then tighten 6 bolts fixing the
bracket of the fender. fender to the body to 7–10Nm, and check the torque.
7. Remove 1 bolt (3) at the side corner of the A/C air And tighten 2 screws fixing the fender to the body.
inlet grille. 6. Fit the front bumper bracket, tighten 4 screws fixing
8. Remove 1 bolt securing the middle bracket of the the left and right brackets of the front bumper to the
fender from the door. body to 3–4Nm, and check the torque.
9. Remove 1 screw (5) connecting the bottom of the 7. Fit the A pillar exterior trim panel.
fender to the body. A Pillar Exterior Trim Panel Refit
10. Remove 1 bolt (6) connecting the bottom of the fender 8. Tighten the bolt above the headlamp to 3–5Nm, and
to the bodyside outer panel and 1 screw (7) to the check the torque.
wheelhouse liner.
9. Fit the front bumper assembly.
11. Remove the fender.
Front Bumper Assembly Refit

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Front Closures Body Systems
Front-end Module 10. Disconnect the bonnet lock release cable assembly
Remove from the lock assembly to remove the lock assembly.
1. Remove the front bumper assembly. Bonnet Lock Assembly Remove
Front Bumper Remove 11. Remove the front bumper beam.
2. Remove the headlamp assembly. Front Bumper Beam Remove
Headlamp Assembly Remove 12. Remove the tweeter harness from the front-end
3. Remove the wind scoopers on both sides. module.

Wind Scooper - Left Remove 13. Remove the reservoir oil return pipe assembly.

Wind Scooper - Right Remove Reservoir Oil Return Pipe Assembly Remove

4. Remove 4 bolts fixing the middle support bracket of 14. Remove 2 screws connecting the front-end module to
the front bumper to the upper part of the front-end the radiator shock pad to disconnect the front-end
module, and remove the middle support bracket of the module intercooler and radiator, and remove the
front bumper. front-end module.

5. Remove the bolt fixing the bottom deflector to the

front-end module.
Bottom Deflector Remove
6. Remove the air inlet pipe assembly.
Air Inlet Pipe Remove
7. Remove 2 bolts connecting the upper mounting panel
of the right headlamp and the front-end module.

Refit
1. Fix the front-end module to the intercooler and
radiator.
2. Fit the reservoir oil return pipe assembly.
Reservoir Oil Return Pipe Assembly Refit
3. Fit the tweeter harness to the front-end module.
4. Fit the front bumper beam.

8. Remove 2 bolts (1) connecting the upper mounting Front Bumper Beam Refit
panel of the left headlamp and the front-end module. 5. Fit the bonnet lock assembly.
9. Remove 2 bolts (2) fixing the bracket of the coolant Bonnet Lock Assembly Refit
expansion tank to the front-end module. 6. Locate the upper mounting panel of the right headlamp
to the front-end module, tighten 2 bolts connecting the
upper mounting panel of the right headlamp and the
front-end module to 7–10Nm, and check the torque.
7. Locate the upper mounting panel of the left headlamp
to the front-end module, tighten 2 bolts connecting
the upper mounting panel of the left headlamp and the
front-end module to 7–10Nm, and check the torque.
8. Fit 2 bolts fixing the bracket of the coolant expansion
tank to the front-end module, tighten to 7–10Nm, and
check the torque.
9. Fit the air inlet pipe assembly.
Air Inlet Pipe Refit

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Body Systems Front Closures

10. Fit the bolt fixing the bottom deflector to the front-end Bonnet Assembly and Hinge
module. Remove
Bottom Deflector Refit Warning: Take special attention to avoid vehicle damage
11. Fix the middle support bracket of the front bumper and personal injury.
to the upper part of the front-end module, fit 4 bolts, 1. Open and support the bonnet properly.
tighten to 4–6Nm, and check the torque. 2. Mark the position of the hinges relative to the bonnet
12. Fit the wind scoopers on both sides. for positioning during refitting.
3. Remove 4 nuts (2) fixing the hinges (bonnet side) on
Wind Scooper - Left Refit
both sides to the bonnet.
Wind Scooper - Right Refit
4. With assistance, remove the bonnet.
13. Fit the bonnet support rod assembly.
5. Remove 4 bolts (1) fixing the hinges (body side) on
14. Fit the headlamp assembly. both sides to the front-end of the body.
Headlamp Assembly Refit
15. Fit the front bumper assembly.

Front Bumper Refit

6. Remove the hinges on both sides.

Refit
Warning: Bonnet will drop under its own weight during
removal and refit, ensure panel is fully supported.
1. Properly locate the hinges (body side) on both sides
to the original position of the front-end hinge of the
vehicle body respectively.
2. Fit 4 bolts fixing the hinges (body side) on both sides
to the front-end of the body, tighten to 26–34Nm,
and check the torque.
3. With assistance, locate the bonnet to the vehicle, and
align it with the position marked when removing.
Caution: DO NOT damage the thread on the bolt when
inserting the bolt into the fit hole.

4. Fit 4 nuts securing the bonnet and the hinges (bonnet

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

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Front Closures Body Systems
Bonnet Adjustment
Adjustment
1. Adjust the rear part of the bonnet.

a. Mark the profile of the bonnet hinges with a non

permanent marker.

b. Loosen the nuts (2) fixing the hinges to the bonnet.

c. Adjust the clips and the bonnet bumper block to align

the bonnet with the fender.

d. Tighten the locking nuts of the clips.

e. Adjust the bumper block.

4. Adjust the gap/front rake.

a. Mark the profile of the two hinges on the vehicle

body with a non-permanent marker.
c. Adjust the bonnet and align it with the fender.
b. Loosen the bolts (1) fixing the hinges to the body.
d. Tighten the hinge nuts to 19–25Nm.

2. Rear Bonnet Height Adjustment

a. Loosen the locking nuts of the bonnet hinge.

b. Rotate the detent lever to adjust the rear part of the

bonnet to an appropriate height.

c. Adjust the position of the bonnet at lateral and

front/rear direction to align the bonnet with the
fender, and the front rake of the bonnet should be
horizontal with the fender.

d. Tighten the hinge bolts to 26–34Nm, and check

3. Adjust the front part of the bonnet.
the torque.
a. Rotate the bumper block to the end.

b. Loosen the locking nuts of the clips.

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Body Systems Front Closures

Bonnet Lock Assembly torque at this step.

Remove 5. Close the bonnet, observe the relative position of the
1. Open and support the bonnet properly. lock and lock catch, adjust the lock and allow the lock
2. Mark the lock position on the front-end module so that catch to enter into the lock tongue.
proper location can be found for refitting. 6. After adjustment, tighten 3 bolts to 7–10Nm, and
3. Disconnect the harness connector (1) of the bonnet check the torque.
lock. 7. Close the bonnet.
4. Remove 3 bolts (2) fixing the bonnet lock to the
front-end module.

5. Disconnect the bonnet lock release cable assembly

from the lock assembly to remove the lock assembly.

Refit
1. Connect the lock end of the bonnet release cable
assembly and the lock assembly firmly, i.e. fit the
spherical end of the cable core wire into the hook slot
of the bonnet lock, put the core wire into the long slot
of the bonnet lock case, and align the circular groove of
the main cable pipe connector with the mounting slot
of the lock case, then press it hard until it clicks.
2. Locate the bonnet lock assembly to the bracket of the
front-end module, and align it with the position marked
when removing.
3. Connect the harness connector of the bonnet lock.
4. Fit 3 bolts fixing the lock assembly to the bracket of the
front-end module, and do not tighten to the specified

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Front Closures Body Systems
Bonnet Release Cable and Handle onto the upper mounting panel of the left headlamp,
Remove and fit the clip into the sheet metal.
1. Open the bonnet and support it with a rod firmly. 3. Fit the bonnet lock assembly.
2. Remove the bonnet lock. Bonnet Lock Assembly Refit
Bonnet Lock Assembly Remove 4. Insert the end of the cable assembly into the base of
3. Remove the release handle of the bonnet in the the release handle.
direction of inside body and discard it. 5. Fit the A pillar lower trim panel.
A Pillar Lower Trim Panel Refit
6. Fit the new release handle of the bonnet, and ensure
the handle is pressed till the end.
7. Pull the release handle of the bonnet in the driver
compartment, and check if the bonnet works properly
when it is opened.

4. Remove the A pillar lower trim panel.

A Pillar Lower Trim Panel Remove
5. Remove the end of the cable from the base of the
release handle.

6. Loosen the clips fixing the bonnet release cable to the

upper mounting panel of the left headlamp in proper
order.
7. Release the bonnet release cable from the engine
compartment.
8. Pull the cable assembly out of the engine compartment.
Refit
1. Locate the bonnet release cable assembly to the engine
compartment, fit the flat blade end to the driver
compartment through the bulkhead hole of the front
engine compartment, and secure it in the bulkhead hole
with the rubber seal ring of the cable assembly.
2. Arrange the cable into the engine compartment and

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Body Systems Rear Closures

Rear Closures
Specifications
Torque
Description Value
Bolt -Tailgate kniqhthead to body 7–10Nm
Nut - tailgate hinge to body 26–34Nm
Bolt - tailgate hinge to tailgate panel 7–10Nm
Bolt - Tailgate hinge to tailgate 7–10Nm
Bolt - tailgate lock to tailgate panel 6–8Nm
Bolt - striker to body 8.5–11.5Nm
Bolt - fuel filler flap to body 8–12Nm

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Rear Closures Body Systems
Service Procedures Caution: To avoid damaging the airtightness of the air
Tail Gate Gas Spring and Mounting Bracket spring, never hold the centre of the air spring and laterally
Remove apply force to it by hand.
1. Open the tail gate, and when removing the tail gate, 6. Align the ball cup at piston end of the left gas spring
make sure it is securely supported. with the ball head on the tail gate inner panel. Hold the
end of the piston, push the ball cup into the ball head
Warning: As the large weight of the tailgate, operations
with thumb, if the two parts are fitted well, a "crack"
should be performed after the safety feature is set, and
sound will be heard.
take extra care to prevent the vehicle from damaging and
personal injury. 7. Repeat step 1-6 to fit the right gas spring and the
mounting bracket of the tail gate.
2. Carefully pry off the steel spring retaining clip on both
sides of the left gas spring, forcibly unplug the ball cup 8. Close the tail gate.
at piston end from the ball head of the tail gate.
3. Then pull the ball head socket of gas spring sleeve from
the ball head of left body bracket.Then forcibly unplug
the ball cup at socket end of the gas spring from the ball
head of the left body side bracket.
4. Remove 2 bolts fixing the mounting bracket of the
left gas spring to the body, and remove the gas spring
mounting bracket.

5. Repeat step 2-4 to remove the right gas spring and its
mounting bracket.
Refit
1. Align the mounting bracket of the left gas spring with
the hole on the luggage compartment.
2. Fit 2 bolts fixing the mounting bracket of the tail gate
gas spring to the body, tighten to 7–10Nm, and check
the torque.
3. Check the steel spring piece on both ball cups of the
air spring, ensure it is properly located in the spring
piece slot.
4. Align the ball cup at socket end of the gas spring with
the ball head on the left mounting bracket, and make
sure the gas spring piston is downward.
5. Hold the sleeve, push the ball cup into the ball head
with thumb, if the two parts are fitted well, a "crack"
sound will be heard.

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Body Systems Rear Closures

Tail Gate Assembly and Hinge

Remove
1. Open the tail gate.
2. Disconnect the battery negative.
3. Release the cables of the coat rack from the hooks of
the tail gate.
4. Remove the high-mounted stop lamp assembly.
High-mounted Stop Lamp Assembly Remove
5. Remove the interior trim panel of the tail gate.

Tail Gate Interior Trim Panel Remove

6. Disconnect the harness connector of the rear window
wiper motor. 11. Pry off the steel spring retaining clip on both sides of
the gas spring, forcibly unplug the ball cup at piston end
7. Disconnect the connector of the tail gate lock.
from the ball head of the tail gate, and remove the tail
8. Release the interface of the resistance heater wires at
gate assembly.
both sides of the rear window.
Warning: As the large weight of the tailgate, operations
9. As indicated by the arrow, release the harness sheath at
should be performed after the safety feature is set, and
both sides of the tail gate, draw the electrical harness
take extra care to prevent the vehicle from damaging and
from the tail gate cavity.
personal injury.
12. Remove the lock assembly and the rear window wiper
motor from the tail gate assembly as necessary.
Tail Gate Lock Assembly Remove
Rear Window Wiper Motor Remove
13. Release the roof interior trim panel at the tail gate to
access the retaining nut of the tail gate hinge.
14. Remove 2 nuts (1) fixing the left/right tail gate hinges to
the body so as to remove the tail gate hinge assembly.
Refit
1. Locate the tail gate hinge assembly to the body, fit 2
nuts, tighten to 26–34Nm, and check the torque.
10. Mark the position of the tail gate hinge on the tail 2. With the help of an assistant, locate the tail gate to the
gate with a non-permanent marker. With assistance, body, and align it with the marked position.
remove 4 bolts (2) fixing the hinges on both sides to 3. Fit the connecting bolt between the tail gate and the
the tail gate. hinge, but do not tighten to the fixed torque.
Warning: As the large weight of the tailgate, operations Warning: As the large weight of the tailgate, operations
should be performed after the safety feature is set, and should be performed after the safety feature is set, and
take extra care to prevent the vehicle from damaging and take extra care to prevent the vehicle from damaging and
personal injury. personal injury.
4. Press the ball cup at piston end of the gas spring on
both sides into the ball head of the tail gate side panel
till it clicks.
Caution: Oil seals are waxed and must not be lubricated
prior to fitting.

5. Fit the harness into the tail gate cavity, and connect the
interface of the resistance heater wires at both sides of
the windshield.
6. Connect the harness connector of the lock, and fit the

1.0 560
Rear Closures Body Systems
tail gate lock assembly. Tail Gate Adjustment
Tail Gate Lock Assembly Refit
Adjustment
1. Mark the position of the tail gate hinge on the tail gate
7. Connect the harness connector of the rear window
with a non-permanent marker.
wiper motor, and fit the wiper motor.
2. Loosen 4 bolts fixing the left and right hinges to the
Rear Window Wiper Motor Refit
tail gate.
8. Fit the high-mounted stop lamp.

High-mounted Stop Lamp Assembly Refit

9. Check and adjust the fit clearance and surface distance
between the tail gate and the bodyside/rear end panels.
After adjustment, tighten the bolt to 7–10Nm, and
check the torque.
10. Fit the interior trim panel of the tail gate.

Tail Gate Interior Trim Panel Refit

11. Hang the cables on both sides of the coat rack on the
hooks of the interior trim panel of the tail gate.
12. Connect the battery negative.
13. Close the tail gate.
3. Adjust the tail gate to make the gap between the tail
gate and the tail lamp and that between the tail gate and
the rear bumper fascia uniform and make the tail gate
flush with the tail lamp and the rear bumper fascia.
4. For gap information, please refer to Body Repair, "Body
Dimension".
5. Tighten the bolts on the tail gate hinge to 7–10Nm,
and check the torque.

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Body Systems Rear Closures

Tail Gate Lock Assembly Tail Gate Lock Catch

Remove Remove
1. Open the tail gate. 1. Open the tail gate.
2. Disconnect the battery negative. 2. Unscrew 2 bolts on the tail gate lock catch to remove
3. Remove the interior trim panel of the tail gate. the lock catch.

Tail Gate Interior Trim Panel Remove

4. Remove 2 bolts securing the lock and 1 bolt inside.

Refit
1. Locate the lock catch to the tail gate sill of the body,
ensure the arrow on the lock catch towards the inner
5. Remove the tail gate lock sleeve. of the vehicle, and pay attention to the correspondence
6. Pull the lock out of the tail gate cavity, disconnect the between the position tick mark on the lock catch and
connector, and remove the tail gate lock assembly. the tick mark on the vehicle body.
Refit 2. Secure the lock catch of the tail gate to the body with
1. Fit the lock assembly into the tail gate cavity, and bolts, but do not tighten them.
connect the connector. 3. Close and open the tail gate repeatedly for several
2. Fit 3 mounting bolts, but do not tighten them. times, check and adjust the fit clearance and the surface
distance between the tail gate and the surrounding
3. Check and adjust the fit clearance and the surface
sheet metal parts. After the adjustment is done, secure
difference between the tail gate lock and the
the bolts to 8.5–11.5Nm.
surrounding panels, then tighten the lock bolt to
6–8Nm, and check the torque. 4. Make sure that the tail gate lock is fully locked, and
check if the electrical signal of the tail gate lock is
4. Fit the tail gate lock sleeve.
correct.
5. Fit the interior trim panel of the tail gate.

Tail Gate Interior Trim Panel Refit

6. Connect the battery negative.
7. Close the tail gate.

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Rear Closures Body Systems
Fuel Filler Door Assembly Fuel Filler Door Release Cable Assembly
Remove Remove
Warning: Apply masking tape to painted body edges to 1. Open the fuel filler door.
avoid paint damage. 2. Open the tail gate, and remove the right trim panel of
1. Pull up the fuel filler door release handle under the the luggage compartment.
driver side instrument panel assembly to open the fuel
Luggage Compartment Side Trim Panel Remove
filler door.
3. Remove the luggage compartment carpet, and loosen
2. Release the fuel filler door release handle from the
the clip fixing the cable to the floor.
fuel filler door.
4. Remove the driver side A pillar lower trim panel.
3. Remove 2 mounting bolts connecting the fuel filler
door and the body. A Pillar Lower Trim Panel Remove
5. Remove the B/C pillar lower trim panel.

B/C Pillar Lower Trim Panel Remove

6. Remove the sill trim panel of the left rear door.
7. Remove the left D pillar lower trim panel.

D Pillar Lower Trim Panel Remove

8. Remove the cable from the base of the release handle.
9. Loosen all clips of the cable, and pull the cable out of
the fuel filler door.
Refit
1. Fit the handle of the fuel filler door release cable
assembly into the luggage compartment through the
4. Remove the door assembly. mounting hole on the right bodyside panel, push the
Refit filler door of the fuel filler door release cable into the
mounting hole along the hole axis till it clicks and clips
1. Locate the fuel filler door to the body, fit 2 bolts,
on both sides are completely stuck into the side panel.
tighten to 8–12Nm, and check the torque.
2. Fit the cable assembly to the rear compartment through
2. Fit the fuel filler door release cable.
the right luggage compartment, and secure the cable in
3. Verify the release operation. sequence with clips along the bottom of the rear seats
to the left compartment, then fit the cylindrical end of
the cable assembly into the notch of the release handle
base along the D pillar lower trim panel at the left side
of the body and the left sill.
3. Fit the driver side A pillar lower trim panel.

A Pillar Lower Trim Panel Refit

4. Fit the B/C pillar lower trim panel.

B/C Pillar Lower Trim Panel Refit

5. Fit the sill trim panel of the left rear door.
6. Fit the left D pillar lower trim panel.
D Pillar Lower Trim Panel Refit
7. Fit the luggage compartment carpet.
8. Fit the right trim panel of the luggage compartment.

Luggage Compartment Side Trim Panel Refit

9. Pull the fuel filler door release handle at the driver side
sill, check the connections of the fuel filler door release
cable assembly.

1.0 563
Body Systems Horns

Horns
Specifications
Torque
Description Value
Nut-Horn to Front impact bar 7–10Nm

1.0 564
Horns Body Systems
Service Procedures
Tweeter
Remove
1. Disconnect the battery negative.
2. Remove the front bumper assembly.

Front Bumper Assembly Remove

3. Disconnect the harness connector (1).
4. Remove 1 nut (2) fixing the horn to the front bumper
beam.

5. Remove the horn.

Refit
1. Fix the horn to the front bumper beam, fit 1 nut,
tighten to 7–10Nm, and check the torque.
2. Connect the harness connector.
3. Fit the front bumper.
Front Bumper Assembly Refit
4. Connect the battery negative.

