Manual de Servicio Tm3

Beijing FOTON TM1
Service Manual
Foton International Trade Co., Ltd,Beijing

Axle and drive shaft - AX-1
Table of Contents
Introduction.............................................................................. IN
Diagnosis ................................................................................. DI
Engine section ........................................................................EG
Transmission and control mechanism ................................. TR
Axle and drive shaft ............................................................... AX
Frame, suspension and wheel............................................... FR
Steering system...................................................................... ST
Brake system ..........................................................................BR
Body ....................................................................................... BW
Electric system ....................................................................... EL
IN Introduction
How to use the manual........................................... 1
Identification information ....................................... 5 IN
General Rules for Maintenance and Service

Operation ................................................................17
Safety rules ............................................................25
Cleaning specification...........................................31
How to troubleshoot the vehicle...........................37

Introduction - How to use the manual IN-1
How to use the manual
Overview
1. Overview
a. This Manual gives the general instructions for fulfilling the maintenance and service. Operating
according to the instructions will contribute to ensure the service quality and efficiency.
b. In general, service operation will be divided into the following main parts: IN
• Diagnosis.
• Replacement (removal and installation), inspection & repair.
c. This Manual describes the "Diagnosis" (Refer to Chapter DI Diagnosis) and "Replacement
(removal and installation), Inspection and Repair".
d. This Manual does not describe the essential operations in the actual service listed below:
• Operate with jack or lifter.
• Clean the removed parts as required.
• Visual inspection.
2. Preparations
The Manual lists out the special tool, recommended tool, devices and auxiliary materials as
required for maintenance and service in each chapter.
3. Maintenance procedures
a. Insert the component drawing for illustrating the system according to the requirements of each
chapter.
b. Component drawing is in explosion diagram which clearly describes the assembly relationship
among each part and also illustrates the part name in the list behind the figure.
IN-2 Introduction - How to use the manual
Example:
Assembling relationalship
Part diagram
IN
1 Left lower wing arm assembly 6 Pivot

2 Right lower wing arm assembly 7 Lower swing arm pin
Left front traveler assembly with
3 Subframe assembly 8
brake
Right front traveler assembly with
4 Left thrust bar assembly 9
brake
5 Right pull rod assembly
Part name list
c. If the installation procedure opposite to the removal, only describe the key parts.
d. Repair procedures in this Manual only describe the important parts and illustrate the operation
objects and operation contents with the illustrations. Details and standard values of operating
Introduction - How to use the manual IN-3
method and precautions for operation, etc. are listed in the procedure instruction.
e. Certain similar models may share one illustration in the Manual. Under this condition, the related
content may be slightly different from the actual vehicle model.
f. The operation procedures are presented in the following manners:
• Operation procedure illustration express "what to do" and "where to do".
• Operation procedure title express "what to do". IN
• Operation procedure description express "how to do", and give the additional information
including "repair specifications" and "warnings for repair", etc.
Example:
Operating step title Operating step description
Repair warning information
Operating step illustration
4. Term definition
It is expressed in bold font, and providing additional instructions, helpful for

Note
improving the working efficiency of service.
It is expressed in bold font, and indicating that it may damage the device
Warning
under the repair or use.
It is expressed in bold font, and indicating that it may cause personal injury
Danger
on you or others.
IN-4 Introduction - How to use the manual
5. Unit -- International System of Units

a. "Unit" in the Manual applies international System of Units (SI unit).
Example:
Torque: 30N•m
6. Applicable model
IN Model Engine Emission standard
BJ1030V4JV2-BH DAM15R China NS-V

Introduction - Identification information IN-5
Identification information
Vehicle identification number (VIN)

1. Vehicle identification number (VIN)
a. The vehicle identification number (VIN) will be stamped on the vehicle identification label (VIN
label) and vehicle identification nameplate (VIN nameplate).
• The vehicle identification label (VIN label) -- Fixed at the right front side of instrument panel, IN
near the windscreen pillar，and can be seen through the windshield glass.
• Stamping location of frame VIN label - Stamped beneath the front passenger seat for
semi-integral models.
• The vehicle identification nameplate (VIN nameplate) -- Affixed in the cab and is located at
right B-pillar guard panel.
IN-6 Introduction - Identification information
Coding rules for vehicle identification number (VIN)

1. Composition of VIN
The VIN consists of 3 parts: the first part of VIN is the code of world manufacturer identification (WMI),
the second part is vehicle description section (VDS), and the third part is vehicle indication section (VIS)
as shown in the figure below.
IN
VIN: vehicle identification code

VIN (total 17 digits) = WMI (1~3 digits)+VDS(4~9 digits) +VIS (10~17 digits)
• WMI: the first part of VIN is used to represent the vehicle manufacturer, when used in
conjunction with the rest part, it can make sure the uniqueness of VIN among the vehicles
manufactured worldwide within 30 years.
• VDS: second part of VIN is the description part and it gives the information describing the
general characteristics of the vehicle.
• VIS: the last part of VIN is the approval part of the vehicle, and it is a set of words designated
by the manufacturer for distinguishing different vehicles.
2. Composition and Meaning of WMI
IN
a. World Manufacturer Identifier (WMI) - shall be used after application, approval, and filing.
b. ① is a letter or number that indicates a geographic area;
② is a letter or a number that indicates a country in a special region;
the combination of the① and ② can guarantee the uniqueness of national identification mark;
c. ③ is the letter or number that indicates a certain special manufacture;
the combination of ① , ② , and ③ can guarantee the uniqueness of manufacturer’s identification
mark.
WMI used by various vehicles of FOTON
N1-class (with a maximum design total mass ≤3500kg) truck (including

1 LVA
low-speed truck and non-complete vehicle)
N2-class and N3-class (with a maximum design total mass>3500kg) truck

2 LVB
(including low-speed truck and non-complete vehicle)
3 LVC M-class vehicle
4 LVD O-class trailer

3. Composition and Meaning of VDS (Category N)
IN
Note: a WMI of N1-class complete vehicle (including low-speed trucks) and its non-complete
vehicle shall be LVA
b WMI of N2-class and N3-class complete vehicle (including low-speed trucks) and their
non-complete vehicle shall be LVB
a. The first digit of VDS denotes the vehicle type. The code and meaning are as below:
Meaning Code
Class II truck chassis V
Class III truck chassis Y
Semi-trailer tractor S
Low speed truck L
Integral body truck C
Chassisless truck (Excluding low speed truck) W

b. The second digit of VDS denotes the gross mass. The code and meaning are as below:
Meaning (Gross mass, kg) Code
≤1800 1
＞1800~≤3500 2
IN
＞3500~≤6000 3
＞6000~≤12000 4
＞12000~≤16000 5
＞16000~≤25000 6
＞25000 7
c. The third digit of VDS denotes the body type. The code and meaning are as below:
Meaning (Body type) Code
Cab-over-engine single-row cab J
Cab-over-engine single-row cab with sleeper P
Cab-over-engine double-row cab A
Long-nose single-row cab K
Long-nose single-row cab with sleeper L
Long-nose single-row cab with sleeper M
No body (No cab or cargo body) O
Integral body Z
d. The fourth digit of VDS denotes the engine type. The code and meaning are as below:
Meaning
Displacement, L (Power, kW for Code
Fuel
electric engine)
<2.0 A
2.0~<4.0 B
Diesel
4.0~<7.0 D
≥7.0 E
<2.0 V
Gasoline
≥2.0 W
<75kW 0
Electric
≥75kW 4
<8.0 C
Natural gas
≥8.0 T
Meaning
Displacement, L (Power, kW for Code
Fuel
electric engine)
<8.0 L
Liquefied petroleum gas
≥8.0 U
IN <8.0 R
Bi-fuel
≥8.0 S
<8.0 9
Dual fuel
≥8.0 8
e. The fifth digit of VDS denotes the vehicle wheelbase. The code and meaning are as below:
Meaning (Vehicle wheelbase, mm) Code
≤2200 A
＞2200~≤5000 B
＞5000~≤8500 C
＞8500 D
Note: The wheelbase denotes the distance from 1st shaft to the last shaft.
f. The sixth digit of VDS denotes the check digit.

4. Composition and Meaning of VIS (Category N)
IN
a. The first digit of VIS denotes the year.
Year Code Year Code
1999 X 2015 F
2000 Y 2016 G
2001 1 2017 H
2002 2 2018 J
2003 3 2019 K
2004 4 2020 L
2005 5 2021 M
2006 6 2022 N
2007 7 2023 P
2008 8 2024 R
2009 9 2025 S
2010 A 2026 T
2011 B 2027 V
2012 C 2028 W
2013 D 2029 X
2014 E
b. The second digit of VIS denotes the vehicle assembling plant and assembling line.
Vehicle assembling plant and assembling line Code
First assembling line (Auman export

H
vehicles and military vehicles)
Second assembling line (Auman export
IN K
Third assembling line (Auman export
Beiqi Foton Motor Co., Ltd. L
Fourth assembling line (Auman export
T
Fifth assembling line (Auman export
R
Nanhai Auto Plant of Beiqi Foton Motor Co., Ltd. C
First assembling line S

Shandong Multifunctional Vehicle
Plant of Beiqi Foton Motor Co., Ltd.
Second assembling line U
First assembling line J

Beijing Multifunctional Vehicle
Plant of Beiqi Foton Motor Co., Ltd.
Second assembling plant A
First assembling line N

Changsha Auto Plant of Beiqi
Foton Motor Co., Ltd.
Second assembling line D
First assembling line Z
Second assembling line W

Zhucheng Auto Plant of Beiqi
Third assembling line X
Fourth assembling line Y
Beijing plant M
Beijing AUV Bus Company of Beiqi
Guangdong plant G
Zhucheng Ollin Auto Plant of Beiqi Foton Motor Co., Ltd. E
Huairou Heavy-Duty Machinery Plant of Beiqi Foton Motor Co., Ltd. V
Xuanhua Foton Loxa Pumping Machinery Plant of Beiqi Foton Motor Co., Ltd. P
Note: The code for the assembling plant of Hubei Foton Special Vehicle Co., Ltd. is “F”.
c. The third ~ eighth digits of VIS denote the manufacture serial number of the vehicle.
Serial number (SN)

1. The engine block number is located on the side
face of cylinder block on the exhaust side, near
the flywheel.
IN
2. The rear axle serial number is stamped on the

left axle tube of rear axle.
Main technical parameters of complete vehicle

Item Parameter
Flat-bed BJ1030V4JV2-BH BJ1030V4JV2
Model
Van - BJ5030XXY
IN Vehicle number 1030V4JV2-BHD021 1030V4JV2-BHD030

Overall Chassis 4470×1590×1850 4670×1590×1850
dimensions of
vehicle (Length × Flat-bed 4650×1680×1920 4880×1680×1920
width × height)
(mm) Van 4700×1695×2420 4930×1695×2420
Internal Chassis / -
Body dimensions of
Flat-bed 2820×1560×360 3050×1560×360
dimensions cargo body
(L×W×H) (mm) Van 2820×1560×1570 3050×1560×1570
Wheelbase(mm) 2400 2600
Front 1320
Wheel tread(mm)
Rear 1410
Body width(mm) 1520
Chassis 2805
Gross mass(kg) Flat-bed 2795
Van 2795
Chassis -/2
Load mass
Masses (kg)/Seating Flat-bed 1455/2
capacity
Van 1355/2
Chassis 975
Curb mass (kg) Flat-bed 1210
Van 1310
Top traveling speed (km/h) 110
Engine model DAM15R
Manufacturer Harbin Dong’an Auto Engine Co., Ltd.
Emission standard China NS-V
Displacement (L) 4.087
Power(KW) 82
Engine
Torque(N·m) 142
Major parameters
Fuel injection
Multi-point electronic injection
system
Voltage 12V
Fan Electronic fan
Type Three-way catalytic converter
After-treatment Model FT52003
Encapsulating manufacturer Beiqi Foton Motor Co., Ltd.
Item Parameter
Battery Model 6–QW-45Ah(350A)-L
Main characteristics Single plate, dry type, and diaphragm spring
Clutch Specification mm φ200×φ130
Clutch control Hydraulic control
IN
Model DAT18R
Transmission Manufacturer Zhejiang Wanier Group Co., Ltd.

case Main characteristics Manual (MT)
Type Flexible shaft operation
Brake type Hydraulic brake
Front brake Hydraulic disc brake
Service brake
Rear brake Hydraulic drum brake
Adjustment mode of braking force Load-sensing proportional valve
Parking brake Type Wheel handbrake
Steering
Type of steering gear Rack and pinion type
mechanism
Type of rear axle Tubular type
Model 102
Rated load (T) 1.5
Rear axle
Cross section (mm) φ80×6
Speed ratio 4.778
Rear axle manufacturer Liuzhou Wuling Automobile Industry Co., Ltd.
Type Integral body
Overall width (mm) 1150
Frame
Cross section (Front/middle/rear) of
Front 100×60/ Middle 200×60/Rear 130×60
longitudinal beam (mm)
Front
Type McPherson independent suspension
suspension
Front-wheel Kingpin inclination angle 12.2°±30′
alignment
parameters Kingpin caster angle 3.04°±30′
Front wheel camber angle 0.77°±30′
Front wheel toe-in (One-sided) 14′±5′
Non-independent suspension, longitudinal
Rear Type
leaf spring + telescopic shock absorber
suspension
Number of spring plates 5
Cab type Single-row
Body type
Body status 1520
Model 175R148PR
Tire Quantity 5
Front/rear tire pressure (kPa) 450±10
Item Parameter
Electric Battery 12V/45Ah

devices Starter motor 12V,1.0KW,12V,1.2KW
Diagnostic Model Kingtec KT660

apparatus Purchase network Beiqi Foton Motor Co., Ltd.
IN
Introduction - General Rules for Maintenance and Service Operation IN-17
General Rules for Maintenance and Service Operation
Precautions for operation

1. Precautions for basic maintenance
a. Precautions for maintenance operation
IN
• Unified and clean working clothes must be worn.

1 Clothing
• Safety helmet and working shoes must be worn.
• Before maintenance and service, prepare the front grille protection pad,
2 Vehicle protection
fender protection pad, seat cover and carpets, etc.
• When 2 or more people operating jointly, the safety of other people must be
considered.
• When operating when the engine is running, make sure the good ventilation
in the working room.
• When operating the parts under high-temperature, rotation, moving or
3 Safety operation vibration, required protective clothes must be worn to prevent from being
burned or hurt.
• When lifting the vehicle, make sure to operate at the specified support point
and ensure the secure support.
• When lifting the vehicle, make sure to operate with safe and qualified
equipment.
IN-18 Introduction - General Rules for Maintenance and Service Operation
Preparations of
• Before maintenance and service operation, make sure tool stand, special
tools and
4 tool and measuring instrument, auxiliary materials for complete vehicle, rag
measuring
and replacement parts.
instrument
• Perform complete analysis and diagnosis on the symptom of failure, and
apply effective solution.
IN • Before removing the part, check its general condition for deformation or
Disassembled to damage, etc.
install and
5 • In case of complex operating procedure, the operating procedure shall be
dismantled to
assemble record or marked for assembly, in order to prevent its functions from being
damaged.
• Clean the removed part as required and re-install it after comprehensive
inspection.
• Place the removed part in sequence to prevent from being disrupted or
contaminated.
6 Removed part • Place the removed part in sequence to prevent from being disrupted or
contaminated.
• Keep the replaced part for customer check.
b. Lifting and supporting the vehicle.

• When lifting and supporting the vehicle, be extremely careful and make sure the operation
is made in a proper location.
c. Rubberizing part.
• Rubberizing part means the part is applied with sealant before delivery, such as bolt and
nut, etc.
• If a certain rubberizing part needs to be released and re-tightened or moved in any way,
the specified sealant must be re-applied.
• When re-use a certain rubberizing part, the old sealant must be clean completely and dried
by compressed air, then the bolt, nut or thread will be applied with specified sealant.
Danger
Torque inspection shall be performed in accordance with the lower limit of the torque
requirements.
• When applying sealant, sometimes it needs to wait for a while until the sealant is cured.
d. Shim.
• Install seal ring on the liner as required to avoid oil leaking.
e. Bolt, nut and screw.
• Tighten well with torque wrench strictly following the regulations in tightening torque.
f. Fuse.
Same rated current • When replacing the fuse, make sure the
rated current of new fuse comply with the
requirements, and do not use the fuse with
undesirable rated current.
Illustration Illustration Part name
Fuse
IN
Fuse
g. Buckle
Removal and installation method for the buckle commonly used by body parts as shown in the
table below.
Caution
If the buckle is broken during the service, make sure to replace with a new one.
Shape (example) Removal / Installation

Shape (example) Removal / Installation
IN
h. Use a torque wrench with an extension handle.

• When using torque wrench with service
special tool or extension handle, if the
displayed torque of that wrench is reached
the specified value, it means the actual
torque is already excessive.
• In this Manual, only the torque value that
needs special indication is described. When
using torque wrench with service special tool
or extension handle, calculate the torque
according to the following formula.
• Formula: T ’ =T×L2/(L1 + L2)

T’ Torque wrench reading (N•m)
T Actual torque (N•m)
Service special tool or extension handle length

L1
(mm)
IN
L2 Length of torque wrench (mm)
2. Electrical control
a. Disconnect and connect the negative cable of
battery.
• Before electrical repairing, be sure to
disconnect the negative cable of the battery,
to prevent accident caused by short circuit
etc.
• Before disconnecting, connecting the
battery cable, be sure to turn off the ignition
switch and light switch, and completely
loosen the cable fixing nut, never twist and
pry it.
• After disconnecting the negative cable of
the battery, the clock, radio etc. will be
reset. Before repairing, record all the
necessary data.
b. Operate the electrical elements.
• If there is no special requirement, never
open the control module housing (If the IC
pin is touched by accident, it will be
damaged because of static electricity).
• When disconnecting wire harness
Incorrect connectors, be sure to pull the connectors
and never pull the wire harness.
• Operate carefully, and never drop the
electrical elements (such as sensor, relay
etc.) If they are dropped on the solid floor,
be sure to replace them and never use them
again.
• When using steam to clean the engine, be
sure to prevent electrical element, air filter
and emission control system related parts
from the influence of the steam.
• Never use an impact wrench to remove or
install a temperature control switch or
temperature sensor.
• When checking the conductivity of the wire

harness connectors, be sure to insert the
probe carefully to prevent the pins from bing
twisted or damaged.
• After replacing the electrical element, be
IN sure to conduct function inspection to the
electrical element, and ensure its function
being normal.
3. Removing, installing fuel control system parts
a. Notice of working place for removing and installing fuel system parts.
• Be sure to select the place with good ventilation, and there is no any equipments or objects
that may produce open fire including welding, grinder, electric drill, motor and oven.
• Never select filling station or the place near it, because the evaporated fuel may have filled
the entire space.
b. Removing, installing the parts of fuel system.
• Be sure to prepare the fire extinguisher before the operation.
• In order to prevent the static electricity from being produced, be sure to connect the
complete vehicle, fuel tank etc. to the ground, ban keep the workshop floor dry to avoid
slipping.
• Never use any appliances such as motor or working light, to avoid producing spark or high
temperature.
• Be sure to avoid using hammer to avoid producing spark.
• Use fireproofing container and discard the rag with fuel.
4. Removing, installing the parts of engine intake system
Caution
If the buckle is broken during the service, make sure to replace a new buckle.
• When removing, installing the parts of the intake system, seal the opening of the parts
removed with clean rag or tape.
• When installing the parts of intake system, make sure that there is no any metal debris.
5. Operation of hose clamp

Spring hoop a. Before removing the hose, check the insertion
depth of the joint and the position of the
clamp, so as to reinstall the hose correctly.
b. If the hose has deformation or sink, replace it.
c. If the hose can be used again, be sure to set
the spring clamp to the imprint left.
Hoop indentation d. For the spring type clamp, after installation, its
position can be adjusted forcibly in the
direction of the arrow.
6. Precautions for engine oil
Contact with used engine oil for a long time and repeated contact with used engine oil may cause
skin cancer, so it is required to avoid direct contact of your skin with used engine oil as far as
possible. If your skin contacts with the used engine oil, it is required to wash your skin with soap
or cleaning liquid thoroughly.
Throw the used engine oil and old oil filter to designated place or deliver them to a used oil
recycling station. In case of any doubts, it is possible to consult local official offices for disposal.
Pouring the used engine oil on the ground or into sewage pipe or sewers are illegal. The
regulations on environment pollution are varied in different countries.
7. Precautions for A/C
When the refrigerant of the A/C system has to be drained, be sure to use refrigerant recycling
equipment. IN
8. Precautions for using the jack
a. Before using, check individual parts of the jack are in normal condition.
b. During using, observe requirements specified in main parameters, and be sure to avoid overload
resulting in oil leakage at top end of the oil pump.
c. In the event the oil in the manual pump is insufficient, it is required to fully filtered hydraulic oil in
the pump.
Warning
If an electric pump is used, it is required to make reference to instructions for operation of

electric pump.
d. It is required to choose suitable gravity center of the part, and chose the supporting point of the
jack reasonably, and that the bottom surface must be leveled.
Warning
If the ground is soft, a rigid wood block must be padded.
e. It is prohibited to use the jack on an overloading parts to prevent damage to the jack.
f. Jack is only used for lifting, and after lifting immediately use vehicle bracket for supporting.
g. During using, it is required to avoid vibration of the jack.
h. When using the jack, do not use the jack in the place where there are acid, alkaline and corrosive
gases.
9. Precautions for vehicle rescue
a. Pull out the cable of the equipment, and do not contact with any parts of the suspension, steering
brake and cooling system.
b. Be sure to pull out the cable from the front or rear end of the vehicle straightly, and do not pull the
vehicle in a lateral angle.
c. When towing the vehicle, it is not recommended to use dragging equipments such as rope or
delivering belt.
10. Precautions for vehicle towing
a. Position of the front towing hook
Front towing hook is located in the right frame rail.
b. Position of the rear towing hook
Rear towing hook is located in the left frame rail.
c. When the vehicle is towed, the towing connecting equipment should be locked securely, and the
gear box must be protected carefully before towing. For safety reason, the drive shaft should be
disconnected in principle, take care to align the marks when reinstalling the drive shaft.
d. Must follow all the local laws which are applicable for towing operation.
e. When the vehicle is dragged, do not shift to R position.
f. Frequently check whether the parking brake is applied during traction.
Danger
Towing is over, do not forget tightening the stud to its original position! Must use draw bar! When
the parking brake is released mechanically, brake can not be applied to the vehicle by foot brake
or parking brake. Ensure that the vehicle will not move when the parking brake is released!
Check the wheel mat wood and connect the draw bar!
IN
Introduction - Safety rules IN-25
Safety rules
Safety rules
1. Description
Many operations that are related to vehicle maintenance and repairing will affect personal safety
or healthy issue, some related dangerous operations and materials and equipments have been
listed in this section, and the safety code for avoiding harm of this kind is also listed. This section IN
does not include all the matters of concerned health and safety, so all the working and procedure
and handling of the materials should be performed on the basis of safety and health. Before using
any products, refer to the Operation Manual of the products provided by the manufacture or
supplier.
2. Acid and alkaline
For example sodium carbonate and sulfuric acid which are corrosive.
They are used for cleaning of battery or other materials.
They have irritation or corrosion to the eyes, skin, smell and throat, and will cause burn to human
and damage the ordinary protective clothes.
Avoid splashing in the eyes, skin and clothing, wear proper protective clothes, gloves and goggles
to avoid inhaling spray. Be sure to prepare the washing equipment nearby, for example: washing
bottle for eyes, basin and soap etc., make it easy to get aids timely at all time when the splashing
accident occurs.
Mark the sign for eyes danger at striking position.
3. A/C refrigerant
Skin contacting may cause frostbite.
Must follow the instruction provided by the manufacture, avoid bare light, and wear proper
goggles and protective gloves. If the skin or eyes contact with the refrigerant, wash the contacted
area with water immediately. Use proper washing solution to wash the eyes, and do not rub eyes
and seek the medical help depending on the situations.
A/C refrigerant -- operations should be avoided
Do not store the refrigerant in the place with sun exposure or heat source.
When adding, do not keep the refrigerant bottle upright, and face their valves downwards.
Do not expose the refrigerant bottle in frost and snow.
Do not drop the refrigerant bottle.
Under no condition can the refrigerant be discharged into the atmosphere.
Do not mix the refrigerants, for example R12 (dichlorodifluoromethane) and R134a
(tetrafluoroethane).
4. Adhesive and sealant
Important precautions for adhesive/sealant using.
Before using adhesive/sealant, be sure to keep the surface of the application area clean, and use
special cleaner to wipe it, avoiding affecting adhesion effect. When using sealant, do not let the
glue which is room-temperature-setting enter into the blind hole of the thread, if the
room-temperature-setting sealant enters into the blind hole of the thread, hydraulic locking effect
will occur when the fastener is being tightened, accordingly the fastener and (or) other parts will
be damaged, and that may also cause that correct clamping force can not be got when the
fastener is being tightened, making the sealing effect of the sealant become worse, which will
cause that the fastener can not be tightened correctly, the parts are loose or separated, resulting
in parts like engine being damaged seriously.
IN-26 Introduction - Safety rules
Health and safety.

Materials used in adhesive/sealant include harmful material, which will cause diseases such as
acute poisoning and chronic poisoning, occupational disease, skin disease etc. after contacting
with them for a long time. When applying, use ventilating and air change device to keep the
ventilation of the workshop; when operating, wear protective gloves, mask and protective clothes
IN etc., after the work, wash both hands carefully, and keep the workshop clean, tidy and keep the
environment clean.
Waste which is polluted by wasted glue or solution should be cleared timely and can not be
stacked for a long time.
Generally the products should be stored in no-smoking area, take care to keep clean when using,
and use applicator or container for application as much as possible.
Adhesive/sealant repairing.
When the vehicle is failed or in accident, phenomenons like body deformation, steel cracking, and
welding spot falling off will be caused generally, and sometimes partial damage of other
assembling parts such as engine, chassis etc. will also be caused, resulting in falling off, damage
of some adhesive/sealant like products. During the vehicle being repaired, select the adhesives
with the same performance according to the material and function requirements for the parts, the
adhesives/sealants which can be used for vehicle repairing are listed below which can be
selected when the vehicle is being repaired.
a. Body repairing.
After the body interior and steel plate are suffered from deformation or crack, the adhesive coated
in the body falls off or cracks, during repairing, it is needed to repair the area coated with
adhesive.
First remove the adhesive on the body surface with knife, and the remaining can be wiped clean
with alcohol; wipe the coating area with special cleaner, prevent impurities such as residual
adhesive from being left on the applying surface; coat the adhesive for repairing on the original
applying area, reaching to the effect of being bonded and sealed.
b. Parts repairing.
Areas such as some interior parts, engine, and transmission are damaged, it is needed to repair
the bonding and sealing. When coating the sealant, clean the application surface to avoid burr,
crack, which affects the bonding.
Precautions for construction
a. The function of the adhesive/sealant is preventing water and dust from entering intothe vehicle,
and they also have anti-corrosion function. The original sealing joints are obviously, if these
sealing sections are damaged, seal them again. When sealing the opening seam with
adhesive/sealant, select filling with high consistency. Operate according to the instruction of the
materials selected.
b. When applying adhesive/sealant like materials, must take prevention measures, to avoid applying
to the opening of the parts (such as door lock, window lifting groove, window regulator and seat
belt retractor) and any moving, rotating parts, especially parking brake cable. After applying
adhesive/sealant, ensure all the drain holes of the body being open.
c. When the construction operation is performed, wear special goggles and gloves to avoid hurting
people.
d. When the vehicle leaves the factory, all the metal plates of the body have been coated, after
repairing and/or replacing the part, all the bare metal surface must be treated with rust preventive
primer, and after that sealant application can be performed.

e. After repairing of sealant application, some adhesive/sealant need to be dried and solidified, and
the baking condition is (70~80) ℃, 20~30min.
5. Asbestos
Inhaling asbestos dust will cause hurt to the lung easily, even resulting in cancer.
When disposing the asbestos dust waste, wet it and put it into the sealed container, and make IN
obvious mark on the container surface, which is convenient for safely disposing. If it is needed to
try cutting or drilling in the material with asbestos, firstly wet it, and only manual tool or low-speed
power tool can be used.
6. Battery acid
The gas that released when charging is explosive, do not operate with open flame near the
charging battery or the battery that has just finished charging. Good ventilation must be
maintained.
7. Chemical materials
Pay attention to the use, storage and process of chemical materials, e.g. solvents, sealants,
adhesives, coatings, resin foam, battery acid, engine coolant, brake fluid, fuels, lubricating oil and
grease. They maybe peculiar smell and dust of which are toxic, harmful, erosive, pungent or
highly flammable, and highly dangerous.
The effects of long-term excessive exposure to chemical environment probably are instant or
chronic, temporary or permanent, cumulative, superficial, life-threatening or even influence the
lifespan.
Chemical materials -- Operations shall be performed.
a. Read carefully and follow the warnings and precautions in the material container, and any
attached leaflet, poster or other instructions, health and safety information form of raw materials,
all these can be obtained from the manufacturer.
b. The chemical materials stained on skin and clothes shall be removed as soon as possible, and
the clothes that has been heavily soaked shall be changed and cleaned thoroughly.
c. Strictly following the instructions of working steps and wearing protective clothing to avoid direct
contact with skin and eyes.
d. After the processing of chemical materials, body must be cleaned first before resting, eating and
drinking, smoking or using toilet facilities.
e. Keep the working area clean and tidiness and the chemical materials shall not be splashed out.
Chemical materials -- Operations shall be avoided.
a. The chemical materials shall not be mixed randomly unless there is instructions from the
manufacturer; Some chemicals can produce other toxic or harmful chemical substances, and
release toxic and harmful gas and also may cause accidents like explosion when mixing them.
b. Do not spray chemical materials in closed environment.
c. The chemical materials shall not be heated unless there is instructions from the manufacturer,
because some chemical materials are highly flammable, and some may release toxic and harmful
gas.
d. Do not remain the chemical materials container open, because the emitted gas may accumulates
to the degree of toxic, harmful and explosive. Some gas is heavier than air, so they can
accumulate in closed space.
e. Chemical materials can't be put into containers without mark.
f. Chemical materials can't be used to clean hands and clothes. Chemicals, especially solvents and
fuels, will make skin dry, cause allergy and skin inflammation, or influence physical health by
absorbing toxic and harmful substances directly through skin.
g. Unless the container has been cleaned under supervision, otherwise the empty container can't be
used randomly to contain other chemical materials.
h. Do not sniff or smell the chemical materials randomly. Temporarily exposure to gas of high
IN concentration may still cause poisoning or hurt.
8. Dust
Powder, dust and dirt probably are pungent, harmful and toxic, powdered chemical materials and
dust kicked up by dry friction shall be avoided to inhale, if the ventilation is poor, respiratory mask
protection device shall be wore to prevent from breathing dust.
Fine dust of combustible material may cause explosion, explosion and combustion source shall
be avoided.
9. Electric shock
Electric shock can be caused by wrongly use of the electrical equipment or abuse of equipment
that in good condition.
Be sure to maintain the electrical equipment and conduct frequent test in the specified time. The
failed equipment should be marked, it is better to move it outside the working area.
It is prohibited to make the wire, cable, plug and socket to be worn, twisted, cut, broken or
suffered from other damage, never contact the electrical equipment and wire with the water.
Ensure that the fuse of the electrical equipment is protected correctly.
It is prohibited to misuse the electrical equipment, and never use any equipments that have
hidden faults, and the results may affect personal safety.
Make sure that the cables of the electrical equipment will not be pinched and damaged.
Must perform basic emergency training to the special electrical operator.
When the electric shock occurs:
a. Turn off the power first before contacting the victim.
b. If the power can not be turned off, remove the power of the victim with dry insulation materials.
c. If you are specially trained in first aid, give the first aid immediately.
d. Ask for medical assistance.
10. Exhaust gas
Exhaust gas includes toxic and harmful chemical substances, such as materials of carbon oxide,
nitrogen oxide, acetaldehyde, lead and aromatic hydrocarbons etc. The engine can only run
under the condition that the exhaust gas drawing equipment or ordinary ventilation equipment is
available and the space is open.
11. Fiber isolation
It is used for isolating noise and sound.
The fibrous material and sharp edge may cause skin allergy.
During operation, you should follow working procedure specification and wear gloves, preventing
the skin from contacting with the fiber excessively.
12. Fire
Many vehicle repairing related materials are extremely flammable. After the combustion of some
materials, toxic, harmful gas will be produce.
When storing and handling flammable materials and solutions, be sure to follow the fire safety,
especially at the places near the electrical equipment or where welding operation is being
performed.
Before using electrical and welding equipment, must confirm there is no fire hazard firstly.
When welding or using heating equipment, a proper fire extinguisher should be prepared around
the operation area.
13. First aid
It not only needs to comply with the legal, but also personnel specially trained in first aid are better
to be available in work place. IN
If eyes are suffered from the chemical solution spilling, wash eyes with water for at least 10min.
If the skin is polluted, it is necessary to wash the polluted area with soap and water.
If you are suffered from frostbite, soak the frozen area in ice water or cold water.
Personnel who inhales toxic gases should be transfered to the place where fresh air is available,
if the poor reaction occurs continuously, he/she should be taken to the hospital for medical
assistance.
If you have taken the fluid mistakenly by carelessness, tell the information indicated on the
container or the label to the doctor, unless there is indication on the label, do not induce vomiting
blindly.
14. Foam - polyurethane
Maturing foam is used for the buffer gasket.
Follow the instruction of the manufacture.
The component that has no chemical reaction has irritation, which is harmful to the skin and eyes,
it is necessary to wear gloves and goggles for operation.
The personnel who has problems of chronic respiratory disease, asthma, bronchitis etc. or atopy
should not handle or approach the materials that have not been matured.
Its parts, steam or spray will cause direct irritation and allergic reaction, and they may be toxic and
harmful.
Remember that do not inhale steam or spray, and these materials must be used under the
condition that good ventilation is available and breathing is protected well. Do not take off the
mask immediately after spraying, must wait for the steam, spray being dissipated completely.
Combustion of the non matured components and matured components will produce toxic and
harmful gases, during foam working, unless the steam and spray have been dissipated
completely, it is prohibited to smoke, use fire and electrical equipment, and any hot heating cuts
of the foam material or special foam material should be performed in the environment with good
ventilation.
15. Fuel
Let the skin contact the fuel directly as little as possible, if the skin contacts with the fuel,
immediately clean the skin that directly contacting with the fuel with soap and water.
16. Ordinary workshop tools and equipments
It is very important to always keep all the tools and equipments in good condition, and use them
for correct operation.
Remember that do not use the tools or equipment for the purpose that goes against its design
function. Do not let the equipments such as crane, jack, axle and chassis bracket or sling etc. to
bear the maximum limited load that is more than that they can bear. Damage caused by overload
will not occur at right, and it may cause serious accident when it is used next time.
Do not use the tools or equipments which have been damaged or they are in poor working
condition, especially some high-speed equipments, for example: grinding wheel. The damaged
grinding wheel will be broken in the condition without early warning, and cause serious injury.
When using grinding wheel, chisel or sandblasting equipment, wear proper protective equipment
for eyes.
When using sandblasting equipment, handling the material with asbestos or working with
spraying equipment, must wear proper breathing mask.
Ventilation equipment which is able to control the dust, spray, and smoke content must be
IN available.
17. Lubricant and grease
• Avoid contacting with mineral grease repeatedly for a long time, and all the lubricating oil
and grease have irritation to the eyes and skin.
• Avoid contacting with oil repeatedly for a long time, especially used and oil.
• Wear protective clothes, and if it is possible, use isolation gloves.
• Do not put the rags with oil in the pocket.
• Do not let the oil stick to the clothes, especially the underclothes.
• Do not wear very dirty clothes and shoes with oil. Clean the full set of working clothes
periodically.
• For skin injury and other body injuries, first aid should be able to made immediately.
• Before working, coat protective cream on the skin so as to clean the oil easily.
• Cleaning with soap and water, ensure removing all the oil (cream and nailbrush will be
helpful). Use lanolin instead of the oil of natural skin that has been washed off.
• Do not use gasoline, kerosene, diesel, gas oil, thinner or solution to clean the skin.
• If the skin has some discomfort, take medical measures immediately.
• If it is possible, before using the parts, remove the oil.
• If there is risk of entering into the eyes, wear the goggles or face mask; for example
chemical goggles or face mask; in addition, the equipment for eye washing should be
equipped.
Precautions for environment protection:
• Wasted oil and oil filter should be given to the waste disposal dealer who will deliver them
to the specified waste disposal site or to the wasted oil recycling enterprise. If you have
some doubt about waste disposal, contact the related local department.
• It is illegal to splash the wasted oil to the ground, pour the wasted oil into the sewage, the
drain or source of water; regulations on environment pollution are varied in different
regions.
18. Noise
Noise of very high decibel will be produced when some operations are performed, which may
cause hearing injury. At this time, wear proper protective equipment for hearing.
Introduction - Cleaning specification IN-31
Cleaning specification
Cleaning specification
1. Definition of cleaning
Debris on the part which may pollute any engine system must be cleared. It does not mean that
the part must be bright and clean as new.
It is not necessary to polish the gasket surface with sandpaper until the marked position for plant IN
machining, and the sealing effect is damaged often.It is very important to keep the tolerances for
polishing and flatness, so as to make good sealing surface. Gasket is used to fill the uneven
position on special surface.
If edge molded gasket is used, generally it is not necessary to polish gasket surface with
sandpaper. Edge molded gasket is that the edge of metal sheet is applied with sealing material, at
the same time connection between the metals forms, and stability is provided.
It is better to use blunt scrapper to remove any sealing materials of small amount which is sticked
to the part, and do not spend time using automatic polishing machine or grinding wheel to polish
the entire surface.
For those gaskets which have no molded edges, almost all the gaskets have used some materials
with release agent which can prevent adhesion. Certainly it does not mean that some gaskets will
be removed without difficulty because the gaskets have been installed for a long time, they have
been overheated, or the release agent fails due to using some sealant. But our target is only
removing the gasket without damaging the mating surface, at the same time the engine will not be
polluted (small particles are not allowed to fall to the place where they can not be removed).
It is not necessary to clean the piston crown through shot blasting until the black stain is removed.
What is needed is only removing the deposit from the top ring and ring groove. There is more
information about shot blasting and piston cleaning in later part of this document.
It is not suggested to polish or grind the carbon ring on the top of the cylinder liner with sandpaper
to the degree that clean metal could be seen. This will damage the cylinder liner, and any fault
sign on the upside-down indicating arrow (like dedusting mark) of the top ring will be damaged.
Carbon ring must be removed so that the piston can be removed more easily. As long as the
rated speed more than that of the power tools used, high quality and medium bristle wire wheel
could have the same high speed, and the damage caused will be smaller. After the piston is
removed, must carefully find the broken wire. But it is very easy to see the wire, and attract it with
magnet.
Oil of the parts that removed from the engine will adsorb dirt in the air. Dirt could be attach to the
oil. If it is possible, let the used oil leave on the part until it is ready to clean, check and install the
part, and then clean the part and remove any dirt attached. If the part is cleaned and placed
outside the engine, it must be cleaned again before installation. Be sure to use clean oil to
lubricate the parts and then install them. They do not need to be coated completely with oil, but oil
must be applied between the moving mechanical parts (or before towing the engine, good
pre-filling process of the lubrication system has been performed).
Generally it is not necessary to clean the paint from the parts surface through shot blasting. Parts
will be painted again soon, so what you need to do is removing any peeling paint.
2. Polishing sand disk and sandpaper
Keyword is "Polishing". No engine parts which could be protected from wear. That is all of them
are locked together or slide over each other. Friction materials and dust particles will weaken the
two functions.
IN-32 Introduction - Cleaning specification
Caution
Must keep the oil passage and part worn point clean. Otherwise, bearing and bushing fault may
be caused, and main components damage will be resulted as time passes, and they can not be
used again. Main bearing and linkage bearing are especially so.
It is not suggested that polishing any assembled engines or any parts of the components,
IN
including but not limited to removing deposit section from the cylinder liner or cleaning surface or
holes of the cylinder block.
When using grinding appliance to clean the engine parts, especially the engine which is partly
assembled, must be very careful. Friction cleaning appliance have many types and dimensions.
They include aluminum oxide fine grain, carborundum, sand or some other similar solid materials.
These fine grains are more solid than most parts in the engine. Because they are more solid, if
they are pressed to softer materials, these materials will be damaged and the grains will also be
inserted into the materials. During using these grinding appliances, these materials fall off the
grinding appliances. If using these appliances in power device, the fine grains will be thrown and
fall around the engine. If these thin grains falls between two moving mechanical parts, moving
mechanical parts damage may be caused.
If the diameter of the fine grain is smaller than the clearance between the moving mechanical
parts when they are stationary (engine is stopped), but it is bigger than the moving clearance,
when the parts are moving relatively, parts damage will be caused (engine is started). When the
engine is running and there is oil pressure, the fine grain whose diameter is smaller than the
bearing clearance may pass through the clearance between two parts without causing damage to
the parts, and then they are blocked by oil filter. However, the fine grain whose diameter is bigger
than the bearing clearance will wear off the materials of a certain part, and it may also be inserted
into a certain part. Once the grain is inserted to a part, it will wear another part until two part will
not contact again. If the damage significantly affects the oil film, two parts will contact directly, and
premature wear is caused or fault may occur due to lack of effective lubrication.
The friction fine grains may be spread out in all directions during cleaning, it is very important to
prevent these fine grains from entering the engine as much as possible. For the oil port and oil
passage holes, especially these ports and holes located in the downstream of the oil filter, which
should be more so. Block these ports and holes, but do not try to blow the friction fine grains and
debris away with compressed air, because in general doing so can just blow the debris further
into the oil passage.
All the original gasket material must be removed from gasket surface of the part. However, it is
not necessary to clean and polish the gasket surface until the machining mark is worn off.
Excessive sandpaper burnishing or polishing may damage the gasket surface. Many new type of
gaskets are edge molded (steel substrate has sealing part sticks to the steel plate). Remove very
little sealing materials attached with scraper or putty knife. Generally it is wasting time that using
sand disc or sandpaper to clean the surface of the gasket with molded edge.
Caution
Excessively polishing or grinding the carbon ring on the top of the cylinder liner may damage the
cylinder liner, which make it unable to be used any more. Surface layer may be damaged, friction
fine grains may be pressed to cylinder liner material, which may cause premature wear of the
cylinder or piston ring fault.
Before using sand disc or wire brush, seal all the openings which are connected into any IN
components with tape or block them with block plugs. If power tool with sand disc must be used
really because of time reason, seal the oil passage with tape or use block plug to block it, and
use this tool to clean most of the surface as much as possible, but clean the part around the oil
hole with hands, to prevent the oil passage from pollution. Then, remove the tape or the block
plug, and do not use tool to clean the rest. Do not use compressed air to blow out the debris from
the oil passage of assembled engine! That may well be counterproductive, debris may be blown
into the oil passage further. If both of the two ends of the oil passage can use compressed air, but
this condition is rare for the engine assembled.
3. Gasket surface
The purpose of cleaning gasket surface is to remove any gasket materials, but not polish the
gasket surface of the part again. Liquid gasket scavenger of any special band is not
recommended. If the liquid gasket scavenger is used, check the instruction to ensure that the
clean materials are not damaged.
Pneumatic gasket scraper could save time but you must be careful, and do not damage the
surface. Angulation part must be opposite to the gasket surface, to prevent the blade from
inserting into the surface. When using pneumatic gasket scraper on the parts which are made of
soft materials, being skilled and careful are needed, to avoid damage.
Avoid scraping or brushing the entire gasket surface as much as possible.
4. Solvent and acid cleaning
Some solvents or acid detergents can be used to clean the dissembled parts of the engine
(Except for piston. See below). Experience shows that if the detergent can be heated to 90~95℃ ,
the best cleaning effect will be gained. Kerosene lotion detergent has different temperature
specifications, see below. The cleaning tank which can mix and filter the cleaning solution
continuously can ensure the best cleaning effect. Using special detergent is not recommended.
Just using it by following the instruction of the detergent manufacture. Before placing the parts in
the cleaning tank, use wire brush or scraper to remove all the gasket materials, O-rings and the
deposited oil dirt and carbon deposits from the parts. Be careful not to damage any gasket
surface. If it is possible, clean them with steam before placing them in the cleaning tank.
Warning
When cleaning with solution, acid or alkaline materials, you should follow the use method
recommended by the manufacture. Wear the goggles and protection clothes to avoid personal
injury.
Experience shows that using kerosene lotions based detergent to clean the piston have the best
effect. These detergents should not be heated to the temperature more than 77℃ . These
solutions will be decomposed when the temperature is more than 82℃ , and the effect will be
weakened.
Do not use the solution which is composed of chlorohydrocarbon, cresol and/or creosote. When
removing the deposits from the ring groove, the effect is generally not obvious, and the cost will
be higher when conduct correct handling.
The solution with approximate pH value more than 9.5 will make the aluminum be blackened.
Chemicals with pH value more than 7.0 are regarded as alkalinity substance but they are acids
when the pH value is less than 7.0. Alkalinity or acidity will be stronger as the deviation between
IN pH value and neutral 7.0 gets bigger.
Before placing the parts in the cleaning tank, use wire brush or scraper to remove all the gasket
materials, O-rings and the deposited oil dirt and carbon deposits from the parts. Be careful not to
damage any gasket surface. If it is possible, clean them with high temperature and high pressure
water and steam before placing them in the cleaning tank. Before placing the parts in the cleaning
tank, removing the thickest dirt will make the detergent more effective, and the detergent will last
longer.
Flush all the parts with hot water after cleaning. Thoroughly dry the parts with compressed air.
Blow-drying the water in all bolt holes and oil passages.
If the parts are not used immediately, please dip them in some proper anti-rust agent. Before
assembling or installing the parts to the engine, must remove the anti-rust agent from the parts.
5. Steam cleaning
Steam cleaning can remove the dirt of all types which will contaminate the cleaning tank. This is a
good method for cleaning oil passage and coolant passage.
Warning
When using steam cleaner, wear goggles or protective mask and wear protection cloths. Hot
steam may cause serious personal injury.
The following parts can not be cleaned with steam:
• Electrical Components
• Wire harness
• Fuel injector
• Fuel pump
• Belt and hose
• Bearing (Ball or taper roller)
• Electronic control module (ECM)
• ECM connector
• Injection control unit
• Nitrogen oxide sensor
6. Plastic shot blasting cleaning