1.0 565
Body Systems Body Control Module

Body Control Module

Specifications
Torque
Description Value
Bolt-Body control module to body 5–7Nm

1.0 566
Body Control Module Body Systems
Description and Operation
System Layout

1. Body Control Module (BCM)

1.0 567
Body Systems Body Control Module

System Control Diagram

A = HS CAN Bus; B = Diagnosis HS CAN Bus; C = LIN Bus; D = Hard Wire

1.0 568
Body Control Module Body Systems
Description 4 Front Wiper/Washer Switch
Mounting position: 5 Driver Window Down Switch
BCMThe BCM is on the right front side panel. 6 -

BCMIt consists of the low power microprocessor, electrically 7 Driver Side One-button Down
Switch
erasable programmable read-only memory (EEPROM),
CAN, LIN transceiver and power supply. BCMIt contains 8 Rear Wiper Homing Signal
discrete input/output terminals which controls most of the 9 Rear Wiper Switch
body functions. It interacts with other primary electrical 10 Front Wiper Mode Selection
systems through the HS CAN bus and with other secondary Switch 1
electrical systems through the LIN bus. BCMThe power 11 Right Direction Indicator Lamp
mode master control module (PMM) of the BCM provides Switch
power for most of the vehicle electric components. 12 Position Lamp Switch
The BCM communicates directly with the following 13 Driver Window Up Switch
components through the HS CAN bus: 14 Tail Gate Unlock Switch
• HVAC(Air conditioning system) 15 Driver Door Unlocked
Warning Switch
• FICM
16 Driver Door Locked with Key
• IPK Signal
• ECM 17 High Beam Flash Switch
• ABS/SCS 18 IMMO SPI Bus Data Line
• TCM (if equipped) 19 IMMO SPI Bus Clock Line
• SDM 20 N Gear/Clutch Switch
• TPMS (if equipped) 21 KL.R (ACC switch)
The body control module communicates directly with the 22 KL.15 (ignition switch)
following components through the LIN bus: 23 Reverse Gear Switch
• EBS (if equipped) 24 Low Beam Switch
• Intelligent Alternator (if equipped) 25 -
BCM Connector 26 -

The BCM has four connectors which interacts with other 27 Heated Rear Window
related systems via the harness and provides input/output 28 Front Wiper Homing Signal
signals for the BCM. 29 Front Wiper Mode Selection
Switch 2
BCM Harness Connector BY026
30 Hazard Warning Lamp Switch
31 Left Direction Indicator Lamp
Switch
32 -
33 Luggage Compartment Lid
Unlocked Warning Switch
34 Passenger Door Unlocked
Warning Switch
35 Driver Door Unlocked with
Key Signal

Pin No. Description 36 High Beam Switch

1 - 37 Rear Fog Lamp Switch

2 KL.50 38 CAN L

3 Rear Wiper/Washer Switch 39 CAN H

40 -

1.0 569
Body Systems Body Control Module

BCM Harness Connector BY025 BCM Harness Connector BY027

Pin No. Description

Pin No. Description
1 Right Direction Indicator Lamp
1 - Output
2 High Beam Relay Coil 2 Rear Fog Lamp Output
3 Horn Relay Coil 3 Luggage Compartment Motor
4 Drive the Driver Window 4 Washer Relay
Down
5 Power Supply
5 Starter Motor Relay Coil
6 -
6 -
7 Window Up/Down Function
7 - Enable
8 Safety Lock Relay Coil 8 - 10 -
9 - 11 Power Supply
10 -
BCM Harness Connector BY084
11 -
12 Door Lock Status Indicator
13 Front Compartment Cover
Switch Status Signal
14 Wiper Intermittent Time
Selection Signal
15 Front Wiper Speed Relay
16 Rear Wiper Relay Coil
17 Width Lamp Relay Coil
18 Front Wiper Enable Relay Coil
19 Wiper Analog Ground
Pin No. Description
20 -
21 - 1 Power Supply
22 - 2 Low Beam Output
23 - 3 Door Lock Output
24 - 4 Power Supply
25 Daytime Running Lamp Relay 5 Ground 1
26 - 6 Left Direction Indicator Lamp
Output
27 Internal Central Lock Switch
7 Front Reading Lamp Output
28 -
8 -
9 Warning Request Signal

1.0 570
Body Control Module Body Systems
10 Door Unlock Output
11 Ground 2

1.0 571
Body Systems Body Control Module

Operation Sleep Mode

Overview With the ignition switch off, and the CAN and LIN buses
When the ignition switch is enabled, the BCM will wake up the disabled, if the battery is still connected, the BCM will stay in
security system, lighting system and diagnostic system. When sleep mode and be prepared for receiving the signal from the
the ignition switch is in "ACC" position, the BCM allows the CAN and LIN buses.
washer/wiper and power window system to operate. When Wake-up Mode
the ignition switch is in "ON" position, the fuel system starts to
In sleep mode, when one of the following operations is done,
work, and the BCM communicates and transmits information
the BCM will be waked up.
with other ECUs through the CAN and LIN bus.
Load Management • Activation signal of hazard warning lamp switch is
received.
BCMThe BCM can manage the load of some electric
• Activation signal of direction indicator lamp switch is
appliances by configuration and ensure low battery power
received.
consumption during storage and transportation or idle time.
• LOCK signal of internal lock is received.
Production Mode
• UNLOCK signal of internal lock is received.
It is configured for the BCM during vehicle assembly. • Activation signal of driver door switch is received.
Transportation Mode • Activation signal of passenger door switch is received.
After vehicle assembly, programme the BCM so that the • Receive the activation signal of the luggage compartment
transportation mode can be used during transportation. lid switch.
And low battery problem can be avoided when the factory • Receive the activation signal of the luggage compartment
delivers the vehicle to the authorized local after-sales service lid Release switch.
centre. This mode may restrict the function of some electric
• Activation signal of driver door lock switch is received.
appliances:
• Activation signal of driver door unlock switch is received.
• The rear fog lamp does not work when the engine is off.
• Ignition switch is in "ACC" position.
• The high beam headlamp does not work when the engine
• Ignition switch is in "ON" position.
is off.
• Activation signal of internal lamp switch
• The low beam headlamp does not work when the engine
• LINWake-up signal from LIN bus
is off.
• CANWake-up signal from CAN bus
• The reverse lamp does not work when the engine is off.
• Wake-up signal from local hard wire
• The direction indicator lamp does not work when the
engine is off. • Valid radio frequency signal
• The daytime running lamp (if equipped) does not work Load Management
when the engine is off. To meet the demand of the starter motor for high current
• "Follow Me Home" function cannot be realized. during engine start, some electric appliances shall be powered
• If the engine is disabled, the hazard warning lamp off. For example, disconnect the power of the HRW,
backlight does not work, but the function of this lamp is intelligent Stop/Start energy saving system DISABLE switch,
not affected. high beam headlamp, reverse lamp, horn and interior lamp, etc.
After the engine is started, reactivate each electric appliance
• When the engine is disabled, the window can be
to limit the current consumption of the battery.
ascended, but cannot be descended.
Diagnosis
With the aftermarket diagnostic tool, the local MG Authorised
Repairer can shift the vehicle load management configuration BCMThe BCM monitors information input and output, if
from transportation mode to normal mode. any fault is detected, the corresponding DTC will be stored
in the fault records. BCMThe BCM can detect short and
Normal Mode
open circuits as well as wrong signals of the CAN and LIN
This mode applies the default setting, after completion of the buses. When any fault is detected, the BCM will close the
PDI, the vehicle can enter into normal operation. corresponding functions. When the fault is eliminated, the
corresponding function will be activated next time when the
activation request is received.

1.0 572
Body Control Module Body Systems
The BCM can exchange information with the aftermarket of the driver side instrument panel (driver's leg) and is made
diagnostic tool through the DLC. It is on the closure panel according to the ISO standards.

1.0 573
Body Systems Body Control Module

Service Procedures Add Key and Disable Key

Body Control Module (BCM) Add Key
Remove 1. Ensure the key to be added locates in the key slot, place
1. Disconnect the battery negative. the ignition switch in "RUN" position (position 2) and
2. Remove the glove box assembly. ensure the engine is still.
2. Connect the diagnostic tool and communicates with
Glove Box Assembly Remove
the vehicle successfully.
3. Disconnect the connector of the BCM.
3. Use the "Key Match - Add" function of the diagnostic
4. Remove 2 bolts fixing the BCM to the body. tool and strictly follow the interface prompts.
4. Use the key added to start the vehicle and confirm if
the key can start, lock or unlock the vehicle.
Disable Key
1. Connect the diagnostic tool and communicates with
the vehicle successfully.
2. Use the "Key Match - Disable" function of the diagnostic
tool and strictly follow the interface prompts.
3. After the key is successfully disabled, please read the
key information again and ensure the key is disabled.

5. Remove the BCM.

Refit
1. Fix the BCM to the body, fit 2 bolts, tighten to 5–7Nm,
and check the torque.
2. Connect the connector of the BCM.
3. Fit the glove box assembly.

Glove Box Assembly Refit

4. Connect the battery negative.
5. Program the BCM.

a. Connect the diagnostic tool to the vehicle and access

the SIPS.

b. Select "Programming and Coding - BCM -

Replacement", and operate as per the instructions
on the screen.

1.0 574
Panel Repair Body Repair
Panel Repair
Roof Panel

1. Roof Panel - Sunroof

2. Roof Panel
3. Roof Rear Cross Beam
4. Sunroof Reinforcement Plate Assembly
5. Roof Front Cross Beam Assembly
6. Roof Middle Cross Beam

1.0 575
Body Repair Panel Repair

Engine Compartment Panel

1. Right Dash Panel Side Panel Assembly 10. Left Front Longitudinal Beam Inner Panel Assembly
2. Right Frame Assembly 11. Left Front Longitudinal Beam Outer Panel Assembly
3. Right Tower Cover Plate Front Assembly 12. Left Front Bumper Mounting Bracket Assembly
4. Right Front Longitudinal Beam Outer Panel Assembly 13. Left Front Longitudinal Beam Assembly
5. Right Front Longitudinal Beam Inner Panel Assembly 14. Left Frame Assembly
6. Right Front Longitudinal Beam Extension Panel 15. Left Tower Cover Plate Front Assembly
7. Right Front Bumper Mounting Bracket Assembly 16. Left Dash Panel Side Panel Assembly
8. Right Front Longitudinal Beam Assembly
9. Left Front Longitudinal Beam Extension Panel

1.0 576
Panel Repair Body Repair
Dash Panel

1. Dash Panel Upper Panel Assembly

2. Vent Panel Assembly
3. Dash Panel Lower Panel Assembly
4. Dash Panel Beam Assembly
5. Dash Panel Upper Beam

1.0 577
Body Repair Panel Repair

Bodyside Panel

1.0 578
Panel Repair Body Repair
1. Bodyside Panel Assembly
2. Front Door Frame Reinforcement Assembly
3. Frame Inner Panel
4. Bodyside Closing Plate Assembly
5. Rear Bodyside Inner Panel Assembly
6. Bodyside Outer Panel Assembly
7. Tail Lamp Mounting Frame Assembly
8. Bodyside Outer Panel
9. Fuel Filler Panel Assembly
10. D Pillar Crash Panel Reinforcement Assembly
11. A Pillar Outer Panel Vibration Isolator
12. B Pillar Outer Panel Vibration Isolator
13. Rear End Outer Panel Vibration Isolator
14. C Pillar Lower Vibration Insulator
15. A Pillar Outer Panel Vibration Isolator
16. Front Bodyside Outer Panel
17. Rear Bodyside Outer Panel

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Body Repair Panel Repair

Front Floor

1. Front Floor Assembly

2. Right Sill Inner Panel Assembly
3. Left Sill Inner Panel Assembly
4. Sill Reinforcement Plate Assembly

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Panel Repair Body Repair
Rear Floor

1. Rear Floor Assembly

2. Spare Tyre Compartment Assembly
3. Right Rear Longitudinal Beam Assembly
4. Left Rear Longitudinal Beam Assembly
5. Rear Floor 1st Beam Assembly

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Body Repair Panel Repair

Door Panel

1. Front door assembly

2. Rear door assembly

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Panel Repair Body Repair
Bonnet Panel Assembly

1. Bonnet Panel Assembly

1.0 583
Body Repair Panel Repair

Tail Gate Panel Assembly

1. Tail Gate Panel Assembly

1.0 584
Collision Repair Body Repair
Collision Repair
Body Material
For different strength requirements of different body parts, this model adopts various high strength steel plates and ultra high
strength steel plates (hot formed steel plate). The detailed positions of different materials are as follows:

Only services as per relevant instructions in the Manufacturer's Service Manual and services of high strength steel plates
and hot formed steel plates as per the modern inverter technology are allowed.

During the service of the galvanized steel plate, the following matters should be noted:

• The paint and zinc coating should be completely ground off before grinding. Be careful when grinding.
• Apply the spot welding paint between the weld contact surfaces before the spot welding (with a hairbrush or a spray).
• Particles on the surfaces will be absorbed by the electrode, so it is necessary to clean the electrode tip frequently.

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Body Repair Collision Repair

Damage Diagnosis
Damage Detection
During damage detection, visually inspect the location collided
to determine the direction and size of the impact, and check
for potential damages. For vehicles damaged in an accident,
query the vehicle speed, impact location or rollover location,
direction and angle when the accident happens, and understand
the impact form, location and angle of the impacted vehicle,
etc, use an intuitive method to determine the location damaged • Characteristics of damage caused by middle impact
by the impact and areas that may be affected by the impact.
Test drive and measuring instrument can also be used for the
thorough check of the vehicle, confirm if the underbody is
deformed, and if the whole body is damaged and twisted, check
if the door can function properly, etc to determine the level of
damage and the method of repair.

1. Vehicle Visual Inspection

• Characteristics of damage caused by rear impact

2. Detail Visual Inspection

Damage Measurement
Accurate measurement is one of the necessary processes for
completion of impact repair. For integral bodies, measurement
is more important for a successful damage repair, because the
steering system and suspension are on the body, and some
suspensions are designed according to the requirement for
assembly. To ensure correct steering and driveability, the
fit tolerance of the key machining size shall be within the
permissible range.

Measurement shall combine with remove operation, or it is

Damage Determination impossible to determine the damage. To facilitate body repair
Deformation occurs not only at the impact location, but also and thorough examination of damage and avoid damage of the
at the whole body such as beam, suspension and engine, parts removed due to repair, remove the related parts. The
etc. Along the course of the impact, systematically check the principle for remove is to avoid any component damage.
related parts for damage until there is no any sign of damage Measuring Point Selection
and the damage in the surrounding area is found. • Screw hole, process hole of the component;
Characteristics of body damage: • Overlap of the body steel sheet;
• Characteristics of damage caused by front impact • Machining gap or raised imprint on the steel sheet.

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Collision Repair Body Repair
Method of measurement:
• Distance measurement: the simplest and most practical
method is to measure the distance between the
reference points of the component with a steel tape.

• Centreing: measure by locating the centre.

• Three-dimensional coordinate measurement: measure
the data of the three-dimensional coordinate on the
measuring point selected, and compare the data with
those of the vehicle to determine body damage.
• Electronic measurement: more accurate and more
effective.
Reasons for error in body size measurement:

The error is due to the accuracy of the measuring tool or

equipment itself;

Error due to human factor:

• Failure to locate the measuring point;

• Wrong method is used for measurement;
• Failure to use the measuring tool and equipment in a
proper way.
Precautions for measurement:
• Level the body before measurement;
• Mark measuring point on the body to prevent confusion;
• Make accurate measurements;
• Carry out multiple measurements;
• Recheck the results of the measurement.

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Body Repair Collision Repair

Repair Plan Determination

Underbody Correction
When the vehicle is severely damaged, the underbody is
deformed, no need to replace the whole body, correct
the underbody first. Underbody correction ensures the
three-dimensional position of the underbody and the general
position of the body, determines the position of the engine
assembly and front suspension and recovers the angle for
wheel alignment and the position of other assemblies. After
underbody correction, repair the body panel.
Body and Covering Component Correction
After an impact, if the body and covering component only
have repairable depression or deformation, no serious damage
occurs, no need to replace the component, recover its shape
by correction.
Sheet Metals Replacement
When the body part has a damage at one location or more
than one location, and the damage or corrosion is beyond the
specified degree, it is worthless to repair it or a repair cannot
help it to achieve the specified technical standard and function
requirement, then replace the sheet metals.
Body Replacement
When the vehicle is severely damaged, the whole body is
smashed by the impact, the underbody is seriously deformed,
the two sides, roof cover, engine hood and trunk lid are
almost destroyed, and the whole body is unrepairable, then
replace the body according to user's demands. Remove
usable assembly and component from the damaged vehicle,
thoroughly check and repair the major assembly such as
engine. Replace the body assembly and parts that shall be
replaced, and reassemble them according to the assembly
process of the vehicle.
Partial Replacement
When impact occurs, and only local damage appears, for
example, damage to the front/rear fender, door, engine hood
or trunk lid, partial replacement can be performed for the
body, this saves trouble, time and reduces the cost.
Body Pillar Replacement
When the body pillar, windshield pillar, front or rear pillar is
badly damaged and cannot be corrected by a simple repair,
replace it. Recover the large-scale deformation before
replacing the pillar.

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Collision Repair Body Repair
Body Correction
The purpose of body correction is to recover the correct
position and size of the sheet metal by eliminating the
deformation (plastic deformation) and residue stress caused
by collisions.
Introduction of Correcting Equipment
The correcting equipment shall provide the following features:
• The equipment shall have high-strength body positioning
device and fixture. Correction/Drawing Method
• It shall have a service puller with various shapes and Drawing Sequence
different functions that can meet the repair requirements Note the method and procedure for drawing: during drawing,
for different locations. draw for a little while, then release the chain, unload and make
• Be able to perform multipoint and comprehensive measurements. Operate from inside to outside.
correction/drawing. 1. Take length as the priority. Draw the vehicle in the
• Be able to accurately measure and detect the deviation longitudinal direction along the centreline of the vehicle.
and repair error for each reference point. 2. Then correct the width. Correct the vehicle in the
Operation Process for Correcting Equipment horizontal direction.

Regardless of the type of the equipment used, its operation is 3. Finally correct the height.
broadly divided into the following 4 steps: Stress Elimination
1. Get on the vehicle. Eliminate the stress during drawing;
2. Position, clamping. • Knock the raised location beside the deformed region
3. Drawing. and the back;
4. Measurement. • Knock the welding location of the deformed region;

Auxiliary fixture: • Knock the ridge of the deformed region;

• Prevent motion of the vehicle; • Knock the reinforcement of the deformed region;

• Force caused by even and disperse drawing;

The high-strength integral body is susceptible to heat, so

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

Note: Do not service the body by heating oxygen-acetylene.

Apply tensile force to the predetermined location, recover the

size and shape of the damaged steel sheet carefully and slowly,

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Body Repair Collision Repair

completely eliminate the stress of the curved steel sheet to

achieve accurate repair of the body.

Note: overstretch shall be avoided during body correction.

The only solution to overstretch is to replace the damaged
sheet metals.

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

Local heat shrinkage is a commonly used method for sheet

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

The hammer and jacking block method is a conventional

method for sheet metal repair. The metaler holds the hammer
with one hand and the jacking block with the other hand or
uses other tools to strike the sheet metal for repair. The
manual work of the sheet metal requires the metaler to have
the appropriate skill and experience, good repair skill cannot
be obtained overnight, repair of the sheet metal includes
repair of the deformed surface and correction of the shape
line.
Technical Requirement for Panel Repair
No matter which method is used to repair the body surface,
the specified technical requirement shall be met, and the
performance and appearance quality of the vehicle shall be
resumed.
Shape Recovery

For repair, the shape of the large smooth structure and the
wedge structure of the local transition shall be recovered.
When it is hard to recover the shape, change the original shape
in an appropriate way, the shape shall be symmetrical, beautiful,
firm and durable.
Integrity and Fineness of Continuous Surface

Most of the car bodies are produced by mould stamping, which

have the integrity and fineness of the surface. For repair,
the streamline surface shall have a continuous transition; the
transition point of the surface shall have a smooth transition;
the external surface repaired shall be as bright as a new surface,
ripple, wrinkle, dent, knock mark, scratch and visible defect or

1.0 591
Body Repair Collision Repair

Sheet Metal Replacement

The process for sheet metal replacement is as follows:

1. Preparation before cutting new/old sheet metals.

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

1. Do not cut the energy absorption area;

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

3. Carry out rough cut and remove the welding spot.

1.0 592
Collision Repair Body Repair
3. Mark the punch position for welding the plug hole.
Treatment and corrosion prevention before
welding
1. New body parts: grind the location for welding and
sealant application to remove the paint film.
2. Grind the location for welding and sealant application to
remove the old paint film, burr and rust (20mm from
the welding joint), but do not grind the cross section of
the joint.

4. Remove the damaged sheet metals.

Position, adjustment and cutting of new parts
1. Position the new panel on the body and adjust its position
and size.

• Compare the hole;

3. Clean the location for welding and sealant application on

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

• Adjust the difference between the high surface and the low
surface;

2. Cut the new/old panel by overlap, take care not to cut

the reinforcement inside the body, remove the new panel,
and cut the excess old panel section by section. 2. Compare the hole;

1.0 593
Body Repair Collision Repair

3. Adjust surrounding clearance; Caution: Use arms not exceeding 300 mm in length.

2. Fit the resistance spot welding arm and test equipments

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

4. Adjust the difference between the high surface and the

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

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

Treatment after Welding

Process for Corrosion Prevention
1. Use P36 disc polisher or belt polisher to grind or finish
all welding locations, and clean the location.

• Length of the welding rod holder of hand spot welding

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

1.0 595
Body Repair Painting

Painting
Overview
The purpose of automotive painting is to provide an excellent
appearance, decoration, gloss protection, colour protection,
corrosion resistance and a longer service life, so it has
distinctive features:

• Automotive painting is a high-level protective painting,

the coating shall have a superb corrosion resistance,
weather resistance, acid/alkali resistance, inclusion
resistance and an extensive adaptability, etc.
• Automotive painting (mainly refers to body painting) is
a high-level decorative painting, and careful design, good
working environment and conditions are required for Function of Each Coating
providing the coating with good decoration. Vehicle 1. Zinc Coating: with a good function of
decoration mainly relies on painting, the quality of the anti-corrosion/anti-rust, good paint adhesion,
painting has a direct influence on the commercial value decorative performance and forming property.
of the vehicle. 2. Zinc Phosphate Coating: the first paint that is directly
• Automotive painting is the most typical industrial applied to the treated workpiece surface and is the base
painting, it requires reasonable and effective for the whole coating. Its characteristics are as follows:
pretreatment method, drying method and process
• It shall have a good adhesion to the treated surface of
preparation.
the workpiece, and the primer film formed shall have an
• Automotive painting is a multi-coating painting system, excellent mechanical strength;
and the painting quality and process control of each
coating is of great importance. • It shall serve as a corrosion inhibitor, and the primer
coating shall have an excellent corrosion resistance, water
Coating Introduction
resistance and chemical resistance;
Coating Composition
• It shall well fit the intermediate coating or top coat;
During manufacture, paint application consists of the corrosion
resistant coating (zinc coating) of the raw material, zinc • It shall have a good workability.
phosphate coating, electrocoating, intermediate coating and 3. Electrocoating: enhance cavity corrosion resistance;
top coat. improve the uniformity and leveling of the paint film
thickness; raise the quality of the paint film, painting
efficiency and paint utilization efficiency.
4. Putty Coat: used for the object surface with primer
precoat so as to fill the pit, weld seam, scratch, rust hole,
etc. on the object surface. until the surface becomes
smooth.
5. Intermediate Coating: it is the last intermediate coat
before applying the top coat, its binder content is
between the primer and the top coat, and the paint film is
bright and semi-bright. It provides the following functions:
• Enhance the adhesion between the primer and the top
coat;

Aftermarket paint repair is composed of the primer coat, putty • Increase the total thickness of the coating and improve the
coat, intermediate coating, pigmented paint coating and varnish film build;
coating. • Improve the corrosion resistance and weather resistance
of the primer/top coat;
• Repair minor defects on the substrate surface;
• Raise the decoration performance of the top coat.

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Painting Body Repair
6. Top Coat: top coat is used for the final coating of 7. In order to thoroughly clean the area of exposed metal
the multi-coatings, it directly affects the decoration due to damage of the painted surface, the cleaning area
performance, weather resistance, gloss protection, shall be larger than the original damaged area.
colour protection, chemical resistance, contaminant 8. Use phosphate to eliminate the dust, contaminant, etc on
resistance and appearance of the vehicle. the exposed metal, and offer a good repair environment
Classification of Top Coat for the new coating.
The classification of the top coat by colour effect is as follows:
• Pure pigmented paint: containing resin, pigment and
additive only.
• Metallic paint: containing metal powder, with better gloss
and saturation.
• Pear paint: comparing with the metallic paint, instead
of using metallic paint, it uses mica powder coated with
titanium dioxide and ferrum dioxide to improve the
texture and gloss of the paint film.

By application procedure, it can be classified into the following

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

1. Use the certified jointing sealant to seal the inner and

outer jointing.
2. Repair all damaged parts of the sealant under the vehicle
body.
3. Use two-pack paint to repair the system and it shall be
consistent with the original production parts.
4. Apply the inner wax to the entire inner surface without
paint finishing.
5. Steam cleaner or high pressure cleaner must be used to
clean the vehicle thoroughly before paint repair.
6. Clean the local part needing requirement with warm and
water soluble cleaning solution, then thoroughly clean it
with solvents. Painting must be done immediately after
this operation.

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Body Repair Painting

Painting Process
Generally, automobile painting can be divided into two parts: 1.
metal treatment before painting (also known as pretreatment);
2. application process.
Surface Pretreatment
Surface pretreatment consists of the following works:
1. Surface cleaning: before painting, thoroughly remove the
mud, dirt other foreign materials on the vehicle, especially
the dirt on the door frame, luggage compartment, engine
cover seam and wheel house, failure to do so may cause
the new paint film to be contaminated.

• Treatment of dissolved substance: apply degreaser to the

surface with the special cloth, then remove the degreaser
and grease residue, etc with a clean and dry cloth.

• Treatment of moisture and dust: use a clean and dry cloth

to remove moisture and dust, and dry with a high-pressure
air gun.

2. Coating identification and damage assessment:

• Coating identification: identification of the coating on

the body panel is crucial for the reapplication process.
Improper identification may lead to serious problems for
top coat application. If no respray is performed, the type
of the coating can be determined by the vehicle manual,
but the type of the coating for the resprayed body shall Precautions for mechanical grinding:
be determined for repair.
a. Do not use an electric grinding machine to grind
• Damage assessment: correct assessment of the damage surfaces with a big radian, highly raised surfaces or
is one of the key factors for determining the service concave surfaces in a cross way;
cost and ensuring the quality of painting. Range of the
b. Do not use an electric grinding machine to grind the
repair/treatment process, transitional region, location to
corner, wrinkle seam, weld, junction or location with
be covered for protection and part to be removed, etc
plastic sealant;
are determined by correct assessment of the damage,
this lays the foundation for correct implementation of c. For grinding, the grinding machine can be started only
the subsequent processes and guarantee of a satisfactory when it contacts the surface of the sheet metal, in this
repair quality. Assessment of the damage to the paint film process, do not apply too much force, or deep groove
includes visual inspection, touch and ruler evaluation: may occur, and the grinding machine shall be aligned
with the edge line to be ground before initiation of
3. Removing old paint film: clean the body, and check the
the machine;
body paint carefully to see if there is any sign of damage
such as bubble, crack, peeling, rust and partial damage d. To avoid thermal deformation of the sheet metal, do
caused by baking/repair, gas welding, etc. For the above not stay the grinding machine at one position for a
damages, the old paint film shall be removed, selection of prolonged time;
partial elimination or full elimination of the old paint film e. Do not allow coarse grinding material to contact
is made according to the degree of the damage and the with the intact paint surface of the accessory in the
quality requirements after recoating. Sandpaper P80–P180 grinding area, it's better to protect the intact coating
is recommended for grinding feather edge (not less than with tapes.
3cm). Operation of sanding: a fine processing of the surface
treated by coarse grinding, its purpose is to acquire a
flatter surface. Align the front of the rotating grinding
wheel the surface to be ground, and slightly keep the
rear away from the surface. Maintain this angle, move the

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Painting Body Repair
grinding machine up and down, the proper coverage area
of each grinding mark is 50%-60%.

Replacing sheet metal: use sandpaper P280–P320 to grind

the electrophoretic primer by dry grinding.

4. Degreasing and descaling of the metal surface:

• Remove surface rust. Descaling of the metal includes

manual descaling (polishing, grinding and high-pressure
water, etc.), mechanical method, chemical method
and ultrasonic method. Different rusts apply different
methods for descaling.

• Clean the metal surface again.

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Body Repair Painting

Coating Application care not to grind the surrounding area. When using a
grinding block, grind in the horizontal direction, and begin
For paint repair of the pretreated sheet metal of the finished
with the top, then move down gradually;
surface, please refer to the detailed processes below:
• Clean the repair surface with an air gun.
1. Primer application
• Cover the area around the region to be repaired;
• Use a soft cloth with detergent to wipe the surface to
be painted, and use another clean cloth to wipe off the
detergent residue on the surface;
• Purge the surface with compressed air;
• Spray anti-rust primer and dry it;

• Use a soft cloth with detergent to wipe, and dry with

another clean cloth;

3. Intermediate Coat Application

• Cover the area around the repair region, prepare to apply

intermediate coat, the surrounding of the covered area
shall be larger than the area to be sprayed (above 10cm);

• Use a soft cloth with detergent to wipe the surface to

2. Putty application (not required for new parts)
be painted, and use another clean cloth to wipe off the
• Mix the putty and curing agent according to the ratio detergent residue on the surface;
specified by the instruction;
• Purge the surface with compressed air;
• Use a clean putty mixing plate; only mix putty enough for
• Mix intermediate coat, curing agent and diluent according
current use;
to the ratio specified by the instruction;
• Fill sandpaper mark and pore first, then apply putty in the
full scale; • Apply a thin film of intermediate coat first, flash off for
5min, and make two wet applications;

• Flash off for 5min after application, and bake it with the
infrared baking lamp according to the instruction of the • After a levelling of 10-15min, cure the paint film with an
putty; infrared baking lamp;

• Wear dust mask, select appropriate sandpaper and hard • Coat a grinding indicator layer on the surface so that the
grinding block, rail grinding machine can be used, and take uneven surface can be easily found during grinding;

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Painting Body Repair
• Cover the surrounding of the repair area, paste paper from
the inside of the repair area, and take care not to tear the
covering paper;

• Purge the panel to be painted and the vehicle with

compressed air, take care not to damage the covering
paper, then wipe the surface with a cloth;

• To prevent dust, particle, etc from entering into the paint,

use a strainer to pour the mixed paint into the cup of the
spray gun;

• Carry out a trial application, check the barometric

pressure, paint output, sector and atomization;

• Spray two wet paste coatings, the leveling of each shall be

• Perform coarse grinding with P240 – P400 sandpaper first,
5-10min;
then perform fine grinding with sandpaper P600 – P800;
• For silver paint, virtual spraying can be carried out at the
last to guarantee the silver powder is uniform;

5. Varnish Application

• After the pigmented paint is applied, flash off for about

15min (when the paste coating loses its gloss completely),
apply varnish, spray wet varnish first, flash off for 5-10min;
spray the second wet varnish, flash off for 15min before
baking; (note: do not turn off the ventilation system of
the spray booth during drying.).

• Use the temperature and duration specified by the

product to bake the paint film. Infrared baking lamp can
also be used to perform a forced drying for 15min;

• Remove the covering paper from the surrounding of the • After baking, further treatment can be done only when the
repair area, purge the inner/outer surface of the repair paint film is completely cool (such as grinding, polishing,
area with compressed air, and thoroughly remove the etc).
abrasive debris and moisture; 6. Polishing/waxing
4. Top Coat Application • When the paint film is completely cool, use sandpaper
• Check the colour code, and check the colour formulation P1500 or P2000 to grind the dust, sag, etc on the paint
according to the code; film;

• Polish the body surface around the repair area to acquire • Use slack wax and wool wheel to grind the location to
correct colour; be polished. At the beginning of polishing, the speed of
the polisher shall not be high, the speed shall be increased
• Check for the difference between the colour mixed and
gradually;
that of the original body in the stage fluorescent lamp or
sunlight; • Polish with polishing wax and sponge wheel.

• When it is consistent with the vehicle to be painted • Use a clean sponge wheel, use polishing wax to remove
(dilution ratio, distance, pressure, paint output, the swirl mark caused by polishing to restore the gloss of
temperature, flash-off time, etc), paint the colour test the paint film;
panel; • Check if the colour of the painted location is correct in
• Flash off the test panel for 15min, bake the test panel as the lamplight, then check it in the sunlight.
per the specified temperature and time. Take care not to
7. Hairdressing/cleaning
overheat the test panel during baking;
• Use a soft cloth with detergent to wipe the area to be
repaired, and dry with another clean cloth;

1.0 601
Body Repair Painting

8. Process information for paints of different brands

Recommend paint brand information
PPG Sherwin-Williams Akzo Nobel
P565-895 E2G973 Priming Filler 680 Grey
P565-9850 GBP988-AR Primer Surfacer EP
Primer
P565-9085 UPO7299 Sikkens 1K All Plastics Primer
UPO7226-3 Washprimer 1K 1CF/EF
P551-1050 18380221 Kombi Filler
Putty P551-1052 Polykit IV Set
P551-1057
Buffer P565-510/511 P30 Autosurfacer Classic
layer P565-5601/5605/5607 P50 Autosurfacer Rapid
P190-376 CC645HS Autoclear Plus HS (HSR)
P190-6850 HPC15 Autoclear Xcel SET
P190-6060 CC939 Autoclear II
Varnish P190-6208+P210-6863 CC931 Autoclear Rapid
P190-588AP210-790/938/939 CC930 Autoclear Mat
P190-588+P210-760/790 CC655

NEXA Autocolor 2K（Oily paint） Ultra 7000（Oily paint） Sikkens（Oily paint）

Topcoat Aquabase plus（Water-based paint） AWX（Water-based paint） Sikkens Autowave（Water-based
paint）

1.0 602
Painting Body Repair
General Film Coating Defects • Low product temperature, low spraying pressure, slow
Paint Film Defects Caused by Application and gunning speed, short distance to spray gun, thicker film;
Treatments • Large caliber of spray gun, poor atomization of spray gun;
Particles • Slow solvent evaporation rate and low paints' viscosity;
The phenomenon that bumps in the film coatings are spread • Short distance between spray gun and workpiece, slower
over the whole or local surface in granular form. gunning speed, thicker spraying coatings;
Analysis of Possible Causes: • Insufficient flash-off intervals between layers;

• Poor air cleanliness and impurities in the painting Preventive Measures:

environment, such as dust;
• Improve the painting environment, control the
• Workers wear dirty clothes or the fibers contained in appropriate ambient temperature, humidity and wind
the materials are easy to fall out, substrates that are not speed.
properly handled have bumps, the vehicle body is not
• Choose the correct solvent and pay attention to select
cleaned thoroughly, etc.
the dissolving capacity and evaporation rate of the
• The painting pressure is insufficient, atomization is poor, solvent;
the spray gun is not cleaned up and an improper screen
• Strictly control the viscosity and the temperature for
is selected;
coating application;
• The pigments or flashing materials in the paints are
• Reduce the amount of paints from spray gun, and increase
badly dispersed, the paints are unfiltered or filtered
the gun distance and gunning speed;
improperly, the paints become deteriorated and show
• Full flash-off between layers;
abnormal signs, such as separate out, flocculation.
• The film is moved out of the baking booth before drying Defect treatments: For the slightly local varnish sagging, it
the surface to dust-free. can be sanded to eliminate the sagging defects before being
polished if this defect exists; or if the sagging defect is more
Preventive Measures:
severe or it appears on the surfacer layer and the color paint
• Ensure that the spraying environment is clean; layer (finally revealed on the layer of varnish), the sagging must
• Ensure that the objects to be painted and workers are be sanded thoroughly and make the spraying again.
cleaned thoroughly before entering the baking booth; Pin Holes/Eyes
• Ensure the paints' performance, the deteriorated and The blisters or solvent bubbles appear on the film and there are
poorly dispersed paints are not applicable; small needle holes on the top of them, which are referred to as
• Set the optimal parameters for paints' application and use pin holes (the solvent contained in the film coatings evaporates
the spray gun to spray after the paints being filtered. rapidly during the surface drying, its left trace forms hole );
these pin holes are known as defects that the holes are still
Defect treatments: The tiny dirty spots can be polished after
visible on the surface after spraying the finish due to some holes
removed by abrasive paper; if the impurity particles are large
on the substrate are not filled up. They are easily generated at
or the dirty spots on the surfaces of primer and even surfacer
the corners of workpieces.
can only be ground to the extent that the spots disappear
completely, perform the spraying again. Analysis of Possible Causes:
Sags • Pin hole: The paints are mixed with impurities, for
example water enters into the solvent based coating; the
Upon the liquid paint is sprayed onto the workpiece surfaces,
painted objects have dirt on their surfaces; the flash-off
some wet film surface runs down, creating unevenly stripes
intervals between layers is insufficient during application;
and sags, which are thin on the top and thick on the bottom,
the continuous spraying is too thick; the temperature
resulting in the local thicker film on vertical surface. It can
rises up suddenly and the surface is dried rapidly when
be divided into sinking, sagging and running depending on the
stoving.
shapes of sags.
• Pin eyes: The uneven locations on the original workpiece
Analysis of Possible Causes: surface are not filled up;
• The painted workpieces' surface is too cold;
Precautions and Improvements:
• Low application environment temperature, slow wind
speed and high solvent vapor content in the ambient air; • Set appropriate temperature and humidity for
application. Wind speed and other conditions;

1.0 603
Body Repair Painting

• Mix the paint and solvent in proportion to ensure the • The substrate is not flat or the finish coating is sprayed
proper fluidness; to the surfacer surfaces without having the orange skin
• It should be heated up slowly to avoid the rapid solvent ground smooth;
evaporation. • The ambient temperature is high, the wind speed is fast
• Full flash-off intervals between layers; and the substrate temperature is high;
• The diluent volatilizes rapidly, the paint has high viscosity
Defect treatments: The defects should be completely ground
and the film is too thin;
to remove the pin holes and pin eyes, then repaint it.
• The distance from spray gun is too far, the gunning speed
Blistering is too fast, the spraying pressure is low and the amount
Part of the film coating floats off the painted surface or prime of paint out of spray gun is little;
coat and is filled with liquid or gas, which is about 1 ~ 5mm in
Preventive Measures:
diameter or floats off in large pieces. If there is some water
under the film, the vapor generated by evaporation of water • Grind the intermediate coating completely smooth
will plump up the film to form blister when the temperature according to the process requirements;
rises up. • Control the ambient temperature and wind speed (0.2 -
Analysis of Possible Causes: 0.6m/s);
• Use the diluent suitable for that temperature, and
• The ambient humidity is high and the film is dried
adjust the paint viscosity as per the paint manufacturers'
naturally after spraying, resulting in moisture infiltrating
product instructions.
into the film;
• Adjust the gun pressure, then regulate the gun to
• The substrate is not dried properly, the drying time is
proper distance and reduce the gunning speed as per the
short between coatings, the heating and drying are too
manufacturers' instructions;
fast;
• Spray the appropriate layers to ensure that the film get
• Grind the putty while adding water and the putty absorbs
the desired thickness;
water;
•
• There is oil or water in the compressed air lines;
Defect treatments: Only perform the grinding and polishing if
Preventive Measures:
the defect of orange skin is slight; the orange skin should be
• Grind the dry putty; ground to completely removed and then be resprayed if the
• Ensure that the previous coating has met the defect is serious.
requirements for cleanness and dryness before spraying; Sanding Scratches
• Reduce the humidity in the painting and spraying room;
The sanding scratches left by sanding substrate are visible
• Use the curing agent and diluent suitable for environment on the film after spraying the paint. Sometimes, the sanding
temperature, make it dry as soon as possible once the scratches on the substrate will extend due to the erosion
spraying is completed to prevent the moisture from caused by solvent contained in the film, the upper film would
infiltrating into the film. be subsided gradually after a period, resulting in the sanding
Defect treatments: Once blisters appear on the film surface, scratches more and more obvious.
this surface should be ground to remove the blistering Analysis of Possible Causes:
defects completely, then respray it depending on the surface
• If the improper abrasive papers are used to sand the
conditions.
substrate, the sanding scratches will be wide and unable
Orange Skin to be covered and filled up by upper film;
The orange skin is used to describe the leveling property of • If the lower film is sanded and sprayed with upper film
the film: When you observe the film surface against the light, over it before it isn't totally dry, it is easy to make the
you can see different ripples of 1 - 5mm presenting on the sanding scratches to extend due to the erosion caused by
film surface, and the brightness and plumpness vary in different solvent in the upper film and form the sanding scratches
ripple areas, such texture on the film surface, which is similar defect;
to orange peel, is known as orange skin.
• The diluent that has high solubility for upper paint or too
Analysis of Possible Causes: slow to dry has been misused.

Preventive Measures:

1.0 604
Painting Body Repair
• When you select the abrasive paper number to make Defect treatments: Once the putty marks appear, those areas
sanding, you should observe the principle that the should be sanded, and apply the putty again and respray the
abrasive paper number should not be jumped by 2 levels surfacer and finish.
each replacement;
Lifting
• Ensure that the lower film is totally dry before sanding;
The lower-layer paint is single-component, or even if it is
• Select the correct upper film solvent as per the product two-component, it is not dry and cured completely (including
instructions; improper amount of curing agent is used), when the paint
Defect treatments: For slight sanding scratches, they can be is sprayed above it, the solvent contained in upper film will
removed or made less obvious by sanding and polishing as they erode the lower film, causing the uplift and shrinks present on
have been filled up by paint; For the sanding scratches that the lower film surface.
are more obvious, they cannot be removed by sanding and Analysis of Possible Causes:
polishing, it should be resprayed after removing the scratches.
• The lower film is not totally dry;
Putty Marks
• The lower film becomes deteriorated;
A putty mark means the defect that trace is left along the edges
• The continuous spraying of surfacer or finish results in
of putty application areas after spraying the surfacer or finish.
too thick surface, or the used curing agent and diluent
Analysis of Possible Causes: are too slow to dry, or the diluent with high solubility
is used, or the flash-off intervals between layers are too
• The feather edges are improperly treated before putty
short when spraying the surfacer or finish, or the low
application;
air temperature during the spray causes the infiltration
• The putty is mixed with curing agent in improper
and erosion of solvent contained in the surfacer or
proportion;
finish, resulting in the lifting occurred at the putty edges,
• The next action is taken before the putty is completely one-component putty or surfacer edges.
dry (sanding, spraying the surfacer, etc.);
Preventive Measures:
• The putty is not flat enough, the feather edges do not
meet the standard, and it is higher or lower than the old • For the film not totally dry, it must be sanded and sprayed
surrounding coatings or metal; with the next layer paint after it is completely dry. If
it cannot be totally dry due to the improper adding of
• The curing agent and diluent mixed in the surfacer or
curing agent, it needs to respray the paint mixed with
finish are dried slowly, or the flash-off intervals between
proper curing agent after film removal.
layers are too short when spraying the surfacer or finish,
and the solvent penetrates and erodes the putty, resulting • For the deteriorated film, shown as chalking, cracking,
in the edges expanded and extended. loss of gloss, they must be removed totally and resprayed
with two-component surfacer or finish;
Preventive Measures:
• Use the correct mating curing agent and diluent, and
• The width of the feather edges must be 20 - 30mm ensure the flash-off interval between layers is enough.
and the surface is smooth without steps before putty
• Use the two-component putty and surfacer.
application;
Defect treatments: When the lifting defect appears, it should
• Adding the curing agent in proper proportion according
be sanded to remove any defects at the lifting area, if the lifting
to the product instructions;
is severe, the film that has lifting should also be sanded and
• Make sure to perform the sanding and spray the surfacer
removed completely, then spray the two-component surfacer
when the putty is totally dry.
and finish.
• Use the correct curing agent and diluent, and ensure the
Paint Film Defects Caused by Operating
flash-off interval between layers is enough. Environment and Treatments
• The periphery of putty must be sanded to be qualified. Paint film defects caused by external corrosive
Not only the putty, but also the extended old materials
surrounding coatings should be sanded when you sand
Defect phenomenon: The film defects occur when the film
the putty edges to allow the putty together with the
is affected by the acidic and alkaline materials as well as
surroundings to form flat surface.
industrial fall-outs, such as asphalt, oil, battery electrolyte,
bird droppings, sap, acid rain, pollen, dust produced by steel
plant and black carbon from boiler stack. It generally appears

1.0 605
Body Repair Painting

as uplift, discolor and even cracking and peeling caused by the

contaminants infiltrating into the film.