Using glass shot blasting or walnut shell medium on any engine parts is not recommended. Only
using plastic shot blasting medium or equivalent on any engine parts is recommended. Never use
sand as shot blasting medium to clean the engine parts. When using glass and walnut shell
mediums without following the suggestion of the medium manufacture, they may cause excessive
dust and may be inserted into the engine parts, which will result in friction wear of the parts and
make the faults occur too early.
Plastic shot blasting cleaning can be used to remove the deposits on several engine components.
Cleaning process steps are determined by plastic pills using, working pressure and cleaning time.
Warning
Do not use shot blasting cleaning method to clean aluminum piston skirt or any pin holes of the
piston, piston skirt or piston crown. Little fine grain of this medium will be inserted into
aluminum or other soft metals, and premature wear of the cylinder liner, piston ring, piston pin
and pin hole will be resulted. At the same time, parts such as valve, turbocharger shaft etc. will
be damaged. Please follow the shot blasting cleaning points listed in the steps below.
IN
Do not let foreign objects and plastic shot blasting pollute the cleaning tank and box-type
solution cleaner. Use compressed air, high temperature and high pressure water or steam to
remove the foreign objects and plastic shot blasting, and then place the parts in cleaning tank or
cleaner. Foreign objects and plastic shot blasting may pollute the cleaning tank and any other
engine parts cleaned in the tank. The polluted parts may cause the fault due to friction wear.
Shot blasting can not damage the metal surface. If the metal surface is damaged, then engine
may be damaged because the clearance between the parts is increased and the parts surface on
which relative moving between the engine and other parts occurs is not smooth enough.
When cleaning the piston, it is not necessary to remove all the black stain from the piston. What is
needed is only removing the deposit from edge and ring groove. You'd better let the air sprayed
blow the parts horizontally but not directly. If the machining mark is worn off during shot blasting,
the pressure may be too high or air spraying time of some point is too long. Shot blasting can not
damage the metal surface.
Sometimes shot blasting material of walnut shell is used for cleaning black metal (iron and steel).
If the air pressure in the shot blasting machine is increased to the value that is more than the
suggested value from the medium manufacture, walnut shell shot blasting will produce a lot of
dust. In order to avoid risk of engine being polluted caused by medium insertion, it is suggested
that using walnut shell medium to clean engine parts.
It is suggested that the glass shot blasting medium should not be used to clean the engine parts.
It is very easy for the glass medium to be inserted in the materials, especially soft materials, and
the condition above will be more obvious when the air pressure used is more than the value
suggested by the medium manufacture. Glass is a kind of friction material, so when it is inserted
in the moving mechanical part, all the parts that contact with the part will be worn by it. When
higher pressure is used, the medium is broken, and the dusts with very small diameter forms,
which easily float in the air. If only using compressed air (and cold water) to blow the medium,
especially after the dusts have been remove from the air spraying cabinet, this kind of dusts can
not be controlled easily (blowing the parts in the cabinet may remove large deposits but can never
remove all the mediums).
It is better for shot blasting to be used for removing the stubborn dirt/deposit which can not be
removed after steam/higher pressure cleaning and cleaning in the hot water cleaning tank.
Especially for the piston. Firstly, clean the piston with steam and soak it, and then use plastic shot
blasting method to safely remove the rest of deposit in the ring groove (do not take the risk of
using wire wheel, which will cause the surface layer of the ring groove to be damaged or the
piston ring to be broken). Ensure the parts bing dry without oil, and then conduct shot blasting
cleaning, to prevent the loop in the shot blasting machine from bing blocked. Always face the shot
blasting jet to the parts "horizontally", but not directly. This makes it possible for the shot blasting
to enter below the material that should be removed.
Keep the jet moving, but not pointing one place. Letting the jet facing to one place for a long time,
will cause the metal overheating and moving around. Remember not to spray air to the dirt or
deposit. If the machine marks on the piston groove or the edge are worn out, that is because of
insufficient jet moving or too high air pressure.
Never use shot blasting method to clean the valve stem. During the shot blasting cleaning, use
tape or sleeve to protect the valve stem. Face the jet to the valve seat surface and radius
IN horizontally but not directly. The purpose is to remove any deposits, and it is wasting time that
removing the stain by continuous shot blasting.
7. Fuel system
Before repairing any fuel system components, these components may suffer from pollution before
removal, so clean the pipe joint, mounting parts as well as the area around the part to be removed.
If the surrounding area is not cleaned, the fuel system may get dirty or contaminated.
The internal oil passages of some fuel injectors are generally very small, which is very easy to be
blocked by contaminant. Some fuel injection systems can work under very high pressure.
High-pressure fuel can make single dirt and rust particles to become the contaminants which
have very strong abrasiveness, which will damage the high-pressure pumping part and fuel
injector.
If the steam cleaning tool is not available, electrical contact cleaner can be used. When cleaning
the dirt and debris on the pipe joint of the fuel system, use electrical contact cleaner, but not use
compressed air. Diesel of the fuel system parts which is exposed will absorb the contaminant in
the air.
Select non-dust cloth to perform the operation in the fuel system.
As long as the fuel system is opened, fuel pipes, joints and fuel port should be covered or blocked.
As long as the fuel pipe or any other components get loose or are removed from the engine, rust,
dust and paint may enter the fuel system. In many examples, it is a good practice to loosen the
pipes or pipe joints to make the rust and paint fall, and then clear these fallen materials.
When removing fuel pipe or pipe joint from the engine that is painted newly, ensure removing the
fallen off paint debris/chips, these debris/chips form when the wrench contacts the painted
pipeline nuts or pipe joints or the quick broken pipe joint is removed.
Fuel filter specification is measured in micron. The word "micron" is the abbreviation of
micrometer, or one millionth of a meter.
Micron specification is the dimension of the smallest particles captured by filter medium. Filtered
contaminant is much smaller than the object seen by eyes, magnifier or low-time microscope.
The tool used for fault determination and troubleshooting in the fuel system needs to be cleaned
to avoid pollution. Like the fuel system parts, if the tool surface is covered with oil or fuel, they will
absorb the contaminant in the air. For fuel system tool, please remember the following points:
• Keep the fuel system tool as clean as possible.
• Before returning the tool back to the tool kit, clean and dry it.
• If possible, preserve the fuel system tool in a sealed container.
• Before using, ensure that the fuel system tool is clean.
Introduction - How to troubleshoot the vehicle IN-37
How to troubleshoot the vehicle
Overview
This model uses a lot of circuits. Generally speaking, when troubleshooting the complicated circuit, the
maintenance personnel is required to have rich knowledge and skills. However, most of the faults only
need checking the circuit one by one, as long as the maintenance personnel has sufficient
understanding of each system and basic circuit knowledge, it is enough for performing correct diagnosis IN
and necessary repairing, and the faults are troubleshooted accordingly.
This manual is written on the basis of the principle above, and it provides correct and effective fault
solution for the maintenance personnel. For troubleshooting procedures, see the details described later.
System Reference
Chapter DI Diagnosis - Fault diagnosis of electric appliances section -

Lighting system
Fault diagnosis of body electrical control - Lighting system fault

Audio system
Fault diagnosis of body electrical control - Audio system fault

A/C System
Fault diagnosis of body electrical control – A/C system fault

Wiper and washer
Fault diagnosis of body electrical control - Wiper and washer fault fault
Chapter DI Diagnosis - Electric and Electronic Malfunction Diagnosis -

Reversing sensor
Body Electronic Control Malfunction Diagnosis - Reversing Sensor
malfunction
Malfunction
Chapter DI Diagnosis - Electric and Electronic Malfunction Diagnosis -

Combination instrument Body Electronic Control Malfunction Diagnosis - Combination Instrument
Malfunction

Horn
Fault diagnosis of body electrical control - Horn fault

Cigarette lighter
Fault diagnosis of body electrical control - Cigarette lighter fault
About using diagnostic tester

1. Before using diagnostic tester, be sure to read the instruction carefully.
2. Connect the diagnostic tester to instrument panel diagnosis wire connector, and turn the
ignition switch to ON. If the diagnostic tester can not communicate with control module, it
shows that the vehicle or the diagnostic tester may fail.
a. If communication is normal when the diagnostic tester is connected to another vehicle, check the
power circuit of instrument panel diagnosis wire or control module.
b. If the communication still can not be established after the diagnostic tester is connected to
another vehicle, it means that the diagnostic tester itself may have fault. Perform operation
according to the self-diagnosis procedure in the Operation Manual for Diagnostic Tester.
How to conduct troubleshooting
Caution
• Only the most basic operation procedure is listed here.
• Please troubleshoot according to the operation procedure described later.
• For each circuit, this Manual provides descriptions for the most effective troubleshooting
method. (Refer to Chapter DI Diagnosis)
IN-38 Introduction - How to troubleshoot the vehicle
• Before starting the repairing operation, be sure to determine the troubleshooting

procedure of the related circuit firstly.
IN
3. Failed vehicle brought to the workshop.

4. Analysis of the fault described by the customer.
a. Ask the customer about the situation and environment in which vehicle is failed.
5. Symptom confirmation and DTC (and data flow) inspection.
a. Measure the voltage of the battery.
Voltage: 12V (Engine is OFF) IN
b. Visually check the wire harness, connector and fuse for an open circuit or short circuit.
c. Start the engine and warm it up to normal operation temperature.
d. Confirm the symptom and set condition, and check the DTC.
Whether DTC occurs?
Yes > Go to Step 6.
No > Go to step 7.
6. Check the DTC list.
a. Check the DTCs gained in step 5, and then check the DTC list, and make the inspection
procedure for system or part according to "Fault area".
Directly go to step 7.
7. Check symptom table.
a. Check the DTCs gained in step 5, and then check the DTC list, and make the inspection
procedure for system or part according to " suspected area ".
8. Circuit and part inspection.
a. Check system circuit or part with risk of being failed obtained in step 4 and 5.
b. Determine circuit or part that has fault.
9. Repair.
a. According to the inspection result in step 6, adjust, repair or replace failed circuit or part.
10. Confirmation test.
a. After the repair, be sure to confirm whether fault has been removed.
b. If the fault does not reoccur, vehicle and environment condition in which the fault occurred for the
first time should be simulated for confirmation test.
11. Completed.
Analysis of the fault described by the customer

Caution
• During troubleshooting, never be preconceived, be sure to make correct judgment to
confirm the symptom.
IN • It is very important to ask the customer about the situation and environment in which
vehicle is failed.
• For some fault and repairing experiences which seem to be not related, they will be helpful
in fault analysis sometimes. Therefore collect information as much as possible, the
information related to the symptom could be used as reference for troubleshooting.
• In order to confirm the symptom correctly, the following 5 items should generally be
considered emphatically when the fault described by the customer is analyzed.
What has happened? Model, system name
When? Date, time, and frequency
Where? Road condition
Running condition, driving condition, and weather

What are the conditions?
condition
How does it happen? Symptom
Symptom confirmation and DTC (and data flow) inspection

Caution
Diagnosis system has many functions.
1. The first function is diagnosis trouble code (DTC) inspection. Fault signal of the control
module circuit will be stored in the memory of the control module in form of code. When
the maintenance personnel is operating, previous DTC can be checked.
2. Another function is input signal inspection. Check whether the signals from each
switch have sent to control module correctly. using these functions, it is helpful to
narrow troubleshooting range quickly, and improve the repairing efficiency.
a. When DTC is checked, it is very important to judge whether the fault indicated by this code is
happening or it has happened but now returned to normal. In addition, when the symptom is
checked, the fault indicated by this DTC must be checked for having direct relation with the
symptom. Therefore, before and after the symptom is confirmed, DTC inspection must be
performed to determine the current condition of the vehicle. Otherwise, unnecessary fault
diagnosis and troubleshooting will be made to normal system, and the difficulty for finding fault
is increased or some irrelevant repair operation will be made. So, be sure to follow operation
procedure for DTC inspection.
b. How DTC inspection is used for performing troubleshooting procedure, see the following
diagram. This procedure shows how DTC inspection is used efficiently. At last, this procedure
shows how to use DTC and symptom for troubleshooting.
1. DTC inspection.
2. Record the DTC occurs and clear the DTC.
Caution
If DTC occurs when DTC inspection is performed for the first time, there may be faults in circuit
wire harness or connector, please check the related wire harness or connector. (Refer to Chapter
IN Introduction - How to troubleshoot the vehicle, Circuit inspection)
3. Symptom confirmation.
IN
Whether the symptom still occurs?
Yes > Go to Step 4.
No > Go to step 5.
4. Symptom simulation inspection. (Refer to “Chapter IN Introduction - How to troubleshoot
the vehicle, General”)
5. Perform DTC inspection again.
Whether DTC occurs?
Yes > Troubleshoot the fault showed by the DTC.
No > System is normal.
6. Symptom confirmation.
Whether there is symptom?
Yes > Go to step 7.
No > System is normal.
7. Use symptom table to troubleshoot.
Fault occurred goes out of the detection range for vehicle diagnosis system (previous DTC may
show the past fault or it is not the key to the problem).
8. Completed.
Symptom simulation inspection

Caution
• For troubleshooting, it is the most difficult condition in which no symptom is found. In this
case, must thoroughly analyze the fault described by the customer and then simulate the
IN vehicle and environment conditions when the fault occurs. For a maintenance technician,
regardless of how experienced and skilled he/she is, if he/she troubleshoots without
symptom confirmation, some important in formations during service operation could be
certainly ignored and incorrect surmise will be made.
• For example, for those faults which only occur when the engine is cold or caused by
bumpy road during driving, they will never be found when the engine is hot or the vehicle
is stationary. For vibration, high temperature and water leakage (wet) etc. are also the
common cause for the faults and they are difficult to be found, so the symptom simulation
inspection method is introduced here, by simulating the outer factors this method is
effective when the vehicle is parked.
1. Symptom simulation points:

a. Firstly, be sure to confirm the symptom and find the area or part in which fault occurs. In order to
do this, before perform the symptom simulation inspection, you should connect diagnostic tester
and narrow the troubleshooting range of the fault according to the symptom.
b. Then, perform symptom simulation test to judge the circuit tested for being damaged or normal, at
the same time confirm the symptom. Check symptom table of each system, and narrow the range
of possible causes for the symptom.
2. Shaking method -- for the fault that may be
Shake lightly
caused by vibration
a. Part and sensor.
• Gently shake the sensor which could have
fault with fingers, and check whether the
fault will occur.
Caution
If excessive force is applied, relay circuit will be open.
b. Connector.
• Gently shake the connector in horizontal
and vertical directions.
Shake lightly
c. Harness.
• Gently shake the wire harness in horizontal
and vertical directions. Connection part of
the wire harness and connector is the main
Shake lightly
area which needs to be checked carefully.
3. Heating method -- for the fault that may be

caused when some part is heated
a. Using hair dryer or equivalent, heat the part which
may cause the fault, and check whether the fault
occurs.
Caution IN
• Heating temperature never be more than 60℃
to avoid damaging the part.
• Never heat the part in the control module
directly.
4. Raining method -- for the fault that may be caused by rainy day or high humidity
environment
a. Spray water to the vehicle and check whether the fault occurs.
Caution
• Never spray water to the electrical element directly.
• If the vehicle has water leakage, liquid leaked may damage the control module.
5. High electrical loading method -- for the fault that may be caused by too high electrical
load.
a. Open all the electrical equipments including A/C, headlamp, rear windshield heating, and check
whether the fault occurs.
Diagnosis trouble code (DTC) list

Take the DTC list for engine control system for example, as shown in the following table.
This table shows DTCs, and the corresponding detection procedures are listed. Troubleshooting
according to this table will improve the efficiency and accuracy significantly.
IN
RM.TM1.IN.000011
Table of malfunction symptoms

Symptom table is use to show the possible cause (such as circuit and part) for each symptom, as shown
in the following table. When the diagnostic tester shows that the system is normal but the fault still
occurs, symptom table can be used for troubleshooting. S/N in the table shows the inspection sequence
for the circuits or parts.
IN
If vehicle diagnosis system can not detect fault and there is real symptom, it is showed that the fault
occurs has gone out of the detection range of the vehicle diagnosis system.
RM.TM1.IN.000012
Circuit detection
How to read and use the circuit detection section of this manual, as shown in the following table.
IN
RM.TM1.IN.000013
1. Basic inspection
a. Resistance measurement condition for electrical element.
• Unless otherwise specified, all the resistance measuring operations should be performed
in the environment temperature of 20℃ .
• High temperature will be produced when the vehicle is running, the resistance measured in
this high temperature may exceed the range specified. As a result, make sure that
resistance measurement is made after the engine is cooled down.
b. Operation precaution for connector.

Using hair dryer or equivalent, heat the part which
may cause the fault, and check whether the fault
occurs.
• When removing the connector with lock,
slightly squeeze the connector along the IN
connection direction, and then gently press
the buckle to open the lock.
• When removing the connector, be sure to
hold the connector and never pull the wire
harness.
• When connecting the connector, be sure to
check the connector for deformation,
damage or pin missing.
• When connecting the connector with lock,
be sure to hear a sound of "click" to ensure
the connector is connected securely.
• When checking the connector with
multimeter, be sure check with micro probe
on the back side (one side of the harness) of
the connector.
Caution
• Because waterproof connector can not be
checked from backside, please connect sub
harness and check again
• Be sure to be careful when moving the probe,
never damage the pin of the connector. Check
points for the connector.
c. Check points for the connector.

Loose curled edge Check with the connector connected:
• Hold the connector, and check the insertion
and locking condition (i.e. connection
Wire core
condition).
Bent pin Check with the connector disconnected:
• Gently pull the wire harness, and check the
Pull lightly pin for missing, being bent, and the center
harness for being broken.
• Visually check the connector for rust, being
mixed with metal filings, water entering, and
check the pin for bend, rust, being mixed
with foreign objects or deformed.
Check the contact pressure of the pins:

• Prepare a male plug and insert it to the
female plug, check the connection condition
and sliding resistance.
Caution
IN When detecting the gold-plated female plug, be sure
Same material to use gold-plated male plug.
d. Maintenance method for the connector pin.

• If the contact has oil, be sure to clean it with
air gun or rags, never polish it with
sandpaper, otherwise, the electroplated
coating may be damaged.
• If the contact pressure is abnormal, replace
the female plug. At this time, if the male plug
Correct Incorrect
is gold-plated, be sure to replace the female
plug with a gold-plated one; if the female
plug is silver-plated, be sure to replace the
female plug with a silver-plated one.
e. Operation precaution for wire harness.
Incorrect
• Before removing the wire harness, be sure
to check the positions of wire harness and
its band to reinstall it correctly.
• Never excessively twist, pull and hang the
wire harness.
• Never contact the wire harness with high
temperature, rotating, moving, vibrating and
sharp (such as panel edge, screw tip) parts.
• When installing the part, never squeeze or
clamp the wire harness.
• Never cut or break the insulating sleeve of
the wire harness. If it is broken by accident,
be sure to replace the wire harness or bind
up the broken part with insulating cloth.
2. Basic inspection
a. Circuit is shown in the left figure. Check the
Open conductivity and voltage in step (b) and (c)
circuit
Sensor separately to confirm the open-circuit position.
b. Conductivity inspection.
• Disconnect connector A and C, and
measure the resistance between them.
Resistance: ≤ 2Ω
Sensor Caution
Gently shake the wire harness in horizontal and IN
vertical directions and measure the resistance.
Take this circuit for example:

If the resistance between connector A and pin 1 of
connector C: ≥ 1MΩ,
but the resistance between connector A and pin 2
of connector C: ≤ 2Ω
It can be concluded that there is open circuit
between connector A and pin 1 of connector C.
• Disconnect from connector B, and measure the
resistance between the connectors.
Sensor
If the resistance between connector A and pin 1 of
connector B1:≤ 2Ω,
but the resistance between connector B2 and pin 1 of
connector C: ≥ 1MΩ
It can be concluded that there is open circuit between
connector B2 and pin 1 of connector C.
c. Voltage inspection.
• When the circuit is energized, it can be
determined whether the circuit is open by
voltage inspection.
Sensor
• Take this circuit for example, each
connector is still connected. Separately
measure the voltage between No.1 pin of
connector A, No.1 pin of connector B, No.1
pin of connector C (at 5V output pin of the
control module) and the ground.
If measurement result is as follows:
Voltage between No.1 pin of connector A and the ground:
5V
Voltage between No.1 pin of connector B and the ground:
5V
Voltage between No.1 pin of connector C and the ground:
0V
It can be concluded that there is open circuit between
connector B and No.1 pin of connector C.
3. Short circuit inspection

a. As shown in the left figure, the wire harness is
Short
circuit short to the ground. In step (b), check the
Sensor conductivity between it and the ground to
determine the short-circuit position.
IN
b. Conductivity inspection.
• Disconnect from connector A and C, and
measure the resistance between No.1 pin,
No.2 pin of connector A and the ground
Sensor
separately.
Resistance: ≥ 1MΩ
Caution
Gently shake the wire harness in horizontal and
vertical directions and measure the resistance.

If the resistance between No.1 pin of connector A and the
ground: ≤ 2Ω,
but the resistance between No.2 pin of connector A and
the ground: ≥ 1MΩ
It can be concluded that there is short circuit between
No.1 pin of connector A and No.1 pin of connector C.
• Disconnect connector B, and measure the
resistance between No.1 pin of connector A, No.1
pin of connector B2 and the ground separately.
Sensor
If the resistance between No.1 pin of connector A and the
ground: ≥ 1MΩ,
but the resistance between No.1 pin of connector B2 and
the ground: ≤ 2Ω
It can be concluded that there is short circuit between
No.1 pin of connector B2 and No.1 pin of connector C.
DI Diagnostics
Fault diagnosis of electric appliances section ................. 1
Engine electronic control malfunction diagnosis ............ 1

Diagnosis of body electronic control malfunctions ..... 103
DI
Mechanical fault diagnosis ............................................. 366
Mechanical fault diagnosis overview ......................... 366
Integrated vehicle fault ............................................... 373
Engine fault ................................................................ 375
Clutch fault ................................................................. 386
Transmission is hard to engage a gear...................... 390
Vehicle axle, transmission shaft fault ......................... 394
Frame, suspension fault............................................. 397
Wheel and tire fault .................................................... 401
Steering system fault.................................................. 404
Brake system fault ..................................................... 408
Body fault ................................................................... 415

Diagnostics - Fault diagnosis of electric appliances section DI-1
Fault diagnosis of electric appliances section
Engine electronic control malfunction diagnosis

Engine electronic control malfunction diagnosis
Overview
1. Description
Harbin Dong’an DAM15R gasoline engine fuel injection system adopts MPI electronic control
multi-port fuel injection system and Continental EASY-U2.5 electronic injection management
DI
system. The various sensing units installed at specific locations of engine are functioned to input
the intake volume, crankshaft speed and position, camshaft phase, oxygen sensor signals, and
some other auxiliary signals into the ECM and the ECM processes the signals as per the preset
control programs and then controls the actuators and fuel injectors to accurately control the fuel
injection volume, in order to achieve the gas mixture of optimal concentration under diversified
working conditions of the engine, maintain the gas mixture at reasonable inflammable gas mixture
proportion (air-fuel ratio), ignition the gas mixture at appropriate timing (Ignition timing), and
realize ideal power performance, economy, and emission indicator.
In addition, the electronic gasoline injection system can also realize cranking enrichment,
warm-up enrichment, acceleration enrichment, full-load enrichment, deceleration enrichment,
forced idling cut-off, automatic idling speed control and other functions via the control program in
ECM, thus to satisfy gas mixture requirements under special engine conditions to enable the
engine to obtain good fuel economy and emission level with improved working performance of the
vehicle. In addition, the ECM also has several malfunction diagnostic modes to simplify the
detection of malfunction.
2. Function of fuel injection system
The fuel injection system is functioned to inject an appropriate amount of high pressure fuel into
the combustion chamber at appropriate timing. Meanwhile, the ECM automatically adjusts the
fuel injection volume depending on the engine load to guarantee the stable running of the engine.
DI-2 Diagnostics- Fault diagnosis of electric appliances section
Precautions
1. Safety precautions
a. It’s prohibited to cut off the battery from the electric circuit while the engine is running at high
speed, in order to prevent the generated transient high voltage from damaging the ECM and
sensor.
b. Cut off the power supply of ECM before electric welding on body. Pay special attention during the
body repair operations near ECM or any sensor.
DI c. When a terminal contact or part installation is malfunctioned, disassembling and reinstalling
possibly malfunctioned parts can probably completely or temporarily restore the system to normal
state.
d. Unless otherwise specified in the test, do not use the pointer type multi-meter to test the ECM and
sensor, but use the high-impedance digital multi-meter to do this.
e. Do not test any electric device connected to the ECM by a test lamp.
f. Never reverse the polarity of battery. Ensure the negative ground.
g. The ECM and sensors must be guarded against moisture. It’s prohibited to damage the sealing
device of ECM or any sensor or flush the ECM or sensor by water.
h. Guard the ECM against human body electrostatic: While checking the ECM or replacing any chip,
the operator must ground his body (namely wear the grounding strap, wrap one end of grounding
strap to his waist, and clamp the other end to the vehicle), in order to guard the ECM against the
human body electrostatic.
i. To determine the malfunction location, ensure to check the vehicle status at the occurrence of
malfunction. For instance, check the outputs of diagnostic trouble codes (DTC) and record the
status before disconnecting any connector or disassembling and installing parts.
j. Unless otherwise specified in the checking procedure, ensure to disassemble and install the ECM,
actuators, and all independent sensors when the ignition switch is turned off.
k. While reassembling any disassembled and installed ECM, actuator, or sensor, ensure to check
the system for normal functioning after assembling. Check for DTC by a special diagnostic unit.
l. Check the engine ECM terminals by a digital multimeter.
2. Cleaning Precautions
a. Thoroughly clean the connectors before disconnecting the connectors and ensure to keep clean
their surrounding areas.
b. Never disassemble any part from the installation position randomly, in order to prevent the ingress
of foreign materials from influencing the working performance.
c. Place the disassembled parts on a clean surface and cover properly. Never use a fuzzy rag.
d. If no immediate repair is to be taken, cover or lock the opened parts.
e. Only install clean parts. Unpack the spare parts only immediately before the installation and do
not use any loose part (Such as the parts in the toolbox).
f. Ensure the absolute cleanliness during the use of auxiliary assembling tools. The containers for
placement of assembling parts or auxiliary tools must be kept clean and must be covered to
ensure cleanliness when they are not in use.
g. The electronically controlled common rail diesel injection system requires a high fuel injection
pressure and requires smaller fuel injection orifices and more accurate adjustment than traditional
injection system. During the repairs of common rail diesel injection system, ensure to keep
absolute cleanliness.
h. All lubricants and sliding agents shall contain no water.
3. Inquire the software and hardware version identification information of electronic control
system by a diagnostic unit.
DI
Preparations
Recommended tools
Figure Name Application scope
DI Multi-meter Test of voltage and resistance
Wire subassembly Check circuit.
Read and clear trouble codes, read

data stream, execute action test,
Kingtec KT660: V1.3.7 and read ECU control system
hardware or software version
identification information.
Main functions of engine control system

1. Start control
2. Idling speed control
3. λ Closed-loop control
4. Knock control
5. Warm-up and three-way catalyzer heating control
6. Acceleration/deceleration and drag fuel cutoff control
7. Evaporative emission control
DI
8. Overvoltage protection
9. A/C compressor control
10. Fault diagnosis
System diagram (Control system parts)
DI
E001 Engine ECU E014 Odometer sensor

E002 Fuel injector 4 E015 Crankshaft position sensor
E003 Fuel injector 3 E016 Switch, backup light
E004 Fuel injector 2 E017 Front oxygen sensor
E005 Fuel injector 1 E018 Knock sensor
E007 Ignition coil 2 E019 Intake pressure/temperature sensor
E010 Camshaft position sensor E020 Canister solenoid valve
E011 Ignition coil 1 E021 Starter motor coil
E012 Coolant temperature sensor E022 Crankshaft position sensor
E013 Rear oxygen sensor E023 Stepping motor
Description on system components

No. Component Quantity Function
ECM will optimize the control system depending on the

1 Engine ECM 1 signal derived from the sensor to adapt it to the engine
working conditions.
Detect the rotating position and revolution of the engine
2 Speed sensor 1
crankshaft
DI
Provide the crankshaft and camshaft position information
to ECM, i.e., the information needed to distinguish the
3 Phase sensor 1
compression top dead center and exhaust top dead
center of the crankshaft
Check the intake temperature and volume and determine
4 Air flowmeter 1
the engine load.
Intake pressure/ Detect the temperature and flow rate of air entering the
5 1
temperature sensor cylinder and execute pressure control
Check the engine for knock, check the throttle position,
6 Electronic throttle 1
and adjust the opening extent of throttle.
The pedal position signal is converted to an electric
7 Accelerator pedal 1
signal to indirectly adjust the opening extent of throttle.
8 Ignition coil 1 Ignite the gas mixture
9 Fuel pump 1 Convey fuel.
10 Injector 1 Inject fuel via the ECM signal
Coolant temperature Check the engine coolant temperature and determine

11 1
sensor the working condition of engine.
Supply the fuel vapor from the carbon canister into the
12 Canister solenoid valve 1
intake passage based on the digital pulse square wave.
Control the engine oil flow to the camshaft position
13 Intake OCV valve 1
actuator to change the intake phase
Check the oxygen concentration contained in the
14 Front oxygen sensor 1
exhaust gas and determine the air-fuel ratio.
Check the oxygen concentration contained in the
15 Rear oxygen sensor 1 exhaust gas and determine whether the exhaust
emission conforms to the standard.
Check the engine for knock and accordingly influence
16 Knock sensor 1
the ignition advance angle.
Determine the driving condition and stabilize the engine
17 Clutch switch 1
speed during gearshifts.
Introduction to system functions

1. ECM control structure diagram
Fuel injector 1
Ignition switch
Fuel injector 2
Diagnosis K-line
DI
Fuel injector 3
Front oxygen sensor
Fuel injector 4
Rear oxygen sensor
Ignition coil 1
Coolant temperature sensor
Ignition coil 2
Speed sensor
Ignition coil 3
Knock sensor
Ignition coil 4
Accelerator pedal module
Malfunction indicator signal

Crankshaft position sensor Engine ECM
Oxygen sensor heating
Air flowmeter
Electronic throttle motor

Intake pressure & temperature sensor
OCV valve
Vehicle speed signal

Main relay
A/C medium pressure switch

Canister solenoid valve
Power steering switch

RPM output
Clutch switch
5V output
Crankshaft position sensor
Air conditioner compressor relay
Airbag collision signal

Oil pump relay
2. Introduction to system functions

a. Start control
During the start, take the special calculation method to control the filling amount, fuel injection,
and ignition timing.
At the initial stage of this process, the air within the intake manifold is still and the internal
pressure of intake manifold is indicated as ambient pressure. The electronic throttle opens by an
angle as a constant parameter depending on the start temperature.
The fuel injection volume varies depending on the engine temperature to drive the formation of oil DI
film on intake manifold and cylinder walls. Increase the concentration of gas mixture before the
engine reaches certain speed. The system immediately starts to reduce the cranking
enrichment once the engine starts running and completely cancels the cranking enrichment after
the start condition is completed (600~700r/min engine speed).
The ignition angle under the start condition adjusts continuously depending on the engine
temperature, intake temperature, and engine speed.
b. Warm-up and three-way catalyzer heating control
After the engine is started at a low temperature, the quantity of air in the cylinder, fuel injection
and ignition will be adjusted to compensate the higher torque requirement of the engine. This
process will go on till the engine temperature rises to a certain threshold value (the engine
temperature is similar to the engine coolant temperature).
The three-way catalytic converter is functioned to convert the harmful gases exhausted after the
engine combustion into harmless gases and exhaust to the open air. As the working temperature
of the three-way catalytic converter is above 300°C, the most essential issue of the warm-up
process is the quick heating of the three-way catalytic converter. Under such a working condition,
the exhaust gas is utilized to heat the three-way catalytic converter by appropriately postponing
c. Control of fuel injection volume, pressure, and timing
The accurate control on the fuel injection volume, pressure, and timing is an important item of
diesel engine electronic control system. The size and the value of the fuel injection volume,
pressure, and timing mainly depend on the speed of diesel engine and the opening extent of
accelerator. Based on the received speed signal of diesel engine and opening extent signal of
accelerator pedal, the system calculates the fuel injection parameters for corresponding working
condition and thus realizes the accurate control on fuel injection parameters. In addition, the
system can also correct these fuel injection parameters based on the signals of intake
temperature, pressure, coolant temperature, and ambient pressure.
d. Idling speed control
The idling control is to control the engine revolution when the accelerator pedal is depressed.
The idling control includes the steady engine revolution control in the idling operation of the car.
Furthermore, this control also addresses the idling speed regulation when the load is increased,
for example, activation of air conditioner, power steering system and headlamp.
The system is provided with a stepping motor (integrated in the electronic throttle ) to
automatically regulate the throttle openness and realize the high-precision idling speed control.
e. Idling control
Cummins series diesel engine performs feedback control on the idling fuel injection volume to
ensure that the idling speed of diesel engine is stabilized at the preset target speed, in order to
prevent the unstable speed of diesel engine and slow startup of vehicle due to external load
interferences (Such as A/C) during the idling of the diesel engine.

f. Closed-loop control
Oxygen content Control command

λ Closed-loop control Front oxygen sensor Fuel injection
Voltage signal time
DI Engine
Control command
λ Open-loop control Fuel injection time Engine
g. Knock control
The system will detect the characteristic vibration induced by knock via the knock sensor installed
between the No.2 cylinder and No.3 cylinder, and convert it into the electronic signal and transfer
it to ECM for processing.
The ECM utilizes a special processing algorithm to detect the knock in each combustion cycle of
each cylinder. Once any knock is detected, the knock closed-loop control will be activated.
After the knock danger disappears, the influenced cylinder will be advanced to its preset ignition
advance angle again.
h. A/C compressor control
After the air conditioner switch is turned on, ECM will receive a signal called “air conditioner
request” , prepare for loading of air conditioner depending on the current working conditions of the
engine, and then turn on the air conditioner compressor.
ECM will turn on or off the air conditioner provided that the air conditioner itself is properly
protected. To ensure the power output and protect the engine, the system will interrupt the air
conditioner under certain working conditions.
i. Evaporative emission control
Due to the external radiation heat and the heat transferred by the return fuel, the fuel in the tank
will be heated to produce fuel steam.
As limited by the evaporative emission regulations, such steam containing massive HC
components is not allowed to e directly discharged into the atmosphere. The fuel steam in the
system is collected in a charcoal canister via the guide pipe and washed into the engine to take
part in the combustion in good time.
The flushing gas flow rate is regulated by the canister solenoid valve which is controlled by ECM.
Such a control will only work when the λ closed-loop control system is working in the closed-loop
mode.
j. Radiator fan control
The car is equipped with an electric dual-speed engine cooling fan.
Electric fan control function: The ECM determines the turn-on of various fans based on the
coolant temperature of engine and turn-on condition of A/C to reduce the internal power
consumption of engine.
k. Self-diagnosis
The system fault self-diagnosis is an indispensable of the engine control system. When one or
more system components work abnormally, the system will timely remind of the user of
performing necessary inspection and repair by illuminating the fault indicator lamp. When any
fault occurs, the system will also apply a temporary emergency program to control the engine
operation to ensure that the user can drive the car to the service station.
When the abnormal operation of certain sensor and actuator is detected, the engine fault indicator
lamp will illuminate to remind the driver. DI
The RAM data in the ECM related to the sensor and actuator can be read via the fault diagnoser.
Furthermore, in a certain case, the actuator can be driven forcibly.
How to perform troubleshooting
Caution
Use a malfunction diagnostic unit to diagnose vehicle.

1. Send the vehicle to repair shop
Yes >to step 2.
2. Collect and analyze the malfunction symptom described by the customer.
DI
Yes >to step 3.
3. Connect a malfunction diagnostic unit to the DLC.
Yes >to step 4.
4. Check the DTC and freeze-frame data.
Yes >to step 5.
5. Clear the DTC and freeze-frame data.
Yes >to step 6.
6. Perform visual observation.
Yes >to step 7.
7. Confirm the fault symptoms
Check the result (If the engine fails to start, perform the following “Check for DTC” and basic
checking)
Result Turn to
No occurrence of malfunction Go to step 8
Occurrence of malfunction Go to step 12
8. Simulate the malfunction symptom.

Result Turn to
No occurrence of malfunction Go to step 9
Occurrence of malfunction Go to step 12
9. Check for presence of DTC.

Checking result
Result Turn to
Occurrence of trouble code Go to step 10
No occurrence of trouble code Go to step 11
10. Refer to DTC table.

Yes >to step 13.
11. Perform basic checking.
Checking result
Result Turn to
The malfunctioned part can’t be determined. Go to step 12
The malfunctioned part can be determined. Go to step 16
12. Refer to the fault symptom table.

Checking result
Result Turn to
13. Check ECM power circuit.

Yes >to step 14.
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14. Check circuit.
Checking result
Result Turn to
15. Inspect for intermittent failure.

Yes >to step 17.
16. Inspect the components
Yes >to step 18.
17. Confirm the failure
Yes >to step 18.
18. Adjust or repair.
Yes >to step 19.
19. Perform verification test.
Yes > End.
Intermittent malfunction
In event of an intermittent malfunction, diagnose as per following procedure:
Warning
• In event of an intermittent malfunction, in many cases, the malfunction can be self-solved

(The function of part or circuit restores normal without any interfering measure). It should
be understood that the customer’s complaint will probably not occur during the checking
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of DTC and the most common cause for an intermittent malfunction is the poor electric
connector. Therefore, the status at occurrence of malfunction is unclear. Therefore, the
checking of electric circuit, as one part of the standard diagnostic procedure, probably
can’t indicate the specific malfunction zone.
• In such case, ensure to understand the detailed condition at occurrence of the malfunction
from the customer, inquire the owner of the detailed driving status, weather condition,
occurrence frequency, and malfunction symptom, perform analysis, simulate the same or
similar condition and environment when the malfunction occurs, and then determine
whether the malfunction symptom is caused by vibration, temperature, or other factor.
• No matter how rich the experiences and how skillful the techniques are for the repair
personnel, the malfunction diagnosis without verification will surely neglect some
important factors during repairs to result in incorrect guess and incorrect or failed repairs.
1. Vibration method
When it’s considered that the vibration is the main cause of the malfunction, check the connectors
and components to determine the occurrence of malfunction symptom. Simulate the malfunction
by following method:
a. Connectors: Lightly shake the connectors in vertical and horizontal directions, check the
connectors and the harness connectors of corresponding components for looseness, check their
terminals for dirt, rusting, corrosion, and bending, and check for loose contact due to stretched
terminals.
b. Harnesses: Lightly shake the wire harnesses in vertical and horizontal directions, thoroughly
check the connection vibration area of the connectors, and check for disconnected harnesses in
engine/cab instruments.
c. Relays, parts, and sensors: Flap by hand lightly a relay, relay, or part suspected as the
malfunction case and check for presence of failure. However, do not forcibly flap the relay,
otherwise it will probably result in open-circuit of relay.
2. Heating method
If it’s considered that the malfunction is caused by a suspicious area, heat up the most possible
component for the malfunction by a hair dryer or similar device and check for occurrence of
malfunction.
Warning
Do not heat up to >60°C (Heat up in such manner that the parts can be touched by bare hands)
and do not heat up the electronic control module.
3. Water spray method

When it’s considered that the malfunction occurs under rainy or moisture weathers, spray the
water to the vehicle and check for occurrence of malfunction.
Warning
• Do not directly spray water to the engine. Splash the water to the front face of radiator to
indirectly change the temperature and humidity.
• Do not directly splash water to any electronic part.
• While splashing water to leaking vehicle, ensure to take special cautions as the leaking
water will probably damage the ECM.
DI
4. Turn-on method of all electric devices
a. When the malfunction is probably caused by over-high electric load, turn on all electric load
including heater fan, headlamp, and rear windscreen defroster and check for occurrence of
malfunction.
b. During the malfunction symptom simulation test, while verifying the malfunction symptom, ensure
to find out the malfunction location or part. To do so, before starting the test and pre-connecting
the tester, narrow the scope of possibly malfunctioned circuit based on the malfunction symptom,
perform the simulation test, and judge for normal status of tested circuit.
c. In event of a difficult malfunction, utilize sufficiently the troubleshooting and diagnostic trouble
code table to perform malfunction analysis and diagnosis, in order to narrow the malfunction
scope and rapidly find out the malfunction location. This method is really practical and effective.
5. In event of a difficult malfunction, utilize sufficiently the troubleshooting and diagnostic
trouble code table to perform malfunction analysis and diagnosis, in order to narrow the
malfunction scope and rapidly find out the malfunction location. This method is really
practical and effective.
Use the data stream capture function on the diagnostic unit. While observing the data stream on
the diagnostic unit, simulate the malfunction status as per the malfunction freeze-frame data
status recorded on the diagnostic unit.
6. Oscilloscope method
Capturing the waveform by an oscilloscope will be more helpful to detect the intermittent
malfunctions.
7. Other methods
Replacement method: Before replacing the ECM or other control module, sufficiently diagnose
the other external factors. The control modules are products of high reliability and expensive
price.
Warning
While checking a possibly damaged control unit by replacement, install the possibly damaged
control unit to a non-malfunctioned vehicle for testing. Do not install a new control unit to a
malfunctioned vehicle for testing, in order to prevent damaging the control unit.
Basic inspections
If the malfunction can’t be determined by DTC checking, check all possible circuits for the malfunction to
perform troubleshooting analysis. In many cases, following the engine basic checking shown in the
flowchart below can rapidly and effectively find out the malfunction location. Therefore, it’s really
necessary to take this checking method during the troubleshooting of engine malfunctions.
1. Check the battery voltage
DI Warning
Perform this checking item when the engine is stopped or the ignition switch is at LOCK
position.
Checking result
Result Turn to
11V or higher Go to step 2
Lower than 9V Replace battery or charge the battery.