Defect treatments: If the film defect is tiny, it can be

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

Causes: As the water contains mineral substances, such as

calcium, when the water is heated to evaporate, some warm
water will infiltrate into the softened film with heat, and the
left mineral substances infiltrate into the coating.

Defect preventions and treatments: Try not to wash the car

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

Defect treatments: When the stone-crash damages occur,

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

When new original parts are sprayed, if the finish is directly

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

Defect treatments: Color fading is a representation of film

aging, it is usually shown up together with chalking and full loss
of gloss. Once any one of these defects occurs, the defective
film must be sanded and removed thoroughly, then respray the
two-component surfacer and finish.

1.0 606
Seal Body Repair
Seal Clean the affected seam, re-process the exposed metal area
Overview with proper etch primer;
Process Area of Underbody Seal Coat proper sealant at the required places;
Underbody areas and doorsill outer panels should be Process the affected area with acid-etch primer (chassis sealant
processed with plastisol PVC underbody sealer. This sealer is also acceptable), and apply proper colour paint film.
shall not be reused. When repairing the sealer for the
After reassembly or refit of parts, if the seam is plugged, then
underbody areas, the underbody sealer upon delivery should
apply paste seam sealant to such seam. Blockage of the seam
be removed and returned to the proper breakpoint. Expose
may occur after panel repair. In this case, apply sealant and
the clean metal surface, and the current sealing edge shall also
paint before final assembly. If the inlet is of proper size, apply
fit firmly to the panels.
seam sealant to the two sides of the joint to be repaired. If the
Use new chassis sealant between the primer and the spray can be only done to one side (such as compartment),
intermediate primer. If necessary, use the seam sealant before then use cavity wax to process the affected compartment
applying the chassis sealant. Before coating the chassis sealant, beam.
fit the plugs and insulating ring on the disk type floor (except
Seams which require sealant when assembling in the plant is
the part for wax spray). Refit the heat-fusible plugs damaged in
described in the figure below.
repair with heat blower or replace them with rubber insulating
ring. Caution: Look through all the joints near the fixed areas.
If necessary, all the combined ,fixed or replaced areas
Before using new chassis sealant, cover the suspension, wheel,
should be sealed. These areas can’t be ruined. Sealing
tyre, power unit, exhaust system and brake system (including
could protect from waters and wind noises and so on.
all mounting points).
Before the final inspection, it is necessary to look through
Seam Sealant all the sealed areas.
For factory assembly, apply PVC sealant treated by baking to
special joint weld and sheet metal edge. This kind of material
is not suitable for repair, so approved special sealant shall be
used for aftersales service.

Seam sealant is used after the primer and before the

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

Remember to seal all the seams to be processed after each

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

1.0 607
Body Repair Seal

Application of PVC sealant:

Operation
Process Implementation effect section view Application location
method
Mating faces for fitting the parts, welds
Sealant with appearance requirement; such as
Elimination tail lamp, side body and roof joint, visible
location after assembly
PVC Welds without appearance requirement
sealant Sealant or assembly requirement (covered weld,
Application with a width < 50mm); such as seam of
interior floor, underbody
Sealant Edge of four doors and two covers (thickness:
Injection 1-2.5mm, width: 5-9mm)

Plug
Plug type One-component plug Two-component plug
Workshop Painting workshop or general assembly Painting workshop
workshop
Material EPDM, TPE, PA6, TEEE, etc. (PA6-GF) + hot melt adhesive, metal sheet + hot melt
TPE + hot melt adhesive, etc
Sealing 30mm water column, 10min, no water leak 500mm water column, 10min, no water leak
Performance
Application 4 doors, side body, etc Floor, spare tyre compartment, etc
Location
Remark Seals holes with no direct connection with Used to seal holes directly connecting passenger
passenger compartment or waterproof holes compartment and external horizontal holes

1.0 608
Seal Body Repair
Sealing Performance Test damaged, aged or displaced. Meanwhile, align the door with
Overview the seal.

Process of the leaking problem needs to combine techniques, Note: Check the colour of the water around the leak. If
experiences and instincts to take proper and effective the water is dirty, the leak is from under the vehicle. If the
measures. Do not come to conclusions fast only by naked water is clean, it is from above.
eyes.
When a leaking spot is found, the methods below are
Test Tool and Instrument necessary for resolution of the leak problem:
When checking and correcting the leaking problems, the below 1. Replace all of the damaged, displaced and aged door hole
tools and instruments are recommended to use: seal and weatherstrip.
1. Garden Sprayer (manual) 2. Check all the body seals and ensure it is fixed on the
2. Wet/Dry Vacuum Cleaner fixing flange/fixing face correctly. If necessary, the simitar
can be used.
3. Dry, Absorbent Cloth
3. Blow the body weld seam to be processed with
4. Battery Torch
compressed air and/or hot blower when necessary.
5. Mirror
4. If necessary, apply sealant to the outside of the connector
6. Weatherstrip Locating Tool
to prevent water.
7. Trim Panel Remover
5. When correcting leakage of the windshield and
8. Small Wooden or Plastic Wedges weatherstrip (or polish between the upper glass and
9. Dry Compressed Air Supply the body directly), try not to remove the glass. Use
10. Hot Blower qualified materials at proper places (such as glass to the
weatherstrip or glass to the body).
11. Sealer Applicators
Initial Door Seal Replacement
12. Ultrasonic Leak Detector
The initial seals for both front and rear doors are stuck on the
When checking for leak, at least the following parts should be
specified positions. Always comply with the regulations below
checked:
when replacing the weatherstrip:
• Front Inner Space;
• Clean the position where the door weatherstrip is
• Rear Seat Space; located. Do not clean the doors with paint diluent agent.
• Storage Compartment or Luggage Compartment • The ideal temperature for sticking the weatherstrip is
Test Method and Measure 25℃ (77℉). For either the door or the weatherstrip,
The operators at the fittings center can judge from where to when the temperature is less than 18℃ (64℉), it is hard
check the leakage by information offered by the customers. to stick the weatherstrip.
The next step is to find the leaking spot after the leaking place • Do not apply too much force to stick the weatherstrip,
is founded. this will make disassembly or re-installation much easier.
If the weatherstrip shall be refitted, do not touch the
For the first case, an easy and effective method is the common
contact face or stain it.
garden sprayer. Nozzle of this extruding garden sprayer ought
to be adjusted, so that water can be sucked into the nozzle
directly and spray out proper spray. At the dark corners, a
mirror or battery torch cab be used (the test light using supply
voltage is not available).

The test order is very important. Begin from the lowest point
and go up gradually, this can avoid blocking off the other leaking
place when an area is being checked. If the test is begun from
the windscreen, any water flowing into the pumping chamber
may drop on the pedal by baffle insulating ring. Even though, it
may be judged wrongly that seal of the windscreen fails.

Another part for leaking check is to visually observe whether

the door hole sealer, insulating ring or weather strip is

1.0 609
Body Repair Seal

Sealant Position Information

Body Seal Identification

1. Between Panels - Connected with Bolts 7. Riveting Joints - Type (a)

2. Panel Edges - Connected with Bolts 8. Riveting Joints - Type (b)

3. Between Panels - Spot Welding 9. Riveting Joints - Type (c)

4. Panel Edges - Spot Welding 10. Panel Gaps - Type (a)

5. Between Panels - Bonding 11. Panel Gaps - Type (b)
6. Panel Edges - Bonding 12. Lap Joints

Sealant Information • For any place not specifically described in the figure
below, brushing glue is applied.
After the panel is welded or replaced for repair, it is required
to use PVC sealant to seal the weld seam and the new
panel according to the following construction principles
and the instructions on gluing position given by the original
manufacturer to guarantee the repair quality:
• PVC brushing glue requirements: cover the weld seam
to make the surface smooth and even without fillets, and
the width < 50mm.
• PVC tube glue requirements: cover the weld seam to
make the surface smooth and even, the width is within
5-9mm and the thickness within 1-2.5mm.
• PVC frictioning glue requirements: cover the weld seam
to make the surface smooth and even without pinholes
or bubbles.

1.0 610
Seal Body Repair
Front Compartment

1.0 611
Body Repair Seal

1.0 612
Seal Body Repair
Front Floor

1.0 613
Body Repair Seal

Dash Panel

1.0 614
Seal Body Repair
Rear Floor

1.0 615
Body Repair Seal

Bodyside Panel

1.0 616
Seal Body Repair

1.0 617
Body Repair Seal

Front Door

1.0 618
Seal Body Repair
Rear Door

1.0 619
Body Repair Seal

Bonnet

1.0 620
Seal Body Repair
Tail Gate

1.0 621
Body Repair Seal

Position Information of Foam Parts

1.0 622
Seal Body Repair
Gasket Position Information
Damping mats are used in the base plate, dash panel, rear end panel, rear wheelhouse and central passage. When making
sheet metal repairs or replacements in these areas, tailor new gaskets according to the size of original ones and paste
them as the following instructions:

• Clean the position pasted-to-be on the sheet metal before pasting new gaskets.
• Follow the size requirements in the figure below.

1.0 623
Body Repair Seal

Gasket Pasting Position Information

1.0 624
Seal Body Repair
Gasket Size Information

1.0 625
Body Repair Corrosion Protection

Corrosion Protection During service, do not remove the protective wax or paint
Overview from the underbody or lower part of the engine cover. If the
above areas shall be cleaned with steam, then apply a new layer
Treatment in Production
of protective wax or an underbody protection layer as soon as
During production, the vehicle body applies the following possible.
methods for anti-corrosion treatment:
Maintenance Check
• Use galvanized steel sheet;
When doing the anti-corrosion check on the body, observe
• Phosphate anti-corrosion primer dip-coating, the following steps:
electrophoresis;
• Lift the vehicle, visually inspect the underbody sealant for
• Chip-resistant coating;
any damage;
• Underbody coating: spray on the underbody of the main
• Lower the vehicle, check the body exterior paint for
floor and rear floor, and on the rear wheel opening;
damage, and the body panel for corrosion.
• Cavity wax: spray on the sheet metal parts such as
doorsill and rear window sill, side extensions and the Note: If the vehicle is dirty, it will need to be washed prior
lower sheet metal of the door; to inspection of bodywork.

• Protective wax: spray on the opening not covered by the The above check refers only to visual check. When checking
wheel house. for corrosion and paint damage, do not remove the decorative
panels or sound insulation materials.
Whenever repairing the body, make sure the anti-corrosion
materials from the repair area is also repaired or updated. 1. Lift the vehicle, and use the test lamp or spotlight to
Ensure the materials used are the approved anti-corrosion perform a visual check for the following:
materials. • Corrosion damage and paint damage, and conditions of
Precautions for Body Repair and Operation the lower panels of the front/rear vehicle, doorsill and the
underbody sealant at the wheel opening;
In the workshop, it is necessary to exercise caution in the
operation of the vehicle. For example, when lifting the vehicle, • Damage to underbody sealant. Erosion conditions in
any carelessness and negligence can cause damage to the surrounding areas of the suspension mounting point and
underbody sealant, seam sealing materials, underbody sealing fuel tank mounting point.
wax and body panels, etc. Note: for unexposed metals, the little bubble on the underbody
When fitting the accessories, ensure that the vehicle sealing material can be neglected.
anti-corrosion protection is not impaired by broken protective Pay special attention to damage of the sheet metal or
layer or moisture. anti-corrosion material due to incorrect lifting method.

Do not screw the self-tapping screws directly into the body

Warning: It is essential to follow the correct jacking and
panels. Pre-fix the matching plastic inserts to the body panels.
lifting procedures.
Always brush the sheet metal, chassis component and drill hole
edge of other body parts with proper zinc-rich or acid-etch
2. After lowering the vehicle, visually check all the visible
primer, and brush the surrounding area with wax.
painted surfaces for sign of damage and corrosion, and
Never contact the painted metal surface of the part with pay special attention to the following areas:
the body without taking appropriate protection measures.
• Leading edge of the engine cover;
Between the metal surfaces requiring bolt connection, be sure
to have appropriate media, such as weldable zinc-rich primer • Visible flanging of the engine compartment;
or zinc strip, etc. • Underbody and door panel.
The heat from the steam cleaning equipment has the risk of Take feasible measures to correct or repair any body
damaging some decorative parts, softening or liquefying certain damage or corrosion found during the inspection as soon
adhesives and anti-corrosion materials, so the equipment shall as possible. These include diminishing breakage and
be adjusted so that the nozzle temperature does not exceed ensuring the long-term effectiveness of the anti-corrosion
90℃ (194℉). Do not have the steam nozzle stay in one place treatment performed in the production. If the corroded
for a long period of time, the distance between the nozzle and area is increasingly clear, and diffuses or expands from
the sheet metal surface shall be at least above 300mm. the bottom of the replaceable parts (such as various trim
panels, window glass, seats, etc.), then replace the parts
to achieve the most effective repair.

1.0 626
Corrosion Protection Body Repair
Underbody Protective Maintenance 7. Use approved underbody sealant for service to spray the
affected area;
Whenever doing maintenance work of the body, ensure that
the body sealing and anti-corrosion protection is recovered 8. Remove all the covering on the mounting surfaces of the
to the original condition. This applies not only to the repair components.
work on damaged areas, but also to the recovery work on the After refitting the above mechanical parts, including hoses,
protective layer of certain areas indirectly weakened due to pipes and other clips, cover the brake disc, spray a layer of
accidents or maintenance operations. approved underbody protective wax. After repairing the sheet
Before straightening or doing panel repairs, you must remove metal at the damaged wheel opening, spray new wax which is
the corrosion protection layer of the damaged area. It's also applicable for the painted surface and underbody sealant.
particularly important, especially for the panels with a Remove the old wax on the underbody, and the range of the
protective wax layer, the underbody with polyvinyl chloride underbody wax is at least 200mm larger than the range of the
(PVC) sealing materials, and the sound barrier areas. new underbody sealant.

Warning: DO NOT use oxy-acetylene gas equipment to Note: Where repairs include the application of finish
remove corrosion prevention materials. Large volumes of paint coats in the areas requiring underbody wax, carry
fumes and gases are liberated by these materials when out paint operations before applying wax.
they burn. Cavity Wax Injection
Note: The device used for removing strong After repair, be sure to use approved cavity wax for treatment.
anti-corrosion sealant can provide several speeds In addition, for all inner surfaces damaged by the repair,
and efficiency. The scraper (not pneumatic chisel) whether these areas have been treated in the production
driven by compressed air provides a relatively process, they shall be subject to a cavity wax treatment. This
quiet mechanical method by using a very rapid includes all the cavities and the door interior. If necessary,
reciprocating motion. Move the operating edge of allow additional holes to be made for wax injection, but these
the tool along the workpiece surface to remove the holes can not be located in the load-bearing parts. Make sure
sealing material. that these holes are treated by using the proper zinc-rich
primer, and brushed with protective wax, and finally sealed
The most common way is to remove the sealing material
with the rubber ring.
by using hot air dryer integrated with a blade. One of the
most effective ways is to use a "hot knife" with fast cutting Before injecting the wax, make sure the cavity to be treated
characteristics. This tool uses a wide blade that can easily is free of contaminants and foreign materials. If necessary, use
access the outline area where it is difficult to reach in some compressed air to remove the debris in the cavity.
other way.
Always ensure cavity wax injection is performed after the final
When doing the repair on the underbody sealants, follow the finish and before re-assembling other components.
following steps:
During the spray process, ensure that the cavity wax covers
1. Remove the existing underbody coating; all the flanges and seams, and be fully distributed to the repair
2. After the sheet metals are repaired, use solvents to clean areas of all new and existing sheet metals.
the affected area and use the etching phosphate materials It is noteworthy that there is no wax injection process when
to process bare metal; assembling new sheet metal and complete body shell. Such
3. Apply new primer to the affected areas; operation shall be performed after repair.
Caution: DO NOT, under any circumstances, apply It is quite essential to take efficient cavity wax protective
underbody sealer directly to bare metal surfaces. measures. Always observe the following points:
4. Replace all damaged heat-fusible plugs. If this type of plug • Before wax injection, ensure the paint repair work is
does not use such rubber grommet of appropriate size, completed;
ensure this type of plug be implanted to the sealant; • If necessary, clean the body panel areas and blow the
5. After the mechanical parts, hoses and pipe clips on the cavity prior to the operation;
underbody are removed, cover all the mounting surfaces. • During wax injection and drying, the temperature should
The underbody sealant must be sprayed before the above be at 18 ℃ (64 ℉);
components are refitted:
• Check the pattern of the injection equipment;
6. Brush all exposed seams with sealant;

1.0 627
Body Repair Corrosion Protection

• Cover all areas where no protective layer is needed and

the area that may be contaminated due to overspray;
• In case of possible contamination, remove the body
device, such as seat belt retractor;
• Before dealing with the internal structure of the door, lift
the door glass up to the completely closed position;
• Before refitting the components, spray wax on the body
areas which are usually covered by trims;
• After the wax layer is completely dry, check whether the
drain hole on the body and door is clean;
• Keep the equipment clean and tidy, especially the wax
nozzle.

1.0 628
Corrosion Protection Body Repair
Anti-corrosion Products and Construction Caution: Do not force the lance into access holes when
Equipment and Supplier using this attachment.
Cavity Waxing Machine and Technology 1100 mm movable nylon spray gun pipe: the elastic nylon
spray gun shares the same type with the rigid spray gun, but
it provides a stronger penetrability, it can be used to spray the
inaccessible vessel of the curved section or nozzle. The main
disadvantage of the elastic nylon spray gun is that it cannot
precisely position the internal compartment. When spraying,
spray outwards by the stroke of the spray gun. When pulling
the spray gun out, retract it slowly and ensure the integrity of
the finished spray. Do not pull the spray gun out with a rush.
Ensure the nylon pipe of the spray gun is away from the edge
and located in the hole so that wear of the nylon pipe can be
avoided and the service life of the nylon pipe can be prolonged.
Ensure the spray operation is stopped before removing the
nozzle from the port. To assist in the completion of this step,
1. Air Inlet use red paint to mark the rear of the nozzle (30 mm).

2. Flow Control (adjust spray mode) Hook Nozzle of Movable Spray Gun
3. Pressure Cup (1L) Max. Pressure 140 PSI (9.7 bar, 9.84 The spray gun with rigid hook nozzle provides a forward
kg/cm³) spray, its conical spray is characterised by long range and good
4. Spray Gun Connector dispersion. The combination of these two features provides a
good capability of orientation and a good effect on the short
5. Nozzle Connection of Spray Gun Pipe
and narrow locations to be sprayed, besides, it can also be
6. Retractable Spray Gun Pipe used for direct spray of the inner wheel arc, etc.
7. Rigid Hook Rod (forward, conical spray)
When using, place the smooth area at the end of the spray gun
8. Movable nylon spray gun pipe (1100 mm), 360° spray to form an angle of 180° with the location to be sprayed. For
9. Rigid spray gun pipe (1100 mm), 360° spray locations hidden in a box or hole, this helps to finish the spray
For repair, if the waxing area is scratched, handle it again. successfully.
Compressed air spray guns with the integral pressure cup and For general spray, arch the nozzle, and move from one end
replaceable spray gun pipe shall be used. to the other as required, and ensure complete spray of the
According to the configuration of the add-on device, please surface.
strictly observe the following in use: Note: Always clean gun after use with appropriate solvent
• When handling the film area, use the rigid or movable to maintain efficiency.
spray gun to give a 360° spray to ensure a maximum Recommended Equipment
coverage; 3M Schutz Pistol Spray Gun 08996 for Body: The pistol spray
• For restricted openings, use a hook nozzle to provide gun is constructed of the housing and machined light alloy,
a more directional spray (narrow inside or short which is fitted by 3M bolts to the Schutz container.
compartment);
3M Pneumatic Cartridge Pistol Spray Gun 08012: The direct
• Wax is directly sprayed to the bottom surface through feed pneumatic gun is used for the 3M cartridge product. It has
the smaller spray pipe of the spray gun, disconnect the a good performance in smooth spray, and an adjusting valve for
liquid. additional control is provided.
1100 mm rigid spray gun: the nozzle of the rigid spray gun gives 3M pneumatic pistol spray gun-08006/7: direct feed pneumatic
a forward conical spray of 360° circumference. Though the guns are used for the 3M product sealed in bags (spray gun
wax film is sprayed by a single stroke, it can affect all surfaces 08006 is used for products of 200 ml and 310 ml in bags, and
of the compartment, internal and external spray can provide spray gun 08007 is used for products of different models in
effective and complete wax coverage for the long/straight bags, including products of 600 ml).
structure and compartment. By visual inspection, the rigid
spray pipe also provides position accuracy for handling the Other applicable spray guns: heavy pistol 08013.
shapely location.

1.0 629
Body Repair Corrosion Protection

3M glue gun 08190: this model is used for 3M structure gluing • The cutting surface or damaged coating of the sheet
08120. metal panel requires zinc spray;

3M cavity wax film glue gun 08997: This machine can load • Zinc shall be sprayed on the contact surface of the
a tank of 1L, it is equipped with a hose of 750 mm. The welding to prevent rust of the spot welding.
approved system can be obtained from the 3M surface repair
coefficient. The Cooper Greux falcon preliminary spray gun
(airtight) is used for spraying transit wax, which has a 5L
container with a complete manual pump and achieves effective
spray without compressed air or additional operation. Use
of the nozzle, spray gun, hose length and a trigger valve
with complete filter can facilitate the application. Other
applications include general service, wax spray liquid and paint
spray. The operation may use heavy materials. All components
can be replaced and configured with different nozzles.

SATA Schutz gun UBE: the SATA gun is used for retreatment of
the bottom vehicle coated with protective paint, the spray gun
is in the special one-way container (1L). Thread parts (inner
thread of the gun) conform to the standard of most of the
Schutz product packages.
Specification of UBE:
Air consumption 7 ft3/min (200 litres/min) @
45 lbf.in2
Weight: 23.3 oz (220 grams)

SATA HKD1 waxing machine: used for retreatment of cavity

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

Note: Always clean gun after use with appropriate solvent

to maintain efficiency.
Contact information of 3M supplier
3M (China) Co. Limited

Address: No. 38 building, Maxdo Centre, No. 8 Xing Yi Road,

Shanghai, China

Zip Code: 200336

Tel: 86 21 62753535

Website: www.3M.com
Zinc Spray
For locations needing MIG/MAG welding or spot welding, apply
the primer rich in zinc to the area near the connector surface,
and do not process the welding area.

Zinc spray is used for the following two situations:

1.0 630
Corrosion Protection Body Repair
Information of Cavity Wax Application
Doorsill

1.0 631
Body Repair Corrosion Protection

Door and Luggage Compartment Lid

Spray cavity wax from the process hole inside the door and luggage compartment lid to cover the internal sheet metal and
frame with a layer of protective film. Most of the cavity wax deposit is at the bottom of the sheet metal cavity, and it will be
finally drained from the hole at the bottom.

1.0 632
Corrosion Protection Body Repair

1.0 633
Body Repair Corrosion Protection

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

1.0 634
Welding Process Body Repair
Welding Process Resistance spot welding
Welding Process Overview The resistance spot welding is the most common method for
Characteristics of welding process: welding the integral body. This method can be used for the
non-deformable thin steel sheet on the body which requires a
• It is applicable to any shape and can be used to connect
high welding strength. Suitable for roof, window, doorsill and
the integral body, and the vehicle body integrity can be
external components, etc. The quality of the resistance spot
maintained after welding;
welding depends on the voltage, current, pressure time and
• Mass reduction can be achieved due to lack of the
thickness of the metal panel to be welded, etc, the details are
connecting parts;
as follows:
• Good sealing performance for air and water;
• Material and cleanness of the weldment: the location
• High production efficiency; between the weldments or the contact point between
• The welding connector strength is affected by the skill the weldment and the electrode shall be clean;
level of the operator; • Electrode pressing force: insufficient force can cause
• Excessive heating may cause surrounding panels spatter on the contact point; excessive force can
deformation. generate large current, but it will lead to small welding
spot diameter and penetration due to increase of the
For modern vehicles, the body welding repair usually adopts
heat distribution zone;
MAG shielded arc welding, resistance spot welding and
soldering. For the body panel welding repair, an optimum • Welding current: the welding spot diameter and welding
welding method that will not reduce the original strength and strength increase with the current, and large current
durability of the body shall be applied depending on the specific and small pressure may also lead to spatter between the
situations, spot welding or inert gas welding is preferred. panels; the spatter will be otherwise minimized;

MAG Shielded Arc Welding • Welding time: long welding time will cause much heat,
large diameter and deep penetration of the welding spot.
MAG shielded arc welding is mainly used for welding high However, prolonged welding time will lead to electrode
strength, low alloy steel body and aluminum casting, etc. impress and thermal deformation rather than increase of
Advantages of the MAG shielded arc welding include: the welding spot.
• Easy operation; • Arrangement of the welding spot: the gap and margin
• This method can melt the base metal completely, low of the welding spot (distance between the spot and the
current can be used to weld thin metal, which can panel edge) is also crucial for determining the welding
diminish damage to the adjacent area strength; spot strength. Welding spot gap decrease can improve
• Stable and controllable arc; the weldment connection strength, but the effect is
• Suitable for welding locations with gap and misalignment; actually limited. Excessive gap may cause the welding
current to transfer through the last welding spot or
• Temperature and duration of the welding is controllable,
leak, then the added welding spot will not strengthen
short heating time of the welding zone reduces fatigue
the connection strength of the weldment any more, and
and deformation of the base metal.
it will have an adverse impact, therefore, the gap of the
Typical welding locations and methods: welding spot shall be beyond the area of current leak.
• Butt welding. Fit two adjacent metal edges together, fit Correct welding sequence shall be applied for the resistance
mutually along the two metal panels or weld the butted spot welding, continuous welding in one direction is generally
edge; not allowed, when the electrode tip is hot and discolours, stop
• Overlap welding. Weld two overlapping metal panels; welding and allow it to cool down. To avoid crack due to stress
• Plug welding. Punch a hole on one or several exterior concentration, do not weld the boundary of the corner.
workpieces, arc passes through the hole before entering
into the interior workpiece, and the hole is filled with the
melting metal;
• Spot welding. When the wire feed timing pulse is
triggered, current will be introduced into the two metal
panels to be welded.

1.0 635
Body Repair Welding Process

Welding Protection Measures

Electronic Control Unit
Before welding repair is operated, in consideration of the
electronic control unit (ECU) refitted on the vehicle, the
following protection measures must be followed. The plentiful
heat and sharp vibration produced during these operations
may damage the electronic control unit.

When disconnect or remove the airbag control module

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

Try best to use the original production assembly, including rivet

joints of seat belts, or the layout of cutting line should not
interfere with the original rivet joints of seat belts.

Carefully check the welding quality of the jointing for seat belts
rivet joints within 250mm, including the spot welding spacing.

1.0 636
Welding Process Body Repair
Welding Parts Remove
1. Expose the resistance spot welding. Use a rotary bowl
grinder or a wire brush installed into the air drill, or
manual wire brush for the spot welding is not obvious.

3. Location for laser welding: use grinder and grinding disk.

Caution: In wheel arch areas it may be necessary to soften

underbody coating, using a hot air gun, prior to exposing
spot welds.

2. The drill or clamping platoon welder for spot welding can

be used to remove the welding spot.

4. CO2-MAG Arc Welding Location

5. Rivet Junction

1.0 637
Body Repair Welding Process

6. Big panel cutting • d. Overlap cutting

• a. Cutting by edge of steel panel

Caution: On certain panel joints MIG welds and braze

• b. Plastic sample panel cutting should be removed using a sander where possible, before
cutting out the panel bulk.

7. Separate the electric welding point with hammers, base

plate chisels and pincers, and remove the penal scraps.

• c. Dimension measurement

1.0 638
Welding Process Body Repair
Welding Information of OEM
Welding Identification

—2 layers of welding

—3 layers of welding

—MAG welding/CMT welding

1.0 639
Body Repair Welding Process

Welding Information of Main Parts

Engine Compartment
Structure

A - Front Wheelhouse Assembly

B - Dash Panel Upper Beam Assembly
C - Dash Panel Upper Beam
D - Dash Panel Assembly
E - Front Longitudinal Beam Front Bumper Mounting Bracket
Assembly

1.0 640
Welding Process Body Repair
Front Wheelhouse Assembly

1. Weld the front wheelhouse assembly (A) to the front

longitudinal beam assembly.

Front Longitudinal Beam Front Bumper Mounting Bracket Assembly

1. Weld the front longitudinal beam front bumper mounting

bracket assembly (E) to the front longitudinal beam assembly
(MAG welding length is 8mm).

2. Weld the dash panel upper beam assembly (B) to the front
wheelhouse assembly (A).

3. Weld the dash panel upper beam (C) to the front

wheelhouse assembly (A).

4. Weld the dash panel assembly (D) to the front wheelhouse

assembly (A).

1.0 641
Body Repair Welding Process

Bodyside
Structure

A - Bodyside Outer Panel

B - D Pillar Crash Panel Reinforcement Assembly
C - Tail Lamp Mounting Frame Assembly
D - Rear Wheelhouse - Bodyside Extension Panel
E - Front Door Frame Reinforcement Assembly
F - Frame Inner Panel
G - Bodyside Closing Plate Assembly
H - Rear Bodyside Inner Panel Assembly

1.0 642
Welding Process Body Repair
The bodyside assembly is welded with A, B,C, D, E, F, G and 4. Weld the fuel filler housing assembly to the right bodyside
H. Firstly weld A, B, C and D into the bodyside outer panel outer panel (A).
assembly, then weld the bodyside outer panel assembly to E, F,
G and H.

1. Weld the D pillar reinforcement assembly (B) to the

bodyside outer panel (A).

5. Weld E, F, G, H and the bodyside outer panel assembly in

turn into an assembly.

2. Weld the tail lamp mounting frame assembly (C) to the

bodyside outer panel (A).

3. Weld the rear wheelhouse - bodyside extension panel (D)

to the bodyside outer panel (A).

a - Bodyside Outer Panel

b - Front Door Frame Reinforcement Assembly

c - Bodyside Closing Plate Assembly

1.0 643
Body Repair Welding Process

a - Bodyside Outer Panel

b - Rear Bodyside Inner Panel Assembly

1.0 644
Welding Process Body Repair

A - Bodyside Assembly
B - Front Outer Frame Assembly

1.0 645
Body Repair Welding Process

Weld the bodyside assembly to the body assembly and weld

the frame assembly to the body assembly.

1. Weld the bodyside assembly to the body assembly.

a - Bodyside Outer Panel

b - Rear Bodyside Inner Panel Assembly

c - Rear Wheelhouse Inner Panel Assembly

a - Bodyside Outer Panel

b - Front Door Frame Reinforcement Assembly

c - Dash Panel Side Panel Assembly

1.0 646
Welding Process Body Repair

2. Weld the frame assembly to the body assembly.

a - Front Wheelhouse Assembly

b - Frame Inner Panel

c - Front Outer Frame Assembly

1.0 647
Body Repair Welding Process

Bodyside Outer Panel Service in Sections

Structure

A - Front Bodyside Outer Panel

B - Rear Bodyside Outer Panel

1.0 648
Welding Process Body Repair
"Service in Sections" is widely used in the service of bodyside outer panel, because in accidents, the damaged parts are always
the front bodyside outer panel or the rear bodyside outer panel.

1. Weld the front bodyside outer panel

2. Weld the rear bodyside outer panel

a - Bodyside Outer Panel

b - Rear Bodyside Inner Panel Assembly

c - Rear Wheelhouse Inner Panel Assembly

1.0 649
Body Repair Welding Process

Rear End Panel Assembly

Structure

A - Rear End Panel Assembly

1.0 650
Welding Process Body Repair
1. Weld the rear end panel (A) to the bodyside assembly.

2. Weld the rear end panel (A) to the rear door assembly.

1.0 651
Body Repair Welding Process

Roof Panel
Structure

A - Front Roof Beam Assembly

B - Middle Roof Beam
C - Rear Roof Beam
D - Roof Panel

1.0 652
Welding Process Body Repair
Weld the roof beam (A, B, C) to the body assembly then to the roof panel (D).

1.0 653
Body Repair Welding Process

Sunroof
Structure

A - Sunroof Window Reinforcement Assembly

B - Rear Roof Beam
C - Roof Panel - With Sunroof

1.0 654
Welding Process Body Repair
Weld the roof beam (A, B) to the body assembly then to the roof panel - with sunroof (C).

1.0 655
Body Repair Welding Process

1.0 656
Body Dimension Body Repair
Body Dimension
Point to Point Dimensional Information
Bodyside and Top Information

1.0 657
Body Repair Body Dimension

1.0 658
Body Dimension Body Repair
Bottom Plate Information

1.0 659
Body Repair Body Dimension

Rear End Information

1.0 660
Body Dimension Body Repair
Internal Information

1.0 661
Body Repair Body Dimension

Front End Information

1.0 662
Body Dimension Body Repair
Gap Information
Body Side and Fuel Filler Cap Information

1.0 663
Body Repair Body Dimension

Front End Information

1.0 664
Body Dimension Body Repair

1.0 665
Body Repair Body Dimension

Rear End Information

1.0 666
Body Dimension Body Repair
Sunroof Information

1.0 667
1.0 668
Vehicle Access Safety and Restraints
Vehicle Access
Description and Operation
System Layout

1. Horn
2. Body Control Module
3. Right Front Door Lock Assembly
4. Right Rear Door Lock Assembly
5. Tail Gate Lock Assembly
6. Left Rear Door Lock Assembly
7. Driver Side Door Lock Assembly
8. Central Lock Switch
9. Remote Key
10. Ignition Switch
11. Instrument Pack
12. Engine Control Module

1.0 669
Safety and Restraints Vehicle Access

System Control Diagram

Vehicle Access and Safety Control Diagram

A = HS CAN Bus; B = RF Signal; C = Hard Wire

1.0 670
Vehicle Access Safety and Restraints
Description
Security System
The function of the security system is to prevent illegal
start of the vehicle. When the ignition switch is turned
to ACC position, the anti-theft system can be disabled by
the transmitter on the remote key, this transmitter can be
identified by the reader coil around the ignition switch, and
the coil transmits electric power and data to the remote key
in a frequency within a certain distance away from the signal
reader coil. The security system includes:

• Door switch
• Luggage compartment switch
• Bonnet switch
• Security warning lamp
• Hazard warning lamp button
• Remote key
• Ignition switch
• Body control module (BCM)
Door Switch
Each door lock assembly contains a microswitch to notify
the BCM of the door status. When the door is open, the
microswitch contact will close to connect the ground circuit of
the BCM. When the door is closed, the microswitch contact
will disconnect and convert into an open circuit. Door switch,
bonnet and luggage compartment open switches are the main
components of the alarm system. When the alarm system
works, these switches will monitor the external intrusion into
the vehicle. The door open signal is also used by the BCM to
indicate the door status information in the instrument pack
information centre and control the interior lighting.
Luggage Compartment Switch
The luggage compartment lock motor contains a microswitch
used to notify the BCM of the luggage compartment lid status.
When the luggage compartment lid is closed, the microswitch
contact disconnects and the circuit of the BCM becomes an
open circuit. When the luggage compartment lid is open, the
switch will be closed and the ground circuit of the BCM will
be connected. CANWhen the bus detects that the ground
circuit is connected, it will trigger the alarm. The luggage
compartment open microswitch is also used by the BCM to
indicate the luggage compartment status information in the
instrument pack information centre and automatically control
the interior lighting.

1.0 671
Safety and Restraints Vehicle Access

Operation When the security system enters the complete anti-theft

Overview status, the BCM will allow the direction indicator lamp to
give three flashes.
Operation of Vehicle Access System
Complete Anti-theft Status to Partial Anti-theft
The vehicle security system includes the following three parts:
Status
1. Peripheral system:
In the complete anti-theft system, if a valid UNLOCK request
• Bonnet alarm (if fitted), door and luggage compartment lid of the luggage compartment lid is received, the BCM opens
open switches the luggage compartment lid and the security system enters
• Ignition switch the partial anti-theft status.
Partial Anti-theft Status
• Central lock (LOCK/UNLOCK) switch
If the error lock is caused by zone 1 only (for example, the
2. Acoustic alarm: vehicle horn
bonnet is open), zone 2 and 3 will enter the complete anti-theft
3. Visible alarm: hazard warning lamp
status.
The security system is divided into three independent zones,
If the error lock is caused by zone 2 only, expect driver door
and each zone includes many discrete input signals (see the
(for example, 1 door or more doors are open), zone 1 and 3
table below). When the security system is working, any
will enter the complete anti-theft status.
intrusion into these zones can trigger the alarm.
If the error lock is caused by zone 3 only (for example, the
Safety zone Discrete signal
luggage compartment lid is open), zone 1 and 2 will enter the
1 (front) • Bonnet open switch complete anti-theft status.
• Driver door open switch Partial Anti-theft Status to Complete Anti-theft
• Front passenger door open switch Status
• Left rear door open switch When each safety zone is in the security system, the vehicle
• Right rear door open switch will enter the complete anti-theft status.
2 • Driver door key unlock (timed for For partial locks caused by error lock due to open door,
(middle/inside)
15s) when the security system enters the anti-theft status, it can be
• Wrong key is inserted into and disabled after being enabled within 5 seconds, and the alarm
placed in "ACC/ON" position will not be triggered.
• Central lock LOCK/UNLOCK If the partial anti-theft is caused by several zones, when the
switch relevant doors/covers of these zones are closed, these zones
• Luggage compartment lid release will enter the complete anti-theft status. The entire security
3 (rear) system enters the complete anti-theft status only when all the
switch
zones enter the status.
Complete Anti-theft Status
Error Lock Alarm
When the three zones of the security system are closed, if
With the door (bonnet, luggage compartment lid) open, and
a LOCK request from the remote control or mechanical key
the ignition switch in the ACC gear, ON gear or START gear or
is received, the security system formally enters the complete
the engine running, when using the mechanical key or remote
anti-theft status. Once in the complete anti-theft status, all
key to send the LOCK request outside the vehicle, the BCM
activated safety zones will be monitored at all times. When
will activate the horn to send an acoustic alarm (appr. 30ms)
the switch of zone 2 or 3 is enabled, if you attempt to lock
to indicate error lock.
the system from outside, the vehicle will enter the partial lock
status and give an error lock alarm. Disable Security System

BCMIt will monitor the following outside LOCK request Any of the following operations will cause the BCM to disable
signals: the security system:
• Valid LOCK request from the remote key is received. • Valid UNLOCK request from the remote key is received.
• Valid LOCK request from the driver door lock switch is • Valid UNLOCK request from the driver door switch is
received. received.
• A valid emergency key is inserted into the ignition switch
and switched from the ACC gear to the ON gear.

1.0 672
Vehicle Access Safety and Restraints
Caution: If the driver door unlock switch is stuck
or the switch circuit is short-circuited, the
emergency key will not be used to disable the
alarm; while the remote key will not be affected.
When the security system is disabled, the BCM will allow the
direction indicator lamp to flash once.
Unlock Triggered by Impact

When the airbag control module senses an impact, it will

send an UNLOCK request, and then the door will unlock
automatically except in the case of external locking.
Auto Relock

After being unlocked with the remote key, the vehicle will
automatically return to the previous locked status if there is
no operation within 30 seconds. In the auto relock status, if
the ignition switch is in ACC position or a valid key exists, the
current timing of the relock timer is cancelled, and the auto
relock function is cancelled.
Auto Lock

If the driver door is closed and the vehicle is unlocked, when

the vehicle speed reaches a certain value (preset), the door
will lock automatically.
Auto Unlock

With the vehicle internally locked, turn the ignition switch to

the "OFF" position or pull out the key, the vehicle will unlock
automatically.
Door Lock Controlled by Internal Central Lock
Switch

With the driver door closed and the impact signals disabled,
press the LOCK button of the central lock switch to lock all
doors.

With the vehicle doors internally locked, press the UNLOCK

button of the central lock switch to unlock all doors.

When an impact occurs and the impact signal is triggered,

the door unlocks automatically. The door cannot be relocked
within current ignition cycle even if the LOCK button of the
central lock switch is pressed. When the vehicle doors are
externally locked, the LOCK/UNLOCK buttons of the central
lock switch do not work.

1.0 673
Safety and Restraints Alarm System

Alarm System
Description and Operation
System Layout

1. LF Anti-theft Coil

1.0 674
Alarm System Safety and Restraints
System Control Diagram

A = HS CAN Bus; B = RF Signal; C = Hard Wire

1.0 675
Safety and Restraints Alarm System

Description
The vehicle is configured with an anti-theft system connected
with the ECM. The characteristic value from the RF transceiver
will be verified, if the value matches the corresponding data,
the engine can be started. When the power is connected, the
key sends the characteristic value to the LF anti-theft coil and
the serial data circuit to the BCM through the hard wire.
Mounting Position
• LF anti-theft coil: on the IGN lock cylinder.
End View and Pin Information of LF Anti-theft Coil
Harness Connector FC009

Pin No. Description

1 IMMO Transmission Line –
2 -
3 IMMO Transmission Line +

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Alarm System Safety and Restraints
Operation
The function of the anti-theft system is provided by the BCM,
ECM and modules which store and report environment
identifiers.

• LF anti-theft coil: when the ignition key is inserted into

the IGN lock cylinder and the ignition switch is in "ON"
position, the RF transceiver of the key will be switched on
by the LF anti-theft coil of the IGN lock cylinder. Then,
the RF transceiver transmits a signal which contains its
characteristic value. BCMThe BCM receives the signal
and compares the value with that stored in the memory.

If the two values match, the BCM sends a pre-cancellation

password to the ECM through the serial data circuit. If the
characteristic value of the RF transceiver is wrong, the BCM
sends fuel disable password to the ECM.

When ECM receives the pre-cancellation password from

BCM, the ECM will verify the password. ECMThe ECM
returns the password verified to the BCM through the serial
data circuit. ECMThe ECM and BCM calculate the password.

If the result calculated by the BCM and ECM is consistent,

the ECM will allow the vehicle to start.

1.0 677
Safety and Restraints Alarm System

Service Procedures
Anti-theft Coil
Remove
1. Disconnect the battery negative.
2. Remove the steering column trim cover.

Steering Column Trim Cover Remove

3. Disconnect the connector of the anti-theft coil.
4. Release the clip and remove the anti-theft coil.

Refit
1. Connect the connector of the anti-theft coil.
2. Fasten the clips and fit the anti-theft coil.
3. Fit the steering column trim cover.