2. Check the engine for start.
Check if results are normal?
Yes >to step 3.
No >Go to fault symptom list
3. Check the air filter
Is checking result normal (Containing dust, dirt, or oil)?
Yes >to step 4.
No > Replace or clean filter.
4. Check idling speed.
Yes >to step 5.
No >Go to fault symptom list
5. Check ignition.
Yes > check ends.
No > Solve ignition system malfunction.
Engine control module (ECM) malfunction

Overview
The electronic control module (ECM) is the core of electronically controlled common rail system. The
ECU acquires the current working information of engine via various sensors and switches, performs
analysis and calculation, and controls the fuel injection volume, timing, and pressure of the engine as per
the pre-calibrated optimal working parameters for corresponding condition, in order to adjust the working
status of engine and realize the fuel-saving, high efficiency, and low emission. DI
ECM is provided with a self-protection feature. Failure of start may occur in service, but after the ECM is
replaced, all will be ok. This seems that the ECM is in trouble, but indeed ECM is ok, and it just works in
the self-protection mode and will recover the normal operation after a while. The ECM is installed on the
right side in the engine compartment, neighboring the battery.
ECM terminal diagram
Caution
The terminals not indicated in the table are vacant terminals.
Terminal Terminal
Function Function
No. No.
1 Upstream oxygen sensor heating control 42 Intake temperature signal
2 2nd and 3rd cylinder ignition coil control 44 Main relay output power supply 1
3 GND 45 Main relay output power supply 2
Downstream oxygen sensor heating
4 46 Canister solenoid valve control
control
5 1st and 4th cylinder ignition coil control 47 4th cylinder fuel injector control
6 2nd cylinder fuel injector control 50 —
7 3rd cylinder fuel injector control 51 GND
8 Rotation speed signal 53 GND
Engine ECU module battery power Downstream oxygen sensor
12 55
supply monitoring signal
Terminal Terminal
Function Function
No. No.
13 Engine ECU module IG1 power supply 59 Vehicle speed signal
14 Main relay ER06 control 61 GND
15 Crankshaft position sensor power supply 62 CAN-H
Throttle position/camshaft
17 position/intake pressure/temperature 63 Main relay output power supply 3
DI sensor power -
Upstream oxygen sensor monitoring
18 64 Stepping motor actuator B-
signal
19 Knock signal 65 Stepping motor actuator A+
22 Evaporator temperature signal 66 Stepping motor actuator A-
27 1st cylinder fuel injector control 67 Stepping motor actuator B+
28 Engine malfunction warning signal 69 Compressor relay control
29 Engine SVS malfunction signal 70 Fuel pump relay control
31 Engine water temperature signal 71 K wire
Throttle position/camshaft
33 position/intake pressure/temperature 75 A/C request switch signal
sensor power +
34 Crankshaft position signal 76 Headlamp load signal
Coolant temperature/knock/ evaporator
35 77 —
temperature sensor ground
36 Upstream oxygen sensor - 79 Camshaft position signal
37 Intake pressure signal 80 GND
38 Throttle position signal 81 CAN-L
39 Coolant temperature signal
Diagnosis system
1. System overview
ECU integrated diagnosis belongs to electronic controlled engine management system. The input
and output signals and the control unit communication are monitored by the self-testing unit of
ECU integrated diagnosis.
On-line fault diagnosis electronic system is a system that by using "intelligent software", the
control unit performs self-monitoring (inspection and storage) and diagnoses the fault. It does not
require any auxiliary equipment during on-line fault diagnosis operation.
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Monitoring logic module supervises the input and output signals in driving, also monitors the
whole system and its fault and disturbance during operation. Any fault that has been monitored
will be stored in ECU internal fault storage area. The fault is stored in the form of fault code, which
can be read out by diagnostic tester via fault diagnostic interface.
2. Information storage
a. After the fault occurred and confirmed by the system, each fault, in the form of separate status
code, will be stored in non-volatile area of data memory. Fault code describes the type of fault
(e.g., short circuit, open circuit, distortion and range overrun).
b. Each fault code is accompanied by additional information. That is the state parameter of engine
when fault occurs, including load value, engine speed, fuel pressure speed, coolant temperature,
etc.
3. Error handling
a. If an error occurs at a specific time, it will be classified by signal channel according to the error
category. The system will always use the valid value of the last detection until the end of the error
classification. A standby function will be operated when performing the error classification (e.g.
each actuator of the system is controlled according to the control parameter when the coolant
temperature T=90℃).
b. When the fault is detected, limp strategy will also be operated besides alternate value (e.g.,
engine power output and speed limit). This strategy will help:
• To ensure driving safety.
• To avoid the damage that corresponding to the fault.
• To reduce exhaust gas.
• To maintain timely.
4. Fault lamp
a. Fault indicator lamp on instrument panel is
controlled according to the ECU internal calibration.
The lamp illuminates when there is fault.
b. When the system is fault-free.
• When ignition switch is in "ON" position, the
engine performs self-diagnosis and the fault
lamp is off after illuminates for 2s.
• When ignition switch is in "LOCK" position,
the fault indicator lamp is off immediately.
• If the fault disappears (e.g. poor contact), the
fault information still stored in fault memory,
and the fault indicator lamp is off after 3
circles in fault-free form
c. When the system has fault

• Ignition switch is in "ON" position, the fault
light illuminates.
• After the fault of electronic fuel injection
system disappears, the fault indicator lamp is
off automatically in the next circle of
operation.
DI 5. Diagnostic instructions
a. The fault of electronic controlled engine is not necessarily the problem of electronic fuel injection
system.
b. In most cases, the fault is still the mechanical and fuel pipe fault which is the same as that of
conventional engine, and the experience of the maintainer is very important.
c. The maintainer shall mainly inspect mechanical fault if the fault indicator lamp does not illuminate.
d. If the fault indicator lamp illuminates, it shows that electronic fuel injection system has fault, the
maintainer can read the fault code and do the work accordingly.
e. Maintenance personnel without specialized training is not suggested to conduct the maintenance
work, professionals shall be informed soon to do it.
f. Basic knowledge of diagnosis that maintenance personnel need to know: Fault judgment of
conventional engine, working principle of common rail system, engine harness and control
strategy, etc.
Diagnostic tester application

1. Reading fault code
Caution
• The fault is detected by engine control system and stored in engine control module (ECM),
system fault can be a current or historical fault.
• If the battery voltage is too low and ECM detection code can't be outputted normally, the
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battery voltage must be detected first before inspection, the voltage is about 24V.
• The fault code stored in ECM will be cleared when the battery or the ECM connector is
disconnected.
• Special detection tool shall be used to read engine fault code.
• Before the connection or disconnection of the diagnostic tester, it must be confirmed that
ignition switch is in "LOCK" position.
ECM has fault self-diagnosis function, once it detects the fault of electronic fuel injection system, it
will produces corresponding fault code and stores it in memory, and automatically goes to
different failure protection strategy according to the severity level of the fault. In most cases,
failure protection strategy can still keep the engine working by reducing the power. When dealing
with a small number of extremely serious fault, failure protection strategy will stop injection and
stop the engine work.
Fault code can be read via special diagnostic tester:
a. Turn the ignition switch to "ON", if the fault indicator lamp illuminates, it shows the system has
fault.
b. Connect the connector of special fault diagnostic tester with diagnostic interface.
c. Read the fault code in diagnostic tester, that is the "fault code" displayed on diagnostic tester.
d. According to the corresponding fault cause to the fault code, check and maintain the harness
associated with corresponding part or replace the relevant part.
e. After the troubleshooting, perform the step of read fault code again after fault diagnostic tester
clear the original fault code, confirm that there is no fault code and then deliver to use.
2. Clearing fault code
Fault code shall be cleared before confirming some accidental faults. If there is fault in system,
the fault code will exist until the fault is removed.
Connect the diagnostic tester and clear the fault code that stored in current control unit.
3. Reading data flow
By reading the data flow displayed on diagnostic tester, the data value of parts including switch,
sensor, actuator and so on can be inspected without removing any parts. As the first step of
troubleshooting, reading data flow is a method of shortening the time for diagnosis.
4. Action test
Action test is a self-learning process of components, it performs test for components including
relay, actuator and other learnings of special operation.
Failure symptom protection table

When the self-diagnostic function of the engine control system detects the failure of a main sensor, a
DTC is registered so that the vehicle is controlled by preset control logic circuit to ensure the driving
safety of vehicle. In addition, in event of failure of sensor or actuator, the following symptoms will occur
on the vehicle:
No. Malfunction item Control descriptions during malfunction
DI • Turn-on of malfunction indicator lamp

• Unstable idle speed
1 Injector • Weakness of engine
• Difficult start of engine
• Deteriorated acceleration performance
• Turn-on of malfunction indicator lamp
2 Relay • System failure
• Engine will not start
• Noise during running of fuel pump
3 Fuel pump
• Deteriorated acceleration performance
• The engine can’t be started
• Cutoff of fuel injection for corresponding cylinder
• Increased target idling speed
• Unstable idle speed
4 Ignition coil
• Weakness of engine
• Deteriorated fuel economy
• Disqualified emission
• Deteriorated ignition
• Delayed closed-loop working of system
• Deteriorated fuel economy
5 Oxygen sensor
• Acceleration lag
• Deteriorated drive force
• Closed carbon canister solenoid valve
• Turn-off of system basic fuel control closed-loop
6 Canister solenoid valve
self-learning
• Turn-off of system idling air control self-learning
• Unstable idling or high idling speed
No. Malfunction item Control descriptions during malfunction

• Engine will not start
• Restrained speed after start of engine
• Engine maximum speed no higher than approximately
Crankshaft position
7 4,000RPM
sensor
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• No ignition signal to ECM
• Failure of tachometer
• Engine (rough operation)
• 0% set opening extent of throttle position sensor during
Crankshaft position idling and speed-dependent opening extent of throttle
8
sensor position sensor under other speeds
• Non-increased fuel injection volume and deteriorated
acceleration performance during acceleration
• The intake temperature is used at start of engine and is
fixed after being increased to a specific value along with
time.
• Difficult start of cold engine
Intake manifold absolute • Difficult start of hot engine
9 pressure/temperature • Deteriorated drive force
sensor • The engine is running under default values if the water
temperature sensor circuit is short circuited to power
supply.
• Constant high-speed running of cooling fan
• Flashing of high temperature warning lamp when the
instrument indicates high temperature.
Fault code table

Use the following table to help you to find out the reasons of faults. Check each part as per this order and
replace as the case may be.
Caution
When DTC inspection is made in inspection mode, if certain DTC is displayed, then check the
circuit of the code listed in table below.
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DTC inspection
DTC code DTC defined Failed components
conditions
• Engine ECM
• Poor contact of sensor connector
• Sensor signal circuit open-circuit or high
Inappropriate resistance sensor signal short-circuit to ground
signal of intake
The ignition switch is • Open-circuit of 5V reference voltage wire
P0106 manifold air
turned to ON. • Open-circuit of sensor grounding wire
pressure (MAP)
sensor signal • Reverse connection between sensor 5V
reference voltage wire and grounding wire (This
will result in damage of sensor)
• MAP sensor
• Engine ECM
• Poor contact of sensor connector
• Sensor signal circuit open-circuit or high
Intake manifold resistance sensor signal short-circuit to ground
pressure sensor
During running of • Open-circuit of 5V reference voltage wire
P0107 (MAP) circuit
engine • Open-circuit of sensor grounding wire
short-circuit to
ground • Reverse connection between sensor 5V
reference voltage wire and grounding wire (This
will result in damage of sensor)
• MAP sensor
• MAP sensor
Intake manifold • Sensor signal circuit
pressure sensor
The ignition switch is Short-circuit to 12V power supply
P0108 (MAP) circuit
turned to ON. • Sensor 5V reference voltage wire short-circuit to
short-circuit to
power supply 12V power supply
• Engine ECM
• MAT sensor
Intake temperature • Poor contact of MAT sensor connector
sensor (MAT) The ignition switch is • Open-circuit or high resistance of sensor circuit
P0112
circuit short-circuit turned to ON. • 5V reference voltage wire
to ground Short-circuit to 12V power supply
• Engine ECM
Intake temperature
sensor (MAT) • MAT sensor
The ignition switch is
P0113 circuit open-circuit • MAT sensor 5V reference voltage
turned to ON.
or short-circuit to • Engine ECM
power supply
DTC inspection
conditions
• Throttle body stepping motor
Over-high idling The ignition switch is
P0507 • Poor contact of stepping motor connector
control speed turned to ON.
• Engine ECM
• Throttle body stepping motor
Under-low idling The ignition switch is
P0506 • Poor contact of stepping motor connector
control speed turned to ON.
• Engine ECM DI
• TPS sensor
Over-high voltage • Poor contact of TPS sensor connector
P0123 of throttle position • Sensor circuit short-circuit to power supply or
turned to ON.
sensor (TPS) 1 ground
• Engine ECM
• TPS sensor
With ignition switch at • Poor contact of TPS sensor connector
Under-low voltage
“ON” position or
P0122 of throttle position Sensor circuit short-circuit to power supply or
during running of •
engine
• Engine ECM
• TPS sensor
Over-high voltage • Poor contact of TPS sensor connector
turned to ON.
• Engine ECM
• TPS sensor
Under-low voltage • Poor contact of TPS sensor connector
turned to ON.
• Engine ECM
• TPS sensor
Over-high throttle • Poor contact of TPS sensor connector
P2118 position signal • Sensor circuit short-circuit to power supply or
turned to ON.
deviation ground
• Engine ECM
• TPS sensor
Inappropriate • Poor contact of TPS sensor connector
signal of throttle The ignition switch is
P0121 • Sensor circuit short-circuit to power supply or
position sensor turned to ON.
(TPS) 1 ground
• Engine ECM
• TPS sensor
signal of throttle The ignition switch is
position sensor turned to ON.
(TPS) 2 ground
• Engine ECM
• TPS sensor
voltage correlation The ignition switch is
of throttle position turned to ON.
sensor (TPS) 1/2 ground
• Engine ECM
DTC inspection
conditions
Upstream oxygen
sensor heater • Upstream oxygen sensor
control circuit The ignition switch is • Poor contact of upstream oxygen sensor and
P0031
open-circuit or turned to ON. open-circuit of sensor harness
short-circuit to • Engine ECM
ground
DI Upstream oxygen • Upstream oxygen sensor

sensor heater
The ignition switch is • Poor contact of upstream oxygen sensor and
P0032 control circuit
turned to ON. open-circuit of sensor harness
short-circuit to
power supply • Engine ECM
Upstream oxygen • Upstream oxygen sensor

sensor circuit The ignition switch is • Upstream oxygen sensor harness short-circuit to
P0131
short-circuit to turned to ON. ground
ground • Engine ECM
Upstream oxygen • Upstream oxygen sensor

sensor circuit During running of • Upstream oxygen sensor short-circuit to power
P0132
short-circuit to engine supply
Inappropriate With ignition switch at • Upstream oxygen sensor

response of “ON” position or • Poor contact of upstream oxygen sensor and
P014C
upstream oxygen during running of open-circuit of sensor harness
sensor engine • Engine ECM
Slow switching With ignition switch at • Upstream oxygen sensor

time response of “ON” position or • Poor contact of upstream oxygen sensor and
P0133
upstream oxygen during running of open-circuit of sensor harness
sensor engine • Engine ECM
• Upstream oxygen sensor
Non-readiness of
• Poor contact of upstream oxygen sensor and
P0134 upstream oxygen At startup of vehicle
open-circuit of sensor harness
sensor
• Engine ECM
With ignition switch at
Inappropriate “ON” position and at • Upstream oxygen sensor
heating circuit of power-on or • Poor contact of upstream oxygen sensor and
P0135
upstream oxygen power-off of pulse open-circuit of sensor harness
sensor width modulation • Engine ECM
device
• Downstream oxygen sensor
Downstream
The ignition switch is • Poor contact of downstream oxygen sensor and
P0136 oxygen sensor
turned to ON. open-circuit or short-circuit of sensor harness
circuit open-circuit
• Engine ECM
Downstream • Downstream oxygen sensor

oxygen sensor The ignition switch is • Poor contact of downstream oxygen sensor and
P0137
circuit short-circuit turned to ON. open-circuit or short-circuit of sensor harness
to ground • Engine ECM
DTC inspection
conditions

oxygen sensor The ignition switch is • Poor contact of downstream oxygen sensor and
P0138
circuit short-circuit turned to ON. open-circuit or short-circuit of sensor harness
to power supply • Engine ECM
Inappropriate • Downstream oxygen sensor

response of The ignition switch is • Poor contact of downstream oxygen sensor and
P013A
downstream turned to ON. open-circuit or short-circuit of sensor harness
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oxygen sensor • Engine ECM
Downstream
oxygen sensor • Downstream oxygen sensor
heater control The ignition switch is • Poor contact of downstream oxygen sensor and
P0037
circuit open-circuit turned to ON. open-circuit or short-circuit of sensor harness
or short-circuit to • Engine ECM
ground
oxygen sensor
The ignition switch is • Poor contact of downstream oxygen sensor and
P0038 heater control
turned to ON. open-circuit or short-circuit of sensor harness
circuit short-circuit
• Battery
Inappropriate • Damage of harness or connector between
heating circuit of The ignition switch is battery and ECM
P0141
downstream turned to ON.
oxygen sensor • Real-time clock
• Engine ECM
Knock sensor (KS) • KS

malfunction - During running of • Poor contact of KS connector
P0324
Signal acquisition engine • Short-circuit or open-circuit of KS harness
malfunction • Engine ECM

P0325
Signal absolute engine • Short-circuit or open-circuit of KS harness
value error • Engine ECM

P0326
Signal relative engine • Short-circuit or open-circuit of KS harness
value error • Engine ECM
• CKP sensor
No crankshaft • Poor contact of CKP sensor connector
During running of
P0335 sensor (CKP) • Short-circuit or open-circuit of CKP sensor
engine
signal harness
• Engine ECM
• CKP sensor
Inappropriate • Poor contact of CKP sensor connector
P0336 crankshaft sensor • Short-circuit or open-circuit of CKP sensor
turned to ON.
(CKP) signal harness
• Engine ECM
DTC inspection
conditions
With engine speed • CKP sensor

Synchronization above • Poor contact of CKP sensor connector
loss of crankshaft
P0339
(CKP) sensor 500r/min and battery • Short-circuit or open-circuit of CKP sensor
signal charge rate above harness
minimum threshold • Engine ECM
• CKP sensor
DI With ignition switch at •
Inappropriate Poor contact of CKP sensor connector
“ON” position or
P0373 crankshaft tooth Short-circuit or open-circuit of CKP sensor
during running of •
signal cycle harness
engine
• Engine ECM
• CKP sensor
Inappropriate After running of • Poor contact of CKP sensor connector
exhaust camshaft engine or ignition • Short-circuit or open-circuit of CKP sensor
P0369
position sensor switch at “ON” harness
(CPS) signal position • Exhaust camshaft
• Engine ECM
• CKP sensor
intake camshaft During running of • Short-circuit or open-circuit of CKP sensor
P0344
position sensor engine harness
(CPS) signal • Intake camshaft
• Engine ECM
• CKP sensor
exhaust camshaft The ignition switch is • Short-circuit or open-circuit of CKP sensor
P0366
position sensor turned to ON. harness
(CPS) signal • Exhaust camshaft
• Engine ECM
• CKP sensor
intake camshaft The ignition switch is • Short-circuit or open-circuit of CKP sensor
P0341
position sensor turned to ON. harness
(CPS) signal • Intake camshaft
• Engine ECM
• CKP sensor
• Poor contact of CKP sensor connector
Inappropriate
correlation • Short-circuit or open-circuit of CKP sensor
between The ignition switch is harness
P0017
crankshaft position turned to ON. • Intake camshaft
and exhaust • Timing chain
camshaft position
• Crankshaft
• Engine ECM
DTC inspection
conditions
• CKP sensor
Inappropriate
correlation With ignition switch at • Short-circuit or open-circuit of CKP sensor
between “ON” position or harness
P0016
crankshaft position during running of • Intake camshaft
and intake engine • Timing chain
camshaft position DI
• Crankshaft
• Engine ECM
• CKP sensor
Offset of exhaust With ignition switch at • Short-circuit or open-circuit of CKP sensor
camshaft position “ON” position or harness
P0014
under steady during running of • Exhaust camshaft
working condition engine • Timing chain
• Crankshaft
• Engine ECM
• CKP sensor
Offset of intake • Short-circuit or open-circuit of CKP sensor
camshaft position During running of harness
P0011
under steady engine • Intake camshaft
working condition • Timing chain
• Crankshaft
• Engine ECM
• CKP sensor
Inappropriate • Short-circuit or open-circuit of CKP sensor
synchronization The ignition switch is harness
P0365
signal of exhaust turned to ON. • Exhaust camshaft
camshaft position • Timing chain
• Crankshaft
• Engine ECM
• CKP sensor
Inappropriate • Short-circuit or open-circuit of CKP sensor
synchronization The ignition switch is harness
P0340
signal of intake turned to ON. • Intake camshaft
camshaft position • Timing chain
• Crankshaft
• Engine ECM
DTC inspection
conditions
• Low speed fan relay
• High speed fan relay
Cooling fan relay 1
• Open-circuit of harness between ECM and
circuit open-circuit During running of
P0691 high/low speed fan relay
or short-circuit to engine
ground • Short-circuit or open-circuit of ER7 drive
harness
DI • Engine ECM
Cooling fan relay 1 • High speed fan relay
During running of
P0692 circuit short-circuit • Short-circuit or open-circuit of ER7 drive
engine
to power supply harness
• Engine ECM
• High speed fan relay
Cooling fan relay 2
• Open-circuit of harness between ECM and
circuit open-circuit During running of
P0693 high/low speed fan relay
or short-circuit to engine
ground • Short-circuit or open-circuit of ER3 drive
harness
• Engine ECM
With ignition switch at • Low speed fan relay
“ON” position and at • High speed fan relay
Cooling fan relay 2
power-on or
P0694 circuit short-circuit • Short-circuit or open-circuit of ER3 drive
power-off of pulse
to power supply harness
width modulation
device • Engine ECM
With ignition switch at
“ON” position and at • Fuel injector A
1st cylinder fuel
power-on or
P0201 injector circuit • Fuel injector harness
power-off of pulse
open-circuit
width modulation • Engine ECM
device
3rd cylinder fuel • Fuel injector C

turned to ON.
open-circuit • Engine ECM
4th cylinder fuel • Fuel injector D

turned to ON.
2nd cylinder fuel • Fuel injector B

turned to ON.
1st cylinder fuel • Fuel injector A
injector circuit The ignition switch is
P0261 • Fuel injector harness
short-circuit to turned to ON.

DTC inspection
conditions

short-circuit to turned to ON. DI
1st cylinder fuel • Fuel injector A




Open-circuit of • Open-circuit or short-circuit of carbon canister

carbon canister The ignition switch is solenoid valve harness
P0444
solenoid valve turned to ON. • Carbon canister solenoid valve
circuit • Engine ECM
Carbon canister • Open-circuit or short-circuit of carbon canister

solenoid valve The ignition switch is solenoid valve harness
P0458
circuit short-circuit turned to ON. • Carbon canister solenoid valve
to ground • Engine ECM
Carbon canister • Open-circuit or short-circuit of carbon canister

solenoid valve During running of solenoid valve harness
P0459
circuit short-circuit engine • Carbon canister solenoid valve
• Ignition coil
1st and 4th
The ignition switch is • Open-circuit or short-circuit of ignition system
P0351 cylinder ignition
turned to ON. harness
coil open-circuit
• Engine ECM
• Ignition coil
2nd and 3rd
P0353 cylinder ignition
coil open-circuit
• Engine ECM
1st and 4th • Ignition coil

cylinder ignition During running of • Open-circuit or short-circuit of ignition system
P2300
coil short-circuit to engine harness
DTC inspection
conditions
2nd and 3rd • Ignition coil

cylinder ignition During running of • Open-circuit or short-circuit of ignition system
P2306
coil short-circuit to engine harness
1st and 4th • Ignition coil

cylinder ignition The ignition switch is • Open-circuit or short-circuit of ignition system
DI P2301
coil short-circuit to turned to ON. harness
2nd and 3rd • Ignition coil

cylinder ignition The ignition switch is • Open-circuit or short-circuit of ignition system
P2307
coil short-circuit to turned to ON. harness
• Ignition coil
P0301 1st cylinder misfire
• Engine ECM
• Ignition coil
P0303 3rd cylinder misfire
• Engine ECM
• Ignition coil
P0304 4th cylinder misfire
• Engine ECM
• Ignition coil
2nd cylinder The ignition switch is • Open-circuit or short-circuit of ignition system
P0302
misfire turned to ON. harness
• Engine ECM
Coolant Temperature Sensor Malfunction

P0117-Short-circuit to ground of coolant temperature sensor
P0118 - Water temperature sensor short-circuit to power supply or open-circuit
Overview
1. The water temperature sensor is functioned to measure the engine coolant temperature
and thus enable the ECM to determine the running status of engine and control the fuel DI
injection volume.
2. The water temperature sensor determines the coolant temperature by its built-in negative
temperature coefficient thermistor. The higher the temperature is, the lower the resistance
is. This resistor is a part of the bleeder circuit and the bleeder circuit is charged with 5V
voltage. The measured voltage on the resistor varies depending on the temperature. Every
voltage corresponds to a temperature on the internal characteristic curve of the ECM.
Circuit diagram
Engine ECM
Coolant
temperature signal Sensor GND
Grey Black

Diagnosis procedure
Caution
• Before the diagnosis, ensure the good contact between engine ECM and water
temperature sensor.
• Before the diagnosis and test, refer to the circuit diagrams and part information.
• Before the measurement, check connector pins for breakage, looseness, and rusting and
DI
ensure the good contact of pins.
• Upon detection of either DTC P0117 or P0118, the ECM enters the fail-safe mode. Under the
fail-safe mode, with the ignition switch at ON position, the ECM uses the ECT values and
the cooling fan runs at high speed. The fail-safe mode remains till the ECM detects
qualified conditions.
• To disassemble the water temperature sensor for checking, ensure to cool down the
engine.
1. Read DTC and data on the diagnostic apparatus

a. Start the engine and run it to its normal working temperature.
b. Use diagnostic apparatus and confirm the DTC.
c. Read the sensor data
d. Read the water temperature sensor (WTS) data by a diagnostic unit.
Indicated DTC and temperature Turn to Status
• P0118 Open-circuit or short-circuit to

Go to next step
• Approximately -40℃ power supply
• P0117
Step 5 Short-circuit to ground
• Approximately 140℃ or higher
• P0117 or P0118
Diagnosis procedure Intermittent malfunction
• Between 80℃ and 100℃

Yes> Intermittent failure
No> Go to step 2
2. Read the data on the diagnostic apparatus

a. Ignition switch: LOCK.
b. Connect the pins 1 and 2 of water temperature
sensor connector E012.
c. Ignition switch: ON.
d. Read the coolant temperature indicated by the
diagnostic unit.
Checking result:
Check by a diagnostic unit Standard value
Temperature Approximately 140℃


Yes >to step 3.
No > Verify the good connection of sensor. If the connection is normal, replace water
temperature sensor.
3. Check power circuit of water temperature sensor.

a. Ignition switch: ON.
b. Measure the voltage between pin 1 and ground DI
from the back face of water temperature sensor
connector E012.
Standard voltage:
Multimeter connection Standard value
E012 (1)-grounding About 5V

Yes >to step 4.
No > Check and repair or replace power harness of water temperature sensor.
4. Check and repair or replace power harness of water temperature sensor.

b. Disconnect the battery negative terminal
c. Disconnect the water temperature sensor connector E012 and ECM connector E001 respectively.
d. Measure the resistance between pin 1 of water
temperature sensor connector and pin 39 of ECM
connector E001.
Standard resistance:
E012(1)- E001(39) About 0Ω

Yes >to step 5.
No > Repair or replace the malfunctioned harness.
5. Replace and check the water temperature sensor.

a. Replace coolant temperature sensor.
b. Use a diagnostic unit to perform the DTC verification procedure and read the sensor data stream.
c. Read the water temperature sensor data by a diagnostic unit.
Is checking result normal?

Yes> Replace coolant temperature sensor.
No> Go to step 6
6. Replace ECM.
a. Replace ECM.
DI d. Confirm there is no DTC and the data is acceptable.
Intake manifold pressure/temperature sensor malfunction

P0106 - Inappropriate intake manifold pressure sensor signal
P0107 - Intake manifold pressure sensor short-circuit to ground
P0108 - Intake manifold pressure sensor short-circuit to power supply
P0117 - Intake temperature sensor short-circuit to ground
P0118 - Intake temperature sensor short-circuit to power supply
DI
Overview
The intake manifold pressure/temperature sensor is installed on the intake manifold and is functioned to
measure the absolute pressure and temperature of intake air in intake manifold. It thus plays the
functions of intake flow calculation, turbocharger protection, smoking restraint, and intake temperature
overheating protection. The symptoms for the failure of intake temperature/pressure sensor include
insufficient power, restrained speed, and high fuel consumption.
Circuit diagram
Engine ECM
Intake
Intake temperature pressure
signal Sensor - signal Sensor +
Yellow- Yellow- Blue- Blue-

Purple Red White yellow
Air intake manifold pressure temperature sensor

Diagnosis procedure
Caution
• Before performing the following procedure, ensure the good connection of engine ECM
and intake manifold pressure/temperature sensor connectors.
• Before the electronic diagnosis and test, refer to the circuit diagrams and part information.
DI
• When the ignition switch is at “ON” position and the engine is not running, the manifold
pressure is equivalent to the ambient pressure and the sensor outputs high voltage signal.

d. Read the intake manifold pressure (MAP) sensor data by a diagnostic unit.
Indicated DTC and temperature Turn to Status

Go to next step
• The pressure is ≤10kPa. ground
• P0107
Go to next step Short-circuit to voltage
• The pressure is >115kPa.
• P0106
• The pressure is occasionally Malfunction of intake pressure
Go to next step
less than 115kPa and higher sensor or leakage of pipeline
than 10kPa and is unstable.
• P0107 or P0108
Diagnostic help Intermittent malfunction
• Normal pressure
Go to next step
• <-40℃ voltage
• P0112
Go to next step Short-circuit to ground
• ＞140℃
• P0112 or P0113
Diagnostic help Intermittent malfunction
• Normal temperature

No> Go to step 2
2. Check power circuit of intake manifold pressure/temperature sensor.

b. Measure the voltage between pin 2 and ground on

the back face of intake manifold
pressure/temperature sensor.
Standard voltage:
DI

Yes >to step 3.
No> Repair or change the failed harness
3. Check grounding circuit of intake manifold pressure/temperature sensor.

b. Disconnect the battery negative cable.
c. Disconnect the intake manifold pressure/temperature sensor connector E019 and engine ECM
connector E001 respectively.
d. Measure the resistances between pins 1 and 4 of
intake manifold pressure/temperature sensor
connector E019 and pin 17 of engine ECM
connector E001.
E019(4)-E001(17) About 0Ω

Yes >to step 4.
4. Check the pressure and temperature signal circuit of the sensor.

c. Disconnect the intake manifold pressure/temperature sensor connector E0Q9 and engine ECM
connector E001 respectively.
d. Measure the resistances between pins 1 and 3 of

intake manifold pressure/temperature sensor
connector E019 and pins 37 and 42 of engine ECM
connector E001.
E019(1)-E001(37)
DI About 0Ω
E019(3)-E001(42)

Yes >to step 5.
5. Check and replace intake manifold pressure/temperature sensor.

a. Replace intake manifold pressure/temperature sensor.
b. Use a diagnostic unit to perform the DTC verification procedure and read the sensor data stream.
c. Read the intake manifold pressure/temperature sensor data by a diagnostic unit.

Yes > Replace intake manifold pressure/temperature sensor.
No> Go to step 6
6. Replace ECM.
a. Replace ECM.
c. Read the sensor data stream. Ensure the normal data, without any existing DTC.
Crankshaft position sensor malfunction

P0335 - No crankshaft sensor signal
P0336 - Inappropriate crankshaft sensor signal
P0339 - Synchronization loss of crankshaft sensor signal
P0373 - Inappropriate crankshaft tooth signal cycle
Overview DI
1. The crankshaft position (CKP) sensor generates 58X reference signal. The ECM uses the
58X reference signal to calculate the engine speed CKP. The ECM continuously monitors
the number of pulses on the 58X reference harness and compares it with the number of
received manifold pressure (MAP) signals to, with reference to the signal of camshaft
position sensor, judge the travel position of piston in the cylinder and thus control the fuel
injection timing, fuel injector pressure, and fuel injection volume. If the ECM receives
incorrect number of pulses from the 58X reference harness, the DTC P0336, P0335, P0373,
and P1336 will be registered.
2. The crankshaft position sensor is installed on the right front housing of transmission. The
failure malfunctions of crankshaft position sensor mainly include start failure, difficult
start, and high-speed shiver of engine.
Circuit diagram
Engine ECM
Crankshaft
Sensor + position signal
Red Green
Black

Diagnosis procedure
Caution
• Before performing the following procedure, ensure the good connections of ECM and
crankshaft position sensor.
DI
• If the connections are normal, move the connector and harness and observe the signal
voltage of sensor. If any malfunction occurs, the voltage indicated on the diagnostic unit
will change.
1. Read the DTC and crankshaft position sensor signal on the diagnostic unit.
c. Use diagnostic tester to read the sensor data.
d. The engine is idling
e. Use a diagnostic unit to read the data of crankshaft position sensor.

No> Go to step 2
2. Check the power circuit of crankshaft position sensor.

c. Disconnect the crankshaft position sensor connector E015 and ECM connector E001.
d. Measure the resistance between the crankshaft
position sensor E015 pin 1 and ECM connector
E001 pin 15.
E015(1)-E001(15) About 0Ω

Yes >to step 3.
No > Check and repair or replace power harness of crankshaft position sensor.
3. Check the grounding circuit of crankshaft position sensor.

c. Disconnect the crankshaft position sensor connector E015.
d. Measure the resistance between pin 3 of crankshaft

position sensor E015 and ground.
E015 (3)-grounding About 0Ω
DI

Yes >to step 4.
No > Check and repair or replace grounding harness of crankshaft position sensor.
4. Check the signal circuit of crankshaft position sensor.

c. Disconnect the crankshaft position sensor connector E015 and ECM connector E001.
d. Measure the resistance between the crankshaft
position sensor E015 pin 3 and ECM connector
E001 pin 34.
E015(2)-E001(34) About 0Ω

Yes >to step 5.
No > Check and repair or replace signal harness of crankshaft position sensor.
5. Check and replace crankshaft position sensor.

a. Replace crankshaft position sensor.
c. Read the sensor data and check if the result is acceptable.

Yes > Replace crankshaft position sensor.
No> Go to step 6
6. Check the signal panel of crankshaft position sensor.

b. Check signal panel for looseness and damage and check surface of signal panel for presence of
foreign material.
c. Check the mounting clearance of crankshaft position sensor.

Standard clearance:
Gap Standard value
Crankshaft position sensor and signal panel 0.3~1.5mm

DI Yes >to step 7.
No > Remove the foreign materials (If any). If the signal panel is damaged, replace signal panel.
7. Replace ECM.
a. Replace ECM.
d. Confirm there is no DTC and the data is acceptable.
Carbon canister solenoid valve malfunction

P0444 - Carbon canister solenoid valve circuit open-circuit
P0458 - Carbon canister solenoid valve circuit short-circuit to ground
P0459 - Carbon canister solenoid valve circuit short-circuit to power supply
Overview
1. Upon receipt of ECM signal, the carbon canister solenoid valve opens to, under the action of the DI
manifold vacuum pressure, inhale from the air inlet port of carbon canister for desorption of the
carbon canister.
2. The carbon canister solenoid valve is located on the downstream of the intake manifold.
Circuit diagram
Battery
White
Frame fuse
box
Main relay
White
Purple-white
White
Blue
Purple-white
Main relay control Canister solenoid valve control
Engine
Diagnosis procedure
Caution
• Before performing following procedure, ensure the good connections of ECM and carbon
canister solenoid valve.
DI
will change.
1. Check the carbon canister solenoid valve.

a. Rotate the ignition switch to LOCK position and disconnect the negative cable of battery.
b. Disconnect the canister solenoid valve connector E020.
c. Measure the resistance between pins 1 and 2 of carbon canister solenoid valve.
Standard value:
E020(1)-E020(2) 19～22Ω

Yes >to step 2.
No > Replace carbon canister solenoid valve.
2. Check power circuit of carbon canister solenoid valve.

b. Disconnect the canister solenoid valve connector E020.
b. Use the voltage measurement range of a multimeter
to measure the voltage between pin 1 of carbon
canister solenoid valve connector E020 and ground.
Standard voltage:
E020 (1)-grounding Battery power supply

Yes >to step 3.
No > Replace the harness between carbon canister solenoid valve and fuel injector EF08 fuse
and when necessary replace fuse case.
3. Check carbon canister solenoid valve harness for short-circuit to power supply.
a. Disconnect the carbon canister solenoid valve connector E020 and ECM connector E001.
b. Switch the ignition switch to ON.

d. Measure the voltage between pin 1 of carbon
canister solenoid valve connector E020 and ground.
Standard voltage:
E020 (1)-grounding Battery power supply
DI

Yes >to step 4.
No > Check and repair or replace carbon canister solenoid valve harness.
4. Check control signal harness of carbon canister solenoid valve.

c. Disconnect the carbon canister solenoid valve connector E020 and ECM connector E001.
d. Measure the resistance between pin 2 of carbon
canister solenoid valve connector E020 and pin 46
of engine control module connector E001.
E020(2)-E001(46) About 0Ω

Yes >to step 5.
No > Check and repair or replace carbon canister solenoid valve signal harness.
5. Replace ECM.
a. Replace ECM.
Ignition coil assembly malfunction

P0351 - 1st and 4th cylinder ignition coil open-circuit
P0353 - 2nd and 3rd cylinder ignition coil open-circuit
P2300 - 1st and 4th cylinder ignition coil short-circuit to ground
P2306 - 2nd and 3rd cylinder ignition coil short-circuit to ground
P2301 - 1st and 4th cylinder ignition coil short-circuit to power supply
DI P2307 - 2nd and 3rd cylinder ignition coil short-circuit to power supply
P0301 - 1st cylinder misfire
P0302 - 2nd cylinder misfire
P0303 - 3rd cylinder misfire
P0304 - 4 cylinder misfire
P0300 - Multiple misfires
P0318 - Misfire detected on rugged road
Overview
1. The system adopts the grouped ignition mode.
2. The ignition coil includes two coil groups, of which each group provides the ignition
energy for two cylinder spark plugs in spacing of 360º crankshaft angle. Installation
location: On cylinder head.
Circuit diagram
Battery
White
DI
Frame fuse
box
Main relay 1st cylinder 4th cylinder 2nd cylinder 3rd cylinder
spark plug spark plug spark plug spark plug Self grounded
Ignition coil 1 Ignition coil 2
Purple-white Orange
Orange Orange
Orange Purple-Black White-blue
Purple-white
Main relay control 1st/4th cylinder 2nd/3rd cylinder

ignition control ignition control
Engine
Diagnosis procedure
Caution
• Before performing following procedure, ensure the good connections of ECM and ignition
coils.
DI
will change.
• There are two ignition coils, for which the connectors are E007 and E011. This part takes
the ignition coil 1E011 for instance to describe the diagnostic procedure.
e. Use a diagnostic unit to read the waveform of camshaft position sensor.

No> Go to step 2
2. Check the spark plug.

a. Disconnect the connector E011 of ignition coil 1.
b. Remove the spark plug.

Yes >to step 3.
No > Check and repair or replace spark plug.
3. Check the power circuit of ignition coil.

b. Measure voltage with multimeter.
c. Use the voltage measurement range of a multimeter
to measure the voltage between pin 1 of ignition coil
E011 and ground.
Standard voltage:


Yes >to step 4.
No > Check and repair or replace power harness of ignition coil 1.
4. Check the control circuit between ignition coil and ECM.

c. Disconnect the ECM connector E001 and ignition coil 1 connector E011. DI
d. Measure the resistance between pin 2 of ignition
coil 1 connector E011 and pin 5 of ECM connector
E001.
E011(2)-E001(5) About 0Ω

Yes >to step 5.
No > Check and repair or replace control harness of ignition coil 1.
5. Check ignition coil for short-circuit to power supply.

b. Measure voltage with multimeter.
c. Use the voltage measurement range of a multimeter
to measure the voltage between pin 2 of ignition coil
E011 and ground.
Standard voltage:
E011 (2)-grounding 0V

Yes >to step 6.
No > Check and repair or replace power harness of ignition coil 1 that is short circuited to power
supply.
6. Check and replace ignition coil 1.

a. Replace ignition coil 1.

Yes> Replace the spark plug 1.
No> Go to step 7
7. Replace ECM.
a. Replace ECM.
DI c. Read the sensor data
Camshaft position sensor malfunction

P0369 - Inappropriate exhaust camshaft position sensor signal
P0344 - Inappropriate intake camshaft position sensor signal
P0366 - Inappropriate exhaust camshaft position sensor signal
P0341 - Inappropriate intake camshaft position sensor signal
P0017 - Inappropriate correlation between crankshaft position and exhaust camshaft position
P0016 - Inappropriate correlation between crankshaft position and intake camshaft position DI
P0014 - Offset of exhaust camshaft position under steady working condition
P0011 - Offset of intake camshaft position under steady working condition
P0365 - Inappropriate synchronization signal of exhaust camshaft position
P0340 - Inappropriate synchronization signal of intake camshaft position
Overview
1. The camshaft position sensor is functioned to measure the engine speed and determine
the engine phase. The camshaft signal sensor works with crankshaft position sensor to
provide the correct 1st cylinder top dead center signal to the ECU. The failure of this
sensor will result in difficult start of engine.
2. When the crankshaft position sensor fails, the camshaft position sensor can substitute the
crankshaft position sensor for a short time to start the engine. The failure malfunctions of
camshaft positions mainly include difficult start of engine.
Circuit diagram
Engine ECM
Sensor
Sensor + signal Sensor -
Yellow- Black- Yellow-

blue green red
Sensor for camshaft position sensor

Diagnosis procedure
Caution
• Before performing the following procedure, ensure the good connections of ECM and
camshaft position sensor.
DI
e. Use a diagnostic unit to read the waveform of camshaft position sensor.

No> Go to step 2
2. Check power circuit of camshaft position sensor.

b. Use the voltage measurement range of a multimeter
to measure the voltage between pin 1 and ground
on the back face of camshaft position sensor
connector E010.
Standard voltage:

Yes >to step 3.
No > Check and repair or replace sensor power harness.
3. Check the grounding circuit of camshaft position sensor.

c. Disconnect the ECM connector E001 and camshaft position sensor connector E010.
d. Use the resistance measurement range of a

multimeter to measure the resistance between pin 2
of camshaft position sensor connector E010 and pin
33 of ECM connector E001.
E010(2)-E001(33) About 0Ω
DI

Yes >to step 4.
No > Check and repair or replace sensor grounding harness.
4. Check the signal harness of camshaft position sensor.

c. Disconnect the camshaft position sensor connector E010 and ECM connector E001.
d. Use the resistance measurement range of a
multimeter to measure the resistance between pin 3
of camshaft position sensor connector E010 and pin
79 of ECM connector E001.
E010(3)-E001(79) About 0Ω

Yes >to step 5.
No > Check and repair or replace sensor signal harness.
5. Check and replace camshaft position sensor.

a. Replace crankshaft position sensor.

Yes> Change of camshaft position sensor
No> Go to step 6
6. Replace ECM.
a. Replace ECM.
Fan malfunction
Overview
The fan for this vehicle is controlled by silicone oil clutch and is mainly functioned for heat dissipation of
engine system. The fan is driven for rotation by the engine crankshaft via belt. When the metal
temperature detector of the fan detects the temperature of air around the radiator to deform and drive the
valve plate drive pin and control valve plate for deflection by a certain angle, the oil inlet port opens to
DI allow the flow of silicone oil into the working chamber and utilize the shear viscous force of silicone oil for
transmission of torque.

Malfunction symptom Possible cause Troubleshooting
1. Loose or broken belt • Check belt.

Failure of fan (When the working
conditions are met)
2. Fan malfunction • Check and repair fan.
Diagnosis procedure
1. Check drive belt.
a. Tilt forward the cab.
b. Push the drive belt by hand and check for looseness.

Yes > Adjust the tension of belt.
No> Go to step 2
DI
2. Check the fan.

a. Stop the engine, wait for a period, and forcibly pull the fan blades by hand.
b. Start the engine and run till the normal temperature is reached.
c. Stop the engine and pull the fan blades by hand with a force smaller than the previous operation.

Yes >to step 3.
No > Check and repair or replace fan.
3. Check and replace fan.

a. Replace fan, run the engine till the running conditions of fan are met, and check the fan for normal
running.

Yes > Replace fan.
No>Find the reasons from other fault phenomenon.
Fuel injector circuit malfunction

P0201 - Open-circuit of 1# cylinder fuel injector circuit
P0261 - 1st cylinder fuel injector circuit short-circuit to ground
DI P0267 - 2nd cylinder fuel injector circuit short-circuit to ground
P0270 - 3rd cylinder fuel injector circuit short-circuit to ground
P0264 - 4th cylinder fuel injector circuit short-circuit to ground
P0262 - 1st cylinder fuel injector circuit short-circuit to power supply
P0268 - 2nd cylinder fuel injector circuit short-circuit to power supply
P0271 - 3rd cylinder fuel injector circuit short-circuit to power supply
P0265 - 4th cylinder fuel injector circuit short-circuit to power supply
Overview
1. The control solenoid valve is located on the top of the fuel inject and the fuel injection
volume and timing are controlled by the energization time of the solenoid valve. The
energization time of the solenoid valve is controlled by the electronic control unit
depending on the running condition of the engine.
2. In the common rail fuel injection system, the fuel injection pressure buildup is unrelated to
the engine speed and fuel injection volume and the fuel injection start timing and the fuel
injection volume are realized by the electronically actuated fuel injector. The fuel injection
timing is controlled by the rotation angle or time system of the electronic diesel engine
system (Determined by the crankshaft position sensor and camshaft position sensor).
Circuit diagram
Battery
White
DI
Frame fuse
box Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4
Main relay
White
Purple-white
White White White White
Purple-white Green-white Green-yellow Black-red Yellow-black
Main relay control Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4
control control control control
Engine
Diagnosis procedure
Caution
• Before performing the following procedure, ensure the good connections of ECM and fuel
injector connector.
DI
• The checking method is consistent for the fuel injectors. Here takes the fuel injector 1 for
instance.
a. Start the engine and run at idle speed
d. Use a diagnostic unit to read the fuel injector data.

No> Go to step 2
2. Check the resistance of fuel injector.

c. Disconnect the connector E005 of fuel injector 1.
d. Measure resistance between socket pins 1 and 2 of
fuel injector 1.
E005(1)-E005(2) 11.4～12.6Ω

Yes > to step 3.
No ＞ Replace the fuel injector.
3. Check the harness between fuel injector 1 and engine ECM.

c. Disconnect the fuel injector 1 connector E005 and engine ECM connector E001 respectively.
d. Measure the resistance between pin 2 of fuel

injector connector E005 and pin 27 of engine ECM
connector E001.
E005(2)-E001(27) About 0Ω
DI

Yes > to step 4.
No ＞ Change of Fuel injector harness
4. Check and replace fuel injector.

a. Replace the fuel injector.

Yes> Replace the fuel injector.
No> Go to step 5
5. Replace ECM.
a. Replace ECM.
Communication failure between diagnostic unit and ECM

1. ECM power supply malfunction • Check and repair power circuit.
Communication failure between 2. Malfunction of harness between • Check and repair or replace
diagnostic unit and ECM ECM and diagnostic unit corresponding harness.
DI
3. ECM malfunction • Replace ECM.
Circuit diagram
Engine ECM
K-line
K-line
Diagnostic interface
Diagnosis procedure
1. Check engine data.
b. Connect a diagnostic unit to the malfunction diagnostic interface (16-pin).
d. Turn on the diagnostic unit to read the engine data.
Can diagnostic unit access the ECM to read data stream?

DI
No> Go to step 2
2. Check the data of other modules.

a. Read the airbag or ABS data by a diagnostic unit.
b. Read the data by a diagnostic unit.
Can the diagnostic unit access the airbag or ABS module to read data stream?
Yes > to step 5.
No> Go to step 3
3. Check the ECM communication CAN cable.

c. Disconnect the ECM connector A001.
d. Use a multimeter to measure the continuity between pins 3 and 11 and pin B1 of diagnostic
interface connector C003 and the pins 62 and 81 of ECM connector E001.
e. Measure the continuity between pins 3 and 11 and the ground of diagnostic interface connector
C003 by a multimeter.
f. Place the ignition switch to “ON” position and use a multimeter to measure the resistance
between pins 3 and 11 of diagnostic interface connector C003.
Multimeter terminal block Standard value
C003(3) - E001(62) About 0Ω
C003(11) - E001(81) About 0Ω
C003(3) - C003(11) About 60Ω

Standard value:
C003(3) - E001(62)
Not conducting
C003(11) -E001(81)

Yes > to step 4.
No > Repair the ECM communication CAN cable.
4. Check the ECM power supply and ground.

a. Check ECM power circuit.
b. Check ECM grounding circuit.
DI
Yes > to step 5.
5. Replace ECM.
a. Replace ECM.
b. Read the engine data by a diagnostic unit. Ensure the normal communication between diagnostic
unit and ECM.
The starter motor rotates, but the engine can’t start.

Malfunction Diagnosis Table
1. Poor fuel quality • Replace fuel.
• Check crankshaft/camshaft
2. Establishment failure of working position sensor for intactness.
DI
timing sequence • Check its connector and wires
for intactness.
3. Fuel pressure sensor • Check and replace fuel
malfunction pressure sensor.
• Check fuel injection drive circuit
The starter motor can drive the (Including connectors) for
engine for rotation at normal presence of
speed, with clear ignition symptom, open-circuit/short-circuit.
but the engine can’t start. • Check high pressure fuel pipes
for presence of leakage.
4. Fuel injectors (No fuel injection) • Check fuel injectors for
presence of damage/carbon
deposit.
• Check crankshaft position
sensor.
• Check the position sensor of
camshaft.
5. ECM malfunction • Replace ECM

Diagnosis procedure
1. Check the engine malfunction indicator lamp and DTC.
a. Use a diagnostic unit to read the DTC.
Is a DTC present?
Yes > Perform DTC malfunction diagnosis procedure, with reference to DTC list.
No> Go to step 2
DI
2. Check the secondary ignition system.
a. Unplug the fuel injector fuse.
b. Unplug the high voltage wire and disassemble the spark plug.
c. Connect the spark plug to the high voltage wire and contact the negative post of spark plug to the
cylinder block.
d. Start the engine to test the secondary ignition system.
Standard value:
85-86 Conducting
30-87 Not conducting

Yes > to step 4.
No>Go to the next step.

a. Check the resistance of high voltage coil and clean the connector terminals.
Two terminals of high voltage coil >4kΩ

b. Check the spark plug for carbon deposit and carbon trace, check the ceramic insulation for
electric leakage due to cracking and for normal clearance, check positive and negative posts for
ablation, and clean the spark plug.

Yes > to step 4.
No > Clean and replace malfunctioned part.
4. Check crankshaft position sensor.

a. Use a diagnostic unit to read the data stream of engine crankshaft position (CKP) sensor. The
specified value shall be reached at the time of start.

Yes > to step 5.
No > Check the sensor for correct installation (Refer to Engine Control System - Disassembling
and Installation of Sensors) and repair or replace harness, connector, or damaged part.
5. Check throttle.
a. Lightly depress the accelerator pedal and start the engine. Check the engine for successful start.
DI
Check for successful start.
Yes > Check throttle and idling passage and remove carbon deposit. Unplug the idling stepping
motor connector and measure the connector terminal voltage (12V). The normal resistance range
is 28-33Ω under 20°C temperature. Check the idling stepping motor for blockage and when
necessary repair or replace.
No> Go to step 6
6. Check the water temperature sensor and intake manifold absolute pressure/temperature
sensor.
a. Check the intake manifold absolute pressure/temperature sensor for correct installation.
b. Disassemble the intake manifold absolute pressure/temperature sensor.
c. Check the sensing hole for blockage and check the resistances between various wiring terminals
for conformance with specification.
d. Check the temperature sensor for presence of dirt.
e. With the ignition switch at ON position, read the data steam of engine intake manifold absolute
pressure (MAP)/temperature sensor and water temperature sensor by a diagnostic unit.

Yes > to step 7.
No > Clean and replace malfunctioned part. Go to step 11.
7. Check the electric circuit of fuel system.

b. Check the fuel pump relay and fuel pump for normal functioning.

Yes > to step 8.
No > Repair or replace the fuel pump harness.
8. Check the fuel system pressure.

a. Check the fuel system pressure.

Yes > to step 10.
No > Repair or replace fuel system parts or circuits. If the fuel pressure is less than 300kPa, go to
step 9.
9. Check the fuel supply of fuel system.

a. Check the fuel inlet pipe for presence of leakage or blockage.
b. Check the gasoline filter for blockage.

Yes > to step 10.
DI
10. Check the fuel injector.
a. Unplug the fuel injector connectors.
b. Unplug the fuel distribution pipe along with fuel injectors.
c. Directly charge 12V voltage of battery onto the fuel injectors.
d. Every fuel injector shall spray the fuel of qualified standard flow, with uniform atomization.
Caution
While checking the injection status of fuel injectors, if the injection status is in columnar form
instead of conical form or the injected fuel volumes differ remarkably (>5ml) among the fuel
injectors of four cylinders under same condition, replace the fuel injectors. Check the nozzles of
fuel injectors for presence of gel substance. If present, dip the fuel injectors in detergent and
spray to wash, otherwise it will result in insufficient fuel injection volume or poor acceleration.
Danger
During the test of fuel system:

• Place a “Caution of inflammables” marking in the working area.
• Ensure to operate in a well-ventilated area and prepare a CO2 fire extinguisher.
• The smoking is prohibited during the fuel system related operations. Keep the working
area away from open fire and spark.
• Collect the drained fuel in an explosion-proof container.

Yes > to step 11.
No > Clean the fuel injectors. Re-check the working status of fuel injectors. If the fuel injection of
any fuel injector is still abnormal, replace the fuel injector.
11. Check the cylinder pressure.

a. Perform the cylinder compression pressure test.
Pressures of various cylinders 1200±200kPa
Limit values of various cylinders 1000kPa
Differential limit value among various cylinders <98kPa

Yes > to step 13.
No> Go to step 12
12. Check the engine valve timing.

a. Check crankshaft position sensor for failure.
b. Check crankshaft position sensor for qualified resistance.
c. Check the crankshaft position sensor for dirt.
d. With ignition switch at ON position, read the data stream of crankshaft position sensor by a
diagnostic unit.
DI
Yes > to step 13.
13. Check the engine mechanical part.

a. Observe the inside of cylinder by an endoscope.
b. Observe the variation of feedback voltage.
c. Break up and repair the internal malfunction of engine. Remove the carbon deposit or
disassemble and repair the engine cylinder head. Check the valves and intake manifold for
carbon deposit. The malfunctions include excessive clearance and poor sealing between piston
rings and cylinder block, air leakage of cylinder gasket, loose valve guide, non-sealed closing of
valves, and carbon deposit of valves.

Yes > to step 14.
No > Repair internal mechanical malfunctions of engine.
14. Check and replace ECM.

a. Replace ECM.
b. Check the engine data stream and ensure that the engine system is normal, without any
malfunction symptom.
Difficult start of cold engine and tremble of vehicle

1. Poor fuel quality • Replace fuel.
• Check preheating circuit for

2. Preheating circuit (Insufficient good connections.
DI
preheating) • Check preheater for normal
resistance.
• Check the intake manifold
temperature/pressure sensor
and its connector and wires for
intactness.
• Check the barometric pressure
3. Inappropriate mixture ratio. sensor and its connector and
wires for intactness.
Difficult start of cold engine and • Check the crankshaft/camshaft
tremble of vehicle position sensor.
• Check the coolant temperature
sensor.
(Including connectors) for
presence of
open-circuit/short-circuit.
4. Malfunction of fuel injector • Check high pressure fuel pipes
• Check fuel injectors for
deposit.

Diagnosis procedure
Is a DTC present? Yes

> Perform DTC malfunction diagnosis procedure, with reference to DTC list.
No> Go to step 2
DI
2. Check the battery
a. Check the battery voltage during the start of engine.
Standard voltage:
Battery positive and negative posts About 9.6V

Yes > to step 3.
No > Charge or replace battery.
3. Check starter motor.

a. Check the starter motor or its circuit for presence of malfunction.

Yes > to step 4.
No > Solve the problem and ensure that the symptom no longer exists.
4. Check crankshaft position sensor.

a. Use a diagnostic unit to read the data stream of engine crankshaft position (CKP) sensor. The
specified value shall be reached at the time of start.

Yes > to step 5.
No > Check the sensor for correct installation (Refer to Engine Control System - Disassembling
and Installation of Sensors) and repair or replace harness, connector, or damaged part.
sensor.

Yes > to step 6.
6. Check the intake system

a. Check the vacuum pressure of intake pipe during idling.
b. Check various connectors, gaskets, and vacuum hoses of intake pipe and check the exhaust gas
DI recirculation system and fuel evaporation system.
c. Check air filter element for presence of blockage.

Yes > to step 7.
7. Check throttle.
a. Lightly depress the accelerator pedal and start the engine. Check the engine for successful start.

Yes > Check throttle and idling passage and remove carbon deposit. Unplug the idling stepping
motor connector and measure the connector terminal voltage (12V). The normal resistance range
is 28-33Ω under 20°C temperature. Check the idling stepping motor for blockage and when
necessary repair or replace.
No> Go to step 8
8. Check idling stepping motor.

a. When the ignition switch is turned on, check the idling stepping motor for presence of telescoping.
b. When the ignition switch is turned off, check the idling stepping motor for actuation. The opening
extent shall be maximum under normal status.

Yes > to step 9.
No > Repair or replace connector, harness, or idling stepping motor.


Yes > to step 11.
step 10.


Yes > to step 11.

c. Directly charge 12V voltage of battery onto the fuel injectors. DI
Caution
Danger


Yes > to step 12.


Yes > to step 13.
No> Go to step 12
diagnostic unit.

Yes > to step 14.
DI 14. Check the engine mechanical part.


Yes > to step 15.

a. Replace ECM.
Unstable (Varying) idling

1. Inconsistent engine oil • Replace with specified engine

trademark against specification. oil.
• Check whether the high
pressure fuel pump can provide DI
sufficient fuel rail pressure.
• Check fuel metering unit for
damage.
2. Malfunction of fuel supply • Check low pressure fuel
system pipeline for non-obstructed fuel
supply, check fuel injectors for
blockage, and check high
pressure fuel pipes for cracking.
• Check fuel pressure sensor for
damage.
• Check throttle assembly.
3. Poor idling stepping motor. • Check for poor idling stepping
motor.
Unstable (Varying) idling of engine • Check the air filter and intake
pipeline.
4. Malfunction of intake system
pressure sensor.
• Check crankshaft/camshaft
5. Incorrect working timing position sensor for intactness.
sequence. • Check its connector and wires
for intactness.
presence of
deposit.
Caution
During the idling of engine, if the gas mixture is improperly compounded, the intake system is
leaking, or the individual cylinder fails due to malfunction of ignition system, it will result in
idling failure, over-high idling speed, unstable idling, and poor high-speed idling.
Diagnosis procedure
a. Read the engine DTC by a diagnostic unit.
Is a DTC present?
No> Go to step 2
DI
2. Perform the visual observation and external checking.
a. Observe the running status and jitter of engine.
b. Observe the swing amplitude of engine tachometer pointer and check for deviation from target
idling speed.
c. Observe for normal idling jitter or loaded idling jitter. (Turn on the A/C and lamps, shift to a drive
gear, and rotate the steering wheel)
d. Check the engine accessories for abnormality, check vacuum pipes for falloff and damage, and
check wire connectors for looseness.
e. Check for leakage of oil, water, air, and electricity.
f. Check exhaust pipe for abnormalities such as “chug chug” sound (Which indicates poor
combustion), black exhaust gas, and gasoline smell.

Yes > to step 3.
No > Solve the external problem and ensure that the symptom no longer exists.
3. Check throttle body and idling steeping motor.

a. Check throttle for presence of oil dirt and carbon deposit, check throttle for stagnation, check
intake passage around throttle for oil dirt and carbon deposit, and check idling stepping motor for
carbon deposit.
b. Start and idle the engine.
c. Use a diagnostic unit to test the idling stepping motor.
d. When the diagnostic unit controls the telescoping rotation of idling stepping motor, the engine
speed shall vary synchronously. (The hand touch on the idling stepping motor can feel the
vibration)
e. Unplug the connector of idling stepping motor and measure the connector terminals. There shall
be 12V voltage.
f. When the ignition switch is turned on, check the idling stepping motor for presence of telescoping.
g. While turning off the ignition switch, check the idling stepping motor for actuation.

Yes > to step 4.
No > Clean and repair or replace connector, harness, or idling stepping motor.
4. Check the engine ignition system.

a. Idle the engine, cut off the cylinders one by one, and observe the engine speed for presence of
variation.
b. During the cutoff of various cylinders, the engine speed shall clearly drop or vibrate
correspondingly.

Yes > to step 11.
No> Go to step 5
5. Check the secondary ignition system. DI


b. Check the spark plugs for carbon deposit and carbon trace, check the ceramic insulation for
electric leakage due to cracking and for normal clearance.
Check positive and negative posts for ablation and clean spark plug.
Yes > to step 6.

Caution
Danger


Yes > to step 7.

DI
Yes > to step 8.
step 8.


Yes > to step 9.
9. Check intake and exhaust system.

a. Check engine intake system for leakage.
b. Check intake pipe for loose connection, cracking, deformation, and aged seal.
b. Clamp the vacuum booster hose or unplug and block it and observe for idling variation.
d. Check the intake pipe for “Hiss” leakage sound during running of engine.
e. Check the positive crankcase ventilation (PCV) hose for air leakage and check PCV for excessive
opening extent.
f. Check vacuum pipe of evaporative emission control system for air leakage.
g. Check vacuum hose of fuel pressure regulator for damage, falloff, and cracking.
h. Check three-way catalytic converter for blockage.
i. Check throttle body seals for air leakage.
j. Check intake manifold sealing gasket for air leakage.

Yes > to step 10.
No > Repair or replace the malfunctioned part.
sensor.

Yes > to step 11.
11. Check oxygen sensors. DI

a. Check upstream and downstream oxygen sensors for correct installations.
b. Idle the engine and check the data stream by diagnostic unit. After the coolant temperature
reaches the normal temperature for activation of closed-loop control, observe the oxygen sensors
for normal functioning.
Caution
Normal data of oxygen sensors: Normal variation within 1~1V. There shall be 8 alternate changes
between maximum and minimum values within 10s.

Yes > to step 12.


Yes > to step 14.
No> Go to step 13

diagnostic unit.

Yes > to step 14.


DI Check if results are normal?

Yes > to step 15.

a. Replace ECM.
Over-high idling speed

• Check the air filter and intake

1. Excessive intake volume during pipeline.
idling • Check the intake manifold
pressure sensor. DI
damage.
Over-high idling speed (The idling 2. Excessive fuel injection volume damage.
speed is higher than specified • Check fuel injectors for damage
value) and check their related
harnesses for malfunction.
• Check throttle cable for
over-tight tension.
3. Throttle malfunction
• Check throttle body for
malfunction.
Caution
During the idling of engine, if the gas mixture is improperly compounded, the intake system is
leaking, or the individual cylinder fails due to malfunction of fuel supply system, it will result in
idling failure, over-high idling speed, unstable idling, and poor high-speed idling.
Diagnosis procedure
Is a DTC present?
No> Go to step 2
DI
a. Perform the visual observation and external checking.

Yes > to step 3.

a. Check engine intake system for leakage.
b. Check the intake pipe for “Hiss” leakage sound during running of engine.
c. Check intake pipe for loose connection, cracking, deformation, and aged seal.
Check intake pipe for loose connection, cracking, and deformation. If checking result normal?
Yes > to step 4.
No > Repair and replace or reinstall.
4. Check related accessories.

a. Check vacuum hose of carbon canister solenoid valve for reliable connection and damage.
b. Check vacuum adjustment hose of fuel pressure regulator for reliable installation and damage.
c. Check positive crankcase ventilation vacuum pipe for reliable installation and damage.
d. Check brake system vacuum booster pipe for reliable installation and damage.

Yes > to step 5.
No > tAdjustment or replacement

f. Unplug the connector of idling stepping motor and measure the connector terminals. There shall
be 12V voltage.
g. When the ignition switch is turned on, check the idling stepping motor for presence of telescoping.
h While turning off the ignition switch, check the idling stepping motor for actuation.

Yes > to step 6.
sensor. DI

Yes > to step 7.


Yes > to step 8.
No > Repair or replace fuel system parts or circuits.

Caution
Danger

DI

Yes > to step 9.

a. Replace ECM.
Flameout of cold engine during idling


pipeline.
pressure sensor. DI
• Check the crankshaft/camshaft
position sensor.
sensor.
pressure fuel pump can provide
damage.
Flameout of cold engine during system pipeline for non-obstructed fuel
idling supply, check fuel injectors for
damage.
presence of
deposit.

Diagnosis procedure
Is a DTC present?
No> Go to step 2
DI
b. Observe the swing amplitude of engine tachometer pointer and the engine speed at time of
flameout.
c. Observe for normal idling flameout or loaded idling flameout (Turn on the A/C and lamps, shift to a
drive gear, and rotate the steering wheel).

Yes > to step 3.
No > Solve the abnormality and ensure that the symptom no longer exists.

carbon deposit.
vibration)
e. Unplug the connector of idling stepping motor and measure the connector terminals. There shall
be 12V voltage.

Yes > to step 4.
4. Check the coolant temperature sensor.

a. Check for qualified resistances between wiring terminals of water temperature sensor.
b. Check the water temperature sensor for dirt.
c. With ignition switch at ON position, read the data stream of water temperature sensor by a
diagnostic unit.

Yes > to step 5.
5. Check the intake temperature sensor.

a. Check for qualified resistances between wiring terminals of intake temperature sensor.
b. Check the intake temperature sensor for presence of dirt.
c. With ignition switch at ON position, read the data stream of intake temperature sensor by a DI
diagnostic unit.

Yes > to step 6.

a. Replace ECM.
b. Verify whether the malfunction is solved.
Flameout of engine at startup of vehicle


pipeline.
DI pressure sensor.
position sensor.
damage.
Flameout of engine at startup of supply, check fuel injectors for
vehicle blockage, and check high
damage.
presence of
deposit.

Diagnosis procedure
Is a DTC present?
No> Go to step 2
DI
b. Observe the swing amplitude of engine tachometer pointer and the engine speed at time of
flameout.
c. Observe for normal idling flameout or loaded idling flameout (Turn on the A/C and lamps, shift to a
drive gear, and rotate the steering wheel).

Yes > to step 3.
No > Solve the abnormality and ensure that the symptom no longer exists.

carbon deposit.
vibration)
e. Unplug the throttle sensor connector and measure the connector terminals for presence of
voltage.

Yes > to step 4.
4. Check the intake temperature/pressure sensor.

a. Check for qualified resistances between wiring terminals of intake temperature/pressure sensor.
b. Check the intake temperature/pressure sensor for presence of dirt.
c. With ignition switch at ON position, read the data stream of intake temperature/pressure sensor
by a diagnostic unit.

Yes > to step 5.

DI c. Directly charge 12V voltage of battery onto the fuel injectors.
Caution
Danger


Yes > to step 6.


Yes > to step 7.
step 8.


Yes > to step 8.

Pressures of various cylinders 1200～200kPa

DI
Yes > to step 10.
No> Go to step 9

diagnostic unit.

Yes > to step 10.

carbon deposit.
The malfunctions include excessive clearance and poor sealing between piston rings and cylinder
block, air leakage of cylinder gasket, loose valve guide, non-sealed closing of valves, and carbon
deposit of valves.

Yes > to step 11.

a. Replace ECM.
Slow acceleration response and maladjustment.

pipeline.
pressure sensor.
DI 1. Malfunction of intake system
position sensor.
sensor.
damage.
Slow engine acceleration response supply, check fuel injectors for
and maladjustment. blockage, and check high
damage.
presence of
deposit.
4. Accelerator pedal sensor • Check accelerator pedal
malfunction sensor.
Diagnosis procedure
Is a DTC present?
No> Go to step 2
DI
a. Check various connectors, gaskets, and vacuum hoses of intake pipe and check the exhaust gas
recirculation system and fuel evaporation system.
b. Check air filter element for presence of blockage.

Yes > to step 3.
3. Check the idle running.

a. Check the engine for normal idling.

Yes > to step 4.
No > Ensure that the symptom no longer exists, with reference to the Engine Symptom Diagnosis
List - Idling Malfunction Troubleshooting.
sensor.

Yes > to step 5.
5. Check throttle position.

a. Use a diagnostic unit to check for normal throttle.
b. Check the throttle for normal variation of opening extent when the accelerator pedal is depressed.

Yes > to step 6.

DI c. Directly charge 12V voltage of battery onto the fuel injectors.
Caution
Danger


Yes > to step 7.


Yes > to step 9.
step 8.


Yes > to step 9.

DI
Yes > to step 12.
No> Go to step 11

diagnostic unit.

Yes > to step 12.


Yes > to step 13.

a. Replace ECM.
Poor acceleration and poor performance

• Check accessories (such as

fan) for obstructed rotation.
1. Excessive load • Check the condition of engine
DI oil.
• Check the exhaust brake.
pipeline.
pressure sensor.
position sensor.
sensor.
damage.
Poor acceleration and poor 3. Malfunction of fuel supply • Check low pressure fuel
performance of engine system pipeline for non-obstructed fuel
supply, check fuel injectors for
damage.
presence of
deposit.
5. Accelerator pedal sensor • Check accelerator pedal
malfunction sensor.

Diagnosis procedure
Is a DTC present?
No> Go to step 2
DI
a. Perform the external visual observation.
b. Check whether the handbrake is released.
c. Check the clutch for slip.
d. Check the chassis for normal four-wheel alignment.
e. Check the tires for consistent specification and normal pressure.
f. Check the brake system for normal functioning, solve the braking drag and ABS malfunction, and
ensure the normal return of brake slave cylinders.

Yes > to step 3.
3. Check throttle position.

a. Use a diagnostic unit to check for normal throttle.
b. Check the throttle for normal variation of opening extent when the accelerator pedal is depressed.

Yes > to step 4.
sensor.

Yes > to step 5.


Yes > to step 9.
step 6.

DI b. Check the gasoline filter for blockage.

Yes > to step 7.

Caution
Danger


Yes > to step 8.

a. Unplug the fuel injector fuse.
b. Unplug the high voltage wire and disassemble the spark plug.
c. Connect the spark plug to the high voltage wire and contact the negative post of spark plug to the
cylinder block.
d. Start the engine to test the secondary ignition system.

Yes > to step 10.
No> Go to step 9

Multimeter connection Standard value DI

b. Check the spark plugs for carbon deposit and carbon trace, check the ceramic insulation for
electric leakage due to cracking and for normal clearance. Check positive and negative posts for
ablation and clean spark plug.

Yes > to step 10.


Yes > to step 12.
No> Go to step 11

diagnostic unit.

Yes > to step 12.


Yes > to step 13.
DI
a. Replace ECM.
Starter motor malfunction

• Insufficient or no power of
battery
Battery malfunction.
• Corroded or loose wiring posts
of battery DI
The starter doesn’t work • Check related circuits for
Malfunction of starter system circuit
open-circuit and short-circuit.
• Check and repair or replace
starter motor.
ECM fault • Replace ECM
• Low battery power

Battery malfunction. • Corroded or loose wiring posts
of battery
Weak start of starter motor starter motor.
• Check and repair engine
mechanical malfunctions.
Excessive resistance of engine
• Check the condition of engine
oil.
Idling of starter motor Starter motor malfunction
starter motor.
Starter motor relay malfunction • Replace starter motor relay.
The starter motor continues Starter motor malfunction • Check and repair or replace
rotation after start of engine starter motor.
Blockage of tooth face
starter motor.
Diagnosis procedure
1. Check the battery
a. Check the voltage of battery.
Standard voltage:
Battery positive and negative posts About 24V

DI
Yes > to step 2.
No > Charge or replace battery.
2. Check starter motor and its circuit.

a. Check the starter motor or its circuit for presence of malfunction.
b. Check for normal starter motor relay.

Yes > to step 3.
No > Check and repair the related malfunction.

a. Replace ECM.
b. Verify whether the malfunction is solved.
Diagnosis of body electronic control malfunctions

Reversing sensor malfunction
Overview
The reversing sensor is working in such manner that a group of ultrasonic wave is reflected to the probes
of reversing sensor after being striking onto any object and the reversing sensor controller utilizes the
interval between emitted ultrasonic wave and reflected ultrasonic wave to measure the distance, in order
DI
to alert the driver of the obstacles behind and display them on the display.
Precautions
1. Causes to abnormal operation of the reversing radar system:
a. The reversing radar probe is covered by mud, snow or other foreign matters (the normal operation
is restored after the sensor is cleaned).
b. The reversing radar probe is frozen (the normal operation is restored after the sensor is cleaned).
c. The reversing radar probe is blocked.
2. The detection range may be restricted under following conditions:
DI a. The reversing radar probe is covered by mud, snow or other foreign matters.
b. The vehicle operates in the extremely hot or cold area.
3. The reversing radar probe may detect incorrect information under following conditions, for
example:
a. The vehicle operates on the rugged road surface or unpaved road or in the high grass.
b. The horn sound from another vehicle, the motorcycle engine noise, the noise generated from the
air brake of the large-sized vehicle or the ultrasonic wave from the sonar of another vehicle is
being transmitted in the vicinity of the vehicle.
c. The vehicles moves in heavy rain or the reversing radar probe comes into contact with water.
d. The vehicle is tilted heavily.
e. The vehicle is equipped with any additional protection rod or wireless unit antenna.
f. The reversing radar probe is covered by mud, snow or other foreign matters.
g. The vehicle is moving toward the edge or corner of any object.
4. The reversing radar probe encounters any object which can’t be detected by it, for
example:
a. Wire, rope or other thin objects.
b. Cotton, snow or other materials which can absorb the ultrasonic wave.
c. Sharp objects.
d. Short and small objects.
5. Other precautions:
a. The reversing radar probe can’t detect any object located right beneath the bumper.
b. The reversing radar probe can’t detect any obstacle which is too close.
c. The reversing radar probe may not detect the obstacle when it is detached or is violently
impacted.
Preparations
Recommended tools
Digital multimeter Test the voltage and resistance DI


Use the following table to help you to find out the reasons of faults. Serial number represents the order of
possibility of fault reasons. Check each part as per this order and replace as the case may be.
1. Circuit (open circuit or short Repair or replace the

circuit ) malfunctioned harness
DI 2. Fuse (Burnout) Replace the same type of fuse.

The reversing radar system works
abnormally 3. Reversing radar controller Change of parking distance
(damaged) controller
4. Reversing lamp switch
Replace the reversing lamp switch
(damaged)
When the reversing radar is
working, the multimedia gives no 2. Radio/audio player (Damage) Change of radio and player
warning
3. Reversing radar controller Change of parking distance
(damaged) controller
The reversing radar system works abnormally

Circuit diagram
Ignition switch IG2
DI
Body fuse
case
Radio/audio
Reversing Reversing sensor Reversing player
signal signal sensor -
Reversing
lamp switch
Reversing sensor Multimedia reversing Multimedia reversing

controller power supply sensor signal sensor -
Reversing
sensor
controller
Left sensor Left sensor Left middle Left middle sensor Right middle Wire number of right Right sensor Right sensor
probe - probe signal sensor probe - probe signal sensor probe - middle sensor probe probe - probe signal Ground
Left sensor Left sensor Left middle Left middle Right middle Right middle Right sensor Right sensor
probe - probe signal sensor probe - sensor probe sensor probe - sensor probe probe - probe signal
signal signal
Left sensor probe Left middle sensor probe Right middle sensor probe Right sensor probe

Malfunction symptom Phenomenal description:
Turn the ignition switch to ON and engage the

After the reverse gear is engaged, the reversing radar
reverse gear, the reversing radar system doesn’t work
system works abnormally
or works abnormally
Diagnosis procedure
DI 1. Check the reversing lamp system
b. Engage the reverse gear.
c. Check the rearview lamp.
Is the reversing lamp illuminated ?

Yes > to step 5.
No> Go to step 2
2. Check fuse
b. Open the body fuse box.
c. Take out the reversing lamp switch fuse IF07(10A).
Caution
Dismantle the fuse by special fuse remover, do not pull out by hand, which may bring damage to
fuse.
d. Check whether the middle fusible wires of the

Normal reversing lamp switch fuse IF07(10A) is blown out.
Off
Is the fuse blown out?

Yes > replace the same type of fuse.
No> Go to step 3
3. Check the reverse light switch.

b. Disconnect the reversing lamp switch connector E016.
c. Before engaging the reverse gear, turn the

multi-meter to the resistance mode, and measure
the continuity between No.1 and No.2 terminals of
the reversing lamp switch connector E016.
E016(1)-E016(2) Not conducting

DI
d. After the reverse gear is engaged, use the

multi-meter to measure the continuity between No.1
and No.2 terminals of the reversing lamp switch
connector E016.
E016(1)-E016(2) About 0Ω

Yes > to step 4.
No>Replace rearview lamp switch.
4. Check the power circuit of the reversing lamp switch

d. Turn the multi-meter to the voltage mode, and
measure the voltage between the No.1 terminal of
the reversing lamp switch connector E016 and
GND.
Standard voltage:
E016 (1)-grounding Battery voltage

Yes > to step 5.
No > Repair or replace the power wire of the reversing lamp switch.
5. Check the circuit from reversing lamp switch to reversing radar controller
c. Disconnect the reversing radar controller connector L009.
d. Turn the multi-meter to the resistance mode, and

measure the resistance between the No.9 terminal
of the reversing radar controller connector L009 and
the No.2 terminal of the reversing lamp switch
connector E016.
DI
L009(9)-E016(2) About 0Ω

Yes > to step 6.
No > Repair or replace the circuit from reversing lamp switch to reversing radar controller.
6. Check the earthing circuit of the reversing radar controller

b. Disconnect the reversing radar controller connector L009.
c. Turn the multi-meter to the resistance mode, and
GND.
L009 (10)-grounding About 0Ω

Yes > to step 7.
No > Repair or replace the earthing circuit of the reversing radar controller.
7. Check the circuit from reversing radar probe to reversing radar controller
c. Disconnect the left reversing radar probe connector

L003, turn the multi-meter to the resistance mode,
and measure the resistance between the No.1
terminal of the reversing radar controller connector
L009 and the No.2 terminal of the left reversing
radar probe connector L003, and the resistance
between the No.5 terminal of the reversing radar
controller connector L009 and the No.1 terminal of DI
the left reversing radar probe connector L003.
L009(1)-L003(2) About 0Ω
L009(5)-L003(1) About 0Ω
d. Disconnect the left middle reversing radar probe
connector L004, turn the multi-meter to the
resistance mode, and measure the resistance
controller connector L009 and the No.1 terminal of
the left middle reversing radar probe connector
L004, and the resistance between the No.2 terminal
the No.2 terminal of the left middle reversing radar
probe connector L004.
L009(2)-L004(2) About 0Ω
L009(6)-L004(1) About 0Ω
e. Disconnect the right middle reversing radar probe
the right middle reversing radar probe connector
L007, and the resistance between the No.3 terminal
the No.2 terminal of the right middle reversing radar
probe connector L007.
L009(3)-L007(2) About 0Ω
L009(7)-L007(1) About 0Ω
f. Disconnect the right reversing radar probe

the right reversing radar probe connector L008, and
the resistance between the No.4 terminal of the
DI reversing radar controller connector L009 and the
No.2 terminal of the right reversing radar probe
connector L008.
L009(4)-L008(2) About 0Ω
L009(8)-L008(1) About 0Ω

Yes > to step 8.
No> Repair or replace the faulted circuit.
8. Check the reversing radar probe

b. Replace the reversing radar probe.

Yes > Change of parking distance probe
No> Go to step 9
9. Check the reversing radar controller

b. Replace the parking distance controller

Yes > Replace the parking distance controller
No > Recheck the above procedures.
When the reversing radar is working, the multimedia gives no warning

Circuit diagram
Ignition switch IG2
DI
Body fuse
case
Radio/audio
player
Reversing Reversing sensor Reversing
Reversing
lamp switch
Reversing sensor Multimedia reversing Multimedia reversing

controller power supply sensor signal sensor -
Reversing
sensor
controller
Left sensor Left sensor Left middle Left middle sensor Right middle Right middle sensor Right sensor Right sensor
probe - probe signal sensor probe - probe signal sensor probe - probe signal probe - probe signal Ground
signal signal

Turn the ignition switch to ON and engage the

When the reversing radar is working, the multimedia reverse gear, the reversing radar system works
gives no warning normally; when any obstacle is detected, the
multimedia doesn’t give any warning
DI
Diagnosis procedure
1. Check the entertainment system
b. Check the entertainment system.

Yes > to step 2.
No > Repair the entertainment system.
2. Check the circuit between the reversing radar controller and the radio-cassette player
c. Disconnect the radio-cassette player connector C026.
the No.2 terminal of the radio-cassette player
connector C026, and the resistance between the
No.12 terminal of the reversing radar controller
connector L009 and the No.1 terminal of the
radio-cassette player connector C026.
L009(11)-C026(2) About 0Ω
L009(12)-C026(1) About 0Ω

Yes > to step 3.
No > Repair or replace the circuit between the reversing radar controller and the radio-cassette
player.
3. Check the reversing signal circuit of the radio-cassette player

b. Disconnect the radio-cassette player connector C024.
c. Disconnect the reversing lamp connector E016.

of the radio-cassette player connector C024 and the
No.2 terminal of the reversing lamp connector
E016.
DI
C024(9)-E016(2) About 0Ω

Yes > to step 4.
No > Repair or replace the reversing signal circuit of the radio-cassette player.
4. Check the reversing radar controller

b. Disconnect the reversing radar controller connector.
c. Fit a reversing radar controller under good conditions, refit the connector and check whether the
fault is eliminated.
Is the fault eliminated?

Yes > Replace the parking distance controller
Basic inspections
Procedure Inspection Content Measure
Check the battery voltage. Yes Go to step 2

The battery voltage
1 should be about 12V.
Charge or replace the the
Check if results are No
battery
normal?
DI Check whether the Yes Ending of inspection
reversing radar probe
works normally when the
reverse gear is engaged.
2 After the reverse gear is
engaged, the multimedia No Go to fault symptom list
gives the warning
information normally. Is
the operation normal?
Power window failure

Overview
The occupant can control the electrification phase sequence and time of the window lifter motor by
operating the left or right electric window switch, and open or close the window glass in an electric way to
facilitate the operation of the window glass by the driver and the occupant.
DI
Precautions
1. Ignition switch description
Ignition switch (position) Descriptions of ignition switch.
LOCK Turn off the power master switch
Stop gear, turn on the electric equipment when car

ACC
stops, such as radio and cigar lighter, etc.
DI Travel gear, turn on the electric equipment when car
ON
travels, such as instrument, etc.
Turn the key to Start, and then a start signal will be
START sent. After the engine is started, the key will be
automatically returned to “ON”.
2. Cut off the power supply.
a. Before any electrical device is removed or installed, and when the tool or equipment contacts the
naked electrical terminal, the battery negative cable shall be disconnected first in order to protect
the repair personnel or vehicle.
Caution
Before disconnect the cable at battery cathode, please do not keep the vehicle key inside the
vehicle for fear of door locking.
b. Close the ignition switch unless otherwise specified.
3. Disconnection of the battery negative cable negative terminal may lead to loss of the
stored settings in the audio system.
Caution
After reconnecting the battery negative cable, reset the audio system.
Preparations
Recommended tools


1. Low battery voltage Charge or replace the battery

DI circuit ) malfunctioned harness
All windows don’t work
3. Fuse (Burnout) Replace the same type of fuse.
4. BCM (damaged) Replace BCM

2. Driver side electric window Replace the driver side electric
Only the left front window doesn’t switch (damaged) window switch
work
3. Left front window lifter motor Replace the left front window lifter
(damaged) motor

Only the right front window can’t be
raised or lowered (the left front 2. Assistant driver side electric Replace the assistant driver side
door is operative) window switch (damaged) electric window switch

Only the right front window can’t
work (the left front door is 2. Right front window lifter motor Replace the right front window lifter
inoperative) (damaged) motor

All windows don’t work

Circuit diagram
Battery Ignition switch IG1
DI
Frame fuse Front passenger door

Body fuse
box electric window switch
case
Lower
Up
Battery power Battery power IG1 Power Lowering control of Lifting control of right
supply supply supply right front door front door window
window glass glass
Lowering control of Lifting control of left Lowering control of Lifting control of right Lowering of Lifting of left Lowering of Lifting of right
left front door front door window right front door front door window left front front window right front door front door
window glass glass window glass glass window glass glass window glass window glass
Driver door
electric
Driver door window
electric switch
window Lower (Right
Lower
switch control)
Up Up
Left front window lifter motor Right front window lifter motor

Operate the window lifter switch, and all windows With the ignition switch at “ON”, operate the electric
don’t work. window switch, and the window doesn’t work
Diagnosis procedure
1. Check fuse
DI a. Ignition switch: LOCK.
c. Take out the BCM fuses IF17(7.5A) and IF34(25A).
Caution
fuse.
d. Check whether the middle fusible wires of BCM

fuses IF17(7.5A) and IF34(25A) are blown out.
Off Normal
Check whether the fuse is burnt out?

No> Go to step 2
2. Check the BCM power circuit

b. Disconnect the BCM connectors C034 and C035.
c. Turn the multi-meter to the voltage mode, and
measure the voltage between the No.1 and No.2
terminals of the BCM connector C035.
Standard voltage:
C035 (1)-grounding Battery voltage

d. With the ignition switch at ON, turn the multi-meter

to the voltage mode, and measure the voltage
between the No.1 terminal of the BCM connector
C034 and GND.
Standard voltage:

DI

Yes > to step 3.
No > Repair or replace the BCM power circuit.
3. Check the BCM earthing circuit

b. Disconnect BCM connector C035.
measure the resistance between the No.12 and
No.13 terminals of the BCM connector C035.
C035 (12)-grounding About 0Ω

Yes > to step 4.
No > Repair or replace the BCM earthing circuit.
4. Check BCM
b. Disconnect BCM connector.
c. Fit a BCM under good conditions, refit the connector and check whether the window fault is
eliminated.

Yes > Replace BCM.
Only the left front window doesn’t work

Circuit diagram
DI

Body fuse
case
Lower
Up
window glass glass
Driver door
electric
Driver door window
electric switch
window Lower (Right
Lower
switch control)
Up Up

With the ignition switch at ON, operate the driver side

electric window switch, and the left front window glass
The left front window doesn’t work
can’t be raised or lowered, while the window glass on
the other side can work normally.
DI
Diagnosis procedure
1. Check the left front window lifter motor
b. Disconnect the left front window lifter motor connector J005.
c. Connect both terminals of the left front window lifter motor to the battery positive and negative
terminals respectively.
Does the motor work normally ?

Yes > to step 2.
No >Replace the left front window lifter motor .
2. Check the driver side electric window switch.

b. Disconnect the driver side electric window switch connector J006.
c. Fit a driver side electric window switch under good conditions, refit the connector and check
whether the window fault is eliminated.

Yes >Replace the driver side electric window switch.
No> Go to step 3
3. Check the circuit between the left front window lifter motor and BCM
b. Disconnect the left front window lifter motor connector J005.
c. Disconnect BCM connector C035.
d. Turn the multi-meter to the resistance mode,
of the left front window lifter motor connector J005
and the No.6 terminal of the BCM connector C035,
and the resistance between the No.2 terminal of the
left front window lifter motor connector J005 and the
No.5 terminal of the BCM connector C035.
J005(1)-C035(6) About 0Ω
J005(2)-C035(5) About 0Ω

Yes > to step 4.
No > Repair or replace the circuit between the left front window lifter motor and BCM.
4. Check the circuit between the driver side electric window switch and BCM
DI c. Disconnect BCM connector C034.
of the driver side electric window switch connector
J006 and the No.9 terminal of the BCM connector
C034, and the resistance between the No.5 terminal
J006 and the No.8 terminal of the BCM connector
C034.
J006(3)-C034(9) About 0Ω
J006(5)-C034(8) About 0Ω

Yes > to step 5.
No > Repair or replace the circuit between the driver side electric window switch and BCM.
5. Check the earthing circuit of the driver side electric window switch.
J006 and GND.
J006 (4)-grounding About 0Ω

Yes > to step 6.
No > Repair or replace the earthing circuit of the driver side electric window switch.
6. Check BCM

eliminated.

Yes > Replace BCM.
DI
Only the right front window can’t be raised or lowered (the left front door is
operative)
Circuit diagram
DI

Body fuse
case
Lower
Up
window glass glass
Driver door
electric
Driver door window
electric switch
window Lower (Right
Lower
switch control)
Up Up

With the ignition switch at ON, operate the assistant

driver side electric window switch, and the right front
The right front window can’t be raised or lowered window glass can’t be raised or lowered; however,
the driver side window switch (control the right side) is
operative.
DI
Diagnosis procedure
1. Check the assistant driver side electric window switch
b. Disconnect the assistant driver side electric window switch connector H006.
c. Fit an assistant driver side electric window switch under good conditions, refit the connector and
check whether the window fault is eliminated.

Yes > Replace the assistant driver side electric window switch.
No> Go to step 2
2. Check the circuit between the right front window lifter motor and BCM
b. Disconnect the right front window lifter motor connector H005.
of the right front window lifter motor connector H005
and the No.4 terminal of the BCM connector C035,
and the resistance between the No.2 terminal of the
right front window lifter motor connector H005 and
the No.3 terminal of the BCM connector C035.
H005(1)-C035(4) About 0Ω
H005(2)-C035(3) About 0Ω

Yes > to step 3.
No > Repair or replace the circuit between the right front window lifter motor and BCM.
3. Check the circuit between the assistant driver side electric window switch and BCM

of the assistant driver side electric window switch
connector H006 and the No.13 terminal of the BCM
No.5 terminal of the assistant driver side electric
window switch connector H006 and the No.12
DI terminal of the BCM connector C034.
H006(3)-C034(13) About 0Ω
H006(5)-C034(12) About 0Ω

Yes > to step 4.
No > Repair or replace the circuit between the assistant driver side electric window switch and
BCM.
4. Check the earthing circuit of the assistant driver side electric window switch.
of the assistant driver side electric window switch
connector H006 and GND.
H006 (4)-grounding About 0Ω

Yes > to step 5.
No > Repair or replace the earthing circuit of the assistant driver side electric window switch.
5. Check BCM
eliminated.

Yes > Replace BCM.
Only the right front window can’t work (the left front door is inoperative)
Circuit diagram
DI

Body fuse
case
Lower
Up
window glass glass
Driver door
electric
Driver door window
electric switch
window Lower (Right
Lower
switch control)
Up Up

With the ignition switch at ON, operate the assistant

driver side electric window switch, and the right front
The right front window can’t be raised window glass can’t be raised or lowered; furthermore,
the driver side window switch (control the right side) is
also inoperative.
DI
Diagnosis procedure
1. Check the right front window lifter motor
b. Disconnect the right front window lifter motor connector H005.
c. Connect both terminals of the right front window lifter motor to the battery positive and negative
terminals respectively.
Does the motor work normally ?

Yes > to step 2.
No > Replace the right front window lifter motor
2. Check the earthing point

b. Check the body ground earthing point of the wiring harness for looseness and corrosion.

Yes > to step 3.
No > Repair the faulted earthing point.
3. Check BCM
eliminated.

Yes > Replace BCM.
Basic inspections

The battery voltage
Charge or replace the the
battery
normal?
Check the left front DI
Yes Go to step 3
window lifter motor, with
the ignition switch at ON.
Use the driver side
2 electric window switch to
raise and lower the left No Go to fault symptom list
front window glass.
Check if results are
normal?
Check the right front Yes Ending of inspection
window lifter motor, with
the ignition switch at ON.
Use the driver side
electric window switch
(control the right side) to
raise and lower the right
3 front window glass.
Use the assistant driver No Go to fault symptom list
side electric window
switch to raise and lower
the right front window
glass.
normal?
Fault of power door lock control system

Precautions
a. Before any electrical device is removed or installed, and when the tool or equipment contacts the
naked electrical terminal, the battery negative cable shall be disconnected first in order to protect
the repair personnel or vehicle.
DI
Caution
Before disconnect the cable at battery cathode, please do not keep the vehicle key inside the
vehicle for fear of door locking.
b. Close the ignition switch unless otherwise specified.
2. Disconnection of the battery negative cable negative terminal may lead to loss of the
stored settings in the audio system.
Caution
After reconnecting the battery negative cable, reset the audio system.
Preparations
Recommended tools


Repair or replace the

DI 2. Circuit (faulted)
malfunctioned harness
All electric door locks fail
3. Left door lock (damaged) Replace the left door lock

Use the vehicle key and only the 1. Circuit (faulted)
left front door can be opened or
closed. 2. Right door lock (damaged) Replace the right door lock

1. Circuit (faulted)
Use the vehicle key to open or
close the left front door 2. Left door lock (damaged) Replace the left door lock

All electric door locks fail

Circuit diagram
DI
Frame fuse Body fuse

box case
Battery power Battery power IG1 power

supply supply
Unlocking Locking Locking Unlocking Ground Ground

control control signal signal
Lock actuator, Lock actuator,

door (RH) Lock Unlock
door (LH)

Use the vehicle key to open or close the door, and the
Use the vehicle key to open or close the door, and all
left and right door locks don’t work and the doors
electric door locks fail.
can’t be opened or closed.
Diagnosis procedure
DI 1. Check fuse
c. Take out the BCM fuses IF17(7.5A) and IF34(25A).
Caution
fuse.
d. Check whether the middle fusible wires of BCM

fuses IF17(7.5A) and IF34(25A) are blown out.
Off Normal
Is the fuse blown out?

No> Go to step 2
2. Check the BCM power circuit
b. Disconnect the BCM connectors C034 and C035.
terminals of the BCM connector C035.
Standard voltage:


between the No.1 terminal of the BCM connector
C034 and GND.
Standard voltage:

DI

Yes > to step 3.
No > Repair or replace the BCM power circuit.
3. Check the BCM earthing circuit
b. Disconnect BCM connector C035.
No.13 terminals of the BCM connector C035.
C035 (12)-grounding About 0Ω
C035 (13)-grounding About 0Ω

Yes > to step 4.
No > Repair or replace the BCM earthing circuit.
4. Check the earthing circuit of the left door lock
b. Disconnect the left door lock connector J008.
of the left door lock connector J008 and GND.
J008 (1)-grounding About 0Ω

Yes > to step 5.
No> Repair or replace the earthing circuit of the left door lock.
5. Check the lock/unlock signal circuit of the vehicle key

of the left window lock connector J008 and the
No.17 terminal of the BCM connector C035, and the
resistance between the No.5 terminal of the left
door lock connector J008 and the No.16 terminal of
the BCM connector C035.
DI Standard resistance:
J008(2)-C035(17) About 0Ω
J008(5)-C035(16) About 0Ω
Yes > to step 6.
Check the lock/unlock signal circuit of the vehicle key
6. Check the lock/unlock control circuit

of the left window lock connector J008 and the No.7
terminal of the BCM connector C035, and the
resistance between the No.3 terminal of the left
door lock connector J008 and the No.8 terminal of
J008(4)-C035(7) About 0Ω
J008(3)-C035(8) About 0Ω

Yes > to step 7.
No> Repair or replace the lock/unlock control circuit.
7. Check BCM
eliminated.
Yes > Replace BCM.
Use the vehicle and only the left front door can be opened or closed.
Circuit diagram
DI

box case
Battery power Battery power IG1 power

supply supply


door (LH)
Use the vehicle key to open or close the door, and

Use the vehicle key to open or close the door, and
only the left front door can be opened or closed, while
only the left front door can be opened or closed.
the right front door can’t be opened or closed.
Diagnosis procedure
DI
1. Check the right door lock
a. Remove the right door lock, and fit a new one.
Does the electric door lock works normally ?

Yes > Replace the right door lock.
No> Go to step 2
2. Check the circuit between right door lock and BCM

b. Disconnect the right door lock connector H007.
of right door lock connector H007 and the No.7
terminal of BCM connector C035, and the
resistance between the No.2 terminal of the right
door lock connector H007 and the No.8 terminal of
H007(1)-C035(7) About 0Ω
H007(2)-C035(8) About 0Ω

Yes > Recheck the above procedures.
No > Check the circuit between right door lock and BCM
Basic inspections

The battery voltage
Charge or replace the
battery.
normal?
Check the door DI
Yes Ending of inspection
locking/unlocking
operation. When the
driver locks doors using
the key, all doors shall be
locked.
2
Unlock the door with
No Go to fault symptom list
vehicle key at the driver
side, all doors shall be
unlocked.
normal?
Wiper and washer fault

Overview
The function of the wiper is: The rain or snow that falls on the window glass in rain and snow day will
seriously affect the sight of driver, turn on the wiper can wipe off the water or snow and open the driver's
vision, thus improve the traffic safety. The speed of wiper can be adjusted according to the rainfall or
snowfall, so that drivers can drive safely.
DI
Caution
In heavy rain day, rapid and large raindrops beat against the windshield, it is difficult to scrape
the rain no matter how fast the wiper moves and affect the driver's vision, and the driving shall
be stopped at once to ensure traffic safety.
The function of the washer is: spray washer fluid onto the windshield glass and clean out dust and dirt on
the windshield under the action of the wiper so as to ensure that the driver has a good vision.
Precautions
1. The negative cable of the battery must be removed before disconnecting the connector
and at least wait for 1min, otherwise it may cause personal injury.
2. If the wiper is accidentally blocked during use, the power shall be cut off promptly to
prevent the wiper motor from burnout.
3. During use, the wiper blade shall be kept tightly close to the window glass without
clearance, and any clearance will cause the wiper to lose its wiping effect.
4. The wiper is prohibited from wiping the dry windscreen during use, if the switch of the
DI
wiper switch is accidentally turned on, timely turn it off. The windshield and wiper shall be
cleaned and maintained to prevent dust accumulation.
5. The washer can not work for a long time, and each operating time shall not exceed 10s.
The interval shall be no less than 10s, and do not turn on the washer motor when there is
no washer fluid.
6. The spray pipe shall be tightened, and freely unplugging the spray pipe is forbidden. When
washing the vehicle, do not flush the spray pipe connector for a long time to avoid
corrosion and aging.
7. In low temperature area, washer fluid that meets the local temperature requirements must
be added.
8. Do not use antifreeze for engine or other substitutes to avoid damage to window glass and
body paint.
9. Water fluid is a kind of easy-to-consume liquid, check it regularly (two weeks or a month),
fill washer fluid if it's insufficient.
10. Ignition switch description:
Ignition switch (position) Ignition switch statement
LOCK Turn off the ignition system
Parking gear, energize electrical equipment that works during parking of the
ACC
vehicle, such as radio & player and cigarette lighter.
Driving gear, energize electrical equipment that works during running of the
ON
vehicle, such as instrument and so on.
START Starting gear, automatically back to drive "ON" shift after start
Preparations
Recommended tool
Picture Name Applicable scope
Detect the voltage, current or

DI Digital multimeter
resistance value
Wire components Detection line


Turn on the switch, and the wiper 2. Wiring harness (open or short Repair or replace corresponding
doesn’t work circuit) harness DI
Replace the wiper combination
3. Wiper switch cluster (damaged)
switch
1. Low battery voltage Charge or replace the battery
Repair or replace corresponding

2. Wire harness (bad contact)
harness
The wiper works slowly
3. Motor bearing and reducer gear
Replace wiper motor
(insufficient lubrication)
4. Wiper motor (damaged) Replace wiper motor

switch
The wiper only fails in the 2. Wiring harness (open or short Repair or replace corresponding
intermittent mode circuit) harness
3. Wiper intermittent relay
Replace the wiper intermittent relay
(damaged)
switch
The wiper only fails in the 2. Wiring harness (open or short Repair or replace corresponding
high-speed mode circuit) harness
Repair or replace the wiper switch

The wiper only fails in the cluster
low-speed mode 2. Wiring harness (open or short Repair or replace corresponding
circuit) harness
2. Wiring harness (open or short Repair or replace corresponding

circuit) harness
Turn on the switch, and the wiper
can’t be reset Repair or replace the wiper switch
cluster
4. Wiper intermittent relay
Replace the wiper intermittent relay
(damaged)
Repair or replace the wiper switch
cluster
The washer motor doesn’t work 2. Washer motor (damaged) Repair or replace the washer motor
3. Wiring harness (open or short Repair or replace corresponding

circuit) harness
1. Washing fluid (Insufficient) Add the cleaning solution.
2. Washer hose (damaged) Replace the washer hose

The cleaning liquid can’t be
injected out Repair or replace the washer
3. Washer nozzle (clogged)
nozzle
4. Washer motor (damaged) Replace wash motor

DI
Remove the dust on the wiper
1. Wiper worm (rusted or badly
worm and apply lubricating oil onto
lubricated)
it
2. Wiper arm (deformed for worn
Replace wiper arm.
out)
The wiper produces high noises in
operation 3. Wiper linkage (unmatched) replace the wiper linkage
4. Wiper blade (rubber aged or

Replace wiper blade.
cracked)
5. Wiper linkage (not fixed in
Fasten the wiper linkage
place)
1. Windscreen (With oil stain and
Clean the windshield glass
wax)
2. Washing fluid (Low quality) Change the cleaning liquid
3. Wiper blade (Incorrect model)

Poor wiping (the wiper blade can’t
fully wipe away the water or it 4. Wiper blade (Aged or cracked
dithers) rubber)
Replace the wiper blade or wiper
5. Wiper arm (Deformed or arm assembly
damaged)
6. Wiper arm (Deteriorated spring
force)
Turn on the switch, and the wiper doesn’t work

Circuit diagram
Ignition switch IG2
Wiper
intermittence
DI
relay
Body fuse
case
Washer Wiper
motor Turn
Stop motor
Intermitte Wiper combination
nt
switch
Low
speed
High
speed
Wash
With the ignition switch at ON, turn on the wiper

Turn on the switch, and the wiper doesn’t work
switch cluster, and the wiper doesn’t work
Diagnosis procedure
DI 1. Check fuse
c. Remove the wiper motor fuse IF06 (10A).
Caution
fuse.
d. Check whether the middle fusible wire of the wiper

motor fuse IF06(10A) is blown out.
Off Normal

No> Go to step 2
2. Check the wiper switch cluster

b. Disconnect the wiper combination switch connector.
c. Fit a wiper switch cluster under good conditions, refit the connector and check whether the
window fault is eliminated.