Steering Column Trim Cover Refit

4. Connect the battery negative.

1.0 678
Seat Belts Safety and Restraints
Seat Belts
Specifications
Torque
Description Value
Bolt - front seat belt retractor to ‘BC’ post 30–35Nm
Bolt - front seat belt to upper ‘BC’ post 30–35Nm
Bolt - front seat belt to body 30–35Nm
Bolt - front seat belt buckle 43–53Nm
Bolt - rear seat belt to upper ‘D’ post 30–35Nm
Bolt - rear seat belt retractor to rear inner wheelarch 30–35Nm
Bolt - rear seat belt double buckle 30–35Nm
Bolt-rear middle seat belt retractor 35-45Nm
Bolt - rear seat middle lap belt 30–35Nm

1.0 679
Safety and Restraints Seat Belts

Description and Operation

System Layout

1. Rear Seat Belt Assembly 6. Rear Seat Central Belt

2. Rear Seat Belt Retractor 7. Front Seat Belt Buckle (with alarm function)
3. Rear Seat Belt Double Buckles 8. Airbag Control and Diagnostic Unit
4. Front Seat Belt Assembly 9. Seat Belt Not Tied Warning Lamp
5. Front Seat Belt Retractor With Pretensioner 10. Rear Seat Belt Buckle (if equipped)

1.0 680
Seat Belts Safety and Restraints
System Control Diagram
Airbag Control Logic Diagram

A = HS CAN Bus; B = Hard Wire

1.0 681
Safety and Restraints Seat Belts

Description webbing loose, so that the loads acting on the occupants are
Front Seat Belt Pretensioner reduced.
Front Seat Belt

In case of collision, the front seat belt pretensioner tightens,

this ensures the occupants are securely kept in their seats. The retractor of the front seat belt is fitted on the body, in the
The seat belt pretensioner unit is fixed by bolts to the seat cavity at the bottom of the B/C pillar lower trim panel. Pull
belt retractor assembly in the B/C pillar. The seat belt the belt webbing from the retractor, and fix it to the mounting
pretensioner connector is a 2-pin connector connected with point under the B/C pillar.
the body harness. Rear Seat Belt
In case of collision, the seat belt pretensioner is controlled
by the signal from the SRS ECU. The retractors of the two
pretensioners are positioned and work in the same way. Each
pretensioner unit is provided with an initiator and a propulsion
generator which act on the rotor of the seat belt retractor.

Warning: Once the pre-tensioner has been operated, it

cannot be reset. The gas generator will be exhausted. The
unit must be replaced.
Seat Belt
The seat belts provide the most basic protection for all
occupants. The restraint system also provides further
protection for the front occupants through the airbag module
and the pretensioning seat belts. The front seats are all fitted The retractor of the rear seat belt at both sides is fixed to the
with appropriate retractors and three-point belts. The vehicle reinforcement panel of the rear wheelhouse inner panel with
retractor is a type of emergency locking retractor (ELR). bolts. One end of the webbing is fixed to the upper end of the
The retractor is provided with an additional lock mechanism C pillar, the other end is fixed to the mounting point of the
which includes a webbing sensor and an automotive sensor. body floor; the retractor of the central seat belt is fixed to the
If the webbing is suddenly pulled, the webbing sensor will seat frame with bolts, and the other end is fixed to the lower
immediately start the lock mechanism. If the vehicle is part of the rear seats.
suddenly slowed down or tilts at a large angle, the automotive The right rear seat belt buckle and the central seat belt buckle
sensor will start the lock mechanism. form an assembly which is fixed by one bolt between the right
The retractor will lock in case of impact, so the front seat belt rear seat and the central rear seat. The left rear seat belt
retractor is equipped with load limiters. If the load limit has buckle is located at the occupant's right hip.
exceeded the critical level, the load limiter makes the seat belt

1.0 682
Seat Belts Safety and Restraints
Seat Belt Warning The front seat belt buckles are integrated with the seat belt not
tied warning switch, which is connected to the instrument pack
through SRS ECU. The seat belt warning will be triggered if
the seat belt is not tied firmly during driving. The warning
message comprises an acoustic alarm and a warning lamp on
the instrument panel. To prevent unnecessary warning, some
vehicle specification specifies that a pressure sensor shall be
fitted within the foam of the passenger seat when there is no
passenger on the seat. If there is any passenger on the seat, but
the pressure sensor is not activated, then the seat belt warning
will not be triggered even if the occupant does not wear the
seat belt.

1.0 683
Safety and Restraints Seat Belts

Operation ECU will store a related DTC in a nonvolatile memory and

Overview output a signal to illuminate the SRS warning lamp. The failure
information in the memory can be read with the scan tool.
When the remote key is inserted, the restraint system is
activated. With the ignition switch in "ON" position, the SRS Low Voltage Failure
warning lamp illuminates for 6 seconds, then goes out, this When the voltage supply is not within the specified range, the
indicates that the system is in normal condition. malfunction indicator lamp will illuminate. The DTC is stored
Side Impact in the memory.

Normal operation of the side seat airbag and head curtain Intermittent Failure
airbag depends on whether the severity level of the side impact The warning lamp will illuminate at the moment and remain
detected by the side impact sensor exceeds the threshold on in subsequent driving cycles. The warning lamp will not
for triggering the side impact sensor. When the SRS ECU illuminate in the next ignition unless the failure occurs again,
receives a trigger signal from the side impact sensor, it will but the DTC is still stored in the SRS ECU memory.
activate the side seat airbag and curtain airbag module. The
Permanent Failure
triggered gas generator can produce a large quantity of gas to
expand the airbag. The expanded airbag will eject from the For a permanent failure, the SRS lamp will illuminate when
seat upholstery, similarly, if the head curtain airbag module is the test is started, and it will remain on in every subsequent
triggered, the head airbag will eject from the interior trim panel ignition cycle until the cause of the failure is solved. In addition,
above the door to protect the passenger from head injury. The the diagnosis system will also record the information of the
fully expanded airbag will release excess gas to reduce the risk failure occurred.
of passenger injury. When any failure is detected, the system will retain certain
Warning Lamp Check operating functions:
When the ignition switch is turned on, the SRS warning lamp • If it is detected that the circuit of the SRS outside the
shall illuminate, then check the lamp. If no failure occurs in the SRS ECU is faulty, SRS ECU will still activate the airbag
SRS, the warning lamp shall go out after about 6 seconds to and seat belt pretensioner module.
monitor the subsequent ignition cycles. System check includes • When the SRS ECU failure or power supply failure is
the states of SRS ECU and SRS harness. detected, the whole system will not work.
System Continuity Fault • If the circuit of the SRS warning lamp is faulty, the
With the ignition switch ON, if any of the following faults warning lamp will not illuminate when the ignition switch
occurs in the system, the SRS warning lamp will illuminate is turned on for initial check of the warning lamp; if
and remain on during subsequent ignition cycles: there is no other faults in the system, all functions of the
system are available in case of a crash.
• ECUand SRS failures
Additional information provided by the "scan tool" for DLC
• Harness failure
includes:
• Ground connection failure
• SRS ECUDTC
• Open circuit
• Version Levels of Hardware and Software
• Airbag module failure
• Impact Mode State
• Seat belt pretensioner failure
• Vehicle Identification Number (VIN) Data
If the system detects any failure during driving, the warning
lamp will also illuminate to indicate failure of the SRS system. SRS ECUThe SRS ECU records fault information in the
When the warning lamp illuminates, the SRS will not work memory, and the information can be read by connecting the
when any impact occurs. scan tool to the DLC below the closure plate of the driver
side instrument panel.
With the ignition switch ON, the diagnosis function of the SRS
ECU will monitor the SRS. If any fault is detected, the SRS

1.0 684
Seat Belts Safety and Restraints
Service Procedures
Front Seat Belt Assembly
Remove
1. Remove key from ignition switch, disconnect battery
leads, earth first and wait 10 minutes for theSRS
back-up power circuit to discharge before commencing
work.

Warning: It is imperative that before any work

is undertaken on the SRS system the appropriate
information is read thoroughly.
2. Remove bolt securing seat belt lower anchorage.

6. Disconnect pre-tensioner multiplug, remove front seat

belt.
Refit
1. Position upper seat belt guide to pillar, fit bolt, tighten
to 30–35Nm.
2. Connect pre-tensioner multiplug.
3. Position seat belt reel to body, tighten bolt to
30–35Nm.
4. Fit lower B post trim.

B Pillar Lower Trim Panel Refit

5. Fit bolt securing seat belt lower anchorage, tighten to
3. Remove lower B post trim. 30–35Nm.
B Pillar Lower Trim Panel Remove 6. Connect battery leads, earth last.
4. Remove bolt securing seat belt guide to pillar. 7. Carry out system check by turning the ignition on
and checking the SRS warning light illuminates for 4
seconds and then extinguishes.

5. Remove bolt securing seat belt reel to body.

1.0 685
Safety and Restraints Seat Belts

Front Seat Belt Buckle Rear Seat Belt Assembly

Remove Remove
1. Remove front seat. 1. Remove the rear seat cushion.

Front Seat Remove Rear Seat Cushion Remove

2. Remove bolt securing seat belt buckle to seat. 2. Unscrew 1 bolt fixing the rear seat belt to the lower
part of C-pillar.

3. Remove buckle, carefully extract buckle switch wiring.

Refit 3. Remove 1 bolt fixing the rear seat belt to the body.

1. Position seat belt buckle to seat frame, position buckle

switch wiring.
2. Fit retaining bolt, tighten to43–53Nm.
3. Refit front seat.

Front Seat Refit

4. Unscrew 1 bolt fixing the seat belt buckles of the rear

seats to the body and remove the seat belt buckles of
the rear seats.

5. Remove the rear seat backrest.

Rear Seat Back Remove

1.0 686
Seat Belts Safety and Restraints
6. Remove the C-pillar upper trim panel. 7. Refit luggage compartment trim..
C-pillar Upper Trim Panel Remove Luggage Compartment Trim
7. Remove the C-pillar lower trim panel. 8. Refit rear seat cushion.
C-pillar Lower Trim Panel Remove Rear Seat Cushion
8. Remove the luggage compartment side trim panel.
Luggage Compartment Side Trim Panel Remove
9. Unscrew 1 bolt fixing the rear seat belt to the upper
part of C-pillar.

10. Unscrew 1 bolt fixing the rear seat belt retractor to the
rear wheelhouse inner panel.

11. Remove the rear seat belt assembly.

Refit
1. Position seat belt to body, fit bolt, tighten to 30–35Nm.
2. Position seat belt guide to C post, fit bolt, tighten to
30–35Nm.
3. Pass seat belt through C post trim.
4. Position seat belt bracket to floor, fit bolt, tighten to
30–35Nm.
5. Refit lower C post trim.
C-pillar Lower Trim Panel Refit
6. Refit upper C post trim.
C-pillar Upper Trim Panel Refit

1.0 687
Safety and Restraints Seat Belts

Rear Seat Belt Buckle

Remove
1. Remove rear seat cushion.

Rear Seat Cushion

2. Remove bolt securing seat belt to floor.

8. Remove seat belt.

Refit
1. Position seat belt buckle to floor.
2. Fit retaining bolt, tighten to 30–35Nm.
3. Refit rear seat cushion.
3. Remove luggage compartment side trim. Rear Seat Cushion
Luggage Compartment Trim
4. Remove seat belt reel bolt.

5. Remove upper C post trim.

Upper C Post Trim

6. Remove lower C post trim.

Lower C Post Trim

7. Remove seat belt guide bolt.

1.0 688
Seat Belts Safety and Restraints
Rear Middle Seat Belt Assembly
Remove
1. Remove the rear seat cushion.

Rear Seat Cushion Remove

2. Remove 1 bolt fixing the rear middle seat belt to the
floor.

11. Remove the rear seat back foam and take out the rear
middle seat belt retractor.
12. Pass the middle seat belt webbing through the
decorative frame hole of the seat belt on the rear seat
back, and remove the rear middle seat belt assembly.
Refit
1. Pass the rear middle seat belt webbing through the
3. Release and remove 2 headrest guide pipes.
decorative frame hole of the seat belt on the rear seat
4. Remove the screw securing the seat back release lever, back.
disconnect the connection of the rear seat back release
2. Fix the rear middle seat belt retractor to the rear seat
lever and the cable, and remove the seat back release
back frame, fit 1 bolt, tighten to 35-45Nm, and check
lever.
the torque.
5. Pull the elastic clip out of the upholstery.
3. Recover the rear seat back upholstery.
6. Release and remove the clip securing the rear seat back
4. Fix the rear middle seat belt and buckle to the body, fit
backboard.
1 bolt, tighten to 30–35Nm, and check the torque.
7. Remove the C-ring securing the rear seat back
5. Fit the rear seat cushion.
upholstery.
8. Mark the locations of the C-rings securing the seat back Rear Seat Cushions Refit
upholstery and foam, remove the C-rings, and remove
the upholstery.

9. Remove the rear seat back backboard.

10. Uncover the rear seat back upholstery, remove 1 bolt
fixing the rear middle seat belt retractor to the rear
seat back frame.

1.0 689
Safety and Restraints Supplemental In�atable Restraints

Supplemental In�atable Restraints

Specifications
Torque
Description Value
Screw-front passenger airbag to instrument panel 1.3–1.9Nm
Bolt-front passenger airbag to facia bracket 6–8Nm
Bolt-Airbag control module to body 7–10Nm
Bolt-Side impact sensor to body 7–10Nm

1.0 690
Supplemental In�atable Restraints Safety and Restraints
Description and Operation
System Layout
Airbag Control Diagram

1. Airbag Warning Lamp 6. Side Impact Sensor

2. Passenger Side Airbag 7. Airbag Control ModuleSDM
3. Body Control ModuleBCM 8. Steering Wheel Airbag
4. Communication Module 9. Gateway
5. Driver Seat Airbag

1.0 691
Safety and Restraints Supplemental In�atable Restraints

System Control Diagram

Airbag Control Diagram

A = HS CAN Bus; B = Hard Wire

1.0 692
Supplemental In�atable Restraints Safety and Restraints
Description impact exceeds the preset trigger value, the SRS ECU will
Overview send a signal to activate the corresponding side airbag module
and seat belt pretensioner.
The SRS can provide passive protection for the passenger
when severe impact occurs. This system is usually based on If the severity of the rear impact exceeds the preset trigger
application of the standard protection system (seat belts). value, the SRS ECU will send a signal to activate the seat belt
pretensioner.
The SRS consists of the following components:
Caution: It is important that the SRS ECU is correctly
• Supplementary restraint system ECU (SRS ECU)
mounted and is fitted in the designated location and
• Driver airbag module orientation to ensure correct operation.
• Front passenger airbag module
ECUMonitoring
• Seat side airbag module (if equipped)
After the vehicle is powered on, the SRS ECU monitors the
• Seat belt pretensioner (if equipped) preparation of the SRS module. After start, it monitors the
• Side impact sensor (if equipped) system continuously. SRS ECUThe SRS ECU monitors the
• Rotary coupler status of the following modules:
• SRS warning lamp (on the IPK) • SRS ECUInternal accelerometer
• Seat belt not tied warning lamp (on the IPK) • SRS ECUMicro-processor
SRS ECUThe SRS ECU connects the vehicle DLC through • Side impact sensor (if equipped)
the HS CAN bus. • Driver side airbag module
Supplementary Restraint System ECU (SRS ECU) • Passenger side airbag module
• Side airbag module (if equipped)
• Seat belt pretensioner (if equipped)
• Diagnosis count

If any system failure is detected, the SRS warning lamp will

illuminate to warn the driver.

The recommended diagnostic device can be used to check

the SRS malfunction. The diagnostic information can be read
includes current malfunction, frequency of malfunction and
duration of each malfunction.
Power Supply and Backup Situation
The power supply provides voltage for the SRS ECU through
a special system fuse in the passenger compartment fuse box.
SRS ECUIt determines the affected range of the front impact,
side impact or rear impact through the internal and external In case of power failure, check the connection status of the
impact sensors (if equipped), so as to control the SRS. passenger compartment fuse box and the fuse and harness of
the SRS ECU. When the ignition switch is in "ON" position,
SRS ECUIt is fitted on the central passage beneath the centre
the SRS will be activated.
console, which is secured with three screws. SRS ECUIt is
connected to the body harness through two connectors. SRS ECUThe SRS ECU contains a capacitor which can save
electricity and ensure the corresponding trigger device and
SRS ECUIt monitors the vehicle impact through the internal
ignition circuit can still work within a specific time when regular
accelerometer and the external sensors. SRS ECUIt can
power supply is cut off by an impact.
identify the type and severity level of the impact according to
these input data and ensure normal operation of the airbag. Side Impact Sensor

If the severity of the front impact exceeds the preset trigger For vehicles with side airbag module, the side impact sensor is
value, the SRS ECU will send a signal to activate the front beside the body sill frame, which is fixed on the body by screws.
airbag module and seat belt pretensioners. The sensor is designed with a mounting position for correct
refit. Each sensor includes an electronic circuit and a sensing
When fitting the side airbag, two side impact sensors shall be
unit. The side impact sensor sends an acceleration signal to the
fitted to monitor the side impact. If the severity of the side

1.0 693
Safety and Restraints Supplemental In�atable Restraints

ECU, and the ECU determines whether to trigger it through

calculation.

Caution: The side impact crash sensors must be fitted in

the correct orientation. Ensure the fixing screws do not
damage the sensors or sensor harness when refitting the
front seats.
Driver Airbag Module

1. Airbag housing
2. Airbag cover
3. Airbag connector
4. Gas generator

The front passenger airbag module is on the glove box of the

instrument panel, right before the front passenger seat. The
airbag module is fixed on the instrument panel with bolts.

The front passenger airbag module is triggered by the control

signal from the SRS ECU. A folding airbag and a gas generator
are mounted in the module. When severe front impact is
1. Airbag cover
detected by the SRS ECU, it will trigger the gas generator
2. Housing and expand the nylon bag rapidly.
3. Gas generator Side Airbag (if equipped)
4. Airbag connector
Warning: If a new airbag module shows any sign of
The driver airbag module is fitted on the steering wheel by damage, do not use.
three bulged pins and one airbag module connector. When
fitting the driver airbag module, push the airbag module
towards the steering wheel firmly to embed the wire spring
around the airbag module into the opening of the 3 pins.

The electrical connection between the driver airbag module

and the SRS ECU is realized by the rotary coupler, which is
connected to the steering wheel by a connector.

The driver airbag module is triggered by the control signal

from the SRS ECU. A folding airbag and a gas generator are
mounted in the module. When severe front impact is detected
by the SRS ECU, it will trigger the gas generator and expand
the nylon bag rapidly.
Front Passenger Airbag Module
1. Airbag housing
Warning: After replacing the vehicle windscreen the 2. Airbag connector
Passenger Restraint System may not be capable of normal
3. Bracket
operation for 24 hours.
The side airbag is outside the seat bracket below the seat
Warning: If a new airbag module shows any sign of
upholstery. It can protect the rib, pelvis and upper visceral
damage, do not use.
organs in case of side impact. If the side impact is strong
enough to deploy the side airbag, the SRS ECU will send a
control signal to trigger the side airbag.

The side airbag module connector is a 4-pin connector, which

is below the seat cushion and connected with the SRS ECU
through the body harness.

1.0 694
Supplemental In�atable Restraints Safety and Restraints
Caution: Do not try to remove the connector at the
module end, it is a permanent connection.

1.0 695
Safety and Restraints Supplemental In�atable Restraints

Operation and passenger airbags and seat belt pretensioner are

Overview activated (side airbag may also be triggered).

When the ignition switch is in "ON" position, the SRS will be Warning Lamp Check
activated. With the ignition switch in "ON" position, the SRS When the ignition switch is turned on, the SRS warning lamp
warning lamp illuminates for several seconds, then goes out, shall illuminate, then check the lamp. If no failure occurs in the
this indicates that the system is in normal condition. SRS, the warning lamp shall go out after several seconds to
Front Impact monitor the subsequent ignition cycles.

If the front impact is severe and exceeds the threshold set in System Continuity Fault
the SRS ECU, the front airbag module and front pretensioning With the ignition switch ON, if any of the following faults
seat belt will work. occurs in the system, the SRS warning lamp will illuminate:
When the accelerometer and front impact sensor in the SRS • SRS ECUFailure
ECU detect any impact, the ECU will produce current to
• Harness failure
trigger the front airbag module:
• Ground connection failure
• The driver side front airbag module is activated to expand
• Open circuit
the airbag.
• Airbag module failure
• The passenger side front airbag module is activated to
• Seat belt pretensioner failure
expand the airbag.
If the system detects any failure during driving, the warning
When the front airbag is fully expanded, it will release the gas
lamp will also illuminate to indicate failure of the SRS system.
immediately from the passage port and provide the passenger
When the warning lamp illuminates, the SRS may not work
moving forward with gradual deceleration, this reduces the risk
when any impact occurs.
level of injury to the occupants.
With the ignition switch ON, the diagnosis function of the SRS
SRS ECUThe SRS ECU can determine the type and severity
ECU will monitor the SRS. If any fault is detected, the SRS
level of the impact. If the front impact detected by the sensor
ECU will store a related DTC in a nonvolatile memory and
is severe, the SRS ECU will send an ignition signal to the front
output a signal to illuminate the SRS warning lamp. The failure
airbag module and seat belt pretensioner.
information in the memory can be read with the scan tool.
Side Impact
Low Voltage Failure
Normal operation of the side seat airbag and head curtain
When the voltage supply is not within the specified range, the
airbag depends on whether the severity level of the side impact
malfunction indicator lamp will illuminate. The DTC is stored
detected by the side impact sensor and acceleration sensor
in the memory.
in the SRS ECU exceeds the threshold for triggering the
side impact sensor. When the SRS ECU detects severe side Intermittent Failure
impact, it will activate the side airbag, curtain airbag module When intermittent failure occurs, the warning lamp
and seat belt pretensioner. The triggered gas generator can illuminates, and it will be disabled after the failure is eliminated.
produce a large quantity of gas to expand the airbag. The The warning lamp will not illuminate in the next ignition unless
expanded airbag will eject from the seat upholstery, similarly, the failure occurs again, but the DTC is still stored in the SRS
if the head curtain airbag module is triggered, the airbag will ECU memory.
eject from the interior trim panel above the door to protect
Permanent Failure
the passenger from head injury. The fully expanded airbag will
release excess gas to reduce the risk of passenger injury. For a permanent failure, the SRS lamp will illuminate when
the test is started, and it will remain on in every subsequent
Front Impact with Angle
ignition cycle until the cause of the failure is solved. In addition,
When a front impact with angle happens, whether the airbag the diagnosis system will also record the information of the
and seat belt pretensioner work depends on the speed and failure occurred.
angle of the impact. There are several conditions:
Additional information provided by the "scan tool" for DLC
• The impact is below the threshold of the impact sensor
includes:
in the SRS ECU, and no airbag or seat belt pretensioner
is activated. • SRS ECUDTC
• The speed and angle of impact exceed the triggering • Version Levels of Hardware and Software
threshold of the front impact sensor, and the front driver • Vehicle Identification Number (VIN) Data

1.0 696
Supplemental In�atable Restraints Safety and Restraints
SRS ECUThe SRS ECU records fault information in the scan tool to the DLC below the closure plate of the driver
memory, and the information can be read by connecting the side instrument panel.