Yes> Replace the wiper combination switch
No> Go to step 3
3. Check the power circuit of the wiper switch cluster

b. Disconnect the wiper combination switch connector C014.

terminals of the wiper switch cluster connector
C014 and GND.
Standard voltage:

DI

No > Repair or replace the power circuit of the wiper switch cluster.

Circuit diagram
Ignition switch IG2
DI Wiper
intermittence
relay
Body fuse
case
Washer Wiper
motor Turn
Stop motor
nt
switch
Low
speed
High
speed
Wash
Start the motor, turn on the wiper switch cluster, and

the wiper operates slowly
Diagnosis procedure
1. Check the battery voltage DI
a. Use the multi-meter to measure the battery voltage.
Voltage: Approximately 12V.

Yes > to step 2.
No > Charge or charge the battery.
2. Check wiper motor assembly.

b. Disconnect wiper motor connector C033.
c. Check the wiper operation in the low-speed mode
Connect the battery positive terminal (+) to the No.3
terminal of the wiper motor, and connect the battery
negative terminal (-) to the No.4 terminal. Check
whether the motor operates at low speed.
d. Check the wiper operation in the high-speed mode

Connect the battery positive terminal (+) to the No.2
terminal of the wiper motor, and connect the battery
negative terminal (-) to the No.4 terminal. Check
whether the motor operates at high speed.

Repair > Check or replace the wiring harness.
No>Check wiper motor assembly.
DI
The wiper only fails in the intermittent mode

Circuit diagram
Ignition switch IG2
Wiper
intermittence
DI
relay
Body fuse
case
Washer Wiper
motor Turn
Stop motor
nt
switch
Low
speed
High
speed
Wash
When the ignition switch is at “ON” position and the

The wiper only fails in the intermittent mode wiper combination switch is at intermittent mode, the
wiper can’t work intermittently.
Diagnosis procedure
DI
1. Check the wiper intermittent relay
b. Replace the wiper intermittent relay, and check whether the wiper operates normally in the
intermittent mode.

Yes > Replace the wiper intermittent relay
No> Go to step 2
2. Check the wiper combination switch.

c. Set the wiper switch cluster in the intermittent mode.
and No.7 terminal of the wiper switch cluster.
(4)-(7) About 0Ω
e. Turn the multi-meter to the resistance mode, and

(5)-(6) About 0Ω

Yes > to step 3.
No > Replace the wiper combination switch.
3. Check the circuit between the wiper switch cluster and the wiper intermittent relay
c. Disconnect the wiper intermittent relay connector C006.
the wiper switch cluster connector C014 and the
No.7 terminal of the wiper intermittent relay DI
No.2 terminal of the wiper switch cluster connector
C014 and the No.6 terminal of the wiper intermittent
relay connector C006.
C014(1)-C006(7) About 0Ω
C014(2)-C006(6) About 0Ω

No> Check the circuit between the wiper switch cluster and the wiper intermittent relay.
The wiper only fails in the low-speed mode

Circuit diagram
Ignition switch IG2
DI Wiper
intermittence
relay
Body fuse
case
Washer Wiper
motor Turn motor
Stop
nt
switch
Low
speed
High
speed
Wash

The wiper only fails in the low-speed mode wiper combination switch is placed at low speed
mode, the wiper motor can’t run at low speed.
Diagnosis procedure
DI
c. Set the wiper switch cluster in the low speed mode.
(5)- (8) About 0Ω

Yes > to step 2.
No> Replace the wiper combination switch.
2. Check the circuit between the wiper switch cluster and the wiper motor
c. Disconnect wiper motor connector C033.
of the wiper switch cluster connector C014 and the
No.3 terminal of the wiper motor connector C033.
C014(5)-C033(3) About 0Ω

Yes > to step 3.
No> Repair the circuit between the wiper switch cluster and the wiper motor.
3. Replace the wiper motor and check.

a. Replace with wiper motor of same specification and model and recheck.
Check if the test results are normal?

Yes > Replace wiper motor
DI
The wiper only fails in the high-speed mode

Circuit diagram
Ignition switch IG2
Wiper
intermittence
DI
relay
Body fuse
case
Washer Wiper
motor Turn
Stop motor
Intermitte
nt
Wiper combination
switch
Low
speed
High
speed
Wash

The wiper only fails in the high-speed mode wiper combination switch is placed at high speed
mode, the wiper motor can’t run at high speed.
Diagnosis procedure
DI
c. Set the wiper switch cluster in the high speed mode.
(8)- (9) About 0Ω

Yes > to step 2.
2. Check the circuit between the wiper switch cluster and the wiper motor
c. Disconnect wiper motor connector C033.
of the wiper switch cluster connector C014 and the
No.2 terminal of the wiper motor connector C033.
C014(9)-C033(2) About 0Ω

Yes > to step 3.
No> Repair the circuit between the wiper switch cluster and the wiper motor.
3. Replace the wiper motor and check.


DI
Turn on the switch, and the wiper can’t be reset

Circuit diagram
Ignition switch IG2
DI Wiper
intermittence
relay
Body fuse
case
Washer Wiper
motor Turn
Stop motor
nt
switch
Low
speed
High
speed
Wash
When the ignition switch is at “ON” position, the wiper

motor is running, and the rear wiper combination
Turn on the switch, and the wiper can’t be reset
switch is at OFF position, the wiper blades fail to stop
at initial position.
Diagnosis procedure DI
a. Fit a wiper switch cluster of the same size and model, and check the wiper again.

Yes> Replace the wiper combination switch
No> Go to step 2
2. Check the wiper motor.


No> Go to step 3
3. Check the wiper intermittent relay

a. Fit a wiper intermittent relay of the same size and model, and check the wiper again.

Yes > Replace the wiper intermittent relay
No> Check the failed harness
The wiper works normally, while the washer doesn’t work/ the cleaning liquid can’t
be injected out
Circuit diagram
Ignition switch IG2
DI
Wiper
intermittence
relay
Body fuse
case
Washer Wiper
motor Turn
Stop motor
nt
switch
Low
speed
High
speed
Wash
The wiper works normally, while the washer doesn’t With the ignition switch at ON, when the wiper works
work/ the cleaning liquid can’t be injected out normally, the washer can’t inject water
Diagnosis procedure
1. Check the cleaning liquid DI
a. Check the cleaning liquid level.

Yes > to step 2.
No > Add cleaning liquid.
2. Check the washer hose

a. Check the washer hose.
Is there any leakage from the hose?

Yes > Replace the washer hose.
No> Go to step 3

c. Set the wiper switch cluster in the washing mode.
(3)- (8) About 0Ω

Yes > to step 4.
4. Check the washer motor

a. Check the washer operation
• Fill the water into the washer tank complete
with a washer motor.
• Connect the battery positive terminal (+) to
the No.1 terminal of the wiper motor, and
connect the battery negative terminal (-) to
DI the No.2 terminal. Check whether the water
flows out of the washer tank.

Yes > Repair or change wiring harness.
No > Replace wash motor
Basic inspections

The battery voltage
battery.
normal?
Check the wiper DI
Yes Go to step 3
intermittent mode. Turn
on the wiper via the switch
2 cluster.
normal?
Check the wiper Yes Go to step 4
low-speed mode. Ignition
switch: ON. Turn on the
wiper in the low-speed
3 mode via the switch
cluster. No Go to fault symptom list
normal?
Check the wiper Yes Go to step 5
high-speed mode. Turn
on the wiper in the
4 high-speed mode via the
switch cluster. No Go to fault symptom list
normal?
Check the washer. Turn Yes Check the switch cluster
on the washer via the
5 switch cluster.
Check if results are No Go to fault symptom list
normal?
Fault of A/C system

Overview
The automobile heating and air conditioning system is a device intended to cool, heat, ventilate the cabin
air and to melt the frost and fog on the front windshield glass.
Major functions of the system

DI No. Function No. Function
1 Fan control 3 Compressor control
Control of internal/external circulation
2 4 Control of condenser fan
damper
Precautions
1. To prevent injuries or vehicle damages, before removal or refitting of any electric device,
and where the tool or equipment is liable to touch the exposed electric terminal, do firstly
disconnect the battery negative cable.
2. Never work in the enclosed space and close to the heat source. Never weld the parts which
are filled with refrigerant.
3. Always wear goggles when servicing the refrigerant pipeline. Avoid the contact of liquid
refrigerant with eyes and skin.
DI
4. If the liquid refrigerant contacts eyes or skin, use a lot of clean water to wash the contact
area; if serious, see the doctor immediately.
5. Take much care to handle the system components. Avoid falling and collision of the
system components.
6. Do not operate the compressor if the refrigerating system is not filled with sufficient
refrigerant.
7. Never open the high-pressure pipeline when the compressor is in operation. If the
high-pressure valve is opened, the refrigerant may flow in the opposite direction. This may
result in the breakage of the compressor cylinder block. Therefore, it is only allowed to
open or close the low-pressure valve.
8. Never fill the system with too much refrigerant. Filling too much refrigerant into the system
may result in poor cooling performance, low fuel economy and compressor overheating
etc.
9. When servicing the refrigerating system, do timely cover or seal the disconnected pipeline
connections to prevent the ingress of air-borne moisture or impurities.
10. After replacing refrigerant, make up refrigerant oil in system at first, and then fill in
refrigerant.
11. Refrigerant must be discharged slowly for fear of bringing out refrigerant oil.
12. Low-voltage end shall not be filled with liquid refrigerant, compressor cannot be started
when fill in refrigerant from the high-voltage end.
13. Do not clean the condenser and evaporator with vapor, but to use cold water or
compressed air.
14. Protect the automobile with objects such as protective pad when repair the cooling
system.
15. Do not turn on the air conditioner before the refrigerating system is filled with refrigerant.
16. To store the compressor in a long term, fully discharge the air from the compressor and
then fill up the compressor with refrigerant or dry nitrogen to prevent corrosion.
17. Never directly discharge the refrigerant into the air. Use the specified reclaiming/recycling
equipment to collect the refrigerant when discharging the refrigerant from the air
conditioning system.
18. Before vacuuming operation, carefully check the sealing conditions, and handle the
leakage point properly. After all of installation work is completed, check various vehicle
components work for normal operation, check the cooling system components, cooling
pipelines and electric circuits for integrity, and check the air conditioner for normal
operation.
Preparations
Recommended tools
Used to measure the resistance

DI Digital multimeter and voltage of the air conditioner
compressor and various sensors
Used for diagnosis, filling and

discharge of the air conditioning
Manifold pressure gauge
system refrigerant and for
troubleshooting
Used to detect the specific leakage

Halogen leakage detector point of refrigerant in the air
conditioning system
Used to measure the working

Precise thermometer performance of the air conditioning
system
Description of system function

1. Control of refrigerating system
a. Compressor control
With the engine in normal operation, turn on the blower, press the air conditioner ON/OFF key,
and after ECU detects an evaporator temperature higher than the set value, it will send the air
conditioner ON request signal; if the air conditioner high-pressure pipeline is under a normal
pressure, ECU will turn on the compressor relay after it receives the air conditioner ON request
signal to operate the compressor whilst the condenser fan will start to work.
DI
b. Compressor protection
When the evaporator temperature is lower than the set value, the compressor will stop working to
prevent frosting of the evaporator. When the evaporator temperature is higher than a certain
temperature, the compressor will restore its normal operation.
When the pressure of the high-pressure pipeline of the air conditioning system is higher than
3.2MPa or lower than 0.16MPa, the compressor will stop working to protect the compressor.
If the compressor electromagnetic clutch is closed before the engine is started, the compressor
can be only started again 3.5s after the engine is started.
When the engine works at a high load (for example, too large throttle openness, too high
revolution or too high coolant temperature), the compressor will stop working to ensure the engine
output.
2. Control of blower motor
a. With the ignition switch at ON, rotate the air volume knob on the air conditioner control panel, and
adjust the air volume of the blower as per a certain proportion. When the knob is rotated to the
leftmost point, the lowest air volume is reached; when the knob is rotated to the rightmost point,
the highest air volume is reached.
3. Control of cold/hot air damper
a. Rotate the temperature control knob on the air conditioner control panel, and the temperature
control knob will bring the cold/hot air damper cable to operate the cold/hot air damper actuator,
thus realizing the changeover between cold air damper and hot air damper. When the cold air
damper is opened, the hot air damper will be closed, vice versa.
4. Control of mode damper
a. It is used to regulate the air supply modes of the air conditioning system, and the changeover
between six modes can be realized, i.e., parallel air outlet (blow the face), dual-position face (blow
face & feet), bottom air outlet (large) and defroster (small), defroster (large) and bottom air outlet
(small), and defroster.
b. Rotate the air supply direction control knob on the air conditioner control panel, and then the knob
will bring the mode damper cable to operate the mode air damper actuator, thus realizing the
changeover between the air supply modes.
5. Control of internal/external circulation damper
a. The air conditioner control panel will receive the ON/OFF signal from the internal/external
circulation selection key and control the operation of the internal/external circulation motor, thus to
change the position of the internal/external circulation damper and realize the changeover
between internal circulation and external circulation.

1. Fuse (Burnout) Replace the fuse.
2. A/C control panel circuit (the

DI The whole air conditioner doesn’t
connector is loosened or the
Check and repair circuit or
work connector.
circuit is open)
3. A/C control panel Replace the A/C control panel
1. Internal & external circulation Replace the internal/external

motor (damaged) circulation motor
2. A/C control panel (interior

The internal/external circulation damages or internal/external Replace the A/C control panel
motor doesn’t work circulation selection key faulted)
3. Internal & external circulation

motor circuit (the connector is
connector.
loosened or the circuit is open)
2. Relay (damaged) Replace relay.
3. Blower circuit (the connector is Check and repair circuit or

loosened or the circuit is open) connector.
The blower does not work
4. Damage of fan Change air blower
5. Air volume knob (damaged) Replace the A/C control panel
6. A/C control panel (interior

damages or blower control Replace the A/C control panel
faulted )
1. Speed regulating resistor Change the speed regulation

(damaged) resistance.
Blower speed regulator works 2. Air volume knob (damaged) Replace the A/C control panel
abnormally
3. Speed regulator circuit ( the
connector is loosened or the
connector.
circuit is open)
After leakage detection, refill the

1. Refrigerant totally leaks
system with refrigerant
The compressor doesn’t work 3. Relay (damaged) Replace relay.
4. Evaporator temperature sensor Replace the evaporator

(damaged) temperature sensor
5. A/C pressure switch (damaged) Replace the A/C pressure switch

6. Connector (the connector is

Refit the connector
loosened or separated)
7. Compressor belt (skidding or Readjust the belt or replace the

looseness) belt
8. Compressor (body damaged or

electromagnetic clutch Repair or replace the compressor
damaged) DI
9. ECU (damaged) Replace ECU
10. A/C control panel (damaged) Replace the A/C control panel
Replace the leaking component

1. Refrigerant (leakage) and refill the system with
refrigerant
2. Expansion valve (the openness

Repair or replace the expansion
is too small or the valve is
valve
clogged)
3. Refrigerating system (there is Discharge the refrigerant and refill

air ingress into the system ) the system with refrigerant
The A/C refrigerant is insufficient 4. Condenser (cooling fin
Clean the condenser assembly,
damaged or surface covered by
and repair the cooling fin
dirt)
5. Evaporator (cooling fin

Clean the condenser assembly,
damaged or surface covered by
and repair the cooling fin
dirt)
6. Drying canister (clogged) Replace the condenser assembly
7. Condenser (clogged) Repair the condenser assembly
1. Cabin internal temperature (too That’s normal. Turn off the air
low) conditioner for some time
2. Operation (improper) Proper operation

The air conditioner works normally
at the very beginning, but the air 3. Evaporator temperature sensor
Replace the temperature sensor
outlet doesn’t supply cool air (damaged)
4. Evaporator temperature sensor

circuit ( the connector is
connector.
loosened or the circuit is open)
1. A/C control panel (air supply Check and repair or replace A/C
It is not allowed to change over direction control knob faulted) controller.
between the air supply modes 2. Mode damper actuator (stuck or Repair or replace the mode
damaged) damper actuator
1. A/C control panel (temperature Check and repair or replace A/C

It is not allowed to change over control knob faulted) controller.
between the cold and hot air mode 2. Air mixing damper (stuck or Repair or replace the air mixing
damaged) damper actuator
1. Hot air duct (the connector is

Reconnect the hot air duct
detached)
2. Coolant (insufficient or clogged) Add the coolant

Heating failure or insufficient hot air
output Use the tweezers or fin comb to
3. Air heater core fin (deformed)
rectify the fin
DI 4. Hot air pipeline (clogged) Clean the hot air pipeline
The pipe connection is clogged by 1. Improper fixation, gap, Remove the pipe connector,
the heavy oil and the air loosened connection, broken replace the seal ring, and refill the
conditioner can’t supply cool air seal ring system with refrigerant
1. Blower motor body (with foreign Clear the internal foreign matters of
matters inside) the blower
Abnormal noise from blower
2. Blower motor (broken or aged) Change air blower
1. Compressor assembly (the Retighten the compressor

fixing bolt is loosened) assembly bolt
When the air conditioner works in 2. Compression internal piston,

the cooling mode, the compressor intake and exhaust valves Replace the compressor
constantly produces abnormal (interference or damages)
noises
Vacuum the system again, and fill it
3. Compressor (liquid slugging) with the appropriate amount of
refrigerant
1. There is air ingress into the Discharge the refrigerant and refill
system the system with refrigerant
Discharge the refrigerant until the

2. Refrigerant (too much) refrigerant amount becomes
appropriate
Condenser (cooling fin damaged or

The high-pressure pipeline of the 3. Condenser fin (clogged) surface covered by dirt)
cooling system is too high
4. The condenser fan works
Replace the condenser fan
abnormally
5. Refrigerant pipeline (deformed, Repair or replace the faulted

damaged) pipeline
6. Expansion valve (incorrectly Repair or replace the expansion

adjusted) valve
Replace the leaking component

1. Refrigerant (leakage) and refill the system with
refrigerant
The high-pressure pipeline of the 2. Compressor relief valve faulted Replace the compressor
cooling system is too low
3. Compressor seal ring faulted Replace the compressor seal ring

4. Malfunction of expansion valve
valve

1. Expansion valve (damaged)
valve
Discharge the refrigerant until the

2. Refrigerant (too much) refrigerant amount becomes
The low-pressure pipeline of the
appropriate
cooling system is too high
3. Compressor (damaged) Replace the compressor
DI
4. High-pressure pipe (deformed, Repair or replace the faulted
clogged) pipeline
1. Refrigerant (insufficient) Fill the refrigerant as appropriate

2. Expansion valve (jammed)
The low-pressure pipeline of the valve
cooling system is too low
3. Air ingress in the system Discharge the air
4. Evaporator temperature sensor Replace the evaporator

(damaged) temperature sensor
The whole air conditioner doesn’t work

Circuit diagram
Battery Ignition switch ACC
DI

box case
Heater
relay
Speed regulation
resistor
Blower
Heater relay output Low Intermediate Secondary High speed Heater relay ACC power
power supply speed speed gear high speed gear control supply
gear gear A/C
control
panel
External Internal Back light A/C request Ground Heater motor

recirculation recirculation power ground
A/C
pressure
switch
Internal/external recirculation motor To small lamp relay To engine ECU

Battery
Evaporator
Frame fuse temperature sensor
box
DI
Main relay Compressor
relay
Compressor
Battery power Main relay Compressor relay control Sensor - Evaporator

supply control temperature signal
Engine
ECU
Press the A/C switch, and the compressor doesn’t

work; with the air volume switch at low speed
The whole air conditioner doesn’t work position, there is no air supply; the changeover
between internal and external circulation modes is
not allowed
DI
Diagnosis procedure
1. Check fuse
c. Take out the fuses IF22(7.5A), IF29(25A) and IF30(5A) .
Caution
fuse.
d. Check whether the middle fusible wires of the fuses

IF22(7.5A), IF29(25A) and IF30(5A) are blown out.
Off Normal

No> Go to step 2
2. Replace the air heater relay for inspection

c. Replace the air heater relay IR08.

Yes >Replace with the relay of the same size
No> Go to step 3
3. Check the power circuit of the A/C control panel

b. Disconnect the connector C029 of A/C control panel.
c. With the ignition switch at ON, rotate the air volume control knob to any position other than 0.

measure the voltage between the No.6 & No.12
terminals of the A/C control panel connector C029
and GND.
Standard voltage:

DI

Yes > to step 4.
No > Repair or replace the power circuit of the A/C control panel.
4. Check the earthing circuit of A/C control panel

c. Disconnect the connector C030 of A/C control panel.
of the A/C control panel connector C029 and GND.

of the A/C control panel connector C030 and GND.


Yes > to step 5.
No > Repair or replace the earthing circuit of the A/C control panel.
5. Replace the A/C control panel for inspection

a. Replace with the A/C control panel of the same size , and start another inspection.
DI Check if the test results are normal?

Yes> Replace the A/C control panel
The internal/external circulation motor doesn’t work

Circuit diagram
DI

box case
Heater
relay
Speed regulation
resistor
Blower
gear gear A/C
control
panel

A/C
pressure
switch

With the ignition switch at ON, press the

internal/external circulation selection key, and it is not
The internal/external circulation motor doesn’t work
allowed to change over between the internal and
external circulation modes.
DI Diagnosis procedure
1. Replace the internal/external circulation motor for inspection
a. Replace with the internal/external circulation motor of the same size, and start another inspection.

Yes > Replace the internal/external circulation motor
No> Go to step 2
2. Check the circuit between the internal/external circulation motor and the A/C control panel
c. Disconnect the internal/external circulation motor connector C039.
of A/C control panel connector C029 and the No.7
terminal of the internal/external circulation motor
No.3 terminal of A/C control panel connector C029
and the No.5 terminal of the internal/external
circulation motor connector C039.
C029(2)-C039(7)
About 0Ω
C029(3)-C039(5)

Yes > to step 3.
No> Repair or replace the circuit between the internal/external circulation motor and the A/C
control panel.


Yes> Replace the A/C control panel
The blower does not work

Circuit diagram
DI

box case
Heater
relay
Speed regulation
resistor
Blower
gear gear A/C
control
panel

A/C
pressure
switch

With the ignition switch at ON and the air volume

The blower does not work switch at the speed regulation position, the blower
doesn’t work
Diagnosis procedure
DI
1. Check fuse
c. Take out the fuses IF22(7.5A), IF29(25A) and IF30(5A) .
Caution
fuse.

IF22(7.5A), IF29(25A) and IF30(5A) are blown out.
Off Normal

No> Go to step 2
2. Replace the air heater relay for inspection

c. Replace the air heater relay IR08.

No> Go to step 3
3. Check the blower

b. Disconnect the blower connector C021.
c. Connect the battery positive terminal (+) to the No.1

terminal of the blower, and connect the battery
negative terminal (-) to the No.2 terminal. Check the
blower for normal operation.
DI

Yes > to step 4.
No > Change air blower
4. Check the control circuit of the air heater relay.

b. Open the body fuse box, and take out the air heater relay IR08.
measure the resistance between No.86 pin socket
of the air heater relay IR08 and the No.2 terminal of
the A/C control panel connector C030.
No.86 pin socket -C030(2) About 0Ω

Yes > to step 5.
No > Repair or replace the control circuit of air heater relay.
5. Check the blower power circuit

b. Open the body fuse box, and take out the air heater relay IR08.
c. Disconnect the blower connector C021.
of the air heater relay IR08 and the No.1 terminal of
the blower connector C021.
No.30 pin socket - C021 (1) About 0Ω


Yes > to step 6.
No > Repair or replace the blower power circuit.
6. Check the speed control circuit of the blower

DI c. Disconnect the connector C030 of A/C control panel.
of the blower connector C021 and the No.6 terminal
of A/C control panel connector C030.
C030(6)-C021(1) About 0Ω

Yes > to step 7.
No > Repair or replace the blower speed control circuit.


No> Replace the A/C control panel
Blower speed regulator works abnormally

Circuit diagram
DI

box case
Heater
relay
Speed regulation
resistor
Blower
gear gear A/C
control
panel

A/C
pressure
switch

1. The blower only fails at the highest air volume
2. The blower fails at low, medium and next highest

Blower speed regulator works abnormally air volume levels
3. The blower fails at certain one or two levels of low,
medium and next highest air volume
DI
Diagnosis procedure
1. Confirm the fault symptoms
b. Rotate the air volume knob, and confirm the fault symptoms
Fault symptom 1 > Go to Step 2.

2. Check the blower high speed control circuit

of the blower connector C021 and the No.6 terminal
of A/C control panel connector C030.
C030(6)-C021(1) About 0Ω

Yes > Replace A/C controller
No > Repair or replace the blower high speed control circuit.
3. Check the circuit between speed regulator resistor and blower

b. Disconnect the speed regulator resistor connector C022.
c. Disconnect the blower connector C021.

of the speed regulator resistor connector C022 and
the No.2 terminal of blower connector C021.
C022(2)-C021(2) About 0Ω
DI

Yes > to step 4.
No > Repair or replace the circuit between speed regulator resistor and blower.
4. Check the circuit between A/C control panel and speed regulator resistor
b. Disconnect adjustable resistance connector C022.
measure the resistance between the No.1, No.3
and No.4 terminals of the speed regulator resistor
connector C022 and the No.3, No.5 and No.4
terminals of A/C control panel connector C030.
C022(1)-C030(3) About 0Ω
C022(3)-C030(4) About 0Ω
C022(4)-C030(5) About 0Ω

Yes > to step 5.
No > Replace the A/C control panel the circuit between A/C control panel and speed regulator
resistor.
5. Check the speed regulator resistor

a. Replace with the speed regulator resistor of the same size, and start another inspection.

Yes > Change the speed regulation resistance.
No > Replace the A/C control panel
The compressor doesn’t work

Circuit diagram
DI

box case
Heater
relay
Speed regulation
resistor
Blower
gear gear A/C
control
panel

A/C
pressure
switch

Battery
Evaporator
box
DI
relay
Compressor

Engine
ECU
Start the engine, and the blower starts to work; press

The compressor doesn’t work
A/C switch, and the compressor doesn’t work
Diagnosis procedure
DI 1. Check the compressor belt
a. Check whether the compressor belt skids or gets loosened.

Yes > to step 2.
No > Replace the compressor belt.
2. Check fuse
b. Open the frame fuse box.
c. Take out the compressor fuse EF10(7.5A).
Caution
fuse.
d. Check whether the middle fusible wire of the

compressor fuse EF10(7.5A) is blown out.
Off Normal

No> Go to step 3
3. Check the compressor relay

c. Replace the compressor relay for inspection.

Yes >Replace with the compressor relay of the same size.
No> Go to step 4
4. Check the power circuit of the compressor

c. Take out the compressor relay ER01.
d. Disconnect the compressor connector B009.
measure the resistance between No.5 pin socket of
the compressor relay ER01 in the frame fuse box DI
and the No.1 terminal of the compressor connector
B009.
No.5 pin socket -B009(1) About 0Ω

Yes > to step 5.
No > Repair or replace the compressor power circuit.
5. Check the control circuit of compressor relay

c. Take out the compressor relay ER01.
d. Disconnect the ECU connector E001.
the compressor relay ER01 in the frame fuse box
and the No.69 terminal of the ECU connector E001.
No.1 pin socket -B001(69) About 0Ω

Yes > to step 6.
No > Repair or replace the control circuit of compressor relay.
6. Check the A/C pressure switch

b. Disconnect the A/C pressure switch connector B018.

and No.2 terminal of the A/C pressure switch
connector B018.
B018(1)-B018(2) About 0Ω
DI

Yes > to step 7.
No > Check the air conditioner pipeline pressure. If normal, replace the A/C pressure switch;
otherwise identify and eliminate the fault.
7. Check the A/C switch request signal

c. Disconnect the ECU connector E001.
of the A/C control panel connector C029 and the
No.75 terminal of ECU connector E001.
C029(5)-E001(75) About 0Ω

Yes > to step 8.
No > Repair or replace the A/C switch request signal circuit.
8. Check the evaporator temperature sensor

b. Disconnect the evaporator temperature sensor connector C031.
and No.2 terminal of the evaporator temperature
sensor.

Yes > to step 9.
No > Replace the evaporator temperature sensor

Check if the test results are normal? DI

Yes > Replace A/C controller
Basic inspections
Check time
Check items contents and objects 6 months or 12 months or

Daily driving of initial driving of
5,000km 10,000km
Bad attachment, there are gaps ● ●

Supporting tube
DI Looseness of connecting part and nut ● ●
Bolts Looseness, gap, falling ● ●
Looseness, bending ● ●
Belt Deterioration: wear, scar, crack ● ●
Port amen to, while burning smell, give

●
out heat
Radiating fins damaged ●

Condenser
Solid blockage ● ● ●
Starting inspection: volume of the air

Air conditioner switch output, temperature control ● ●
and temperature
switch Switching of the blow-out port and so
on
Leakage from the connection part of
● ●
Refrigerant leakage the supporting tube
(including oil Leakage of parts (compressor,
leakage) condenser, evaporator, receiver- drier, ●
etc.)
Compressor ●
Idle pulley ●
Noise (in start state)
Blowing-in motor ●
Expansion Valve ●
Temperature
difference between Large temperature difference: The
●
inlet and outlet pipes block in the receiver-drier
of fluid dryer
Inverted entrance for external air
●
(pressure fan)
Air leakage
Invasion of the heat from the heater ●
Test method of air conditioner leakage
Caution
When hesitate that A/C system has leakage or maintenance the system, recommend to take a
leakage test. The common leak detection methods of air conditioner system are: visual
inspection leakage detection, liquid soap leakage detection, electronic leak detector leakage
detection and vacuum leakage detection.
DI
1. Visual inspection and leakage detection
In case of oil stains in the system, this position may leak oil. Despite easy and costless, there are many
drawbacks to visual leakage inspection. It often can't locate leak sources unless they are not large
enough, such as in the cases of abrupt system breakages or colored media. Given tiny leakages in most
cases, and most positions of the air conditioning system are invisible, visual inspection often doesn't
work.
2. Liquid soap leakage detection
Buddle test is a simple and effective method: in case of any oil stains on parts and pipeline surface,
please clean them in advanced. Then smear the soap solution onto the test place; if the contact is tested,
smear the whole cycle uniformly. Observe carefully in all directions, if there is any bubble or bubbling, it
may be judged as leakage. The key is to control well the concentration of soapy water, and if too thin or
too thick, it will not work. This method is relatively economic and practical, and applies to portions
exposed to the appearance and visible to human eyes and occasions surrounded by refrigerant gas. But
the accuracy is poor, it can not check the slight leakage and the part of the compressor, evaporator and
condenser etc. which is not convenient to be coated with liquid soap and to be observed.
3. Leakage detection by electronic leak detector
Small leakage amount can be detected, especially the place that is not easy to contact.
a. Most electronic leak detectors have a check gear, which should be verified to be correct before
using, and make the lights and alarm work.
b. Adjust the instrument to required sensitivity range.
c. During detection, locate the probes in all directions of the position to be detected to prevent
missing.
d. Once the part is found leak, the probe should be removed immediately to shorten the service life
of it.
4. Vacuum leak detection
The purpose of vacuum pumping is to bleed the air and moisture from the refrigeration system, and it is a
specially important procedure in A/C repair. Since the air will enter system when the air conditioner
system is under repair or component is replaced and the air contains certain vapour, so it needs
vacuuming the refrigerating system. Vacuuming can not directly draw the water out of the cooling system,
but the boiling point of the water is lowered after the vacuum is produced, and the water is vaporized and
then drawn out of the cooling system, so the longer is the vacuuming time, the less remaining water in
the system.
Steps of vacuum leak detection:
a. Firstly connect the high-pressure hose of manifold pressure gauge to the high- pressure service
valve of A/C system, and then connect the low-pressure hose to the low-pressure service valve,
finally connect the intermedium tube to the vacuumizer.
b. Switch on the high-pressure and low-pressure manual service valves of manifold pressure gauge,
start the vacuum pump, and observe the vacuum gauge on the low- pressure gauge until
vacuumizing the pressure to approximate -80~-100kPa.

c. Switch off the manual high-low pressure valve on the manifold pressure gauge, turn off the
vacuum pump power switch, and observe whether the pressure on the vacuum gauge rises again.
If it rises, it means that there is leakage of air conditioner system, detect the leakage and repair; if
the pressure gage indicator pointer does not move, re-open the vacuum pump to continue
pumping for 15~30min so that the gauge hand is stable.
d. Upon completion of vacuuming, firstly turn off the high-pressure and low-pressure manual service
DI valves of manifold pressure gauge, and then shut down the vacuumizer.
Caution
• After the completion of system inspection and repair, the refrigerant shall be filled only
after the vacuum pumping finish. For the connection of the refrigerant tank, see refrigerant
filling.
• In the process of vacuum pumping, if it is found that the pressure gauge is always still or
the pointer does not drop to the vacuum degree all the time, it indicates system leakage,
and the system shall be overhauled.
Audio system fault

Overview
The radio & player can receive the AM/FM broadcast through external antenna reception signal;
meanwhile, the radio & player also integrates MP3 function. It can connect mobile equipment through
USB to play the audio in the equipment and add the entertainment of vehicle. In addition, when the
reversing radar detects any obstacle, the radio-cassette player will receive the reversing radar signal and
send a warning signal to remind the driver.
DI
Warning
Any external equipment cannot be charged with USB (such as mobile phone charging).
Other storage devices except U disk are not available for USB here (such as mobile HDD).
Precautions
1. When the battery negative cable is disconnected, the AM/FM broadcasting channel
information stored in the radio & player will be cleared.
Caution
When necessary, please record the channel before disconnecting the battery cathode cable and
reset after connecting the battery cathode.
DI
2. Do not touch the paper cone of speaker.
3. Ensure the bonding is connected securely when installing the antenna assembly.
Caution
Not tight antenna ground connection will generate noise during receiving radio information and
weaken receiving signals.
4. Ignition switch described
ACC
ON
START Starting gear,automatically back to drive "ON" shift after start

Preparations
Recommended tool

Digital multimeter DI
resistance value


Refer to the following table to help you to find out the cause of fault. Serial number indicates the order of
possibility of a failure cause. Check each part according to orders, replace as required.
Symptom Possible cause Troubleshooting
Replace with a fuse of the same

1. Fuse (blown out)
specification
DI Press the power switch, and then 2. The power, ground wire of the
the radio player cannot work. radio & player (open circuit or Repair or replace relevant harness
short circuit)
3. Radio & player (damaged) Replace the radio-cassette player
1. The radio & player is set to

Reset
mute
2. Speaker circuit (open circuit or
Nothing can be heard from the Repair or replace the harness
short circuit)
speaker
3. Radio & player (damaged) Replace the radio-cassette player
4. Loudspeaker (damaged) Replace the loudspeaker
1. Speaker harness or connector

Repair or replace the harness
(open circuit or short circuit)
There is no sound about one
loudspeaker 2. Radio & player (damaged) Replace the radio-cassette player
3. Loudspeaker (damaged) Replace the loudspeaker
1. The external high

electromagnetic wave
interference is received or the Move to the place with good signal
signal transmitted from
Abnormal noise transmitting terminal distorts
2. Antenna(deformation or
Replace the pull rod antenna
damage)
3. Speaker ( burn-in or failure) Repair or replace the loudspeaker
1. The external same-frequency

electromagnetic wave
interference is received
AM / FM broadcast signal can not
be received, or received poorly 2. Rod antenna (deformation or
Repair or replace the rod antenna
damage)
3. Radio & player (damaged) Repair or replace the radio & player
1. Backlight lamp lighting circuit Repair or replace the harness

Radio & player has no illumination
in the nighttime Repair or replace the
2. Radio & player (damaged)
radio-cassette player
Press the power switch, and then the radio player cannot work.
Circuit diagram
DI

To reversing lamp
box case To small lamp relay
switch Radio/audio player
antenna
Battery power ACC power supply Multimedia Back light power

supply reversing signal Radio/audio
player
Left front Left front Right front Right front Reversing sensor
loudspeaker + loudspeaker - loudspeaker + loudspeaker - Reversing sensor - Ground
signal
Left front Right front Multimedia

Multimedia Reversing
loudspeaker loudspeaker reversing
reversing sensor sensor controller
signal sensor -
With the ignition switch at ACC, press the

Failed startup of radio-cassette player radio-cassette player power key, and the
radio-cassette player can’t be started
Diagnosis procedure
DI
1. Check fuse
c. Take out the radio-cassette player fuses IF15(5A) and IF22(7.5A).
Caution
fuse.

radio-cassette player fuses IF15(5A) and
Off Normal
IF22(7.5A) are blown out.

No> Go to step 2
2. Check the power circuit of the radio-cassette player

measure the voltage between No.3 terminal and
No.4 terminal of the radio-cassette player connector
C024.
Standard voltage:


Yes > to step 3.
No > Repair or replace the power circuit of the radio-cassette player.
3. Check the earthing circuit of the radio-cassette player

c. Turn the multi-meter to the resistance mode, and DI
of radio-cassette player connector C024 and GND.

Yes > to step 4.
No > Repair or replace the earthing circuit of the radio-cassette player.
4. Check the radio-cassette player
Caution
Generally, the radio-cassette player assembly can be only accurately tested by the specialized
repair personnel. During the field service, the replacement method is usually applied to judge the
fault.
a. Replace with a new or normally-working radio-cassette player.
b. Connect the circuits properly, turn on the radio-cassette player, and judge whether the fault
symptoms disappear.
Caution
The radio-cassette player of the same size and model shall be used.

Yes > Change of radio and player
Caution
The radio-cassette player can be only dismantled and repaired by the specialized personnel.

Fault diagnosis of electric appliances section
The noise from loudspeaker can’t be heard

Circuit diagram
DI

To reversing lamp
antenna

player
signal

signal sensor -
With the ignition switch at ACC, when the

The noise from loudspeaker can’t be heard radio-cassette player works normally, the
loudspeaker produces no sound
Caution
Firstly check whether the radio-cassette player is set in the mute mode; if not, perform the DI
following diagnosis. Here the left front loudspeaker is used as an example, and the right front
loudspeaker can be serviced using the same method.
Diagnosis procedure
1. Inspect the speaker
b. Disconnect the left front loudspeaker connector J004.
and No.2terminal of the left front loudspeaker.
(1)-(2) About 4Ω

Yes > to step 2.
No > Replace the left front loudspeaker.
2. Check the circuit between the left front loudspeaker and the radio-cassette player
measure the resistance between the No.1 & No.2
terminals of the left front loudspeaker connector
J004 and the No.6 & No.2 terminals of the
J004(1)-C024(6) About 0Ω
J004(2)-C024(2) About 0Ω

Yes > to step 3.
No > Repair or replace the circuit between the left front loudspeaker and the radio-cassette
player.
Caution
DI
fault.
symptoms disappear.
Caution

Caution

One loudspeaker produces no sound

Circuit diagram
DI

To reversing lamp
antenna

player
signal

signal sensor -
With the ignition switch at ACC, when the

One loudspeaker produces no sound radio-cassette player works normally, the
loudspeaker on one side produces no sound
Caution
DI Here the left front loudspeaker is used as an example, and the right front loudspeaker can be
serviced using the same method.
Diagnosis procedure
1. Inspect the speaker
and No.2terminal of the left front loudspeaker.
(1)-(2) About 4Ω

Yes > to step 2.
No > Replace the left front loudspeaker.
2. Check the circuit between the left front loudspeaker and the radio-cassette player
measure the resistance between the No.1 & No.2
terminals of the left front loudspeaker connector
J004 and the No.6 & No.2 terminals of the
J004(1)-C024(6) About 0Ω
J004(2)-C024(2) About 0Ω

Yes > to step 3.
No > Repair or replace the circuit between the left front loudspeaker and the radio-cassette
player.
Caution
DI
fault.
symptoms disappear.
Caution

Caution

The radio-cassette player can’t be illuminated at night

Circuit diagram
DI

To reversing lamp
antenna

player
signal

signal sensor -
Turn the light switch cluster to lamplet / headlamp

The radio-cassette player can’t be illuminated at night position, and the radio-cassette player backlight can’t
be illuminated.
Diagnosis procedure
DI
1. Check the power circuit of the radio-cassette backlight
c. Turn the ignition switch to ON and turn on the lamplet switch.
radio-cassette player connector C024 and GND.
Standard voltage:

Yes > to step 2.
No > Repair or replace the power circuit of the radio-cassette player backlight.
Caution
fault.
symptoms disappear.
Caution

Caution
Basic inspections
Check the battery voltage. The battery Yes Go to step 2

1 voltage should be about 12V.
Check if results are normal? No Charge or replace battery.
Check the fu. Check whether the fuse is Replace the same type of
Yes
fuse.
DI 2 blown out.
Check if results are normal? No Go to step 3
Check whether the antenna is extended to Yes Go to step 4

its maximum position.
Check whether the antenna is covered by
3
any foreign matters. Check whether the Repair the battery or
No
antenna is bent or deformed. replace the antenna
Check the radio wave. The coverage of Yes Go to fault symptom list
AM and FM broadcast varies significantly
with the regions. Sometimes the AM
broadcast can be well received, while the
FM stereo can’t be received in a good way.
The coverage of the FM stereo is highly
restricted and is liable to be interfered by
the electromagnetic wave.
4 Check whether there is any high building Move the vehicle to a
or high mountain around the vehicle which No place where the signal
may obstruct part of signals between the can be well received.
transmission tower and the vehicle.
• For reason of building materials, some
buildings may reflect the broadcast signal,
so that two signals will be received, leading
to mutual interference of signal.
Lighting system failure

Overview
The lighting system is the tool for the vehicle lighting, the lamps can generally be divided into interior
lamp and exterior lamp according to the installation position and purposes.
1. The interior lamp includes:

a. Front dome light: In front of the roof, with open, close and door lamp functions. DI
2. The exterior lamp includes:
a. Front end lamps: include high beam lamp, low beam lamp, front turn signal lamp, side turn signal
lamp, front fog lamp, front position lamp, and day running lamp, used for the illumination and
signaling purposes.
b. Rear end lamps: include rear turn signal lamp, rear fog lamp, brake lamp, rear position lamp and
reversing lamp, used for the illumination and signaling purposes.
c. Fog lamp: it is used for lighting and reminder when driving on a snow or foggy day.
d. License plate lamp: lighting the vehicle license plate to distinguish the vehicle license plate in the
dark.
Precautions
1. Before removing or installing any electrical devices or when a tool or device may easily
touch exposed electrical terminal, disconnect from negative cable of battery to protect the
vehicle and human from being damaged or hurt.
2. Unless otherwise specified, always turn off the ignition switch.
3. The halogen bulb with surface smeared by engine oil will shorten in working life.
4. Be careful, because the internal pressure of the halogen bulb is very high, so as to prevent
DI the bulb from exploding after dropping, thus glass fragments splatter against persons.
5. Do not directly touch the bulb surface by hand.
6. Change the bulb with the one of same specification and same power
7. After installing the bulb, install the bulb cover, otherwise, the window will dim or generate
vapour after water enters the combination lamp.
8. Be sure to wear safety goggles when replacing the bulb with a new one of the same
specification.
9. Ignition switch description:
ACC
ON
START Starting gear,automatically back to drive "ON" shift after start

Preparations
Recommended tool
Check the voltage, current or

resistance value
Auxiliary measuring the voltage or

Wire components
resistance
Technical data
Repair Specification
Bulb Specification Quantity
Position lamp 12V W5W 2
High beam 12V H4 2

Front combination
DI lamp
Low beam 12V H4 2
Turn signal lamp 12V PY21W 2
Reverse lamp P21W 12V 1
Turn signal lamp P21W 12V 2

Exterior
Rear combination
Brake lamp P21W 2
lamp
Rear fog lamp P21W 1
Position lamp 12V P21/5W 2
Front fog lamp H3 12V 55W 2
Side turn lamp W5W 12V/5W 2
License lamp C5W 1
In the vehicle Ceiling lamp 12V/0.2W LED 4


2. Lighting combination switch

(damaged)
Replace the light switch cluster DI
Working failure of both
Headlamp high beam and low 3. Lamplet switch (damaged) Replace the lamplet switch
beam
4. Harness (open-circuit or
Repair or change wiring harness.
short-circuit)
5. Earthing point (looseness,

Check the earthing point
corrosion)
1. Bulb (damaged) Replace the bulb
3. Low beam lamp relay

Low beams on both Replace the low beam lamp relay
(damaged)
sides are out
short-circuit)

Replace the light switch cluster
(damaged)
Only one side of low 2. Fuse (Burnout) Replace the same type of fuse.
Low beam is out
beam 3. Harness (open-circuit or
short-circuit)
short-circuit)
Low beams on both 2. Lighting combination switch

sides are normally on (damaged)
3. Low beam lamp relay

Replace the low beam lamp relay
(damaged)
The height of low beam short-circuit)
lamp can’t be regulated 2. Headlamp control switch Replace headlamp adjustment
(damaged) switch

High High beams on both
beam sides are out 3. High beam relay (damaged) Replace the high beam lamp relay
short-circuit)

(damaged)
Only one side of high 2. Fuse (Burnout) Replace the same type of fuse.
beam is out
DI short-circuit)
short-circuit)
High beams on both 2. Lighting combination switch
sides are normally on Replace the light switch cluster
(damaged)
3. High beam relay (damaged) Replace the high beam lamp relay
Front fog lamps on both 3. Front fog lamp relay (damaged) Replace the front fog lamp relay
sides are out
4. Front fog lamp switch
Replace front fog lamp switch
(damaged)
short-circuit)
Front fog
lamp 1. Bulb (damaged) Replace the bulb
Only one side of front
fog lamp is out 2. Harness (open-circuit or
short-circuit)
short-circuit)
Front fog lamps on both
2. Front fog lamp relay (damaged) Replace the front fog lamp relay
sides are normally on
3. Front fog lamp switch
Replace front fog lamp switch
(damaged)

The rear fog lamp works
Rear fog normally, while the rear 2. Harness (open-circuit or
lamp fog lamp can’t be short-circuit)
illuminated 3. Rear fog lamp switch
Replace the rear fog lamp switch
(damaged)

Turn
signal 2. Harness (open-circuit or
Both the turn signal Repair or change wiring harness.
lamp and short-circuit)
lamp and hazard
hazard
warning lamp don’t work 3. Hazard warning lamp switch Replace the hazard warning lamp
warning (damaged) switch.
lamp
4. Flasher (damaged) Change of flasher
short-circuit)
Turn signal lamps do
not work. 3. Hazard warning lamp switch Replace the hazard warning lamp
(damaged) switch.
4. Lighting combination switch DI

(damaged)
Working failure of 2. Harness (open-circuit or

hazard warning lamp short-circuit)
3. Hazard warning lamp switch Replace the hazard warning lamp

(damaged) switch.
A certain turn signal 2. Harness (open-circuit or

lamp doesn’t work short-circuit)

(damaged)

Brake lamps on both
sides can’t be Repair or change wiring harness.
short-circuit)
illuminated
3. Brake lamp switch (damaged) Replace brake lamp switch
Brake 1. Bulb (damaged) Replace the bulb

lamp One side of brake lamp
is out 2. Harness (open-circuit or
short-circuit)
Brake lamps on both Repair or change wiring harness.
short-circuit)
sides are permanently
illuminated 2. Brake lamp switch (damaged) Replace brake lamp switch
Reverse Reversing lamp does 2. Harness (open-circuit or

lamp not work. short-circuit)
3. Reversing lamp switch

Replace rearview lamp switch
(damaged)
Position 1. Bulb (damaged) Replace the bulb

lamp and A certain position lamp
license and license plate lamp
plate can’t be illuminated. Repair or change wiring harness.
short-circuit)
lamp
Interior The interior lamp can’t 1. Bulb (damaged) Replace the bulb

lamp be illuminated
short-circuit)
Replacement (Interior lamp

4. Front ceiling lamp assembly
assembly)
DI 1. Harness (open-circuit or
short-circuit)
Open the left door or
right door, and the
2. Door control switch (damaged) Replace courtesy switch
interior lamp can’t be
illuminated Replacement (Interior lamp
3. Front ceiling lamp assembly
assembly)
Low beams on both sides are out

Circuit diagram
Battery
DI
Frame fuse
box
Low beam High beam

relay relay Body fuse
case
Small lamp
relay
Headlamp
adjustment
switch
Lighting
Low combination
beam switch
High
beam
Overtaking
lamp
Left front Right front

Right front high
Left
Left front high
Right front
combination combination
low beam
front lamp lamp

beam
beam
low
Small beam
lamp
Headlamp
Small light switch
To engine ECU
With the ignition switch at ON and the switch cluster

Low beams on both sides are out at “low beam lamp” position, the low beam lamps on
both sides are not illuminated.
Diagnosis procedure
DI
1. Test the low beam bulb.
b. Check if the connectors of left and front right combination lamps are loose or fall.
c. Remove the bulbs of low beam lamps of the left and
right front grouped lamps, and check them for
normal operation.

Yes > to step 2.
No > Replace the low beam lamp bulb.
2. Check fuse
c. Take out the low beam lamp fuses IF10(10A) and IF11(10A).
Caution
fuse.
d. Check whether the middle fusible wires of the low

Off
beam lamp fuses IF35(10A)IF10(10A) and
Normal
IF11(10A) are blown out.

No> Go to step 3
3. Replace the low beam lamp relay for inspection

c. Replace the low beam lamp relay IR07. DI

No> Go to step 4
4. Check the power circuit of the low beam lamp

b. Disconnect the connector C005 of front left combination lamp.
c. With the ignition switch at On, turn on the low beam lamp.
left front grouped lamp connector C005 and GND.
Standard voltage:

Yes > to step 5.
No > Repair or replace the power circuit of low beam lamp.
5. Check the control circuit of low beam lamp relay

b. Open the body fuse box, and take out the low beam lamp relay IR07.
c. Disconnect lighting combination switch connector C018
of the high beam lamp relay IR07 in the body fuse
box and the No.5 terminal of the light switch cluster
connector C018.
No.86 pin socket -C018(5) Battery voltage


Yes > to step 6.
No> Repair or replace the control circuit of low beam lamp relay.
6. Check the earthing circuit of low beam lamp relay

DI c. Turn the multi-meter to the resistance mode, and
of the low beam lamp relay IR07 in the body fuse
box and GND.
No.85 pin socket - GND About 0Ω

Yes > to step 7.
No> Repair or replace the earthing circuit of low beam lamp relay.
7. Check the circuit between the light switch cluster and the lamplet switch
b. Disconnect lighting combination switch connector C018
c. Disconnect the lamplet switch connector C017.
of the light switch cluster connector C018 and the
No.1 terminal of the lamplet switch connector C017.
C017(1)-C018(6) About 0Ω

Yes > to step 8.
No > Repair or replace the circuit between the light switch cluster and the lamplet switch.
8. Replace the light switch cluster for inspection

a. Replace with the light switch cluster of the same size, and start another inspection.

Yes> Replace lighting combination switch.
No> Go to step 9
9. Replace the lamplet switch for inspection

a. Replace with the lamplet switch of the same size, and start another inspection.

DI
Only one side of low beam is out

Circuit diagram
Battery
DI
Frame fuse
box
Low beam High beam

case
Small lamp
relay
Headlamp
adjustment
switch
Lighting
Low combination
beam switch
High
beam
Overtaking
lamp

Right front high
Left
Left front high
Right front
low beam
front lamp lamp

beam
beam
low
Small beam
lamp
Headlamp
Small light switch
To engine ECU

at “low beam lamp” position, the low beam lamps on
one side is not illuminated, while the lamp on the
Only one side of low beam is out other side works normally. Here the left front grouped
lamp is used as an example, and the right front
grouped lamp can be serviced using the same
method. DI
Diagnosis procedure
b. Check if the connectors of left front combination lamps are loose or fall.
c. Remove the bulb of low beam lamp of the left front
grouped lamp, and check the bulb for normal
operation.

Yes > to step 2.
2. Check fuse
c. Take out the left front low beam lamp fuse IF10(10A).
Caution
fuse.
d. Check whether the middle fusible wire of the left

Off front low beam lamp fuse IF10(10A) is blown out.
Normal

No> Go to step 3
3. Check the power circuit of the left front low beam lamp
DI c. With the ignition switch at On, turn on the low beam lamp.
d. Turn the multi-meter to the voltage mode, and measure the voltage between the No.3 terminal of
Standard voltage:

Yes > to step 4.
No > Repair or replace the power circuit of left front low beam lamp.
4. Check the earthing circuit of left front low beam lamp.

of left front grouped lamp connector C005 and
GND.
Standard voltage:

Yes > Replace the left front grouped lamp assembly.
No > Repair or replace the earthing circuit of left front low beam lamp.
Low beams on both sides are normally on

Circuit diagram
Battery
DI
Frame fuse
box
Low beam High beam

case
Small lamp
relay
Headlamp
adjustment
switch
Lighting
Low combination
beam
switch
High
beam
Overtaking
lamp

Right front high
Left
Left front high
Right front
low beam
front lamp lamp

beam
beam
low
beam
Small
lamp
Headlamp
Small light switch
To engine ECU
With the ignition switch at ON and irrespective of

whether the light switch cluster is located at “low
beam lamp” position, the low beam lamps on both
sides are permanently illuminated.
c. Replace the low beam lamp relay IR07.

No> Go to step 2

Standard voltage:

Yes > to step 3.


connector C018.
DI

Yes > to step 4.


The height of low beam lamp can’t be regulated

Circuit diagram
Battery
DI
Frame fuse
box
Low beam High beam

case
Small lamp
relay
Headlamp
adjustment
switch
Lighting
Low combination
beam switch
High
beam
Overtaking
lamp

Right front high
Left
Left front high
Right front
low beam
front lamp lamp

beam
beam
low
Small beam
lamp
Headlamp
Small light switch
To engine ECU
With the ignition switch at ON, turn on the low beam

switch, and the low beam lamps on both sides work
normally. Regulate the headlamp level control switch,
The height of low beam lamp can’t be regulated and the height of the low beam lamp can’t be
regulated. Here the left front grouped lamp is used as
an example, and the right front grouped lamp can be
serviced using the same method. DI
Diagnosis procedure
1. Replace the headlamp control switch for inspection
b. Replace headlamp adjustment switch

Yes > Replace with the headlamp control switch of the same size.
No> Go to step 2
2. Check the power circuit of the headlamp control switch

b. Disconnect the headlamp control switch connector C013.
the headlamp control switch connector C013 and
GND.
Standard voltage:

Yes > to step 3.
No > Repair or replace the power circuit of the headlamp control switch.
3. Check the earthing circuit of the headlamp control switch


of the headlamp control switch connector C013 and
GND.

DI

Yes > to step 4.
No > Repair or replace the earthing circuit of the headlamp control switch.
4. Check the circuit between the headlamp control switch and the left front grouped lamp
c. Disconnect the connector C005 of front left combination lamp.
of the headlamp control switch connector C013 and
the No.5 terminal of the left front grouped lamp
connector C005.
C013(5)-C005(5) About 0Ω

Yes > to step 5.
No > Repair or replace the circuit between the headlamp control switch and the left front grouped
lamp
5. Check the power circuit of the left front headlamp control motor

Standard voltage:
DI

Yes > to step 6.
No > Repair or replace the power circuit of the left front headlamp control motor.
6. Check the earthing circuit of the left front headlamp control motor
GND.

No > Repair or replace the earthing circuit of the left front headlamp control motor.
High beams on both sides are out

Circuit diagram
Battery
DI
Frame fuse
box
Low beam High beam

case
Small lamp
relay
Headlamp
adjustment
switch
Lighting
Low combination
beam switch
High
beam
Overtaking
lamp

Right front high
Left
Left front high
Right front
low beam
front lamp lamp

beam
beam
low
Small beam
lamp
Headlamp
Small light switch
To engine ECU

High beams on both sides are out at “high beam lamp” position, the high beam lamps on
both sides are not illuminated.
Diagnosis procedure
DI
1. Test the high beam bulb.
c. Remove the bulbs of high beam lamps of the left
and right front grouped lamps, and check them for
normal operation.

Yes > to step 2.
No Replace the high beam lamp bulb.
2. Check fuse
c. Take out the high beam lamp fuses IF03(10A) and IF04(10A).
Caution
fuse.
d. Check whether the middle fusible wires of the high

Off Normal beam lamp fuses IF03(10A) and IF04(10A) are
blown out.

No> Go to step 3
3. Replace the high beam lamp relay for inspection

DI c. Replace the high beam lamp relay IR06.

No> Go to step 4
4. Check the power circuit of the high beam lamp

c. With the ignition switch at On, turn on the high beam lamp.
Standard voltage:

Yes > to step 5.

connector C018.


Yes > to step 6.
6. Check the earthing circuit of low beam lamp relay

of the low beam lamp relay IR07 in the body fuse
box and GND.

Yes > to step 7.
No> Repair or replace the earthing circuit of low beam lamp relay.
7. Check the circuit between the light switch cluster and the lamplet switch
b. Disconnect lighting combination switch connector C018
c. Disconnect the lamplet switch connector C017.
of the light switch cluster connector C018 and the
No.1 terminal of the lamplet switch connector C017.
C017(1)-C018(6) About 0Ω

Yes > to step 8.
No > Repair or replace the circuit between the light switch cluster and the lamplet switch.


No> Go to step 9
9. Replace the lamplet switch for inspection

a. Replace with the lamplet switch of the same size, and start another inspection.

DI
Only one side of low beam is out

Circuit diagram
Battery
DI
Frame fuse
box
Low beam High beam

case
Small lamp
relay
Headlamp
adjustment
switch
Lighting
Low combination
beam switch
High
beam
Overtaking
lamp

Right front high
Left
Left front high
Right front
low beam
front lamp lamp

beam
beam
low
Small beam
lamp
Headlamp
Small light switch
To engine ECU

at “high beam lamp” position, the high beam lamps on
one side is not illuminated, while the lamp on the
Only one side of high beam is out other side works normally. Here the left front grouped
lamp is used as an example, and the right front
grouped lamp can be serviced using the same
DI method.
Diagnosis procedure
c. Remove the bulb of low beam lamp of the left front
grouped lamp, and check the bulb for normal
operation.

Yes > to step 2.
2. Check fuse
c. Take out the left front low beam lamp fuse IF10(10A).
Caution
fuse.
d. Check whether the middle fusible wire of the left

Off front low beam lamp fuse IF10(10A) is blown out.
Normal

No> Go to step 3
3. Check the power circuit of the left front low beam lamp
c. With the ignition switch at On, turn on the low beam lamp. DI
Standard voltage:

Yes > to step 4.
No > Repair or replace the power circuit of left front low beam lamp.
4. Check the earthing circuit of left front low beam lamp.

GND.
Standard voltage:

Yes > Replace the left front grouped lamp assembly.
No > Repair or replace the earthing circuit of left front low beam lamp.

Circuit diagram
Battery
DI
Frame fuse
box
Low beam High beam

case
Small lamp
relay
Headlamp
adjustment
switch
Lighting
Low combination
beam switch
High
beam
Overtaking
lamp

Right front high
Left
Left front high
Right front
low beam
front lamp lamp

beam
beam
low
Small beam
lamp
Headlamp
Small light switch
To engine ECU
Malfunction symptom Phenomenal description

whether the light switch cluster is located at “low
beam lamp” position, the low beam lamps on both
sides are permanently illuminated.
Diagnosis procedure DI
c. Replace the low beam lamp relay IR06.

No> Go to step 2

Standard voltage:
C005 (2)-grounding About 0V

Yes > to step 3.


connector C018.
DI

Yes > to step 4.


Front fog lamps on both sides are out

Circuit diagram
Battery
DI
Front fog
Frame fuse lamp relay Body fuse
box case
Front fog Rear fog

lamp switch lamp switch
To small lamp relay To combined instrument A
Right front Left front fog

fog lamp lamp
Left rear fog

lamp
Combination instrument A

whether the light switch cluster is located at “front fog
Front fog lamps on both sides are out
lamp” position, front fog lamps on both sides are not
illuminated.
1. Check the bulb of the front fog lamp
c. Remove the bulbs of left and right front fog lamps
and check them for normal operation.

Yes > to step 2.
No > Replace the bulb of the front fog lamp.
2. Check fuse
c. Take out the front fog lamp fuse IF05(15A).
Caution
fuse.
d. Check whether the middle fusible wire of the front

Off Normal
fog lamp fuse IF05(15A) is blown out.

No> Go to step 3
3. Replace the front fog lamp relay for inspection

c. Replace the front fog lamp relay IR02. DI

No> Go to step 4
4. Replace the front fog lamp switch for inspection

a. Replace with the front fog lamp switch of the same size, and start another inspection.

Yes> Replace front fog lamp switch
No> Go to step 5
5. Check the power circuit of the front fog lamp

b. Disconnect the connector T005 of front left fog lamp.
c. Disconnect the connector T002 of front right fog lamp.
d. With the ignition switch at ON, turn on the front fog lamp.
e. Turn the multi-meter to the voltage mode, and
left front fog lamp connector T005 and GND.
Standard voltage:
T005 (2)-grounding Battery voltage
f. Turn the multi-meter to the voltage mode, and

right front grouped lamp connector C002 and GND.
Standard voltage:


Yes > to step 6.
No> Go to step 7
6. Check the earthing circuit of the front fog lamp.

DI c. Disconnect the connector T002 of front right fog lamp.
of left front fog lamp connector T005 and GND.
T005 (1)-grounding About 0Ω

of right front fog lamp connector T002 and GND.

No > Repair or replace the earthing circuit of the front fog lamp.
7. Check the control circuit of front fog lamp relay

b. Open the body fuse box, and take out the front fog lamp relay IR02.
c. Disconnect the front fog lamp switch connector C011.
the front fog lamp relay IR02 in the body fuse box
and the No.5 terminal of the front fog lamp switch
connector C011.


Yes > to step 8.
No > Repair or replace the control circuit of front fog lamp relay.
8. Check the earthing circuit of the front fog lamp relay

b. Open the body fuse box, and take out the front fog lamp relay IR02.
the front fog lamp relay IR02 in the body fuse box
and GND.

Yes > to step 9.
No > Repair or replace the earthing circuit of the front fog lamp relay.
9. Check the power circuit of the front fog lamp switch

b. Disconnect the front fog lamp switch connector C011.
c. With the ignition switch at On, turn on the lamplet.
the front fog lamp switch connector C011 and GND.
Standard voltage:

Yes > to step 10.
No > Repair or replace the power circuit of the front fog lamp switch.
10. Check the earthing circuit of the front fog lamp switch.
b. Disconnect the front fog lamp switch connector C011.

of the front fog lamp switch connector C011 and
GND.

DI

No > Repair or replace the earthing circuit of the front fog lamp switch.
Only one side of front fog lamp is out

Circuit diagram
Battery
DI
Front fog
box case
Front fog Rear fog


fog lamp lamp
Left rear fog

lamp
With the ignition switch at ON , press the front fog

lamp switch, and the front fog lamp on one side is not
illuminated, while the lamp on the other side works
Front fog lamp at one side does not work.
normally. Here the left front fog lamp is used as an
example, and the right front fog lamp can be serviced
using the same method.
DI
Diagnosis procedure
1. Check the bulb of the front fog lamp
c. Remove the bulb of left and right front fog lamp and
check the bulb for normal operation.

Yes > to step 2.
No > Replace the bulb of the left front fog lamp.

c. With the ignition switch at ON, turn on the front fog lamp.
left front grouped lamp connector T005 and GND.
Standard voltage:

Yes > to step 3.
No > Repair or replace the power circuit of left front fog lamp.
3. Check the earthing line of the front fog lamp.


of left front fog lamp connector T005 and GND.

DI

No > Repair or replace the earthing circuit of the left front fog lamp.
Front fog lamps on both sides are normally on

Circuit diagram
Battery
DI
Front fog
box case
Front fog Rear fog


fog lamp lamp
Left rear fog

lamp
With the ignition switch at ON , turn off the front fog

Front fog lamps on both sides are normally on lamp, and the front fog lamps on both sdies are
permanently illuminated
Diagnosis procedure
1. Replace the front fog lamp relay for inspection
DI
c. Replace the front fog lamp relay IR02.

No> Go to step 2
2. Replace the front fog lamp switch for inspection

a. Replace with the front fog lamp switch of the same size, and start another inspection.

Yes> Replace front fog lamp switch
No> Go to step 3

c. Disconnect the connector T002 of front right fog lamp.
d. With the ignition switch at ON, turn on the front fog lamp.
e. Turn the multi-meter to the voltage mode, and
left front grouped lamp connector T005 and GND.
Standard voltage:
f. Turn the multi-meter to the voltage mode, and

right front grouped lamp connector C002 and GND.
Standard voltage:


No > Repair or replace the power circuit of front fog lamp.
DI
The rear fog lamp works normally, while the rear fog lamp can’t be illuminated
Circuit diagram
Battery
DI
Front fog
box case
Front fog Rear fog


fog lamp lamp
Left rear fog

lamp
With the ignition switch at ON , press the front fog

The rear fog lamp works normally, while the rear fog lamp switch, then press the rear fog lamp switch, and
lamp can’t be illuminated front fog lapms on both sides are illuminated while the
rear fog lamp can’t be illuminated.
Diagnosis procedure
DI 1. Check the bulb of the rear fog lamp
b. Check whether the rear fog lamp connector is loosened or separated.
c. Remove the bulb of rear fog lamp and check the
bulb for normal operation.

Yes > to step 2.
No > Replace the bulb of the rear fog lamp.
2. Replace the rear fog lamp switch for inspection

a. Replace with the rear fog lamp switch of the same size, and start another inspection.

Yes > Replace the rear fog lamp switch.
No> Go to step 3
3. Check the power circuit of the rear fog lamp

b. Disconnect the left rear grouped lamp connector L002.
c. Ignition switch: On. Turn on rear fog lamp.
left rear fog lamp connector L002 and GND.
Standard voltage:
L002 (3)-grounding Battery voltage


Yes > to step 4.
No > Repair or replace the power circuit of rear fog lamp.
4. Check the circuit between the rear fog lamp switch and the front fog lamp switch
b. Disconnect the rear fog lamp connector C010.
c. Disconnect the front fog lamp connector C011. DI
of the rear fog lamp connector C010 and the No.5
terminal of the front fog lamp connector C011.
C010(2)-C011(5) About 0Ω

Yes > to step 5.
No > Repair or replace the circuit between the rear fog lamp switch and the front fog lamp switch.
5. Check the earthing line of the rear fog lamp.

b. Disconnect the connector of left rear combination lamp L002.
of left rear grouped lamp connector L002 and GND.

No > Repair or replace the earthing circuit of the rear fog lamp.
Both the turn signal lamp and hazard warning lamp can’t be illuminated
Circuit diagram
DI
Frame fuse Flasher Body fuse

box case
To small lamp relay
Hazard
Closed warning switch Lighting combination
switch
Open Left turn
Right
steering
Left
front Left side Right rear
turn turn Left rear Right front Right side turn
signal signal turn signal turn signal turn signal signal
lamp lamp lamp lamp lamp lamp
To combined To BCM-2 To BCM-2 To combined

instrument B instrument A
With the ignition switch at ON, press the turn signal

Both the turn signal lamp and hazard warning lamp lamp or hazard warning lamp switch, both the turn
can’t be illuminated signal lamp and hazard warning lamp can’t be
illuminated.
Diagnosis procedure
1. Test fuse. DI
c. Take out the fuses IF07(10A) and IF13(15A).
Caution
fuse.

Off IF07(10A) and IF13(15A) are blown out.
Normal

Yes > Replace the same type of fuse.
No> Go to step 2
2. Replace the flasher for inspection

a. Replace with the flasher of the same size, and start another inspection.

Yes > Replace the flasher.
No> Go to step 3
3. Replace the hazard warning lamp switch for inspection

a. Replace with the hazard warning lamp switch of the same size, and start another inspection.

Yes> Replace the hazard warning lamp switch.
No> Go to step 4
4. Check the input (B) circuit of the flasher


b. Open the body fuse box, and take out the flasher.
c. Disconnect the hazard warning lamp connector C025.
measure the resistance between the B pin socket of
the flasher in the body fuse box and the No.4
terminal of the hazard warning lamp connector
DI C025.
B pin socket -C025(4) About 0Ω

Yes > to step 5.
No > Repair or replace the input (B) circuitt of the flasher.
5. Check the output (L) circuit of the flasher

c. Disconnect the hazard warning lamp connector C025.
measure the resistance between the L pin socket of
the flasher in the body fuse box and the No.2
terminal of the hazard warning lamp connector
C025.
L pin socket -C025(2) About 0Ω

Yes > to step 6.
No > Repair or replace the output (L) circuit of the flasher.
6. Check the negative terminal (E) circuit of the flasher


measure the resistance between the E pin socket of
the flasher in the body fuse box and GND.
E pin socket - GND About 0Ω
DI

No > Repair or replace the negative terminal (E) circuit of the flasher.
Brake lamps on both sides can’t be illuminated

Circuit diagram
Battery
DI

box case
Brake switch
Left rear brake Right rear

light brake light
Depress the brake pedal, and brake lamps on both

Brake lamps at two sides do not work.
sides can’t be illuminated
Diagnosis procedure
1. Check fuse
a. Ignition switch: LOCK. DI
c. Take out the brake lamp fuse IF14(7.5A).
Caution
fuse.
d. Check if the middle fuse wire of fuse IF14(7.5A) is

Off Normal
blown.

No> Go to step 2
2. Inspect brake light switch

b. Disconnect the brake lamp switch connector C007.
and No.2 terminal of the brake lamp switch.
Multimeter
Conditions Standard value
connection
Pins 1 and 2 of
(1)-(2) Conducting
B204
The brake pedal is
(1)-(2) Not conducting
not depressed
Yes > to step 3.
No > Replace brake lamp switch
3. Check the power circuit of brake lamp

c. With the brake pedal depressed, turn the
the resistance between the No.4 terminal of left rear
grouped lamp connector L002 and GND.
DI Standard voltage:

Yes > to step 4.
No > Repair or replace the power circuit of brake lamp.
4. Check the earthing line of brake lamp.

c. Disconnect the connector L010 of rear right combination lamp.

of right rear grouped lamp connector L010 and
GND.

No > Repair or replace the earthing circuit of brake lamp.
One side of brake lamp is out

Circuit diagram
Battery
DI

box case
Brake switch

light brake light
Depress the brake pedal, and the brake lamp on one

side can’t be illuminated, while the lamp on the other
One side of brake lamp is out side works normally. Here the left rear brake lamp is
used as an example, and the right rear brake lamp
can be serviced using the same method.
1. Test the brake lamp bulb.
b. Check if the connectors of left rear combination lamps are loose or fall.
c. Remove the bulb of left rear brake lamp and check
whether the bulb works normally.

Yes > to step 2.
No> Replace the bulb of brake lamp.

Standard voltage:

Yes > to step 3.
3. Check the earthing line of brake lamp.

c. Disconnect the connector L010 of rear right combination lamp.


DI

No > Repair or replace the earthing circuit of brake lamp.
Brake lamps on both sides are permanently illuminated

Circuit diagram
Battery
DI

box case
Brake switch

light brake light
Irrespective of whether the brake pedal is depressed,

Brake lamps on both sides are permanently
brake lamps on both sides are permanently
illuminated
illuminated.
Diagnosis procedure
1. Inspect brake light switch
DI
b. Disconnect the brake lamp switch connector C007.
and No.2 terminal of the brake lamp switch.
Multimeter Multimeter
Standard value
terminal block connection
Pins 1 and 2 of
(1)-(2) Conducting
B204
The brake pedal is
(1)-(2) Not conducting
not depressed

Yes > to step 2.
No > Replace brake lamp switch

Standard voltage:

Reversing lamp does not work.

Circuit diagram
Ignition switch IG2
DI
Body fuse
case
Reversing
lamp switch
Right rear
reversing lamp

With the ignition switch at On, locate the gearshift
Reversing lamp does not work. control lever at “reverse”, and the reversing lamp
can’t be illuminated.
Diagnosis procedure
1. Test fuse.
a. Ignition switch: LOCK. DI
c. Take out the brake lamp fuse IF07(10A).
Caution
fuse.
d. Check if the middle fuse wire of fuse IF07(10A) is

Off blown.
Normal

No> Go to step 2
2. Check the reverse light switch.

c. Locate the gearshift control lever at “Reverse”.
measure the continuity between the No.1 terminal
and No.2 terminal of the reversing lamp switch.
(1)-(2) Conducting

Yes > to step 3.
No>Replace rearview lamp switch.
3. Check the power circuit of the reversing lamp switch

DI c. Ignition switch: ON.
the reversing lamp switch connector E016 and
GND.
Standard voltage:
E016 (1)-grounding Battery voltage

Yes > to step 4.
No > Repair or replace the power wire of the reversing lamp switch.
4. Check the power circuit of the reversing lamp

b. Disconnect the connector L010 of rear right combination lamp.
c. Disconnect the connector E016 of reversing lamp switch.
of the reversing lamp switch connector E016 and
the No.2 terminal of the right rear grouped lamp
connector L010.
E016(2)-L010(2) About 0Ω

Yes > to step 5.
No > Repair or replace the power circuit of the reversing lamp.
5. Check the grounding circuit of reversing lamp.

b. Disconnect the connector L010 of rear right combination lamp.

of right rear grouped lamp connector L010 and
GND.

DI

No > Repair or replace the earthing circuit of the reversing lamp.
A certain position lamp or license plate lamp can’t be illuminated.

Circuit diagram
Battery
DI
Body fuse
case
Frame fuse
Small lamp box
relay
Small
lamp
Small lamp switch
Left front Right front Left rear Right rear

Position lamp
Position lamp
Position lamp
Position lamp
combination combination combination combination Rear license

lamp lamp lamp lamp plate lamp
With the ignition switch at ON, turn on the lamplet

switch, and one certain position lamp or license plate
lamp can’t be illuminated while other lamps work
A certain position lamp or license plate lamp can’t be
normally. Here the left front position lamp is used as
illuminated.
an example, and the right front position lamp or
license plate lamp can be serviced using the same
method. DI
Diagnosis procedure
1. Check the bulb of the left front position lamp
c. Remove the bulb of the left front position lamp and
check whether the bulb works normally.

Yes > to step 2.
No > Replace the bulb of the left front position lamp.
2. Check the power circuit of the left front position lamp

c. With the ignition switch at On, turn on the lamplet.
Standard voltage:

Yes > to step 3.
No > Repair or replace the power circuit of left front position lamp.
3. Check the earthing circuit of the left front position lamp

of the left front grouped lamp connector C005 and
GND.
DI Standard resistance:

No > Repair or replace the earthing circuit of the left front position lamp.
The interior lamp can’t be illuminated

Circuit diagram
Battery
DI

box case
Ceiling
lamp
Courtesy switch (LH) Courtesy switch (RH)

With the ignition switch at ON, turn on the interior

The interior lamp can’t be illuminated lamp switch, and the interior lamp can’t be
illuminated.
Diagnosis procedure
1. Check the bulb of the interior lamp
DI
b. Check the interior lamp connector for looseness and falloff.
c. Remove the bulb of the interior lamp and check
whether the bulb works normally.

Yes > to step 2.
No > Replace the bulb of the interior lamp.
2. Check the interior lamp fuse.

c. Take out the interior lamp fuse IF09 (5A).
Caution
fuse.
d. Check the middle portion of interior lamp fuse IF09

Off Normal (5A) for burnout.

No> Go to step 3
3. Check the power circuit of the interior lamp

b. Disconnect the interior lamp switch connector F001.
interior lamp connector F001 and GND.
Standard voltage:
Multimeter terminal block Standard value DI
F001 (2)-grounding Battery voltage

Yes > to step 4.
No > Repair or replace the power circuit of the interior lamp.
4. Check the earthing circuit of the interior lamp

b. Disconnect the interior lamp switch connector F001.
of interior lamp connector F001 and GND.
F001 (3)-grounding About 0Ω

Yes > to step 5.
No > Repair or replace the earthing circuit of the interior lamp.
5. Replace the interior lamp for inspection

a. Replace with the interior lamp of the same size, and start another inspection.

Yes> Replace the interior lamp.
Basic inspections
Inspect the voltage of the storage Yes Go to step 2

battery
1
The voltage of the battery is about 12V.
No Charge or charge the battery.
DI Check the low beam. Yes Go to step 3

Turn combination switch to “low beam”
2
gear, low beam is on.
No Refer to the fault symptom table.
Check the high beam. Yes Go to step 4
Turn combination switch to “high beam”
3
gear, high beam is on.
Check the front fog lamp. Yes Go to step 5
Ignition switch: ON.
Turn the switch cluster to “Front fog
4
lamp” position,
and the front fog lamp is illuminated.
Check the rear fog lamp. Yes Go to step 6
Press the front fog lamp switch, then
5 press the rear fog lamp switch, and the
rear fog lamp is illuminated. No Refer to the fault symptom table.
Check the left turn lamp. Yes Go to step 7
6 Turn combination switch to “left turn”
gear, left turn light is on. No Refer to the fault symptom table.
Check the right turn lamp. Yes Go to step 8
7 Use combination switch to turn to “right
turn” gear, right turn light is on. No Refer to the fault symptom table.
Check the hazard warning lamp. Yes Go to step 9
Press the hazard warning switch,
8
hazard warning lamp is on.
Check the brake lamp. Yes Go to step 10
9 Depress the brake pedal, brake lamp is
on. No Refer to the fault symptom table.
Check the rearview lamp. Yes Go to step 11

10 Operate the gearshift lever to the
reverse gear, and the reversing lamp is No Refer to the fault symptom table.
illuminated. Is the operation normal?
Check the position lamp. Yes Go to step 12 DI
11 Operate the light switch to “Lamplet”,
and the gear position lamp is No Refer to the fault symptom table.
illuminated.
Check the license plate lamp Yes Go to step 13
Turn the ignition switch to ON. Move
the light switch to “Lamplet” position,
12
and the license plate lamp is
illuminated.
Check the room lamp. Yes The basic inspection is ended
13 Open the door or turn on interior lamp
switch, interior lamp is on. No Refer to the fault symptom table.
Combination instrument fault

Overview
The instrument cluster has integrated following components: instrument control unit, engine tachometer,
speedometer, fuel gauge, LCD screen, engine coolant temperature indicator lamp and the prompting
indication/warning lamp, and buzzer.
DI
Function description
DI
1 Tachometer 3 Speedometer
2 Indicator lamp /warning lamp 4 LCD display screen
No. Symbol Name Description
Switch on the turn signal indicator lamp, and the

instrument turn signal indicator lamp and turn signal
lamp will flash simultaneously, with the instrument
cluster buzzer ringing. Switch off the turn signal
indicator lamp, and the instrument turn signal
1 Turn indicator indicator lamp and turn signal lamp will be
DI extinguished, with the instrument cluster buzzer
ceased. Switch on the hazard warning lamp, and the
left and right turn signal indicator lamps and turn
signal lamps will flash simultaneously, with the
instrument cluster buzzer ringing. Hard wire signal.
With the ignition switch at ON, turn on the rear fog

Rear fog lamp indicator
2 lamp, and the rear fog lamp indicator lamp will be
lamp
illuminated. Hard wire signal.
With the ignition switch at ON, turn on the high beam

High beam indicator
3 lamp, and the high beam lamp indicator lamp will be
lamp
With the ignition switch at ON, turn on the low beam

Low beam indicator
4 lamp, and the low beam lamp indicator lamp will be
lamp
With the ignition switch at ON, turn on the front fog

Front fog lamp indicator
5 lamp, and the front fog lamp indicator lamp will be
lamp
Turn on the light switch, and the lamplet indicator

6 Lamplet indicator lamp
lamp will be illuminated. Hard wire signal.
With the ignition switch at ON, the engine will perform

the self-test, and the warning lamp will be illuminated
Engine fault warning and then extinguished. When ECU detects any
7
lamp serious fault in the system, this lamp will be
illuminated while the buzzer will ring all the time. Hard
wire signal.
With the indicator lamp will illuminate at ON, the

battery charge indicator lamp will be illuminated. After
8 Battery charger indicator
the engine is started, the battery charge indicator
lamp will be extinguished. Hard wire signal.
When the level of fuel tank drops to the lower limit as

specified, namely, 1/8 of fuel tank volume, the fuel
9 Fuel level low
level indicator lamp will be illuminated for warning.
Hard wire signal.
No. Symbol Name Description
With the ignition switch at ON, when the coolant

temperature is higher than 105°C, the indicator lamp
Coolant temperature
10 will be illuminated, accompanied with the indicator
high warning lamp
lamp buzz; when the temperature drops to 103°C, the
warning will be cancelled. Hard wire signal.
With the ignition switch at ON, pull up the parking

Parking brake indicator DI
11 brake lever, and the parking brake indicator lamp will
lamp
be illuminated. Hard wire signal.
With the indicator lamp will illuminate at ON, the

Engine oil pressure too engine oil pressure indicator lamp will be illuminated.
12
low warning lamp After the engine is started, this indicator lamp will be
extinguished. Hard wire signal.
With the ignition switch at ON, the brake fault

indicator lamp will be illuminated for 3s to complete
the self-test; thereafter, if the pressure value is lower
Braking system fault than 0.4MPa, the lamp will be illuminated. If the
13
warning lamp pressure value is higher than 0.4MPa, the lamp will
be extinguished. If the ASR fails, the brake fault
indicator lamp will be also illuminated. Hard wire
signal.
With the ignition switch at ON, when the gearshift

lever is located at “Reverse”, the reversing lamp will
14 Reversing indicator lamp
be illuminated and this indicator lamp will be also
When the EPS (electric power steering) system fails,

15 EPS failure warning light this warning lamp will be illuminated. Hard wire
signal.
With the ignition switch at ON, if the driver fails to

16 Safety belt warning light fasten the safety belt, this warning lamp will be
With the ignition switch at ON, if either door is not

17 Door open warning lamp closed, this warning lamp will be illuminated. Hard
wire signal.
Precautions
1. All the indicator lamps and warning lamps are light emitting diodes (LED).
2. The instrument cluster is assembly part, therefore, the disassembly and repairing to it are
prohibited. If there is fault, replace the combination instrument assembly.
3. Check the instrument cluster for any abnormity after installation.
DI

Refer to the following table to help you to find out the cause of fault. Serial number indicates the order of
possibility of a failure cause. Check each part according to orders, replace as required.

1. Instrument cluster fuse (blown)
specification
The whole instrument cluster does 2. Power and grounding circuits DI
not work (open circuit or short circuit)
3. Combination instrument
Replace the instrument cluster.
(damaged)
Repair or replace the speed
1. Speed sensor (damaged)
sensor
2. Vehicle speed sensor circuit (open
Speedometer malfunctions Repair or replace the harness
circuit or short circuit)
(damaged)
1. Crankshaft position sensor Repair or replace the Crankshaft
(damage) position sensor
2. Harness of crankshaft sensor
Tachometer fault Repair or replace the harness
(open circuit or short circuit).
(damaged)
1. Fuel sensor (damaged) Repair or replace the fuel sensor
2. Fuel gauge circuit (open circuit or

Fuel gauge malfunctions Repair or replace the harness
short circuit)
(damaged)
1. Coolant temperature sensor Repair or replace the coolant
(damage) temperature sensor
2. Coolant temperature sensor circuit
(open circuit or short circuit)
Water temperature gauge fault
(damaged)
4. Engine ECU (damaged). Repair or replace engine ECU
Repair or replace the parking

1. Parking brake switch (damaged)
brake switch
Parking braking indicator is not on/ 2. Parking brake indicator lamp
normally on circuit (open circuit or short circuit)
(damaged)
1. Fuel sensor (damaged) Repair or replace the fuel sensor

Fuel level indicator lamp is
normally on 2. Fuel sensor circuit (turnoff or short
circuit)
No time display, or blurry display 1. LCD (damage) Replace the instrument cluster.
1. Current selection is incorrect Reset and adjust

The clock can not be set
2. Reset button (damage) Replace the instrument cluster.
Speedometer cannot display or

1. LCD (damage) Replace the instrument cluster.
displays vaguely
DI
The whole instrument cluster does not work

Circuit diagram
Battery To marker lamp switch

Ignition switch IG1
DI
Small
Frame fuse lamp Body fuse
box relay case
Tachometer Speedometer
Buzzer
PS module
Position Combined
indicator instrument
Back lamp
light
Sensor + Vehicle Sensor -

speed signal
To engine To EPS Odometer sensor

control unit
With the ignition switch at ON, the whole instrument

The whole combination instrument fails
cluster doesn’t work.
Diagnosis procedure
DI 1. Check fuse
c. Take out the instrument cluster fuses IF15(5A) and IF17(7.5A).
Caution
fuse.

instrument cluster fuses IF15(5A) and IF17(7.5A)
Off Normal
are blown out.

No> Go to step 2
2. Check the power circuit of the instrument cluster

b. Disconnect the connector C019 and C020 of combination instrument.
d. Measure the voltage between pin 31,32 of
combination instrument connector C019 and the
ground by the voltage measurement range of a
multimeter.
Standard voltage:

e. Measure the voltage between pin 26 of combination

instrument connector C020 and the ground by the
voltage measurement range of a multimeter.
Standard voltage:
DI

Yes > to step 3.
No> Repair or replace the power circuit of the instrument cluster.
3. Check combination instrument grounding circuit.

b. Disconnect the connector C019 of combination instrument.
No.25 terminals of the instrument cluster connector
C018 and GND.

Yes > to step 4.
No > Repair or replace the earthing circuit of the instrument cluster.
4. Check the instrument cluster
Caution
Generally, the instrument cluster can be only accurately tested by the specialized repair
personnel. During the field service, the replacement method is usually applied to judge the fault.
a. Replace with a new or normally-working instrument cluster.
b. Connect the circuits properly, turn on the ignition switch again, and judge whether the fault
symptoms disappear.
Caution
The instrument cluster of the same size and model shall be used.

Yes > Replace the combination instrument
Caution
The instrument cluster can be only dismantled and repaired by the specialized personnel.

DI
Speedometer fault
Circuit diagram

Ignition switch IG1
DI
Small
box relay case
Buzzer
PS module
Position Combined
Back lamp
light

speed signal

control unit
Diagnosis procedure
1. Check the circuit between the odometer sensor and the instrument cluster
b. Disconnect the instrument cluster connector C019 and the speedometer sensor connector B014.
c. Disconnect the odometer sensor connector E014.
DI No.30 terminals of the instrument cluster connector
C019 and the No.3 and No.1 terminals of the
odometer sensor connector E014.
C019(28)-E014(3) About 0Ω
C019(30)-E014(1) About 0Ω

Yes > to step 2.
No> Repair or replace the circuit between the odometer sensor and the instrument cluster
2. Check the earthing wiring harness of the odometer sensor

b. Disconnect the odometer sensor connector E014.
of the odometer sensor connector E014 and GND.
E014 (2)-grounding About 0Ω

Yes > to step 3.
No > Repair or replace the earthing wiring harness of the odometer sensor.
3. Replace the odometer sensor for inspection

a. Replace the odometer sensor, and start another inspection.

Yes > Replace the odometer sensor.
No> Go to step 4
Caution
symptoms disappear. DI
Caution

Caution

Fuel gauge fault

Circuit diagram

Ignition switch IG1
DI
Small
box relay case
Buzzer
PS module
Position Combined
Back lamp
light

speed signal

control unit
To lighting
To rear fog combination To high To front fog To high beam To front fog To reversing
lamp switch switch beam fuse lamp fuse fuse lamp fuse lamp switch
DI
Indicator light Indicator light

Rear fog lamp of left steering High beam Low beam Front fog lamp Reversing
of right indicator lamp indicator lamp indicator
indicator lamp lamp indicator lamp
steering lamp lamp
Combined
instrument
Charging EPS failure Brake fault Safety belt Low engine Parking Unclosed door
fault warning alarm lamp warning oil press brake warning lamp
indicator light light indicator warning
lamp
Driver
Brake
seat belt
fluid level
warning switch
switch
Engine oil Handbrake Left front Right front

pressure switch door lamp door lamp
switch switch switch
To alternator To EPS control unit

Coolant SVS Engine fault Fuel level low

temperature high indicator warning lamp indicator lamp
alarm lamp lamp
Combined
instrument
DI
Fuel sensor
To engine ECU To engine ECU To engine ECU To engine ECU

Diagnosis steps
1. Check the circuit between the fuel sensor and the instrument cluster
c. Disconnect the fuel sensor connector B017.
of the instrument cluster connector C019 and the DI
No.1 terminal of the fuel sensor connector B017.
C019(26)-B017(1) About 0Ω

Yes > to step 2.
No> Repair or replace the circuit between the fuel sensor and the instrument cluster
2. Check the earthing circuit of the fuel sensor

b. Disconnect fuel sensor connector B017.
of the fuel sensor connector B017 and GND.
B017 (2)-grounding About 0Ω

Yes > to step 3.
No > Repair or replace the earthing circuit of the fuel sensor.
3. Replace the fuel pump for inspection

a. Replace the fuel pump, and start another inspection.

Yes> Replace fuel pump.
No> Go to step 4
Caution
DI symptoms disappear.
Caution

Caution

Water temperature gauge fault

Circuit diagram

Ignition switch IG1
DI
Small
box relay case
Buzzer
PS module
Position Combined
Back lamp
light

speed signal

control unit
To lighting
DI

indicator lamp of right indicator lamp indicator lamp indicator
lamp indicator lamp
steering lamp lamp
Combined
instrument
lamp
Driver
Brake
seat belt
fluid level
switch
warning
switch



alarm lamp lamp
Combined
instrument
DI
Fuel sensor

Diagnosis steps
1. Replace the coolant temperature sensor for inspection
a. Replace the coolant temperature sensor, and start another inspection.

Yes> Replace coolant temperature sensor.
No> Go to step 2
DI
2. Check the circuit between the coolant temperature sensor and ECU
b. Disconnect the coolant temperature sensor connector E012.
measure the resistance between the No.1 and No.2
terminals of the coolant temperature sensor
connector E012 and the No.39 and No.35 terminals
of the ECU connector E001.
B012(1)-E001(39) About 0Ω
B012(2)-E001(35) About 0Ω

Yes > to step 3.
No > Repair or replace the circuit between the coolant temperature sensor and ECU.
3. Check the circuit between the instrument cluster and ECU

of the instrument cluster connector C019 and the
No.31 terminal of ECU connector E001.
C019(27)-E001(31) About 0Ω

Yes > to step 4.
No > Repair or replace the circuit between the instrument cluster and ECU.
Caution
symptoms disappear. DI
Caution

Caution
No> Go to step 5
5. Check the ECU

a. Replace ECU with the one of the same size and model.
symptoms disappear.
Caution
The ECU of the same model and size shall be used.