1.0 697
Safety and Restraints Supplemental In�atable Restraints

Service Procedures Instrument Panel Airbag

Steering Wheel Airbag Remove
Remove 1. Disconnect the battery negative. Wait for 10min until
Warning: It is imperative that before any work the SRS backup circuit is discharged, then start to
is undertaken on the SRS system the appropriate operate.
information is read thoroughly. 2. Disconnect the passenger airbag module connector.
1. Disconnect the battery negative. Wait for 10min until 3. Remove 2 bolts fixing the front passenger front airbag
the SRS backup circuit is discharged, then start to module bracket to the instrument panel bracket.
operate.
2. Adjust the steering wheel to the lowest position.
3. Adjust the depth of the steering wheel so that it can be
pulled outwards to the limit position.
4. Pry the steering column upper trim cover, and put it
aside to leave room for removing the airbag lock ring.
5. Rotate the steering wheel to show the airbag lock ring.
6. Pry three lock rings from the lower part of the steering
wheel with a flat-bladed screwdriver to release the
three pins fixing the airbag to the steering wheel.

4. Remove the instrument panel body assembly.

Instrument Panel Body Assembly Remove

5. Remove 2 screws (1) fixing the passenger front airbag
module onto the instrument panel.

7. Disconnect the airbag connector.

8. Remove the steering wheel airbag.
Refit
1. Connect the driver airbag connector.
2. Place the driver airbag in the steering wheel mounting
position, with the three protruding pins of the airbag
aligned with the three concave holes in the steering 6. Remove 9 clamping jaws fixing the passenger front
wheel. airbag module to the instrument panel, and remove the
3. Push the driver airbag into the steering wheel till a click passenger front airbag module.
can be heard.
4. Position the steering column upper trim cover onto the
lower trim cover, and fit the clip.
5. Restore the steering wheel.
6. Connect the negative battery. Check the system, rotate
the ignition switch, and check whether the SRS warning
lamp illuminates for several seconds, and then goes out.

1.0 698
Supplemental In�atable Restraints Safety and Restraints
Airbag Control Module
Remove
1. Disconnect the battery negative, and wait for 10
minutes until the SRS ECU internal circuit is discharged.
2. Remove the centre console upper trim panel.
Centre Console Upper Trim Panel Remove
3. Remove 3 bolts fixing the airbag control module to the
body.
4. Disconnect the harness connector and remove the
airbag control module.

Refit
1. Fix the passenger front airbag module to the instrument
panel, and fit 9 clamping jaws.
2. Fit 2 screws fixing the passenger front airbag module
onto the instrument panel, tighten to 1.3–1.9Nm and
check the torque.
3. Fit the instrument panel body assembly.

Instrument Panel Body Assembly Refit

4. Fix the passenger side airbag module bracket onto the
instrument panel frame, fit 2 bolts, tighten to 6–8Nm
and check the torque.
Refit
5. Connect the airbag module connector.
1. Fix the airbag control module to the body, fit 3 bolts,
6. Connect the negative battery. Check the system, rotate tighten to 7–10Nm, and check the torque.
the ignition switch, and check whether the SRS warning
2. Connect the harness connector.
lamp illuminates for several seconds, and then goes out.
3. Connect the battery negative.
4. Programme and encode the sensing and diagnostic
module (SDM).
a. Connect the scan tool to the vehicle and access the
SIPS.

b. Select "Programming and Coding - SDM -

Replacement", and operate as per the instructions
on the screen.

c. The procedures for replacement already include

procedures for update, configuration and setting
(lock module).

d. If it prompts "Failed" during the replacement, please

operate as per the interface prompts.

5. Fit the centre console upper trim panel.

Centre Console Upper Trim Panel Refit

6. Place the ignition switch in "ON" position, and check if
the SRS warning lamp illuminates for several seconds
and then goes out.

1.0 699
Safety and Restraints Supplemental In�atable Restraints

Side Impact Sensor

Remove
1. Disconnect the battery negative.
2. Remove the front seat assembly.
Front Seat Assembly Remove
3. Remove 1 bolt fixing the front seat belt to the carpet,
and remove the seat belt.
4. Remove the B pillar lower trim panel.

B Pillar Lower Trim Panel Remove

5. Lift the carpet, and remove 1 bolt fixing the side impact
sensor to the body.
6. Disconnect the harness connector and remove the side
impact sensor.

Refit
1. Fix the side impact sensor to the body, fit 1 bolt, tighten
to 7–10Nm, and check the torque.
2. Connect the harness connector.
3. Fit the B pillar lower trim panel.

B Pillar Lower Trim Panel Refit

4. Fit and tighten 1 bolt fixing the front seat belt to the
carpet.
5. Fit the front seat assembly.

Front Seat Assembly Refit

6. Connect the battery negative.

1.0 700
Park Assistant System Safety and Restraints
Park Assistant System
Description and Operation
System Layout
Parking Distance Control System Layout

1. Instrument Pack
2. Body Control Module (BCM)
3. (I) Entertainment Player; (II) Radio
4. Rear Camera (if equipped)
5. Rear Ultrasonic Sensor (if equipped)
6. Gear Shift Selection Switch (AT)
7. Reverse Lamp Switch (MT)

1.0 701
Safety and Restraints Park Assistant System

System Control Diagram

PDC System Control Diagram - MT

A = HS CAN Bus; B = Hard Wire

PDC System Control Diagram - AT

A = HS CAN Bus; B = Hard Wire

1.0 702
Park Assistant System Safety and Restraints
Description End View and Pin Information of Harness
Rear Obstacle Detection (if equipped) Connector

During reversing, if the vehicle has to go through obstructions End View and Pin Information of Rear Camera
on the road, the PDC will send a warning to the driver. The Connector BY025
system consists of the ultrasonic sensor fitted on the rear
bumper and the instrument pack. When the vehicle is in
reverse gear, the ultrasonic sensor is used to monitor the area
around the rear bumper, if any object is detected within the
monitoring area, the acoustic alarm device in the instrument
pack will send an acoustic alarm. The system is able to detect
relatively hard solid objects and objects like wire fence.

If the rear camera is fitted, the image of the rear vehicle will
be displayed on the entertainment mainframe display during
reversing.
Rear Ultrasonic Sensor (if equipped)
The ultrasonic sensors are fixed on the rear bumper. All the
sensors share the same structure, with the colors matching the
Pin No. Description
vehicle.
1 Signal Ground
The detection range of the rear ultrasonic sensor involves the
2 Ground
area 1200mm away from the back of the bumper. The alarm
3 Video Signal
frequency increases with the shortened distance between the
object and the vehicle when the distance ranges from 300mm 4 Camera Power Supply
to 1200mm. When the object is 300mm away from the vehicle,
End View and Pin Information of Right PDC Sensor
the alarm becomes consecutive alarm. Connector BY202
Acoustic Alarm
The acoustic alarm in the instrument pack can inform the
driver of the system status by acoustic alarm.
Rear Camera (if equipped)

Pin No. Description

1 Ground
2 -
3 LIN2
The rear camera is between the two rear license plate lamps
4 Power supply
under the tail gate, which can provide the driver with real-time
image around the rear of the vehicle and help the reverse
operation.

1.0 703
Safety and Restraints Park Assistant System

End View and Pin Information of Middle PDC Sensor

Connector BY203

Pin No. Description

1 Ground
2 LIN1
3 LIN2

4 Power supply

End View and Pin Information of Left PDC Sensor

Connector BY204

Pin No. Description

1 Ground
2 Ground
3 LIN2
4 Power supply

1.0 704
Park Assistant System Safety and Restraints
Operation Detection Zone
Overview
The system starts to run when the ignition switch is in "ON"
position.

After the ultrasonic sensor receives the reverse gear signal,

it outputs signals to the acoustic warning device, then the
acoustic warning device will give an acoustic alarm ("beep"),
this indicates that the system is activated. Then, it receives
the distance information from the ultrasonic sensor and
determines whether there is any object in the detection range.
If there is no object, it will not send an acoustic alarm; if any
object is detected, it outputs signals to the acoustic warning
device and controls the device to provide a repetitive acoustic
alarm.
The table below shows the relationship between the alarm
From the edge of the detection zone, about 1200mm from the level/obstacle distance and the acoustic alarm:
rear vehicle, the alarm frequency increases with the shortened
distance between the object and the vehicle, when the object is
300mm away from the vehicle, the alarm becomes consecutive
alarm.
SN. Alarm Level Distance (mm) Alarm Cycle (msec)
1 00 = No >1200
Obstacle
2 01 = Zone 1 0 - 300

3 02 = Zone 2 300 - 450

4 03 = Zone 3 450 - 600

5 04 = Zone 4 600 - 750

6 05 = Zone 5 750 - 900

7 06 = Zone 6 900 - 1050

8 07 = Zone 7 1050 - 1200

Caution: Blind spots, areas where the sensor cannot

detect obstructions, may occur if obstructions are present
at distances of around 200 mm from the sensors.

1.0 705
Safety and Restraints Park Assistant System

Service Procedures Camera

Ultrasonic Sensor Remove
Remove 1. Disconnect the battery negative.
1. Disconnect the battery negative. 2. Remove the rear bumper.
2. Remove the rear bumper. Rear Bumper Remove
Rear Bumper Remove 3. Release the clip to remove the rearview camera
3. Disconnect the connector of the ultrasonic sensor. assembly.
Refit
1. Fit the rearview camera to the rear bumper.
2. Fit the rear bumper.

Rear Bumper Refit

3. Connect the battery negative.

4. Remove the ultrasonic sensor from the ultrasonic

sensor bracket.
Refit
1. Snap the ultrasonic sensor in its bracket on the rear
bumper.
2. Connect the connector of the ultrasonic sensor.
3. Fit the rear bumper.

Rear Bumper Refit

4. Connect the battery negative.

1.0 706
Entertainment and Navigation Information and Entertainment
Entertainment and Navigation
Specifications
Torque
Description Value
Nut-Roof antenna to body 3–4Nm
Screw - front door speaker 0.8–1.2Nm
Screw - rear door speaker 0.8–1.2Nm
Bolt-Colour radio to instrument panel 1.4–1.8Nm

1.0 707
Information and Entertainment Entertainment and Navigation

Description and Operation

System Layout

1. Entertainment Control Panel (if equipped) 7. Rear Door Woofer (if equipped)
2. Body Control ModuleBCM 8. USB Port
3. (I) Entertainment Player; (II) Radio 9. Front Door Woofer
4. Microphone 10. Steering Wheel Entertainment Switch (if equipped)
5. Radio Antenna 11. Tweeter
6. Rearview Camera (if equipped) 12. Instrument Pack

1.0 708
Entertainment and Navigation Information and Entertainment
System Control Diagram
Radio System Control Diagram

A = Hard Wire

1.0 709
Information and Entertainment Entertainment and Navigation

Entertainment Player System Control Diagram

A = Hard Wire; B = HS CAN Bus

1.0 710
Entertainment and Navigation Information and Entertainment
Description 2. Entertainment mainframes with medium configuration
Overview support radio, USB, bluetooth phone, video, picture, etc.

According to vehicle configuration and assembly options, there Radio

are two types of entertainment mainframes:

1. Entertainment mainframes with low configuration

support radio, USB, bluetooth phone, etc.

1. Preset Button 1 8. Previous Track

2. Preset Button 2/Random Button 9. Next Track
3. Preset Button 3/Repeat Button 10. Main Menu Button
4. On/Off Button/VOL Knob 11. Microphone
5. Bluetooth Phone 12. Preset Button/Next Folder
6. Play Mode Button 13. Preset Button/Previous Folder
7. USB Button 14. Preset Button/Information Button

1.0 711
Information and Entertainment Entertainment and Navigation

Entertainment Player Control Button

1. Sound Source Switch Button 4. Next Track Button

2. Previous Track Button 5. Mute Button
3. VOL Knob and On/Off Button

1.0 712
Entertainment and Navigation Information and Entertainment
Audio Control Button on Steering Wheel (if
equipped)
The audio device can be controlled by the remote switches
on the steering wheel. These function buttons can allow the
most common functions in the ICE system to be used in a
much more convenient manner.

Antenna
Radio antenna.

Display
The display shows the audio information and relevant
information.
Woofer
The woofers are fitted inside the door and fixed on the door
panel with 3 screws.

Harness Connector of Radio

End View and Pin Information of Harness Connector
BY213 (Radio with Low Configuration)

Tweeter
The tweeters are fitted on the left/right A pillars and fixed on
the A pillar trim panel with clips.

Pin No. Description

1 -
2 Battery Power (when the lamp switch
is in position 1/2)
3-5 -
6 Right Front Audio +

1.0 713
Information and Entertainment Entertainment and Navigation

Pin No. Description Pin No. Description

7 Left Front Audio + A1 -
8-9 - A2 Right Front Audio +
10 Battery Power A3 Left Front Audio +
11 Battery Power (when the ignition A4 -
switch is in ACC position) -
A5
12 Reverse Signal
A6 Right Front Audio -
13 - 15 -
A7 Left Front Audio -
16 Right Front Audio - -
A8
17 Left Front Audio - -
B9
18 - 19 -
B10 Battery Power (when the lamp
20 Ground switch is in position 1/2)
B11 -
End View and Pin Information of Harness Connector
BY214 (Radio with Low Configuration) B12 -
B13 -
B14 Battery Power (when the ignition
switch is in ACC position)
B15 Battery Power
B16 Ground
C1 -
C2 -
C3 Steering Wheel Button Signal
Ground
C4 Steering Wheel Button Signal 1 +
C5 Microphone Ground
C6 High Speed CAN Bus

Pin No. Description C7 -

1 AM/FM signal C8 -

2 Ground C9 -
C10 Steering Wheel Button Signal 2 +
Harness Connector of Entertainment Player
C11 Microphone +
End View and Pin Information of Harness Connector
C12 HS CAN Low
BY218 (Entertainment Player)
D1 -
D2 -
D3 -
D4 -
D5 -
D6 -
D7 -
D8 -
D9 -
D10 -
D11 -
D12 -

1.0 714
Entertainment and Navigation Information and Entertainment
End View and Pin Information of Harness Connector End View and Pin Information of Harness Connector
BY220 (Entertainment Player) BY216 (Radio with Medium Configuration)

Pin No. Description Pin No. Description

1 USB Power Supply 1 AM/FM signal
2 USB Data - 2 Ground
3 USB Data +
4 -
5 USB Ground

1.0 715
Information and Entertainment Entertainment and Navigation

Operation
For more information about the operation of the
entertainment system, please refer to "User Manual" and the
operating instructions inside the entertainment mainframe.

1.0 716
Entertainment and Navigation Information and Entertainment
Service Procedures Front Door Woofer
Radio Antenna Remove
Remove 1. Remove front door trim panel.
1. Disconnect the battery negative. Front Door Trim Remove
2. Remove the roof interior. 2. Disconnect speaker electrical connector.
Roof Interior Remove 3. Remove 3 fixing screws.
3. Remove 1 nut fixing the radio antenna to the roof and
disconnect the harness connector.
4. Remove the radio antenna.

4. Remove speaker
Refit
1. Position speaker in door.
Refit
2. Fit screws, tighten to0.8–1.2Nm.
1. Fix the roof antenna to the body, fit the harness, fit the
3. Refit electrical connector.
retaining nut, tighten to 3–4Nm, and check the torque.
4. Refit front door trim.
2. Fit the roof interior.
Front Door Trim Refit
Roof Interior Refit
3. Connect the battery negative.

1.0 717
Information and Entertainment Entertainment and Navigation

Rear Door Woofer Tweeter

Remove Remove
1. Remove the rear door interior trim panel. 1. Remove the tweeter from A pillar upper trim panel.

Rear Door Interior Trim Remove

2. Loosen the rear door woofer connector.
3. Unscrew 3 screws fixing the woofer to the rear door,
and remove the woofer.

2. Disconnect the electrical connector.

Refit
1. Connect the tweeter connector.
2. Refit the tweeter into the A pillar upper trim panel.
Refit
1. Fix the woofer to the rear door, refit 3 screws and
tighten to 0.8–1.2Nm.
2. Connect the woofer connector.
3. Refit the rear door interior trim panel.

Rear Door Interior Trim Panel Refit

1.0 718
Entertainment and Navigation Information and Entertainment
Player b. For entertainment mainframe with medium
Remove configuration, fix the mainframe (medium
1. Disconnect the battery negative. configuration) to the instrument panel, fit 4 screws,
tighten to 1.4–1.8Nm, and check the torque.
2. Remove the central control panel of the instrument
panel. 3. Connect the battery negative.
Central Control Panel of Instrument Panel 4. Fit the central control panel of the instrument panel.
Remove
Central Control Panel of Instrument Panel
3. Remove the on-board entertainment mainframe. Refit
a. For radio with low configuration, remove 4 screws
fixing the radio (low configuration) to the instrument
panel, disconnect the harness connector, and
remove the radio.

b. For entertainment mainframe with medium

configuration, remove 4 screws fixing the
entertainment mainframe (medium configuration)
to the instrument panel, disconnect the harness
connector, and remove the entertainment
mainframe.

Refit
1. Connect the harness connector.
2. Fit the on-board entertainment mainframe.
a. For radio with low configuration, fix the mainframe
(low configuration) to the instrument panel, fit
4 screws, tighten to 1.4–1.8Nm, and check the
torque.

1.0 719
Information and Entertainment Entertainment and Navigation

Microphone
Remove
1. Disconnect the battery negative.
2. Pry off the microphone assembly.

3. Disconnect the connector of the microphone.

4. Remove the microphone from the microphone bracket.
Refit
1. Embed the microphone in its bracket.
2. Connect the connector of the microphone.
3. Fit the microphone assembly.
4. Connect the battery negative.

1.0 720
Displays and Gauges Information and Entertainment
Displays and Gauges
Specifications
Torque
Description Value
Bolt-Clusters to instrument panel 1.3–1.9Nm

1.0 721
Information and Entertainment Displays and Gauges

Description and Operation

System Layout

1. Instrument Pack

1.0 722
Displays and Gauges Information and Entertainment

1. Tachometer 3. Speedometer
2. Information Centre

1.0 723
Information and Entertainment Displays and Gauges

System Control Diagram

A = HS CAN Bus; B = Hard Wire

1.0 724
Displays and Gauges Information and Entertainment
Description Information type Transmitted by Received by
Overview Oil Pressure
Hard Wire Instrument Pack
The instrument pack is connected to the instrument harness Status
and secured on the instrument panel assembly with 3 screws. TPMS Status TPMS Instrument Pack

The instrument pack is a packaged component (assembly), so Brake Fluid Status SCS Instrument Pack
it cannot be disassembled for maintenance. Press the trip High Beam Status BCM Instrument Pack
computer button on the top of the lamp lever switch to switch Status of
the interface of the information centre and to reset Trip A, Trip Right/Left
BCM Instrument Pack
B, average fuel consumption and average speed. For specific Direction
Indicator Lamp
procedures, please refer to "Trip Computer Button" section.
Key Battery Low BCM Instrument Pack
Communication Signal
Anti-theft Alarm
BCM Instrument Pack
The instrument pack receives/sends information via the HS Status
CAN. Nodes of the HS CAN include: ECM, BCM, TCM, Engine Speed ECM Instrument Pack
SDM, etc. The table below shows the signals received and
Start by Key ECM Instrument Pack
sent by the instrument pack.
Status of Width
Information type Transmitted by Received by BCM Instrument Pack
Lamp
Wheel Speed Rear Fog Lamp
ABS /SCS Instrument Pack BCM Instrument Pack
Pulse Signal State
ABS Malfunction Status of Daytime
ABS Instrument Pack BCM Instrument Pack
Indicator Lamp Running Lamp
Status of Seat Belt Gear Information TCM Instrument Pack
SDM Instrument Pack
(driver)
Transmission
Airbag Warning Failure TCM Instrument Pack
SDM Instrument Pack
Lamp Information
Door Status BCM Instrument Pack
Some of the models are connected with the PDC sensor by
Engine
Malfunction ECM Instrument Pack the hard wire and receive signals from the sensor to assist the
Indicator Lamp driver with parking.
Engine Emission
Malfunction ECM Instrument Pack
Indicator Lamp

1.0 725
Information and Entertainment Displays and Gauges

Harness Connector Pin No. Description

Location Diagram of Instrument Pack Harness 16 Fuel Sensor Signal -
Connector 17 KL.15
18 KL.R
19 Seat Belt (Passenger)
20 Left Direction Indicator Lamp Signal
21 Alternator Charge
22 Engine Oil Pressure
23 Driver Door Open
24 Trip Computer Switch
25 Right Direction Indicator Lamp Signal
26 HS CAN H
27 HS CAN L
28 -
1. Instrument Panel Harness Connector
29 High Beam
End View of Instrument Pack Harness
Connector (FC006) 30 PDC Acoustic Alarm Input
31 Fuel Sensor Signal +
32 -

The instrument pack mainly includes the following

functions:
Tachometer

The tachometer indicates the engine speed in revolutions per

minute (RPM) (X1000). The red section of the high-speed end
of the tachometer is used to warn the driver high engine speed
can damage the engine. When the ignition switch is in ON
position, the instrument pack uses the HS CAN bus to receive
Detailed Pin Information of Instrument Pack
the engine speed signal from the ECM.
Harness Connector
Pin No. Description Speedometer
1 KL.30 The speedometer indicates the vehicle speed with pointer.
2 - ABS calculates the vehicle speed by collecting the wheel speed
pulse signal. The instrument pack receives the vehicle speed
3 IMMO Transmission Line 2
signal from the ABS module via HS CAN bus and displays it
4 IMMO Transmission Line 1
after correction computation.
5 IMMO Clock Line
Fuel Gauge
6 IMMO Data Line
- The fuel level of the fuel tank is indicated in the speedometer
7
by the number of the bar segments illuminated.
8 Ground
Warning Information
9 -
10 BCM Acoustic Request For warning information, please refer to "Information Centre"
in the "Instrument and Control" section of the User Manual.
11 -
12 Brake Fluid Level Warning Lamps and Indicators

13 Seat Belt (Driver) Engine Coolant Temperature Warning Lamp

14 -
It receives the signal from the ECM to inform the
15 Hand Brake
driver of the high/low engine coolant temperature.