Yes > Replace ECU
Turn-on failure or constant turn-on of handbrake warning lamp

Circuit diagram

Ignition switch IG1
DI
Small
box relay case
Buzzer
PS module
Position Combined
Back lamp
light

speed signal

control unit
To lighting
DI

indicator lamp of right indicator lamp indicator lamp indicator
lamp indicator lamp
steering lamp lamp
Combined
instrument
lamp
Driver
Brake
seat belt
fluid level
warning switch
switch


Diagnosis steps
1. Check the hand brake indicator lamp
a. When the ignition switch is at ON and the handbrake handle is pulled up, this indicator lamp turns
on.
b. When the ignition switch is at ON and the handbrake handle is lowered, this indicator lamp turns
off.
DI Check whether the handbrake indicator lamp is constantly on or fails to turn on.
Yes > to step 2.
No > check ends.
2. Check the hand brake switch

b. Lower the handbrake handle.
Caution
Before lowering the handbrake handle, use wedges to block four wheels to prevent the slide of
the vehicle.
c. Disconnect the handbrake switch connector R003.
of the hand brake switch and GND.
(1)-grounding Not conducting

Yes > to step 3.
No > Replace handbrake switch.
3. Check the signal circuit of the hand brake indicator lamp

b. Disconnect the handbrake switch connector R003.
c. Disconnect the connector C020 of combination instrument.

measure the resistance between the No.1 of the
hand brake switch connector R003 and the No.29
terminal of the instrument cluster connector C020.
R003(1)-C020(29) About 0Ω
DI

Yes > to step 4.
No> Repair or replace the signal circuit of the hand brake indicator lamp.
Caution
symptoms disappear.
Caution

Caution

Basic inspections
Warning
The engine shall be up to working temperature for basic check; and at least two persons are
needed for road test.
Step Inspection content Measures

DI Check the tachometer Yes Go to Step 2
Connect the scan tool, and select the engine speed.
Observe the readings of engine tachometer respectively at
1
700, 1,000, 1,500 and 2,000r/min. Refer to the
No
The error shall be between ±70～200r/min. symptom table
Whether the inspection result is acceptable?
Check the speedometer Yes Go to Step 3
Connect the scan tool, and select the vehicle speed.
Separately observe the reading at 40, 60 and 80km/h.
2 Its tolerance should be within +5km/h. Refer to the
At constant speed or constant acceleration, the pointer shall No
symptom table
not jump.
Check the alternator indicator Replace the
Yes
Ignition switch: ON (ACC). instrument cluster.
3 Generator indicator shall be ON.
Refer to the
Engine starts and generator indicator shall be OFF. No
symptom table
Ignition lighter fault

Overview
Cigar lighter is heated by resistance. When the cigar lighter is pressed, the positive and negative
electrodes of cigar lighter resistance wire are connected to form a loop. Thus, passenger can light a
cigar.
Precautions DI
1. The cigar lighter shall be inserted and pulled out vertical to its mounting surface, avoid
shake, otherwise, it will easily result in looseness, short circuit, and overburning of the
fuse and external device.
2. Do not use hand to hold the cigar lighter after pushing it into. Otherwise, the cigar lighter
will probably cause fire disaster because it is overheated.
3. Do not leave the cab when the cigar lighter is pushed. Otherwise fire disaster might be
caused because the cigar lighter is overheated.
4. The deformed cigar lighter fails to automatically rebound to its original position, shall be
replaced timely.
5. If the cigar lighter cannot automatically return in 18s, the cigar lighter malfunction is
indicated. Therefore it is required to use your hand to pull it back to the proper position.
Preparations
Recommended tool

Digital multimeter
DI resistance value
Maintenance data
Technical specifications
Cigar lighter supply voltage 12V

Refer to the following table to help you to find out the cause of the problem. Check each part, and
replace it if necessary.

1. Fuse (blown out)
specification
2. The power circuit of the DI
cigarette lighter (short circuit or Repair or replace the harness
open circuit)
Cigar lighter is unable to work.
Repair or replace the cigarette
3. Cigar lighter (damaged)
lighter
4. The ground circuit of the cigar
lighter (short circuit or open Repair or replace the harness
circuit)
Cigar lighter is unable to work.

Circuit diagram
Ignition switch ACC
DI
Body fuse
case
Cigarette
lighter
With the ignition switch at ACC, the cigarette lighter

The cigarette lighter doesn’t work
doesn’t work
Diagnosis procedure
1. Check fuse DI
c. Take out the cigarette lighter fuse IF21(15A).
Caution
fuse.

Normal cigarette lighter fuse IF21(15A) is blown out.
Off

No> Go to step 2
2. Check the power circuit of the cigarette lighter

b. Disconnect the cigarette lighter connector C028.
cigarette lighter connector C028 and GND.
Standard voltage:


Yes > to step 3.
No > Repair or replace the power wiring harness of the cigarette lighter.
3. Check the earthing circuit of the cigarette lighter

b. Disconnect the cigarette lighter connector C028.
DI c. Turn the multi-meter to the resistance mode, and
of the cigarette lighter connector C028 and GND.

Yes > Replace the cigarette lighter.
No > Repair or replace the earthing circuit of cigarette lighter.
Fault of auxiliary power supply

Preparations
Recommended tools
DI
Detect voltage, current or
Digital multimeter
resistance ion



DI The auxiliary power supply fails
3. Power socket (damaged) Change of PS socket

The auxiliary power supply fails

Circuit diagram
Ignition switch ACC
DI
Body fuse
case
Power
socket
With the ignition switch at ON, the power socket has

The auxiliary power supply fails
no power output.
Diagnosis procedure
1. Check fuse
c. Take out the fuse IF24(15A).
Caution
fuse.
d. Check the middle portion of fuse IF23 (15A) for

burnout.
Off Normal

No> Go to step 2
2. Replace the power socket for inspection

b. Replace the power socket, and start another inspection.

Yes > Change of PS socket
No > Go to step 3
3. Check the power circuit of the power socket

b. Disconnect the connector of power socket C027.

power socket connector C027 and GND.
Standard voltage:
DI

Yes > to step 4.
No > Repair or replace the power circuit of the power socket.
4. Check the earthing circuit of the power socket

b. Disconnect the connector of power socket C027.
of power socket connector C027 and GND.

No > Repair or replace the earthing circuit of the power socket.
Basic inspections
Inspect the voltage of the storage battery Yes Go to step 2

1 The battery voltage shall be about 12V.
Check if results are normal? No
battery.
Check the fuse. Replace the same type of

DI Yes
fuse.
2 Check whether the fuse is burnt out.
Check the power socket Yes Change of PS socket

3
Check the power socket for wear and damages. No Go to fault symptom list
Fault of the charging system

Overview
The function of charging system is to convert the partial mechanical energy of engine into electric energy
through a generator, and supply power to vehicle electrical system.
Precautions
1. Never disconnect the battery when the engine is running.
DI
2. When removing or refitting the generator from or into the vehicle, if the battery negative
cable is not removed, the generator power wire may generate sparks upon its contact with
the body. This may result in the personal injuries and the damages of the electric elements;
therefore, the battery negative cable shall be disconnected prior to the above-mentioned
operation.
3. Before inspection of the charging systems, firstly check whether various connectors and
wiring harness connections are fixed reliably.
4. When disassembling the generator, take care not to damage the outer insulation sleeve of
the coil.
Preparations
Recommended tools

DI Digital multimeter
resistance ion
Technical data
Battery voltage 12v

2. Generator wiring terminal

Repair the wiring terminal DI
(looseness, corrosion)
The battery is undercharged
3. Generator belt (looseness, Repair or change the generator
breakage) belt
4. Generator (damaged) Repair or replace the generator
1. Fuse Replace the same type of fuse.
With the ignition switch at ON, the 2. Circuit (short circuit or open Repair or change wiring harness.
charge indicator lamp can’t be circuit)
illuminated (the engine can’t be 3. Combination instrument Replace the combination
started) (damaged) instrument
1. Generator belt (looseness, Repair or change the generator

corrosion) belt
Generator noise

Circuit diagram

box case
DI
Ignition switch
Fusible wire
To combined
instrument
Battery
Generator
With the ignition switch at ON, the battery charging

voltage is too low.
Diagnosis procedure
1. Check the battery terminal
a. Check the battery positive and negative terminal wires for damages, oxidization, poor contact and DI
looseness.

Yes > to step 2.
No > Repair the faulted point.
2. Check the generator belt

a. Check the generator belt for damages.

Yes > to step 3.
No > Repair or replace the generator belt.
3. Check the battery charging fuse

b. Open the frame fuse box, and check whether the fuse EF01(100A) works normally.

Yes > to step 4.
No > Replace the same type of fuse.
4. Check the generator

a. Check the output voltage of the generator.

Yes > Charge or replace the battery.
No > Repair or replace the generator.
With the ignition switch at ON, the charge indicator lamp can’t be illuminated (the
engine can’t be started)
Circuit diagram

DI box case
Ignition switch
Fusible wire
To combined
instrument
Battery
Generator
With the ignition switch at ON, the charge indicator

With the ignition switch at ON, the charge indicator
lamp can’t be illuminated when the engine is not
lamp can’t be illuminated (the engine can’t be started)
started.
Diagnosis procedure
1. Check the instrument cluster fuse
DI
c. Take out the instrument panel cluster fuse IF17(7.5A).
Caution
fuse.

instrument cluster fuse IF17(7.5A) are blown out.
Off Normal

No > Go to step 2
2. Check the power circuit of the generator charge indicator lamp

d. Measure the voltage between pin 32 of combination
instrument connector C019 and the ground by the
voltage measurement range of a multimeter.
Standard voltage:


Yes > to step 3.
Repair or replace the power circuit of the generator charge indicator lamp.
3. Check the charge indicator lamp signal circuit

DI c. Disconnect the generator wiring terminal B008.
of the instrument cluster connector C019 and the
No.2 terminal of the generator wiring terminal B008.
C019(7)-B008(2) About 0Ω

Yes > to step 4.
No> Repair or replace the signal circuit of the charge indicator lamp.
4. Check the generator

a. Replace the generator with the one of the same size, and check whether the fault is eliminated.

Yes > Replace the generator.
No > Replace the combination instrument
Basic inspections
Check the fu. Check Replace the same type of

Yes
whether the fuse is blown fuse.
1 out.
Check if results are No Go to step 2
normal?
Check the connection of DI
Yes Go to step 3
the battery terminal.
Check whether the battery
terminal is clean and
2 whether the connection is Repair the battery
reliable. No
terminal
normal?
Check whether the Yes Go to step 4
relevant lead wire is
damaged and check all
relevant earthing points.
Check whether the
relevant lead wire is
3
damaged and check
whether all relevant
earthing points are
reliable.
normal?
Check the generator and Find out other fault
Yes
the generator belt. symptoms.
Check the tension of
4 generator belt.
Check the generator. No Go to fault symptom list
normal?
Fault of the horn

Precautions
1. To prevent injuries or vehicle damages, before removal or refitting of any electric device,
disconnect the battery negative cable.
2. The ignition switch must be turned off unless otherwise stipulated.
DI 3. Upon disconnection of the battery negative cable, the daily odometer and clock of the
instrument cluster will be zeroed, but the total odometer will not be zeroed.
4. Ignition switch:
Ignition switch (position) Descriptions of ignition switch.
LOCK Shutdown the ignition system
Stop gear, turn on the electric equipment when car stops, such as radio
ACC
and cigar lighter, etc.
Travel gear, turn on the electric equipment when car travels, such as
ON
instrument, etc.
Turn the key to Start, and after the engine is started, the key will be
START
automatically returned to “ON”.
Preparations
Recommended tools

resistance ion



DI
Sound failure of horn
4. Horn switch (damaged) Repair or replace the horn switch
5. Horn Replace horn
Constant sound of horn 2. Horn switch (damaged) Repair or replace the horn switch


Circuit diagram
Battery
DI
Frame fuse
box
Body fuse
case
Horn relay
Electric horn
Horn switch
With the ignition switch at ON, press the horn switch,

and check whether the horn rings
Diagnosis procedure
1. Check fuse
c. Take out the horn fuse IF24(7.5A).
Caution
fuse.
d. Check whether the middle fusible wire of the horn

fuse IF24(7.5A) is blown out.
Off Normal

No > Go to step 2
2. Replace the horn relay for inspection

c. Replace the horn relay, and start another inspection.

Yes > Replace horn relay
No > Go to step 3
3. Check the horn switch.

b. Disconnect the horn switch connector C016.
c. Check whether the horn switch contact works normally.

Yes > to step 4.
No > Repair or replace the horn switch.
4. Check the horn.

b. Replace the horn, and start another inspection.

Yes>Replace horn. DI
No > Go to step 5
5. Check the earthing circuit of the horn

b. Disconnect the electric horn connector B005.
of horn connector B005 and GND.
B005 (2)-grounding About 0Ω

Yes > to step 6.
No > Repair or replace the horn earthing circuit.
6. Check the horn power circuit

b. Disconnect the electric horn connector B005.
c. Press the horn switch.
horn connector B005 and GND.
Standard voltage:
B005 (1)-grounding Battery voltage

No > Repair or replace the horn earthing circuit.
Basic inspections

battery.

DI Yes
fuse.
Check the horn. Yes Go to step 4

3 Press the horn switch.
Check whether the horn rings ? No Go to fault symptom list
Check the horn switch Yes Go to fault symptom list

Press the horn switch.
4
Release the horn switch. No Replace horn
Check whether the horn can ring normally ?
CAN Communication Malfunction

Preparations
Recommended tools
DI
Digital multimeter
resistance ion

Diagnosis interface terminal diagram
Caution
DI
Terminal Terminal
Function Function
No. No.
1 - 9 -
2 - 10 -
3 CAN-H 11 CAN-L
4 Ground 12 -
5 Ground 13 -
6 CAN-H1 14 CAN-L1
7 K-LINE 15 -
8 - 16 Battery power supply

The diagnoser can’t be started 2. Diagnoser (faulted) Replace the diagnostic instrument
DI
3. Circuit (open circuit or short
circuit )
The diagnoser can’t be started

Circuit diagram
Battery
DI

box case
Battery power
supply
Diagnostic
interface
Power supply Signal ground

K line earth wire
K line
Engine ECU
Diagnosis steps
1. Check fuse
c. Take otu the diagnosis interface fuse IF14(7.5A).
Caution
DI
fuse.

diagnosis interface fuse IF14(7.5A) is blown out.
Off Normal

No > Go to step 2
2. Check the power circuit of the diagnosis interface

b. Turn the multi-meter to the voltage mode, and
diagnosis interface connector C003 and GND.
Standard voltage:

Yes > to step 3.
No > Repair or replace the power circuit of the diagnosis interface.
3. Check the earthing circuit of diagnosis interface

b. Turn the multi-meter to the resistance mode, and

measure the resistance between the No.4 and No.5
terminal of diagnosis interface connector C003 and
GND.

DI

Yes > to step 4.
No> Repair or replace the earthing circuit of the diagnosis interface.
4. Check the diagnoser

a. Replace the diagnoser and start another inspection.

Yes > Replace the diagnostic instrument
EPS fault
Overview
The electric power steering system (EPS) is composed of the controller, motor, mechanical column and
reducer mechanism. Meanwhile, EPS can also receive the speed signal and engine revolution signal
from the ECU via the hard wire, and the EPS controller will send the idle speed boost signal to ECU.
DI
Precautions
1. When checking the steering system, park the vehicle on a level and dry ground.
2. Check whether the tire pressure and size are correct, and whether the designated parts are
used in the steering wheel.
3. Carefully check whether the parts of the steering system are under the application of
abnormal impact frequently. The damaged parts or defective parts shall be replaced timely.
4. The steering wheel shall not be located at its extreme position for more than 5s; otherwise
DI the steering motor may be damaged.
5. Keep the battery under good conditions, and a too low battery voltage may result in the
heavy steering operation.
6. All connectors of EPS shall be protected against moisture and high temperature to ensure
its good conductivity.
7. The battery negative terminal shall be disconnected when servicing the steering column.
8. In event of steering noise, heavy steering, or steering stagnation during the traveling of
vehicle, immediately stop the vehicle for checking and find out and solve the malfunction.
Preparations
Recommended tools

Digital multi-meter DI
resistance ion

Maintenance data
Table of technical specifications
Rated voltage 12V
Voltage range 10~16V
Power range 9~16V
DI Locked-rotor current 45A
Permissible locked-rotor time 1s
Normal working current 20A
Max. current of controller 45A
Max. current time of controller 5s
Insulation resistance ≥2.5MΩ
Dark current ≤0.1mA
Storage temperature -40℃~85℃
Working temperature -40℃~85℃
Protection grade IP5X


No. Component Quantity Function
The EPS control unit is located on the steering column bracket

beneath the instrument panel in the driver compartment.
With the power switch at ON, EPS will conduct the self-test
upon start. In the event of any fault, the warning lamp will be
illuminated; if there is no fault, the warning lamp will not be
illuminated, but no steering power will be supplied. After the DI
engine is started, EPS will perform the self-test. If any fault is
1 EPS control unit 1 detected, the warning lamp will be illuminated, and no steering
power will be supplied. If there is no fault, the warning lamp will
not be illuminated, and the steering power will be supplied
normally.
When EPS works abnormally, the EPS control unit will restrict
the steering power, or turn off the steering power system and
cut off EPS power supply, and restore the mechanical steering
system, depending on the severity of the fault.
The steering motor is a permanent magnet synchronous
brushless motor. The motor shaft and the reducer worm shaft
2 Steering motor 1 are connected via the coupling, and the three-phase wires of
the motor are connected to the controller via the wiring harness
thus to control the motor.
EPS control unit terminal diagram
Caution
DI
Terminal Terminal
Function Function
No. No.
C008-1 Battery power supply C009-4 IG1 power
C008-2 Ground C009-5 K wire
C009-1 Vehicle speed signal C009-6 EPS idle speed boost signal
C009-2 Rotation speed signal C009-7 EPS warning lamp

The use of following table is helpful to find the fault cause. Check each part. Replace corresponding part
when necessary.
2. Circuit (short circuit or open DI

The EPS warning lamp is circuit)
permanently illuminated
3. EPS controller (damaged) Change EPS controller
4. Combination instrument Replace the combination

(damaged) instrument
2. Circuit (short circuit or open

circuit)
4. Steering wheel (incorrectly

Reinstallation
installed)
Heavy steering operation, sticking
5. Steering drive shaft (damaged) Replace.
6. Steering drive shaft universal

Replace.
joint (damaged)
7. Steering gear (damaged) Replace.
8. Steering linkage ball joint (worn

Replace.
or improperly lubricated)
1. Steering drive shaft (incorrectly

Reinstallation
installed)
Abnormal noise in steering 2. Steering motor (abnormal

Replace.
operation noise)
3. Fixing bolt, steering drive shaft

Retighten
(loosened)
1. Circuit or connector ( falsely

Check and repair
connected)
EPS works intermittently 2. Steering motor (abnormal

Replace.
noise)
1. Tire (too low pressure or Check the tire pressure, and

seriously worn) replace the worn tire
The steering wheel dithers
2. Front wheel (incorrect
Perform four-wheel alignment
alignment)
3. Steering gear fixing bolt

Retighten
(loosened)
4. Steering gear (too large

Replace.
clearance)
5. Steering gear linkage ball joint

Replace.
DI (too large clearance)
1. Steering gear (too large

Replace.
clearance or faulted)
The free clearance of the steering 2. Steering gear linkage ball joint
Replace.
wheel is too large (too large clearance)

Retighten
(loosened)
The EPS warning lamp is permanently illuminated

Circuit diagram
DI
Frame fuse
box
Body fuse
case
Battery power IG1 Power

supply supply
Controller
Electric-assisting Electric-assisted Electric-assisted Electric-assisted
indicator lamp idling up K line vehicle speed signal speed signal Ground
Electric-assisted K line Electric-assisted Electric-assisted

idling up vehicle speed signal speed signal
Engine ECU
To combined
instrument
With the ignition switch at ON, the EPS warning lamp

The EPS warning lamp is permanently illuminated
is permanently illuminated.
Diagnosis procedure
1. Check fuse
c. Take out the fuses IF17(7.5A) and IF33(40A).
Caution
fuse.

Off IF17(7.5A) and IF33(40A) are blown out.
Normal

No > Go to step 2
2. Check the power circuit of EPS control unit

b. Disconnect the EPS control unit connector C008 and C009.
EPS control unit connector C008 and GND.
Standard voltage:


between the No.1 terminal of EPS control unit
connector C009 and GND.
Standard voltage:

DI

Yes > to step 3.
No > Repair or replace the power circuit of EPS control unit .
3. Check the earthing circuit of EPS control unit

b. Disconnect the EPS control unit connector C008.
of EPS control unit connector C008 and GND.

Yes > to step 4.
No > Repair or replace the earthing circuit of EPS control unit .
4. Check the signal circuit of the EPS indicator lamp

b. Disconnect the EPS control unit connector C009.
c. Disconnect the connector C019 of combination instrument.
of the EPS control unit connector C009 and the
No.10 terminal of the instrument cluster connector
C019.
C009(7)-C019(10) About 0Ω

Yes > to step 5.
No> Repair or replace the signal circuit of the EPS indicator lamp.
5. Check the EPS control unit

b. Replace the EPS control unit and start another inspection.
DI
Yes > Replace the EPS control unit.
No > Go to step 6
6. Check combination instrument
Caution
symptoms disappear.
Caution

Caution

Basic inspections
Warning
For basic check, engine must reach to work temperature, and the road test must be carried out
by more than two persons.

DI
battery.

Yes
fuse.
Check the middle position of the steering wheel Yes Go to step 4

Check whether the electric steering column and
steering wheel are installed at their correct positions.
3
Park the vehicle right ahead, and determine whether No Check and adjust
the steering wheel is located at the middle position.
Check steering wheel free stroke Yes Ending of inspection
With the front wheels not moving, rotate the steering
4 wheel left and right, and measure the free travel of the
steering wheel. No Check the steering gear
DI-366 Diagnostics- Mechanical fault diagnosis
Mechanical fault diagnosis
Mechanical fault diagnosis overview

Overview
Vehicle failure refers to the phenomenon of partial or total loss of car operational capability, i.e. abnormal
change of parts or the mutual cooperation status, for example, it is hard to start engine, vehicle, oil
leakage, water leakage, lighting system failure, etc. The common fault forms of vehicle are: sudden
change of work condition, abnormal sound, abnormal odor, abnormal smoke exhaust, abnormal
DI temperature, abnormal appearance, abnormal consumption of fuel and lubricant, and leakage, etc.
Diagnostics - Mechanical fault diagnosis DI-367
Reasons
The mechanical fault of vehicle is generally divided into man-made fault and natural fault. The reasons
for vehicle fault are as follows:
1. The adopted vehicle oil doesn't comply with specification, such as fuel, lubricant.
2. The interior quality problem of vehicle, such as poor material, insufficient strength,
improper design. The fault caused by inner deficiency can only be solved by replacing
parts when timely find the problem in routine maintenance.
3. Driver neither conduct maintenance and care regularly, nor conduct technical test
DI
regularly.
4. The maintenance and repair is not done in strict accordance with technical specification,
thus leaving hidden danger accident due to missing inspection or rough handling.
5. Driver fails to follow the driving operating instruction to use vehicle, load improperly and
drive at overspeed; find abnormity in half way, but fail to remove hidden dangers timely.
6. Fault caused by natural wear, corrosion, deterioration and aging of moving parts. Such
fault can only be delayed, but can't be fully controlled.
7. Fault caused by bad moving condition (Such as road, environment and climate), such fault
can also be prevented by taking corresponding measures.
8. The vehicle driver has low technical level, less driving and repair experience, and knows
little of vehicle structure and characteristics.
Fault symptom
1. Abnormal temperature.
Abnormal temperature is the temperature value indicated on water thermometer exceeds the
normal value (80 ~90℃) or overheated temperature can be found through touching by finger.
Overheating phenomenon usually shown on the engine, transmission assembly, drive axle
assembly and brake drum assembly. In normal condition, no matter how long the vehicle works,
these assemblies shall maintain a certain temperature. If the heat is unbearable when touching
DI these assemblies except the engine by hand, the overheating shows that there is fault. Engine
overheating usually indicates that the cooling system has fault and if not removed in time, it may
cause engine knock, premature combustion, driving weakness, or even cause burning accident of
parts like piston and so on. The overheating of transmission and drive axle may caused by lack of
lubricating oil or improper adjustment of bearing installation tightness, and if the fault is not
removed in time, it may cause damage to gear and bearing.
2. Abnormal smell
Abnormal smell indicates that the peculiar smell can be snuffed with nose, e.g., the rubber smell
when circuit is shot or burning; the burnt smell emitted from the burnt clutch friction lining and
brake shoe when there are faults like brake drag, clutch slipping, etc.; the smoke or oil smell that
vented from the exhaust pipe, and special smell also emitted when engine is overheating and
engine fuel or brake fluid is burning. Once there is burning rubber smell during the vehicle running,
the vehicle shall be stopped immediately at the road side, the fault shall be found out and
removed to prevent fire disaster from happening.
3. Abnormal appearance.
The vehicle fault also can be reflected by the changes in the appearance. For example, park the
vehicle on flat ground and check its appearance, if there is phenomenon such as horizontal or
vertical skewness, then its abnormal appearance. The abnormal appearance of automobile are
mostly caused by abnormal frame, body, suspension device, tire, etc., this will cause driving
direction instability, driving wandering, center of gravity offset, uneven tire frictions and other
abnormalities.
4. Abnormal operation.
Abnormal operation is the abnormal working conditions during the vehicle starting and running,
that is the so called sudden change of working condition. For example, the engine is difficult to
start again or even can not be started after suddenly stopped; the engine can not be started easily
or the running is unstable after started; sudden reduce in power performance during driving and
causes driving weakness of the vehicle; sudden braking failure or deviation, steering wheel and
front wheel shaking or even out of control and other situations. The symptom of abnormal
movement is obvious and easy to be observed, but the cause is complex and usually forms from
gradual change to sudden change, thus whether there is suspicious symptoms must be analyzed
carefully to find the real fault and judge where the fault is.
5. Abnormal smoke color
During the process of engine operation, the main component of normal combustion product is
carbon dioxide and a small amount of water vapor. If the engine is of improper combustion, the
exhaust gas contains carbon particles that are of incomplete combustion, hydrocarbon, carbon
monoxide or a large amount of water vapor. At that time, the color of exhaust gas may turned into
black, blue, white, that is abnormal smoke color. But when lubricating oil flees in the cylinder, the
color of exhaust gas is blue; the exhaust gas is black when it's of incomplete combustion and
white when there is water in the fuel.

6. Abnormal fuel & oil consumption.
Abnormal fuel & oil consumption usually indicates the abnormal consumption of fuel and
lubricating oil. The so called abnormal consumption of fuel and lubricating oil is the consumption
of fuel and lubricating oil exceed the specified value. The abnormal consumption of fuel and
lubricating oil is also a kind of symptom. Increase of fuel consumption is generally caused by poor
operating of engine or improper adjustment of chassis's drive train and brake system. Except the
leakage, too much oil consumption is mostly caused by engine fault. It usually followed by the DI
phenomenon of heavy smoking or pulsating smoking at oil filling port, the exhaust smoke color is
abnormal, and the main cause is the excessive fitting clearance between piston and cylinder wall
or the piston ring failure. If the oil volume increases during the process of engine operation, this
may caused by cooling water or gasoline leaking into the oil sump. Therefore the abnormal
consumption of fuel and lubricating oil is an important sign of poor technical state of engine.
7. Abnormal noise.
The vehicle makes noise caused by the operation and vibration of parts after vehicle starting and
during running. This kind of noise is divided into normal noise and abnormal noise. The so called
normal noise is the slight noise that is allowed to exist, e.g.: the friction sound of piston ring and
cylinder wall inside the engine, the splash noise of engine oil, the sound of engine burst formation
and some other noise that allowed during the process of vehicle running. If there is abnormal
sound, it refers to abnormal metal knock sound or other undeserved sound. Such as the noise of
cylinder knocking, pin noise, bearing noise, gas blow by noise, etc. These abnormal noises shows
there is fault and shall be removed immediately. It should be noted that many faults of abnormal
noise can result in serious parts accident thus it must be dealt with carefully. Experience shows
that it's usually malignant fault if the vehicle makes heavy noise and with obvious shaking
phenomenon, and the vehicle shall be stopped immediately at the road side, the fault shall be
found out and removed. Different causes of abnormal noise have different noise characteristics,
for example: the sound of cylinder knocking caused by excessive clearance between piston and
cylinder wall is a kind of metallic tapping noise like "clang" which is clear and rhythmical; the pin
noise caused by loose fit between piston pin and connecting rod bushing or between piston pin
and piston pin bore is a kind of "click" knocking noise like the sound of steel ball collision which is
shrill and rhythmical; the linkage bearing sound caused by bearing and journal abrasion and
looseness is a kind of metallic tapping noise sounds "clatter" which is continuous and rhythmical;
the camshaft bearing noise caused by loose fit between camshaft bearing and journal is a kind of
metallic tapping noise which is continuous and rhythmical "dong"; and the gas blow by noise
caused by bad cylinder seal makes "chirp" sound. Therefore, the fault only can be correctly found
out and quickly removed by carefully observing and listening.
8. Abnormal instrument.
The varies instruments in the vehicle (ammeter, engine oil pressure gauge, water temperature
gauge, air pressure gauge, etc.) indicates the working condition of related part of vehicle, if the
indicator reading is abnormal, which means the vehicle has fault and shall be stopped at a proper
place to perform troubleshooting.
9. Abnormal performance.
The operation performance of vehicle reduces with the increasing of driving distance, but the
process is very slow and not easy to be found, if the vehicle operation performance turns bad
suddenly, it indicates the vehicle has a fault (engine power declines rapidly, serious wigwag
motion suddenly, brake failure, etc.) and shall be stopped immediately for troubleshooting.
10. Abnormal clearance.
The clearance of each part has its standard value, it indicates there is fault if the clearance is too
large or too small, and the clearance shall be adjusted.
11. Leakage
Leakage indicates the leakage of fuel, lubricating oil (engine oil, gear oil), coolant, brake fluid (or
compressed air), power steering system oil, etc. This fault symptom is obvious and can be found
DI by direct observation. Leakage can cause overheat, steering, brake failure, oil consumption
increase and other faults, and also pollutes the parts and the environment, thus the leakage shall
be eliminated immediately once it has been found.
Fault diagnosis methods

Fault diagnosis is the process to find the fault cause and make analysis, judgment and inspection of the
parts. There are mainly two current diagnosis methods for vehicle fault: one is manual intuitive
experience diagnosis method, the other is instrument and equipment diagnosis method.
1. Instrument and equipment diagnosis method.
Instrument and equipment diagnosis method refers to the method to obtain the information
parameters of automotive performance and failure by using instrument and equipment without
disassemble, and the information parameters is compared to that of normal technical condition of
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vehicle, and then gives the diagnosis of technical performance and fault. With the application of
electronic information and computer technology in automobile, the diagnostic apparatus
equipment of vehicle fault is increasingly improving and more and more advanced apparatuses
are applied in automobile fault diagnosis. The instrument equipment has quick speed to fault
diagnosis and the accuracy is high. In addition, it can discover the potential fault and predict the
service life of assembly part.
2. Experience diagnosis
Personal experience diagnosis: Depending on experience, feel and observation, by simple tool
and under the condition of no disintegration or local disintegration, checker will make qualitative
diagnosis to car technical performance and fault through the way of ask, see, listen, touch and
nasil, the specific way is:
a. Visual inspection: Observe the vehicle’s oil leakage, water leakage, electric leakage parts; the
working condition of the instrument signals, the exhaust, deviation, the jitter and steering swing of
the engine and so on.
b. Listening: Listen to the sounds of engine at different speeds, and determine if there is silencer
chug, engine knock or abnormal knocking noise.
c. Touch: Touch to feel the temperature and vibration of the faulty part, overheating of fitting parts,
bearing tightness, looseness of assembly components, pulsation of the high pressure oil pipe of
the diesel engine, etc.
d. Smell: Smell special odors such as smell of scorching of the clutch friction plate, abnormal smell
of burning of lubricating oil, smell of scorching of gummed wire in the circuit, etc. given off when
the vehicle is running.
Fault prevention
1. Seriously make vehicle operation records, pay attention to changes in main technical
parameters at any moment, and perform digital processing to technical parameters upon
statistics, so as to predict the operating condition and possible faults of the vehicle.
2. Regular maintenance and regular testing system are implemented mandatory to establish
a new concept of using the vehicle with preventive measures.
3. Strengthen the daily maintenance of the vehicle, and seriously do well in cleaning,
DI lubrication, locking, check, adjustment and anticorrosion before vehicle operation.
4. The driver should strengthen the study of professional skills and actively participate in
professional technical training, in order to improve their professional skills and sense of
responsibility and dedication. Meanwhile, we should learn to take self-skill summary and
accumulate the driving working experience.
5. The vehicle troubleshooting shall be thorough, and effective measures preventing
recurrence of similar faults shall be adopted. Vehicle driving with fault is strictly
prohibited.
Integrated vehicle fault

Check the battery and replace it as

1. Battery voltage is too low
necessary
2. Battery cable is loose and Clean the battery and fasten the
corroded connection DI
Check the starter and replace it as
3. Starter failure
Engine will not start necessary
4. Fuel filter is blocked, and the
Clean the fuel system and replace
fuel system has too much
the fuel filter
impurities
5. Other related electrical parts Check related electrical parts and
does not work properly replace them as necessary
1. Valve timing is incorrect Check the valve timing
2. Cylinder gasket leaks Replace the cylinder head gasket
Measure the cylinder pressure, and

3. Cylinder pressure value is too
perform inspection and repair as
low
necessary
Check the valve and valve seat,
4. Poor sealing of the valve
and replace if necessary.
Insufficient engine power
5. Exhaust of exhaust system is
Check the exhaust system
not smooth
6. Insufficient intake of intake
Check air intake system
system
7. Valve timing is incorrect Check the valve timing
8. Other related electrical parts Check related electrical parts and

does not work properly replace them as necessary
1. Excessive wear of leaf spring
Replace the leaf spring pin
pin
2. U-bolts is loose or damaged Replace the U-bolts

Vehicle body tilting when driving or
parking 3. Elastic force of leaf spring
declined or inconsistent Replace the leaf spring
stiffness
4. Leaf spring broken Replace the leaf spring
1. The wheel toe-in and camber

angle do not meet the Wheel alignment
requirements
2. Tire pressure does not meet the
Abnormal tire abrasion Check and adjust the tire pressure
requirements
3. Tire imbalanced Make the tire dynamic balance
4. Steering mechanism deformed Replace the steering mechanism

1. The belt pulley hub fractures Replace pulley
2. Flywheel fracture Replace the flywheel

Severe slap when increasing the
torque 3. The crankshaft bearing bush Replace the crankshaft bearing
clearance is too large shell
4. Connecting rod bearing bush Replace the connecting rod
DI has too large gap bearing shell
1. The pressure of the four wheels
Check and adjust the tire pressure
is different
2. Tires are unbalanced Dynamically balance the tires
3. Leaf spring fatigues Replace the leaf spring
4. Steering mechanism severe

Replace the steering mechanism
abrasion
Swing or jitter when driving vehicle 5. Toe-in against with regulation Wheel alignment
6. The engine power output is

Repair the engine
unstable
7. Clutch shakes Repair the clutch
8. Vibration occurs to drive shaft Replace the drive shaft
9. Wheel hub bearing worn Replace hub bearing
1. Incorrect tire specifications Replace the tire.
2. Tire worn Replace the tire.
Drive wandering 3. The tire pressure is incorrect Check and adjust the tire pressure
4. Wheel alignment is incorrect Wheel alignment
5. Wheel hub bearing worn Replace hub bearing

Engine fault
Overview
DAM15R engine is developed utilizing the electronic fuel injection techniques in accordance with the
latest emission regulations promulgated by the State. DAM15R engine is located in the engine
compartment at front end of the vehicle, being a water-cooled in-line horizontal 4-cylinder & 4-stroke
gasoline engine, and is provided with 16-valve double overhead camshaft mechanism which is driven by
the crankshaft via the timing chain to directly drive the valves, featuring compact structure, high power, DI
low fuel consumption, low emission and low noise. The DAM15R Dongan double-VVT engine is widely
applied in cars, being one of the engine models of the largest torque among those engines with the
same displacement and technical features in China, providing the driver a better feeling of control whilst
maintaining the energy-efficient & environment-friendly driving.
Precautions
1. Before any repair operation, do carefully read this manual to avoid unwanted loss due to
the improper operation.
2. When performing any repair work, apply the procedures and methods described in this
manual to avoid technical errors and t hus ensure safety and efficiency.
3. Before the operation, if necessary, put a fire extinguisher at the specified position with
easy access.
DI 4. Before the operation, if necessary, the operator shall wear protection shoes, gloves and
goggles to protect personal safety.
5. Before the operation, make sure that the car is protected properly, for example, covering of
seats, steering wheel, floor and engine compartment.
6. Before lifting the car, check whether the lifter works normally, whether the car is parked at
a proper position and whether the lifting arm is calibrated correctly in relation to the lifting
point of the car. When lifting or lowering the car, make sure that no person or unnecessary
articles are present beneath the car.
7. In the repair work, disconnect the fuel supply, power supply and discharge the pressure as
specified. For example, if the fuel rail is to be removed, the fuel supply shall be
disconnected for pressure discharge; if the eletric part is to be removed, the battery
negative terminal shall be disconnected at first to avoid vehicle damages and threats to
personal safety.
8. After the pipes and joints are disonnected, take protection measures to prevent the pipes
and joints from being contaminated or invaded by foreign matters.
9. When servicing the engine interior, observe the specified procedure, and handle the brittle
and fragile parts with much care.
10. When tightening bolts and nuts, observe requirements on the torque, sequence, direction
or angle parameters, and avoid applying a over-high torque.
11. When overhauling the engine, for example, servicing of crankshaft, piston and cylinder
head, thoroughly clean and lubricate the parts before installation.
12. When servicing the engine, for example, installation of the oil pan, clear off the old sealant
before the operation, ensure the flatness of the bonding face, fit a new gasket and coat it
with sealant.
13. Check the earthing polarity of the battery, and in this car, the negative earthing is applied.
14. It is not allowed to regulate the throttle position screw; otherwise the throttle angle will be
changed when the throttle is closed to render the engine inoperative.
15. When the engine is working, do not remove the spark plug cable. In all cases, the engine
misfire will lead to the entry of unburnt gas mixture into the three-way catalytic converter
to cause ablation. If necessary, remove the three-way catalytic converter.
16. The engine oil of the specified grade and viscosity must be used; otherwise the wear of
engine will be worsened.
17. It is not allowed to use the unauthorized engine parts, but the geninue parts shall be used,
failing which will damage the engine or render the engine inoperative.
18. A new engine shall undergo the running-in period. In the running-in period, abrupt
acceleration or heavy-load operation shall be avoided.
19. When the engine is working, especially at a high speed and high load, do not immediately
stop the engine, but do this after the engine works at a low speed for 3 to 5 minutes to
allow for uniform heat dissipation of the engine.

20. The use of sealant is required on many parts in the engine. This is to achieve sufficient
sealing, and special attention shall be paid to the quantity, position and surface of coating.
Too little coating may lead to leakage, while too much coating will result in the clogging or
narrowing of the water or oil passage by the leaked sealant. Therefore, the sealant shall be
applied as required.
21. In certain cirmustances, the parts must be lightly knocked using the wooden or rubber
hammer or similar tools to destroy the sealant on the bonding face, or the smooth and thin DI
sealant scraper can be lightly driven into the bonding face with much care.
22. Use the sealant scraper or steel wire brush to remove foreign matters on the sealing
surface. Make sure that the sealing surface is flat and smooth, and free from oil or foreign
matters. Do not forget to remove sealant in the mounting hole and threaded hole.
23. Apply the sealant within the specified diameter to fully enclose the mounting hole. The
sealant which is not hardened can be removed. Fit parts at the designated position when
the saelant is wet (within 15 minutes). Take care not to bond the sealant onto any
unwanted position. After installation, wait for the sealant to be fully hardened (wait for
about 1h). Within this period, do not apply oil or water onto the part coated with sealant or
start the engine.
24. Record the engine serial number, engine model and vehicle model, and such data is
needed to contact various service stations of Beiqi Foton for the purpose of engine repair
(the engine serial number is printed on the left inclined plane of the engine cylinder block,
when viewed from the engine front end).

Malfunction symptom Malfunction cause Troubleshooting

Low battery voltage
necessary
Looseness and corrosion of battery Clean the battery and fasten the
cable connection
DI Check the starter and replace it as
Starter failure
necessary
Check the ignition coil and if

Ignition coil fault
necessary, replace it
Check the spark plug cable, and if

Spark plug cable fault
Engine will not start The spark gap of the spark plug is
Replace spark plug
too large
The fuel filter is blocked and the

the fuel filter
impurities.
Check the fuel pump, and if

Fuel pump fault
Refit or replace the synchronizing

Slippage of synchronizing chain
chain
Other related electrical parts does Check related electrical parts and
not work properly replace them as necessary
The spark electrode gap of the

Replace the spark plug
spark plug is too large
The fuel filter is blocked and the

the fuel filter
impurities.
Refit the synchronizing chain and

The valve timing is incorrect
adjust the timing mechanism
Air leakage of cylinder head gasket Replace the cylinder gasket.
Measure cylinder pressure. If

Insufficient engine power Cylinder pressure value is too low
necessary, overhaul it
Check the valve and valve seat,

Valve seal is not strict
and replace if necessary.
Three-way catalytic converter is Replace good quality fuel, replace

blocked three-way catalytic converter
Check the resistance of the spark

The resistance of the spark plug
plug cable, and if necessary,
cable is too high
replace the cable
Test the ignition coil, and if

Ignition coil fault
Replace fuel filter, clean fuel

Bad atomizing of injector injector, and replace when
necessary
The exhaust system does not work

smoothly
The air suction of air intake system

is not sufficient
Check air intake system DI
Check the knock sensor and other

Deviation check of ignition timing
relevant parts
Other relevant electric parts work Check related electrical parts and
abnormally replace them as necessary
Check if the fuse is good. Replace.
Battery power is insufficient Charge
Battery terminal connection is

Fastening
loose
Start switch contact can’t be closed Repair of replace it
Starter electromagnetic switch is

Replace.
worn
Starter brush is worn Replace.
Starter magnetic field or armature

Repair of replace it
circuit is open
warning lamps Fastening or replacement
Spark plug fault Adjust the clearance or replace
Short circuit or open circuit of high

Starting difficulty Repair of replace it
voltage damper
Ignition coil is damaged Replace.
Crankshaft position sensor is

Replace.
damaged or has poor contact
ECM electric power steering

system fails
Throttle valve is damaged Replace.
Water temperature sensor is

Replace.
damaged
Fuel pump relay or fuse fault Examination and replacement
Fuel is insufficient Refuel.
Electric fuel pump fails Replace.
Blockage of fuel filter. Replace.

Air existing in fuel pipeline Repeated starting
Fuel injector is blocked Cleaning or replacement
Fuel pressure is insufficient Checking and adjustment
ECM fault Replace.

DI
Intake manifold is loose Tighten it
Intake air temperature and

Replace.
pressure sensor is damaged
Cylinder head sealing washer is

Replace.
broken
Valve clearance is incorrect Adjust.
Valve spring is damaged Replace.
Timing chain is damaged Replace.
Poor valve combination Repair or replace.
Valve is burned Replace.
Valve rod is blocked Replace the valve guide
Piston, piston ring or cylinder is

Replacement or repair
worn
Fuel quality is bad Replace.
Poor valve combination Repair
Valve rod is blocked Replace.
Piston ring leaks Replace.

worn
Inadequate power
Replace.
broken

Replace.

voltage damper


Replace.
ECM damaged Replace.
Electric fuel pump fault Replace. DI

Fuel filter is blocked Replace.
Fuel pressure regulator works

Examination and replacement
abnormally
Fuel tank outlet is blocked Examination and replacement
The fuel system connector is loose Examination and replacement
Electronic accelerator pedal works

Repair or replace.
abnormally
Air cleaner is dirty or blocked To be cleaned or replaced
Throttle valve is damaged Repair or replace.
Engine overheating Check and repair
Brake drag Repair of replace it
Clutch slips Repair of replace it
Spark plug is damaged or the

clearance is abnormal
Ignition coil aging or electric

Replace.
leakage
Electric leakage of high voltage

Replace.
damper
ECM fault Replace.
Throttle valve fault Repair of replace it
Throttle valve position sensor is

Replace.
Engine surge damaged
Fuel pressure regulator failure Replace.
Cylinder head gasket is damaged Replace.

worn

Replace.
damaged
Water pump performance is poor Repair or replace.
Radiator leakage Repair or replace.
Oil filter is blocked Replace.
Oil filter screen is blocked Replace.

DI
Oil pump performance is poor Replace.
Oil disk or oil pump leakage Replace.
Oil is insufficient Fill
Oil quality is bad Replace.
Main bearing shell is worn or the

Replace.
clearance is big
Connecting rod bearing shell worn

Replace.
or the clearance is big
Connecting rod deformation Repair of replace it
Crankshaft main journal is worn Grinding repair or replacement
Crankshaft connecting rod journal

Grinding repair or replacement
is worn
Abnormal wear of bore hole Bore the cylinder to next repair size
Engine noise is loud The piston, piston ring, piston pin

Replace.
are worn
Piston ring is blocked Replace.
piston ring damage Replace.
Camshaft anti-thrust clearance is

Adjust.
too large
Crankshaft anti-thrust clearance is

Adjust as specified
too large
Valve clearance is too large Adjust as specified

Ignition coil aging or electric

Replace.
leakage
Fuel consumption is high Electric leakage of high voltage
Replace.
damper
Fuel tank or fuel pipe leakage Repair of replace it
Fuel pressure is insufficient Repair of replace it

Air cleaner is dirty or blocked Clean or replace.

Replace.
Valve clearance is incorrect Adjust. DI

Idle speed is too high Checking
Brake is jammed Repair of replace it
Clutch slips Repair of replace it
Tire pressure is incorrect Adjust.
Drain plug is loose Tighten it
Oil disk fixing bolt is loose Tighten it
Oil disk installation surface leakage Reinstallation
Oil seal leakage Replace.
Cylinder head gasket leakage Replace.
Oil filter leakage Fastening or replacement
Oil pressure sensor leakage Fastening or replacement

Oil consumption is high Clear the carbon deposit or replace
Piston ring is blocked
piston ring
Piston ring and ring slot are worn Replace piston or piston ring
Piston ring open position is

Adjust the open position
incorrect
Replace piston and piston ring or

Piston or cylinder is worn
bore reclaim
Valve oil seal is seriously worn Replace.
Valve rod or valve guide is

Replace.
seriously worn

voltage damper
Unstable idle speed

damaged or has poor contact Replace.
Electric fuel pump fault Replace.

DI
abnormally

Repair or replace.
abnormally
Vacuum hose connection loose or

Reconnect or replace
leakage
Cylinder compression pressure is See the previous “Cylinder

lower compression pressure is too low”
Intake manifold bolt and nut are

Tighten it
loose
intake manifold gasket leakage Examination and replacement
Air conditioning signal is wrong Examination and replacement

Replace.
damaged
Replace the spark plug with heat

Spark plug is too hot
value meeting requirement
High voltage or low voltage circuit

Reconnect and fasten
connection is loose
ECM fault Replace.
Gasoline filter or fuel pipe is

Clean or replace.
blocked
Abnormal detonation Fuel nozzle is blocked Cleaning or replacement
Fuel pressure regulator fault Adjustment or replacement
Electric fuel pump and line fault Examination and replacement
Intake manifold, throttle valve

Fastening or replacement
gasket leakage
Piston top or cylinder head

combustion chamber has too much Clearing
carbon deposit
Cylinder head gasket damage

causes too low cylinder Replace.
compression pressure
Valve is blocked Replace.

DI
Valve spring elasticity is weaker Replace.
ECM fault Replace.
Spark plug heat value doesn’t meet Replace the spark plug with heat
requirements value meeting requirement
Fuel nozzle fault Cleaning or replacement
Checking, adjustment or
Fuel pressure is insufficient
replacement
Engine overheating
Intake manifold leakage or loose Refastening or replacement
Coolant is insufficient Supplement coolant
Water pump belt is loose or

Adjustment or replacement
damaged
Thermolator operation is poor Replace.