1.0 726
Displays and Gauges Information and Entertainment
Engine Malfunction Indicator Lamp Width Lamp Indicator

It receives the signal from the ECM to inform It receives the signal from the BCM to remind the
the driver that the EMS failure seriously affects the engine driver that the width lamp illuminates.
performance.
Rear Fog Lamp Indicator
Engine Emission Malfunction Indicator Lamp
It receives the signal from the BCM to remind the
It receives the signal from the ECM to inform the driver that the rear fog lamp illuminates.
driver that the EMS failure affects the engine performance and
Direction Indicator Lamp
emission.
Alternator Malfunction Indicator Lamp It receives the signal from the BCM to remind the
driver that the direction indicator lamp illuminates. If the
It receives the signal from the ECM to inform the hazard warning lamps are enabled, both direction indicator
driver of the alternator failure. lamps will flash together.
Low Oil Pressure Warning Lamp Anti-theft System Warning Lamp

It receives the signal from the hard wire to inform It receives the signal from the BCM. If the anti-theft
the driver that the current oil pressure is low, which may cause system cannot identify the valid key, the lamp illuminates.
serious damage to the engine.
When the BCM receives an RF signal of low battery from the
TPMSWarning Lamp (if equipped) remote key, the lamp flashes.
Door Open Warning Lamp
It receives the TPMS status signal from the TPMS
to inform the driver of the low tyre pressure or TPMS failure.
It receives the signal from the BCM. If any door or
ABSMalfunction Indicator Lamp tail gate is open, the lamp illuminates.
Transmission MIL (if equipped)
It receives the signal ABSfrom the to inform the
driver of the ABS failure.
It receives the signal from the TCM to inform the
Brake System Malfunction Indicator Lamp driver of the automatic transmission failure.
Information Centre
It receives the signal from the SCS to inform the
The information centre provides the followings:
driver of the brake system failures such as lack of brake fluid
or electronic braking force distribution (EBD) failure.
Seat Belt Not Tied Warning Lamp

It receives the signal from the SDM to remind the

driver to tie the seat belt.
Airbag Warning Lamp

It receives the signal from the SDM to inform the

driver of the SRS failure.
High Beam Indicator

It receives the signal from the BCM to remind the

1. Gear Information (if equipped)
driver that the high beam illuminates.
2. Vehicle Information Display

1.0 727
Information and Entertainment Displays and Gauges

Gear Information (if equipped) Trip A and Trip B are two independent mileage records. The
display range is within 0 - 9999km. When the mileage exceeds
With the ignition switch in ON position, it displays the current
9999km, it will reset automatically. Trip A and Trip B can be
shift lever position (P, R, N, D, 1, 2, 3, 4, S) of the automatic
reset independently so that the vehicle can record the trip
transmission.
separately.
Vehicle Information Display
Range to Empty
The vehicle information display provides the followings:
It displays the approximate mileage without refueling. "Range
to Empty" will be recalculated after refueling.

The "Range to Empty" is calculated by the average fuel

consumption and the remaining fuel in the fuel tank of the
latest driving record.
Instantaneous Fuel Consumption
"Instantaneous Fuel Consumption" is calculated by the vehicle
automatically. When the vehicle is stationary or the vehicle
speed is very low, the "Instantaneous Fuel Consumption"
displays “—L/100km”.
Average Fuel Consumption
This function is to calculate the average fuel consumption of the
• Total Mileage current trip since last resetting (the average fuel consumption
is calculated based on the amount of fuel consumed in a certain
• Trip A
mileage). "Average Fuel Consumption" can be reset at any time
• Trip B so as to record the average fuel consumption in a certain trip
• Range to Empty or under certain driving conditions.
• Instantaneous Fuel Consumption Note: "Average Fuel Consumption" is related to the
• Average Fuel Consumption driver's driving style, road condition, vehicle
• Average Speed load, tyre pressure, power of the electrical
• Next Maintenance equipment, oil product, etc.

Short press (less than 2s) the button on the end of the steering
Average Speed
lever switch (as indicated by the arrow) repeatedly, the above This function is to calculate the average speed of the current
information will be displayed in cycles. trip since last resetting. "Average Speed" can be reset at any
time so as to record the average speed in a certain trip or
When Trip A, Trip B, Average Fuel Consumption or Average
under certain driving conditions.
Speed is selected for display, long press (more than 2s) the
button on the end of the steering lever switch, the selected Next Maintenance
item can be reset. It displays maintenance symbols, remaining mileage till next
Total Mileage maintenance.

It displays the total mileage of the vehicle. Note: "Mileage till Next Maintenance" can only be
reset by a local Authorised Repairer.
Trip A and Trip B
It displays the mileage since last resetting.

1.0 728
Displays and Gauges Information and Entertainment
Operation activated, after self-check, the following warning lamps remain
Operation Mode ON:

The specific function of the instrument pack available at a given • Low Oil Pressure Warning Lamp
time depends on the position of the ignition switch. • Engine Emission Malfunction Indicator Lamp
Ignition Switch OFF • Alternator Malfunction Indicator Lamp
When the ignition switch is off, if the vehicle battery is Ignition Switch "Start"
connected, the instrument pack will be kept in "standby When the engine is started, all the lamps will go out. If there's
mode". any warning lamp remains ON, the corresponding system is
Ignition Switch ON failed.
It refers that the ignition switch is powered on, check before
driving is performed by the instrument pack, and CAN bus is

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Information and Entertainment Displays and Gauges

Service Procedures
Instrument Pack
Remove
1. Disconnect the battery negative.
2. Remove the instrument pack frame.

Instrument Pack Frame Remove

3. Remove 3 screws fixing the instrument pack to the
instrument desk.

4. Disconnect the connector of the instrument pack.

5. Remove the instrument pack.
Refit
1. Connect the connector of the instrument pack.
2. Connect the battery negative.
3. Programme and encode the instrument pack (IPK).
Refer to Module Self-learning and Programming Manual,
"IPK Replacement".
4. Fix the instrument pack to the instrument desk, fit 3
screws, tighten to 1.3–1.9Nm, and check the torque.
5. Fit the instrument pack frame.

Instrument Pack Frame Refit

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Power and Signal Power and Signal
Power and Signal
Specifications
Torque
Description Value
Bolt-Engine compartment fuse box to battery bracket 6–8Nm
Nut-Engine compartment fuse box to body 6–8Nm
Bolt-Engine cable to Engine compartment fuse box 6–9Nm
Bolt-Battery positive cable to Engine compartment fuse box 6–9Nm

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Power and Signal Power and Signal

Service Procedures Instrument Panel Harness

Engine Compartment Fuse Box Remove
Remove 1. Disconnect the battery negative.
1. Disconnect the battery negative. 2. Remove the instrument panel assembly.
2. Remove the upper cover of the engine compartment Instrument Panel Assembly Remove
fuse box.
3. Disconnect the body harness connector.
3. Remove 1 bolt (1) fixing the battery positive cable to
the fuse box.
4. Remove 1 bolt (4) fixing the engine harness to the fuse
box.
5. Remove 1 nut (2) fixing the engine compartment fuse
box to the body.
6. Remove 2 bolts (3) fixing the engine compartment fuse
box to the battery bracket.

4. Disconnect the harness connector of the

communication module.

7. Disconnect the harness connector on the back of the

engine compartment fuse box and remove the engine
compartment fuse box.
Refit
1. Connect the harness connector on the back of the
fuse box.
2. Fix the engine compartment fuse box to the battery 5. Loosen the harness retaining clip and remove the
bracket, fit 2 bolts, tighten to 6–8Nm, and check the instrument panel harness.
torque.
Refit
3. Fix the engine compartment fuse box to the body, fit 1
1. Fit the instrument panel harness and secure with clips.
nut, tighten to 6–8Nm, and check the torque.
2. Connect the harness connector of the communication
4. Fix the engine harness to the engine compartment
module.
fuse box, fit 1 bolt, tighten to 6–9Nm, and check the
torque. 3. Connect the body harness connector.

5. Fix the battery positive cable to the engine 4. Fit the instrument panel assembly.
compartment fuse box, fit 1 bolt, tighten to 6–9Nm, Instrument Panel Assembly Refit
and check the torque. 5. Connect the battery negative.
6. Fit the upper fuse box cover.
7. Connect the battery negative.

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Power and Signal Power and Signal
Body Harness
Remove
1. Disconnect the battery negative.
2. Remove the front bumper assembly.
Front Bumper Assembly Remove
3. Remove the battery tray.

Battery Tray Remove

4. Remove the engine compartment fuse box.

Engine Compartment Fuse Box Remove

5. Remove the brake modulator.

Brake Modulator Remove 12. Disconnect the harness connector of the left headlamp.
6. Disconnect the harness connector of the horn. 13. Loosen the ground under the ABS modulator.
7. Disconnect the harness connector of the bonnet lock.

14. Disconnect the harness connector of the reverse lamp

8. Disconnect the harness connector of the cooling fan switch.
motor.
9. Disconnect the harness connector of the cooling fan
relay.

15. Remove the A/C air inlet grille assembly.

A/C Air Inlet Grille Assembly Remove
16. Remove the air filter assembly.
10. Disconnect the harness connector of the electronic
Air Filter Assembly Remove
vacuum pump.
17. Disconnect the harness connector (4) of the engine
11. Loosen the ground of the left front longitudinal beam.
(1.3L).
18. Disconnect the harness connector (5) of the engine
(1.5L).

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Power and Signal Power and Signal

19. Disconnect the left front wheel speed sensor (2). 26. Disconnect the harness connector of the right
20. Disconnect the harness connector (1) of the front headlamp.
wiper motor. 27. Remove the washer reservoir assembly.
21. Disconnect the harness connector (3) of the brake fluid Washer Reservoir Assembly Remove
level sensor.
28. Loosen 2 grounds fixed to the right front longitudinal
beam.
29. Remove the A/C box assembly.
A/C Box Assembly Remove
30. Remove the carpet assembly.

Carpet Assembly Remove

31. Disconnect the harness connector (1) of the BCM.
32. Loosen the ground (3) under the BCM.
33. Remove 3 bolts (2) fixing the passenger compartment
fuse box to the body and remove the passenger
compartment fuse box.

22. Disconnect the harness connector of the vacuum

sensor.
23. Disconnect the harness connector of the neutral
position sensor.

34. Disconnect the harness connector (3) of the

accelerator pedal.
35. Disconnect the harness connector (2) of the brake
pedal.
24. Disconnect the harness connector of the A/C pressure 36. Disconnect the harness connector (1) of the clutch
switch. pedal.
25. Disconnect the harness connector of the right front
wheel speed sensor.

37. Disconnect the harness connector of the wiper lever

switch.

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Power and Signal Power and Signal
38. Disconnect the harness connector of the lamp lever
switch.
39. Disconnect the connector between body harness and
instrument panel harness.

45. Remove the nut fixing the radio antenna to the roof
and move it away.

40. Disconnect the harness connector of the gateway.

41. Loosen the ground under the gateway.

46. Loosen the grounds on both sides of the A/C box.

42. Remove the roof interior.

Roof Interior Remove
43. Disconnect the harness connector of the sunroof
motor.

47. Disconnect the harness connector (1) of the DCDC.

48. Disconnect the harness connector (2) of the airbag
control module.

44. Disconnect the harness connectors of the top curtain

airbags on both sides.

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Power and Signal Power and Signal

57. Loosen 3 grounds around the luggage compartment

lamp.

49. Disconnect the harness connector of the front door.

50. Loosen the ground under the driver door.
58. Pry off the clip, and remove the interior trim panel of
the tail gate.
59. Disconnect the harness connectors (4) of the rear
window heating elements on both sides.
60. Disconnect the harness connector (1) of the rear wiper
motor.
61. Disconnect the harness connector (3) of the tail gate
lock.
62. Disconnect the harness connector (2) of the tail gate
release switch.
63. Loosen the ground (5) under the left rear tail lamp.

51. Disconnect the harness connectors (1) of the seat belt

pretensioners on both sides.
52. Disconnect the harness connectors (2) of the side
impact sensors on both sides.
53. Loosen the ground (3) under the front seat.

64. Remove the high-mounted stop lamp assembly.

High-mounted Stop Lamp Assembly Remove
65. Remove the rear bumper assembly.

Rear Bumper Assembly Remove

66. Pry off the fuel pump cover, and disconnect the fuel
54. Disconnect the harness connector of the rear door. pump harness connector.
55. Remove the luggage compartment side trim panel.
Luggage Compartment Side Trim Panel Remove
56. Remove the tail lamp assembly.
Tail Lamp Assembly Remove

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Power and Signal Power and Signal
motor.
11. Connect the harness connector of the rear window
heating element.
12. Fit the interior trim panel of the tail gate.
13. Tighten 3 grounds around the luggage compartment
lamp.
14. Fit the tail lamp assembly.
Tail Lamp Assembly Refit
15. Fit the luggage compartment side trim panel.
Luggage Compartment Side Trim Panel Refit
16. Connect the harness connector of the rear door.
67. Disconnect the harness connector (2) of the right rear 17. Tighten the ground under the front seat.
wheel speed sensor.
18. Connect the harness connectors of the side impact
68. Disconnect the harness connector (1) of the left rear sensors on both sides.
wheel speed sensor.
19. Connect the harness connectors of the seat belt
pretensioners on both sides.
20. Tighten the ground under the driver door.
21. Connect the harness connector of the front door.
22. Connect the harness connector of the airbag control
module.
23. Connect the harness connector of the DCDC.
24. Tighten the grounds on both sides of the A/C box.
25. Fit and tighten the nut securing the radio antenna.
26. Connect the harness connectors of the top curtain
airbags on both sides.
27. Connect the harness connector of the sunroof motor.
69. Loosen the clip fixing the harness to the body and 28. Fit the roof interior.
remove the body harness.
Roof Interior Refit
Refit
29. Tighten the ground under the gateway.
1. Arrange the harness to the body and secure with clips.
30. Connect the harness connector of the gateway.
2. Connect the harness connector of the left rear wheel
31. Connect the connector between body harness and
speed sensor.
instrument panel harness.
3. Connect the harness connector of the right rear wheel
32. Connect the harness connector of the lamp lever
speed sensor.
switch.
4. Connect the fuel pump harness connector and fit the
33. Connect the harness connector of the wiper lever.
fuel pump cover.
34. Connect the harness connector of the clutch pedal.
5. Fit the rear bumper assembly.
35. Connect the harness connector of the brake pedal.
Rear Bumper Assembly Refit
36. Connect the harness connector of the accelerator
6. Fit the high-mounted stop lamp assembly. pedal.
High-mounted Stop Lamp Assembly Refit 37. Fix the passenger compartment fuse box to the body,
7. Tighten the ground under the left rear tail lamp. fit 3 bolts and tighten them up.

8. Connect the harness connector of the tail gate release 38. Tighten the ground under the BCM.
switch. 39. Connect the harness connector of the BCM.
9. Connect the harness connector of the tail gate lock. 40. Fit the carpet assembly.
10. Connect the harness connector of the rear wiper Carpet Assembly Refit

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Power and Signal Power and Signal

41. Fit the A/C box assembly. Front Bumper Assembly Refit
A/C Box Assembly Refit 69. Connect the battery negative.
42. Tighten the ground fixed to the right front longitudinal
beam.
43. Fit the washer reservoir assembly.
Washer Reservoir Assembly Refit
44. Connect the harness connector of the right headlamp.
45. Connect the harness connector of the right front wheel
speed sensor.
46. Connect the harness connector of the A/C pressure
switch.
47. Connect the harness connector of the neutral position
sensor.
48. Connect the harness connector of the vacuum sensor.
49. Connect the harness connector of the brake fluid level
sensor.
50. Connect the harness connector of the front wiper
motor.
51. Connect the harness connector of the left front wheel
speed sensor.
52. Connect the harness connector of the engine (1.3L).
53. Connect the harness connector of the engine (1.5L).
54. Fit the air filter assembly.
Air Filter Assembly Refit
55. Fit the A/C air inlet grille assembly.
A/C Air Inlet Grille Assembly Refit
56. Connect the harness connector of the reverse lamp
switch.
57. Tighten the ground under the ABS.
58. Connect the harness connector of the left headlamp.
59. Tighten the ground of the left front longitudinal beam.
60. Connect the harness connector of the electronic
vacuum pump.
61. Connect the harness connector of the cooling fan relay.
62. Connect the harness connector of the cooling fan
motor.
63. Connect the harness connector of the bonnet lock.
64. Connect the harness connector of the horn.
65. Fit the brake modulator.
Brake Modulator Refit
66. Fit the engine compartment fuse box.
Engine Compartment Fuse Box Refit
67. Fit the battery tray.
Battery Tray Refit
68. Fit the front bumper assembly.

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Power and Signal Power and Signal
Front Door Harness Rear Door Harness
Remove Remove
1. Disconnect the battery negative. 1. Disconnect the battery negative.
2. Remove the front door interior trim panel. 2. Remove the rear door interior trim panel.
Front Door Interior Trim Panel Remove Rear Door Interior Trim Panel Remove
3. Disconnect the connector between front door harness 3. Disconnect the connector between rear door harness
and body harness. and body harness.
4. Disconnect the harness connector (1) of the window 4. Disconnect the harness connector (1) of the window
regulator motor. regulator motor.
5. Disconnect the harness connector (2) of the speaker. 5. Disconnect the harness connector (2) of the speaker.

6. Disconnect the harness connector of the front door 6. Disconnect the harness connector of the rear door
lock. lock.
7. Release the clip and remove the rear door harness.
Refit
1. Fit the rear door harness and secure with clips.
2. Connect the harness connector of the rear door lock.
3. Connect the harness connector of the speaker.
4. Connect the harness connector of the window
regulator motor.
5. Connect the body harness connector.
6. Fit the rear door interior trim panel.

Rear Door Interior Trim Panel Refit

7. Connect the battery negative.
7. Release the clip and remove the front door harness.
Refit
1. Fit the front door harness and secure with clips.
2. Connect the harness connector of the front door lock.
3. Connect the harness connector of the speaker.
4. Connect the harness connector of the window
regulator motor.
5. Connect the body harness connector.
6. Fit the front door interior trim panel.
Front Door Interior Trim Panel Refit
7. Connect the battery negative.

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Power and Signal Power and Signal

Centre Console Power Socket

Remove
1. Disconnect the battery negative.
2. Remove the centre console upper trim panel assembly.
Centre Console Upper Trim Panel Assembly
Remove
3. Remove the 12V power socket from the centre console
upper trim panel.
Refit
1. Fix the 12V power socket to the centre console upper
trim panel.
2. Fit the centre console upper trim panel assembly.

Centre Console Upper Trim Panel Assembly Refit

3. Connect the harness connector.

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Glossary List Name Description
Name Description NOx Oxides of Nitrogen
A/C Air Conditioning NSW Neutral Start Switch
ABS Anti-lock braking system NTC Negative Temperature
ATF Automatic Transmission Coefficient
Fluid OAT Organic Acid Technology
BCM Body Controller Module PAS Power Assisted Steering
CAN Controller area network PVC Polyvinyl Chloride
CHMSL Centre High Mounted Stop PWM Pulse Width Modulation
Lamp
RON Research Octane Number
CKP Crankshaft Position
SCS Stability Control System
CMP Camshaft Position
SDM Sensing Diagnostic Module
CO Carbon Monoxide
SIPS SAIC Integrated Program
CO2 Carbon Dioxide
System
DTC Diagnostic Trouble Code SRS Supplementary Restraint
EBD Electronic Braking-force System
Distribution TCM Transmission Control
ECM Engine Control Module Module
ECT Engine Coolant Temperature TMAP Temperature, Manifold
ECU Electronic Control Unit Absolute Pressure

EEPROM TP Throttle Position

Electronic Erasable
Programmable Read Only TPMS Tyre Pressure Monitoring
Memory System
ELR Emergency Locking TWC Three-way Catalyst
Retractor TXV Thermostatic Expansion
EMS Engine Management System Valve
EOT Engine Oil Temperature VDS Vehicle Diagnostic System
HC Hydro Carbons VIN Vehicle Identification
HO2S Heated Oxygen Sensor Number

HRW Heated Rear Window

HSLA High Strength Low Alloy
HVAC Heating, Ventilation and Air
Conditioning
ICE In Car Entertainment
ICS Inflatable Curtain Structure
IPK Instrument Cluster
ISO International Organization
for Standardization
LED Light Emitting Diode
LIN Local Interconnect Network
MIL Malfunction Indicator Lamp

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