Clutch fault
Overview
1. Clutch is installed in the clutch shell between engine and transmission, use bolt to fix the
clutch assembly on the rear surface of flywheel, clutch consists of clutch driven plate
assembly and clutch pressure plate assembly.
2. The clutch assembled on this car is of diaphragm-spring clutch, single-plate dry friction
DI clutch, the diaphragm compresses spring, tortional absorber and vibration absorbing
damper are installed on clutch driven plate assembly , clutch driven plate is compounded
by high quality environmental friendly non-asbestos friction materials.
3. Clutch device is the control mechanism to transfer power and separate power, it transfers
the power output by engine to transmission, so as to stably connect or temporarily
separate engine power and transmission, and for ease of vehicle start, stop and shift, etc.
4. When vehicle starts, clutch driven plate assembly and clutch pressure plate assembly
combines gradually, engine power is transferred by the friction force among flywheel,
clutch driven plate assembly and clutch pressure plate assembly to vehicle power train, so
that the vehicle can start stably.
5. During vehicle driving, driver can depress or release clutch pedal as needed, so as to
temporarily separate and gradually connect clutch driven plate assembly and clutch
pressure plate assembly, cut or transfer the power from engine to transmission.
6. Clutch can temporarily cut the power transfer between driving system and engine when
shift gear, to reduce the collision impact of gears, and realize stable shift.
7. The clutch is composed of following components:
a. Clutch pedal assembly
b. Clutch pressure disc and driven disc assembly
c. Clutch master cylinder
d. Clutch slave cylinder
Precautions
1. The discharged brake fluid can’t be used continuously.
2. Special brake fluid must be used, because other brake fluid may cause corrosion, and
shorten the service life of clutch system.
3. Don’t splatter the brake fluid on vehicle, or it may damage paint. If the brake fluid is
splattered on the paint coat, clean it immediately with water.
4. Clutch pressure plate can’t be cleaned with gasoline！
5. There is lubricating grease filled in release bearing, don’t clean with oil or liquid DI
substance.
6. When installing clutch, temperature-resistant and pressure-resistant lubricating grease
shall be used to properly lubricate friction plate spline and transmission input axis spline,
ensure that the friction plate can move freely on transmission input axis spline. Excessive
lubricating grease will cause friction plate sliding.
7. When friction plate is worn to specified wear limit, replace the friction plate assembly
timely, in order to avoid clutch sliding, pressure plate and flywheel surface scratch.
8. When repairing clutch components, it is not allowed to use sanding or dry brush or clean
with compressed air, in order to avoid powder. Water-dampened cloth shall be used to
wipe or dust cleaner shall be used for cleaning.

The clutch pedal bush is damaged. Replace the clutch pedal
The internal parts of clutch is loose Repair

DI
The release bearing is worn or
Change of release bearing
damaged.
Release fork or connecting piece is Replace the release shifting fork or
damaged connector
Check for clutch noise.
Damper spring is broken Change of driven plate
The driven disc assembly is

Replace driven plate
excessively worn.
The release bearing is loose. Change of release bearing
The clutch pedal is distorted. Repair or replace the clutch pedal
The clutch pedal bush lacks

Add the lubricating oil
lubricating oil.
Clutch oil performance decreases Replace clutch oil
The clutch master cylinder is Repair or replace the clutch master

defective. cylinder
The clutch pedal is heavy to
operate. The clutch slave cylinder is Repair or replace the clutch slave
defective. cylinder
The clutch pressure disc assembly Repair or replace the clutch
is defective. pressure plate
The clutch release fork is not well Repair or replace the clutch
lubricated. release shifting fork
The free travel of clutch pedal is
Adjust the free travel of pedal
too large.
The input shaft spline or clutch
Clear the oil dirt or replace the
driven plate spline are
clutch driven plate
contaminated by oil
The clutch pressure disc assembly Change of clutch pressure plate
is defective. assembly
Check for incomplete The clutch diaphragm spring fails. Replace the clutch plate
disengagement of clutch.
The driven disc assembly is worn
abnormally.
The clutch pressure disc with cap
Replace the clutch plate
assembly is deformed.
The release bearing is worn
Change of release bearing
excessively.
The clutch release fork is worn is Replace the clutch release shifting
abnormally. fork
The clutch driven plate assembly is

Check or replace the clutch driven
contaminated by oil or is
plate assembly
excessively worn
The clutch pressure disc assembly
is damaged.
The release fork is seized. Check the release fork

Clutch slips DI
Adjust the free travel of pedal
too small.
excessively worn.
The flywheel warps Replace the flywheel
The clutch diaphragm spring fails. Replace the clutch plate
The clutch driven plate assembly is Check or replace the clutch driven
contaminated by oil or is damaged plate assembly
The clutch pressure disc assembly Change of clutch pressure plate
is damaged. assembly
The torsional spring of the clutch
Replace the clutch driven plate
driven plate assembly is damaged
The clutch is not engaged smoothly
The torsional spring of the clutch
driven plate assembly is deformed Replace the clutch driven plate
or broken
The mounting point of engine is
Tighten the engine fixing point
loose
The flywheel is worn abnormally. Replace the flywheel

Transmission is hard to engage a gear

Overview
The DAT18R transmission can realize five forward gears and one reverse gear via three groups of
synchronizers and three shafts, i.e., input shaft, countershaft and output shaft.
All gears are meshed using the conventional method.
The low-speed synchronizer is fitted on the output shaft and is meshed with the first/second speed gear;
DI the high-speed synchronizer is fitted on the output shaft and is meshed with the third/fourth speed gear;
and the reverse-fifth speed synchronizer is fitted on the output shaft and is meshed with the reverse/fifth
speed gear.
Precautions
1. Operation precautions
a. Correctly adjust the clutch to thoroughly release it and completely engage it.
b. Load the vehicle at the designed load, and avoid any overloading.
c. Conduct the initial maintenance as per the vehicle operation manual.
d. Do not move the vehicle before its operating water temperature and pressure reach the specified
value after the engine is started.
e. Do not shift to a low gear from the high speed or to a high speed from the low gear, and avoid any
DI
inappropriate dragging.
f. Avoid gear shifting at impact, and do not abruptly push, pull or pat the gearshift lever.
g. Before engaging the reverse gear, park the vehicle.
h. Do not coast the vehicle at neutral gear when moving downhill.
2. Precautions in removal
a. Before removal of the transmission assembly from the vehicle, park the vehicle on a flat and safe
place, set the transmission at the neutral gear, shut down the engine, turn off the power master
switch, and block the front and rear wheels.
b. Prior to disassembly of the transmission, thoroughly clean the transmission housing.
c. The transmission shall be disassembled on a clean place to avoid the ingress of dust or other
impurities into the transmission, which may otherwise worsen the wear and cause damages of the
bearing.
d. Use the special tools to remove the bearing, in order to facilitate the removal whist avoiding
damages of the bearing. Carefully clean the removed bearing.
e. When decomposing each subassembly, put all parts on a clean working bench in the sequence of
removal, so as to avoid any loss of parts and also to facilitate the reassembly.
f. Use the circlip pliers to remove the circlip , in order to facilitate the removal whist avoiding
damages of the circlip
g. At removal using the tools, do pay attention to the load applied on the shaft, housing or other parts,
so as to avoid damages of parts. The removal of certain parts is prohibited, and it is absolutely
forbidden to apply a load onto the follower in operation. During removal, do use the soft hammer
and rod.
3. Precautions in reassembly
a. Before reassembly, thoroughly clean all parts to avoid the ingress of dust and impurities into the
transmission case.
b. Clear the residual paper gasket and sealant on each bonding surface.
c. Ensure that the gear, thrust washer and bearing are aligned in their correct direction.
d. All thrust washers, needle roller bearings and synchronizer conical surfaces must be coated with
clean lubricating oil to avoid damages of parts due to dry friction.
e. When refitting the second shaft assembly, check the axial clearance of each gear, and also check
for any too small or too large gap.
f. When refitting the synchronizing ring and synchronizer conical ring, ensure that their positions
and directions are not changed.
g. During refitting operation, ensure that the lubricating oil hole is not clogged and that the working
surface of each gear is free from rust, collision, crack or other defects. Furthermore, clean the
synchronizer conical ring, and coat the working surface of the synchronizer conical ring, oil seal
and bearing with clean lubricating oil.
h. All bolts, screw plugs, nuts and gear switches shall be tightened to the specified torque.
i. When refitting the intermediate shaft gear, coat the immediate area of the countershaft with
lubricating oil.
j. Refit the oil seal and bearing using the special tools, but never directly knock the bearing using
the hammer.
k. Check various oil seal lips for damages; if any, replace the oil seal.
l. Replace parts using those of the same model with the original transmission.
DI

1. The gearshift fork shaft is worn

Replace.
out.
2. The gearshift fork and DI
synchronizer outer gear ring are Replace.
The gear is incorrectly meshed worn out
3. The input and output bearings
Replace.
are worn out
4. The gear sleeve and gear
Replace the gear or gear sleeve
chamfer are worn out
1. The lubricant is insufficient Replace.
2. The free travel of clutch pedal is

Replace.
incorrect
3. The clutch driven disc is
Replace.
damaged or broken
The gearshifting operation is 4. The clutch pressure plate is
difficult Replace.
damaged
5. The synchronizer is worn out Replace.
6. The gear, gear sleeve or

Replace the gear or gear sleeve
chamfer is worn out
7. The gearshift shaft is damaged Replace.
1. The lubricant is insufficient Add lubricating oil
2. The bearing is worn or

Replace.
damaged
Noise
3. The gear is worn or damaged Replace.
4. The synchronizer is worn or

Replace.
damaged
Vehicle axle, transmission shaft fault

Drive shaft assembly
Overview
1. The position of intersection between the transmission output shaft axis and the rear axle
drive gear axis will vary from time to time; therefore, the power transfer between the
transmission output shaft and the rear axle drive gear must be realized via the universal
DI driving device. The drivetrain is composed of the universal joint and the propeller shaft &
sliding yoke assembly, used to transfer the output torque from the engine and
transmission to the driving axle.
2. In this vehicle, the tubular open type propeller shaft is equipped, and it is composed of one
propeller shaft and two universal joints.

1. Universal joint forks (installed in

Reinstallation
different directions)
The propeller shaft dithers or the
vehicle vibrates in operation
2. Drive shaft is twisted or bent Repair or replace. DI
3. Any component (loosened or Repair, dynamic balance test or
significant dynamic imbalance) replacement
1. Telescoping spline (excessively
Replace the transmission shaft
worn)
Abnormal sound of transmission 2. Universal joint bearing (worn,
shaft Replace the spider or bearing
stuck, damaged)
3. Fastener (loosened) Retighten
1. Universal joint bearing (lack of

oil)
The universal joint is heated
Run in the vehicle at a low speed,
2. Oil seal (excessively tightened)
and apply oil onto the blade
Rear axle assembly

Malfunction symptom Possible position Troubleshooting
1. Axle shaft spline (clearance too

Change of half shaft
wide or wear)
DI Intermittent knocking sound (travel)
2. Foreign material gets into the
Check the final drive
final drive.
1. Vent port is blocked Smooth the vent port
Final drive is leaking 2. Gear oil is excessive Check and discharge the gear oil
3. Final drive housing is cracked

Replace.
or has blister
1. Lack of rear axle gear oil Check and fill gear oil
Final drive overheats
2. Rear wheel brake is stuck. Check the rear brake
Frame, suspension fault

Front independent suspension
Precautions
1. Tightening of the rubber parts shall be done with the tires unloaded and free from the
ground. As the lubricant shortens the service life of rubber, the over-flowed lubricant
must be removed away.
2. After the reinstallation of the removed suspension parts, check the wheels for alignment DI
and adjust them if needed.
3. The locknut, belonging to the disposable parts, shall be replaced with the new one every
time. The new locknut shall keep the lubricant prior to tightening them.

1. Lubricant is excessive. Replace the absorber
Shock absorber leaks 2. Seals are invalid or damaged. Replace the absorber
3. Shock absorber is invalid. Replace the absorber
1. Tires wear or is inflated Adjust the tire pressure or replace

abnormally. the tire
2. Wheel alignment is wrong
again
3. The connector for steering
Fasten the loosened parts
Suspension noise system is loosened or wears
4. Wear of wheel hub bearing Replace the hub assembly
5. Steering gear wear or is of

Repair the steering gear
maladjustment.
6. Suspension parts Repair the suspension parts
1. Vehicle overloads Reduce the load

Vehicle body sinks
2. Absorber is worn or damaged Replace the absorber

Sway / incline 2. The connector for steering Fasten the loosened parts, and
system is loosened or wears replace the worn parts

Front wheel swings Perform the tire dynamic balance

2. Wheels (unbalanced)
again


again
5. Wear of wheel hub bearing Replace the hub assembly
6. The connector for steering Fasten the loosened parts, and

system is loosened or wears replace the worn parts
DI 1. Wheel alignment is not in line Perform four-wheel alignment

with the regulations. again
2. Tire pressure is not in line with
Adjust the tire pressure
the regulations.
Tires wear abnormally.
Perform the tire dynamic balance
again

Rear suspension assembly

Precautions
1. Severe overloading, unbalance loading and uneven stress aren't allowed, otherwise, the
steel plate spring camber reduces, and the flexibility weakens.
2. The emergency brake isn't allowed, especially the condition shall be treated in advance
upon the full load to avoid the emergency brake, otherwise the front steel plate spring
would be damaged due to the excessive bending stress.
3. The vehicle speed shall not be excessive, especially driving on the uneven road, because
DI
it would accelerate the deformation amplitude of steel plate spring and increase the
deformation times, promoting the acceleration of bending stress and the fatigue
aggravation.
4. The too quick steering isn't allowed, because the vehicle would generate the centrifugal
force upon the sharp steering, which increases the load of the outside steel plate spring,
the sharper the steering is, the larger the load is, and the larger damage it would incur to
vehicle.
5. The steel plate spring shall be regularly maintained. Upon the overhauling, each
spring shall be painted with the graphite grease, which could avoid the fatigue damage of
steel plate spring, could reduce the wear and could prevent corrosion. Therefore, the
regular prevention shall be conducted in order to lengthen the service life.

1. Seals are invalid or damaged. Replace the absorber

Shock absorber leaks
1. Vehicle overloads -
2. Leaf spring has the rigidity

Vehicle body sinks Replace the leaf spring.
unsatisfying the requirements.
1. Tires wear or is inflated

Check and adjust the tires.
abnormally.
Tilting 2. Leaf spring has the rigidity

Replace the leaf spring.
1. Wheel alignment is not in line

-
with the regulations.
Tires wear abnormally. 2. Tire pressure is not in line with

Check the tires on the vehicle
the regulations.
3. Wheels (unbalanced) Check and adjust the wheels

Rear wheels sway. -

the regulations.
DI
Wheel and tire fault

Overview
1. Wheel and tire are the running parts of car, and installed on vehicle axle. The basic
functions are as follows:
• Support car, bear the car gravity, enable the car to bear load.
• Transfer the driving force, steering force and brake force, so as to control the car
operation. DI
• Reduce the driving resistance and energy consumption.
• Ease the driving impact, and improve the bearing condition.
The wheel with consistent bearing capacity, size and type shall be selected for
replacement. The inconsistence of wheel size and type will influence the wheel and
bearing life, brake cooling, vehicle speed/ milometer accuracy, vehicle body ground
clearance, the clearance of tire from vehicle body and chassis.
2. Wheel replacement condition:
• Wheel bends or depresses.
• The radial runout of the wheel is too large. The tire is worn out.
• The cord is exposed.
• Tire swells.
• The steel rim is deformed or its weld is open.
• The bolt hole is excessively worn to go beyond the specified hole diameter.
• Wheel gets serious rusty.
3. Tire is the final executor of most operation instructions on car, it not only bears the weight
of vehicle body, transfers the vehicle driving force and brake force to ground, keep car
driving direction; but also eliminates the road vibration, improve the sitting comfort,
good-quality tire can also reduce the rolling resistance, so as to improve the fuel
economical efficiency. Spare tire is the emergency tire in case of wheel fault, when the
fault is removed, normal tire shall be replaced timely. Correct tire pressure is very
important to continuously keep good vehicle performance, operability and driving
economy, regular check shall be done to tire pressure, improper tire inflation will bring
negative influence to vehicle performance, and cause the following results:
• Lower fuel economy.
• Tire overload.
• Shorter tire life.
• Serious wear of tire.
• Uneven wear of tire.
• Poor vehicle operability.
• Lower sitting comfort.
Precautions
1. Perform the tire rotation on a regular basis to reduce the partial wear of tires, ensure the
driving performance of the vehicle and prolong the service life of tires.
2. Timely wash off the mud and sand adhered onto the wheels in operation, to avoid dithering
of wheels or damages of tires.
3. Prior to inspection or repair, park the vehicle on a flat ground, and block wheels.
4. Place the wheel blocks in front of the front wheel or behind the rear wheel.
DI 5. The same vehicle shall be equipped with the tires of the same size and tread pattern.
6. If the jack is used, operate it in accordance with the jack operation manual.
7. Confirm that the jack is placed on a flat and solid ground, and that the jack is set at its
correct jacking position.
8. Do not place any human body part beneath the vehicle which is being lifted by the jack;
otherwise this may cause serious injuries.
9. If anybody is present in the vehicle, do not jack the vehicle.
10. Do not start the engine when the vehicle is being jacked.

1. The toe-in and the camber do Adjust the wheel toe-in and the
not meet the requirements. camber
2. Tire pressure is not in line with DI
the regulations.
3. Wheels (unbalanced) Adjust wheel dynamic balance
4. The steering mechanism is Check and repair the steering

deformed mechanism.
1. The front wheel pressures are
Adjust the front wheel pressure
different from each other.

Front wheels swing or shake
Check the absorber and repair it if
3. Shock absorber is invalid.
needed.
4. Steering mechanism wears Check and repair the steering
severely mechanism.
1. Tire pressure is too high. Adjust the tire pressure

Riding comfort is poor. 2. Shock absorber is invalid.
needed.
3. Leaf spring (broken or failed) Check and repair the leaf spring
1. The toe-in is not in line with the

Adjust the toe-in of tire.
regulations.
Front wheel slides sideward.
the regulations.
Steering system fault

Steering mechanism
Overview
Driver controls the whole vehicle’s driving direction by directly controlling the steering wheel, Steering
wheel is the first link between driver and vehicle. Steering wheel is fastened on the steering shaft of
steering column, while the steering column is connected to steering gear through steering transmission
DI shaft. So, the driving direction of whole car can be controlled by controlling the rotation of steering wheel.
Steering column is a component for the whole vehicle anti-theft system, the anti-theft function of steering
column mainly depends on the steering lock, ignition switch, ignition switch lock cylinder and other
components on steering column. Controlling the above component can reduce the risk of vehicle theft.
In addition to the main steering functions of vehicle, the steering wheel and steering column also install
the following components on top: horn button, steering signal control switch, light system control switch,
wiper\washer switch, steering column angle adjustment switch, etc. it will provide great
convenience for driver to control the whole car. The telescoping mechanism of steering column provide
the driver a certain safety protection. Such structure can reduce the driver's injury in case of accident.
Precautions
1. Upon detection that more than 3 thread teeth are damaged for any lock bolt or nut during
the repair, replace the bolt or nut.
2. It’s prohibited to weld any part of steering gear and system linkage by any means.
3. After the steering system is installed, comprehensively check the steering comfort and
flexibility. Turn on the ignition switch, rotate the steering wheel, and the steering system
shall not become slack. Measure the maximum steering angle of the front wheel.
4. Tighten bolts of various components of the steering system to the specified torque.
5. After the steering gear and other steering mechanisms are serviced, check the wheel
alignment.
7. When the steering wheel is locked, do not move the vehicle to avoid damages of parts of
the steering system.

1. Damage of steering column

Replace damaged bearing.
bearings
2. Insufficient lubrication of DI
Add lubricating grease to bearings.
steering column bearing
Heavy steering 3. Insufficient lubrication of
Add lubricating grease to universal
universal joint crossing shaft
joint crossing shaft bearings.
bearings
4. Damage of universal joint Replace damaged universal joint
crossing shaft crossing shaft assembly.
1. Loose fastening bolts Tighten loose bolts.
2. Excessive wear of steering

Excessive free clearance Replace the steering drive shaft
drive shaft spline
bearings
2. Insufficient lubrication of
Add lubricating grease to bearings.
Steering noise or stagnation steering column bearing
steering drive shaft telescopic Add grease
joint
Power steering
Precautions
3. After the steering gear is installed, comprehensively check the steering comfort and
flexibility. Turn on the ignition switch, rotate the steering wheel, and the steering system
DI shall not become slack. Measure the maximum steering angle of the front wheel.
4. Tighten bolts of various components of the steering gear to the specified torque.
5. After the steering gear and other steering mechanisms are serviced, check the wheel
alignment.
7. When the steering wheel is locked, do not move the vehicle to avoid damages of parts of
the steering system.

1. The fuse is damaged Replace the same type of fuse.

The electric power steering (EPS)
system doesn’t work, and the EPS
2. Circuit faulted Repair the damaged circuit
warning lamp is permanently
illuminated
3. EPS control unit faulted Replace the EPS control unit
1. The steering column assembly Replace the steering column

The motor produces abnormal is damaged assembly
noise
2. EPS motor faulted Replace the EPS motor
1. Wheel alignment is not accurate Four wheel alignment
2. Abnormal operation of front

Check the front absorber.
shock absorber
Steering is heavy. 3. Steering gear faulted Replace the steering gear
4. Too large clearance of steering Replace the steering linkage ball

linkage ball joint pin head
5. EPS control unit faulted Replace the EPS control unit
1. Wheel alignment is wrong Four wheel alignment

Dithering of steering wheel Tighten the loosened bolts
loosened
linkage ball joint pin head
4. Front shock absorber faulted Replace front absorber
5. Steering gear faulted Replace the steering gear

Tighten the loosened bolts
loosened
linkage ball joint pin head DI
Too large free clearance of the 3. Steering inner articulated shaft
steering wheel Replace the steering drive shaft
faulted
4. Front wheel bearing worn or
Replace the hub assembly
loosened

Tighten the loosened bolts
loosened
2. Steering inner articulated shaft
Abnormal noise in steering Replace the steering drive shaft
faulted
operation
3. Steering motor faulted Replace the steering motor
1. Open circuit or short circuit Service the wiring harness
2. Electric power steering column

EPS works intermittently Replace the steering column
damaged
3. EPS control unit damaged Replace the EPS control unit

Brake system fault

Service brake system (Hydraulic)
Overview
1. System description
The braking system is a combination of special devices used to reduce the traveling speed. The
braking system is composed of the energy supply device, control device, driving device and brake,
DI and is mainly intended to reduce the speed of the moving vehicle and to maintain the steady
speed of the vehicle moving downhill. This vehicle is equipped with the front disc brake and rear
drum brake.
2. Composition
The braking system is composed of the brake pedal, brake master cylinder, vacuum booster,
brake pipeline, brake caliper, brake drum, brake lining, brake shoe and so on.
3. Operating principle
When the driver depresses the brake pedal, the load applied onto the brake pedal by the driver
will be magnified by the vacuum booster to compress the brake oil in the brake master cylinder to
flow into the brake pipelines of these four wheels; thereafter, the oil liquid will push the brake
piston and brake slave cylinder to engage the friction lining with the brake disc, thus generating a
friction force to reduce the vehicle speed.
4. Requirements of brake system
• High braking efficiency: indicators used to evaluate the braking performance include:
braking distance, braking deceleration, and braking time.
• Easy control: maintain the direction in the braking operation. In the braking operation, the
braking force of the front and rear wheels will be reasonably distributed , and the braking
force applied on the left and right wheels shall be substantially equal to each other , so as
to avoid deviation and sideslip of the vehicle.
• High braking comfort: the braking operation shall be mild and steady, and the brake shall
be capable of being released quickly and thoroughly.
• Good cooling performance and convenient adjustment: to realize this, the friction lining of
brake shoe shall be resistant to high temperature, and can be recovered after it is
moistened; furthermore, the clearance can be adjusted after wear-out, and the resistance
to dust and oil is also required.
Precautions
1. The performance of the service brake may directly influence the operation safety;
therefore, the braking system shall maintain a good performance all the time.
2. Regularly check the braking system to eliminate the potential safety hazard.
3. Use the recommended brake liquid which shall not be mixed with brake liquids of other
models.
4. As the brake liquid is highly corrosive, avoid the contact of brake liquid with the human
skin and the vehicle body paint when servicing the braking system. In the event of such a
DI
contact, immediately wash the contacted area using a lot of water.
5. During the repair, if the brake lining is contaminated by oil or moistened by water, the
friction coefficient will be reduced abruptly to render the brake inoperative. Clean the
removed friction lining using the gasoline, and heat and bake it using the brazing torch to
remove the oil in the depth of the lining. In the event of serious seepage, replace the
friction lining. If the friction lining is soaked in water, dry it by continuously applying the
brake to generate heat and evaporate the water.
6. When removing the brake caliper, do not depress the brake pedal to avoid ejection of the
piston, for this may result in damages of the piston dust cover.
7. Thoroughly clean the brake slave cylinder and brake lining to minimize the damages
arising out of the air-borne particles and other substances.
8. When releasing the air, observe the brake liquid level in the brake oil tank from time to time,
and it shall not be lower than minimum level mark. If necessary, add the brake liquid.
9. After the brake liquid is filled and the air is released, check the braking system for leakage;
if any, timely eliminate the leakage to ensure the driving safety.

1. Brake fluid (insufficient) Add the brake fluid
Check and repair the braking

DI 2. Brake system (oil leaking)
System
The brake pedal is too low or
3. Brake lining (worn) Check and repair the brake lining
weak.
Check and repair the brake master
4. Brake master cylinder (fault)
cylinder
5. Brake system (with air) Air bleeding of brake system
1. Brake pipeline (blocked) Dredge or replace the brake pipeline
Check and repair the brake slave

2. Brake slave cylinder (seized)
cylinder
Braking drag 3. Brake calliper (seized) Check and repair the brake calliper
4. Hub bearing (loose) Replace wheel hub bearing.
5. Free travel of brake pedal (too small) Adjust the free stroke of brake pedal
1. Tires (pressure insufficient) Check the tires on the vehicle
2. Brake shoe (oily) -
3. Brake shoe (one side is worn

Check and repair the brake shoe
extremely)
4. Brake lining (oily) -
5. Brake lining (one side is worn

Braking deviation Check and repair the brake lining
extremely)
6. Brake disc (deformed) Check and repair the brake disc
7. Deformation of brake drum Check and repair the brake drum
8. Brake calliper (the left and right

Check and repair the brake calliper
braking forces differ a lot)
9. Brake slave cylinder (the left and Check and repair the brake slave
right braking forces are different) cylinder
1. Brake lining (overused) Check and repair the brake lining
2. Brake calliper (fastening bolts

Check and repair the brake calliper
become loose)
3. Brake calliper bracket (fastening Check and repair the brake calliper
Unstable braking
bolts become loose) bracket
4. Brake calliper (seized) Check and repair the brake calliper

cylinder
1. Brake lining (over worn) Check and repair the brake lining
The braking force is 2. Brake shoe (over worn) Check and repair the brake shoe
insufficient.
Discharge the air in the brake
3. Brake pipeline (with air)
pipeline
DI
Parking brake
Overview
1. The parking brake system can realize the long-time and safe parking of the vehicle. This
may facilitate the driver to move the vehicle on a slope. In operation, if the service braking
system fails, the vehicle can be braked using the parking brake system in an emergency.
2. The parking brake system is composed of the control lever, parking brake cable and brake
etc.
DI 3. When applying the parking brake, pull the parking brake lever and then the cable will bring
the brake to park the vehicle.
Precautions
1. The parking brake can’t be used instead of the service brake, but it can be only used to
decelerate the vehicle in an emergency.
2. With the service brake in normal operation, check and adjust the parking brake.
3. To service the parking brake system, park the vehicle on a level ground, and block wheels
using the triangle wood.
4. Replace each part carefully and correctly, for the incorrect refitting may influence the
braking performance of the vehicle and may even endanger people’s life.
DI
5. Once the buckle or strap is removed, it shall not be further used.
6. After the parking brake system is repaired, do test the parking brake to ensure its safety
and reliability.
7. Check the clutch every 10000km as described below:
• Check the functions of the parking brake .
• Check the travel of parking brake lever.
• Check all connections for looseness;
• Check the parking brake system for normal operation.

1. Parking brake control lever Adjust the parking brake control

(incorrect travel) lever
DI 2. Brake shoe and brake drum

Clear the oil and adjust the
Inefficient parking operation (too large clearance or
clearance
contamination by oil)
3. Parking brake control cable Replace the parking brake control
(broken, stuck, detached) cable
1. Parking brake lever (too small
Adjust the parking brake lever
travel)
2. Parking brake return spring
Replace the brake return spring
(damaged)
The parking brake drags.
3. Parking brake control cable Straighten out the parking brake
(stuck) control cable
4. Brake shoe gap (adjusted
Adjust the brake shoe gap
improperly)
Body fault
Overview
1. The vehicle body shall provide convenient working conditions for driver, provide
comfortable sitting conditions for passengers, and protect passengers from invasion of
the vibration, noise and exhaust during driving as well as influences of the external
atrocious weather. Some structure measures and equipment on body are helpful for safe
driving and reducing the consequences of accident. DI
2. The body shall ensure the reasonable appearance which can effectively guide the
surrounding airflow at driving of vehicle to reduce air resistance and fuel consumption.
Besides, body should also contribute to boosting steering stability of the vehicle, improve
engine refrigeration condition, and make sure there is good ventilation in the vehicle.
3. Vehicle body structure mainly includes: cab, door, window, sheet metal parts in the front of
the vehicle, inner and outer trim parts of the body, body attachment, seat, seat belt, and
door lock etc.
4. The seat belt and head rest restricting passengers as well as various buffer and cushion
devices preventing passenger injury in case of vehicle collision are widely adopted on
modern vehicles, so as to ensure traffic safety.
Precautions
1. There is a special tool to remove the interior trims, if no, a screwdriver or other equivalent
tools can substitute, but shall be wrapped.
2. When removing the parts with sharp tool, it is necessary to wrap the tool with tape to
prevent the parts from scratching.
3. In the condition in which the part can not be removed, do not remove it forcedly, and you
should check whether any fixing screws are forgotten.
DI 4. Clips are vulnerable parts. Check the removed clips for any damage, and replace with new
ones if any. Check fixing bucket of parts for loss when installing parts.
5. If a certain door window cracks but is still complete, the protective tapes shall be pasted
on the door window presenting cross shape for fear that the door window further damages
or of causing personal injury.
6. When handling with any type of glass or metal plate with sharp-angle or deckle edge,
goggles and gloves are permitted to wear in order to reduce the risk of personal injury.
7. Please wear goggles when using compressed air to prevent the eyes from be injured.
8. When removing the brand of the front grill, use plastic flat blade tool to avoid damaging
the paint.
9. Avoid the window being damaged by impactor due to exposed edge. The vehicle window
shall be lower than metal surface 1mm to avoid damaging window.
Fault diagnosis
In the event of vehicle body failure, visual / routine inspection shall be first performed. inspection items
are as follows:
• Whether the visible or easy to contact part has obvious damage.
• Whether the rubber parts has obvious damage or aging failure.
• Check whether parts are loosened.
• Inspect for any device fitted after sales that may cause system failure.
It is a after-sales refitting device that may cause system fault. In case of any fault, the vehicle will have
DI
related fault phenomenon. Common symptoms and troubleshooting method are as follows:
1. Lock catch (improper

Adjustment
Door fails to meet the sealing adjustment)
requirement after closed. 2. Door lock assembly (door lock
Change
assembly damaged)
1. Inner handle switch (damaged) Change
Unable to open the door from 2. Drawback lock linkage (not

Check and reinstall
inside installed properly)
3. Door lock body (damaged) Replace the door lock
1. Door close incomplete -
Unable to lock the door from inside 2. Lock knob (damaged) Change
3. Drawback lock linkage (not

Check and reinstall
installed properly)
1. Lock core (damaged) Replace the lock cylinder

Unable to lock the door with the
2. Linking rod of the lock core to Check and reinstall the
key
external locking (fall off or door transmission rod or replace the
lock damaged) door lock
Key unable to turn 1. Lock core (damaged) Replace the lock cylinder
EG Engine part
Engine ..................................................................... EG-1
Engine mechanic part .......................................... EG-1
Fuel system ........................................................ EG-90
Lubricating system ........................................... EG-118

EG
Cooling system................................................. EG-133
Intake system ................................................... EG-159
Exhaust system................................................ EG-172
Starting and charging ....................................... EG-185
Ignition system ................................................. EG-198
Engine control system...................................... EG-212
Exhaust gas purifier .......................................... EG-274
Three-element catalyzer .................................. EG-274

Engine part - Engine EG-1
Engine
Engine mechanic part

Engine mechanic part
Overview
DAM15R engine is developed utilizing the electronic fuel injection techniques in accordance with the
latest emission regulations promulgated by the State. DAM15R engine is located in the engine
compartment at front end of the vehicle, being a water-cooled in-line horizontal 4-cylinder & 4-stroke
gasoline engine, and is provided with 16-valve double overhead camshaft mechanism which is driven by
the crankshaft via the timing chain to directly drive the valves, featuring compact structure, high power, EG
low fuel consumption, low emission and low noise. The DAM15R Dongan double-VVT engine is widely
applied in cars, being one of the engine models of the largest torque among those engines with the
same displacement and technical features in China, providing the driver a better feeling of control whilst
EG-2 Engine part - Engine
Precautions
3. Before the operation, if necessary, put a fire extinguisher at the specified position with
easy access.
4. Before the operation, if necessary, the operator shall wear protection shoes, gloves and
goggles to protect personal safety.
EG
5. Before the operation, make sure that the car is protected properly, for example, covering
of seats, steering wheel, floor and engine compartment.
6. Before lifting the car, check whether the lifter works normally, whether the car is parked at
a proper position and whether the lifting arm is calibrated correctly in relation to the lifting
point of the car. When lifting or lowering the car, make sure that no person or unnecessary
articles are present beneath the car.
7. In the repair work, disconnect the fuel supply, power supply and discharge the pressure as
specified. For example, if the fuel rail is to be removed, the fuel supply shall be
disconnected for pressure discharge; if the eletric part is to be removed, the battery
negative terminal shall be disconnected at first to avoid vehicle damages and threats to
personal safety.
8. After the pipes and joints are disonnected, take protection measures to prevent the pipes
and joints from being contaminated or invaded by foreign matters.
9. When servicing the engine interior, observe the specified procedure, and handle the brittle
and fragile parts with much care.
10. When tightening bolts and nuts, observe requirements on the torque, sequence,
direction or angle parameters, and avoid applying a over-high torque.
11. When overhauling the engine, for example, servicing of crankshaft, piston and cylinder
head, thoroughly clean and lubricate the parts before installation.
12. When servicing the engine, for example, installation of the oil pan, clear off the old sealant
before the operation, ensure the flatness of the bonding face, fit a new gasket and coat it
with sealant.
13. Check the earthing polarity of the battery, and in this car, the negative earthing is applied.
14. It is not allowed to regulate the throttle position screw; otherwise the throttle angle will be
changed when the throttle is closed to render the engine inoperative.
15. When the engine is working, do not remove the spark plug cable. In all cases, the engine
misfire will lead to the entry of unburnt gas mixture into the three-way catalytic converter
to cause ablation. If necessary, remove the three-way catalytic converter.
16. The engine oil of the specified grade and viscosity must be used; otherwise the wear of
engine will be worsened.
17. It is not allowed to use the unauthorized engine parts, but the geninue parts shall be used,
failing which will damage the engine or render the engine inoperative.
18. A new engine shall undergo the running-in period. In the running-in period, abrupt
acceleration or heavy-load operation shall be avoided.
19. When the engine is working, especially at a high speed and high load, do not immediately
stop the engine, but do this after the engine works at a low speed for 3 to 5 minutes to
allow for uniform heat dissipation of the engine.

20. The use of sealant is required on many parts in the engine. This is to achieve sufficient
sealing, and special attention shall be paid to the quantity, position and surface of coating.
Too little coating may lead to leakage, while too much coating will result in the clogging or
narrowing of the water or oil passage by the leaked sealant. Therefore, the sealant shall be
applied as required.
21. In certain cirmustances, the parts must be lightly knocked using the wooden or rubber
hammer or similar tools to destroy the sealant on the bonding face, or the smooth and thin
sealant scraper can be lightly driven into the bonding face with much care.
22. Use the sealant scraper or steel wire brush to remove foreign matters on the sealing EG
surface. Make sure that the sealing surface is flat and smooth, and free from oil or foreign
matters. Do not forget to remove sealant in the mounting hole and threaded hole.
23. Apply the sealant within the specified diameter to fully enclose the mounting hole. The
sealant which is not hardened can be removed. Fit parts at the designated position when
the saelant is wet (within 15 minutes). Take care not to bond the sealant onto any
unwanted position. After installation, wait for the sealant to be fully hardened (wait for
about 1h). Within this period, do not apply oil or water onto the part coated with sealant or
start the engine.
24. Record the engine serial number, engine model and vehicle model, and such data is
needed to contact various service stations of Beiqi Foton for the purpose of engine repair
(the engine serial number is printed on the left -front inclined plane of the engine cylinder
block, when viewed from the engine front end).

Low battery voltage
necessary
Looseness and corrosion of battery Clean the battery and fasten the
cable connection
Check the starter and replace it as
Starter failure
necessary
Check the ignition coil and if
EG Ignition coil fault
Check the spark plug cable, and if
Spark plug cable fault
Engine will not start
The spark gap of the spark plug is
Replace spark plug
too large
The fuel filter is blocked and the fuel Clean the fuel system and replace
system has too much impurities. the fuel filter
Check the fuel pump, and if
Fuel pump fault
Refit or replace the synchronizing
Slippage of synchronizing chain
chain
Other related electrical parts does Check related electrical parts and
not work properly replace them as necessary
The spark electrode gap of the spark
Replace spark plug
plug is too large
The fuel filter is blocked and the fuel Clean the fuel system and replace
system has too much impurities. the fuel filter
Refit the synchronizing chain and
Valve timing is incorrect
adjust the timing mechanism
Air leakage of cylinder head gasket Replace the cylinder gasket.
Measure cylinder pressure. If
Cylinder pressure value is too low
necessary, overhaul it
Check the valve and valve seat, and
Valve seal is not strict
replace if necessary.
Insufficient engine power Three-way catalytic converter is Replace good quality fuel, replace
blocked three-way catalytic converter
Check the resistance of the spark
The resistance of the spark plug
plug cable, and if necessary, replace
cable is too high
the cable
Test the ignition coil, and if
Ignition coil fault
Replace fuel filter, clean fuel injector,
Bad atomizing of injector
and replace when necessary
The exhaust system does not work
smoothly
The air suction of air intake system is
Check air intake system
not sufficient

Check the knock sensor and other
Deviation check of ignition timing
relevant parts
Other related electrical parts does Check relevant electric parts and if
not work properly necessary, replace them
Check if the fuse is good. Replace.

Battery power is insufficient Charge
Battery terminal connection is loose Fastening
Start switch contact can’t be closed Repair of replace it EG
Starter electromagnetic switch is
Replace.
worn
Starter brush is worn Replace.
Starter magnetic field or armature

circuit is open
warning lamps Fastening or replacement
voltage damper

Replace.
Starting difficulty damaged or has poor contact
ECM electric power steering system
fails
Throttle valve is damaged Replace.
Replace.
damaged
Fuel pump relay or fuse fault Examination and replacement
Fuel is insufficient Refuel.
Blockage of fuel filter. Replace.
Air existing in fuel pipeline Repeated starting

Fuel pressure is insufficient Checking and adjustment
ECM fault Replace.
Intake manifold is loose Fastening
Intake air temperature and pressure
Replace.
sensor is damaged
Replace.
broken


Timing chain is damaged Replace.
Poor valve combination Repair or replace.
Valve is burned Replace.
Valve rod is blocked Replace the valve guide
Piston, piston ring or cylinder is worn Replacement or repair
Fuel quality is bad Replace.
EG
Valve rod is blocked Replace.
Piston ring leaks Replace.
Replace.
broken
Replace.
sensor is damaged
Inadequate power Repair of replace it
voltage damper
Replace.
ECM electric power steering system
Replace.
fails
abnormally
Repair or replace.
abnormally
Air cleaner is dirty or blocked Repair or replace.
Throttle valve is damaged Repair or replace.
Engine overheated Service
Brake drag Repair of replace it
Slipping of clutch Repair of replace it

Ignition coil aging or electric leakage Replace.
Replace.
damper
ECM fault Replace.
Throttle valve fault Repair of replace it
Throttle valve position sensor is
damaged
Replace. EG
Fuel pressure regulator failure Replace.
Engine surge Cylinder head gasket is damaged Replace.
Replace.
damaged
Water pump performance is poor Repair or replace.
Radiator leakage Repair or replace.
Oil filter is blocked Replace.
Oil filter screen is blocked Replace.
Oil pump performance is poor Replace.
Oil disk or oil pump leakage Replace.
Oil quality is bad Replace.
Main bearing shell is worn or the
Engine noise is loud Replace.
clearance is big
Connecting rod bearing shell worn or
Replace.
the clearance is big
Connecting rod deformation Repair of replace it
Crankshaft main journal is worn Grinding repair or replacement
Crankshaft connecting rod journal is
Grinding repair or replacement
worn
Abnormal wear of bore hole Bore the cylinder to next repair size
The piston, piston ring, piston pin are
Replace.
worn
Piston ring is blocked Replace.
piston ring damage Replace.
Camshaft anti-thrust clearance is too
Adjust.
large
Crankshaft anti-thrust clearance is
Adjust as specified
too large

Valve clearance is too large Adjust as specified
Ignition coil aging or electric leakage Replace.
Replace.
damper
Fuel tank or fuel pipe leakage Repair of replace it
EG
Fuel pressure is insufficient Repair of replace it
Fuel consumption is high Air cleaner is dirty or blocked To be cleaned or replaced

Replace.
sensor is damaged
Idle speed is too high Checking
Brake is jammed Repair of replace it
Clutch slips. Repair of replace it
Tire pressure is incorrect Adjust.
Drain plug is loose Fastening
Oil disk fixing bolt is loose Fastening
Oil disk installation surface leakage Reinstallation
Oil seal leakage Replace.
Oil filter leakage Fastening or replacement
Oil pressure sensor leakage Fastening or replacement
Oil consumption is high Clear the carbon deposit or replace
Piston ring is blocked
piston ring
Piston ring and ring slot are worn Replace piston or piston ring
Piston ring open position is incorrect Adjust the open position
Replace piston and piston ring or
Piston or cylinder is worn
bore reclaim
Valve oil seal is seriously worn Replace.
Valve rod or valve guide is seriously
Replace.
worn
Unstable idle speed Spark plug fault Adjust the clearance or replace
voltage damper
Replace.

abnormally
The fuel system connector is loose Examination and replacement EG
Repair or replace.
abnormally
Vacuum hose connection loose or
Reconnect or replace
leakage
Cylinder compression pressure is See the previous “ Cylinder
lower compression pressure is too low”
Intake manifold bolt and nut are
Fastening
loose
intake manifold gasket leakage Examination and replacement
Air conditioning signal is wrong Examination and replacement
Replace.
damaged
Replace the spark plug with heat
Spark plug is too hot
value meeting requirement
High voltage or low voltage circuit
Reconnect and fasten
connection is loose
ECM fault Replace.
Gasoline filter or fuel pipe is blocked To be cleaned or replaced
Fuel nozzle is blocked Cleaning or replacement
Fuel pressure regulator fault Adjustment or replacement
Electric fuel pump and line fault Examination and replacement
Abnormal detonation Intake manifold, throttle valve gasket
Fastening or replacement
leakage
Piston top or cylinder head
combustion chamber has too much Clearing
carbon deposit
Cylinder head gasket damage
causes too low cylinder compression Replace.
pressure
Valve is blocked Replace.
Valve spring elasticity is weaker Replace.

ECM fault Replace.
Spark plug heat value doesn't meet Replace the spark plug with heat
requirements value meeting requirement
Fuel nozzle fault Cleaning or replacement
Checking, adjustment or
Fuel pressure is insufficient
Engine overheating replacement
Intake manifold leakage or loose Refastening or replacement
Coolant is insufficient Supplement coolant
EG
Water pump belt is loose or
Adjustment or replacement
damaged
The thermostat works badly Replace.
Recommended tools
Figure Name Function
Cylinder head bolt remover Remove the cylinder head bolt
EG
Lifting-type hydraulic jack Lift the engine
Measure the gaps between

Clearance gauge
various mating surfaces
Measure the internal/external

Vernier calliper
diameter of shaft hole
Check cylinder compression

Cylinder pressure gauge
pressure.
Check the shaft outer diameter,

Micrometer
tappet and valve stem dimensions
Used in conjunction with the

Reamer handle
reamer
EG
Reamer Refinish the valve seat.
Piston ring compressor Install piston
Piston ring expander Dismantle piston ring
Disassembling and installation of

Circlip pliers
circlips
Disassembling and installation of

Nipper pliers
circlips
Valve extractor Remove/refit the valve
EG
Engine equalizer Fix the engine assembly
Engine hoist Hoist the engine assembly
High-precision cylinder bore

Check the cylinder bore
gauge
Auxiliary material
Item Quantity Specification
Sealant Specialized sealant designated by Foton
Below the maximum Ethylene glycol -40 (NB/SH/T0521 ), initial quantity

scale mark on the is recommended to be 5.6L
Coolant expansion tank and
above the minimum G03 low-level configuration 6L
scale mark
Engine Oil Level 3.5L DAM15R SL 5W-40

EG
Maintenance data
Engine assembly
In-line 4-cylinder, 4-stroke, water-cooled, multi-point

Type
sequential injection
Number of cylinders 4
Displacement 1.498L
Cylinder bore 74mm
Stroke 87.1mm EG
Maximum torque 150N . m
Revolution at maximum torque 4500r/min
Output power 85kW
Revolution at output power 6000r/min
Compression ratio 10.5
Minimum fuel consumption rate 248g/kW . h
Camshaft
Lift 8.501mm
Base circle radius
Standard value
16.5mm
Intake
Cam thickness 7.5mm
Limit value —
Cam height
Lift 7.739mm
Base circle radius
Standard value
16.5mm
Exhaust
Cam thickness 7.5mm
Limit value —
First shaft neck 28.934~28.955mm
Second shaft neck 22.934-22.955mm
Third shaft neck Standard value 22.934-22.955mm
Forth shaft neck 22.934-22.955mm
Fifth shaft neck 22.934-22.955mm
Camshaft radial runout Limit value 0.03mm
Cylinder head
Cylinder head bottom planeness Limit value 0.05mm

Valve
Intake 2.1 ± 0.2mm

Edge thickness Standard value
Exhaust 2.4 ± 0.2mm
Standard value 39.2-40.8mm

Free length of valve spring
Limit value 39.08mm
Engine assembly
Pre-tightening torque of the valve spring 110-126N

EG Standard value
Verticality of the valve spring 1.0mm
Intake 5.465-5.48mm
Valve stem diameter Standard value
Exhaust 5.44-5.455mm
0.01-0.045mm
Intake Standard value
Radial clearance 0.07mm
between valve stem and
guide pipe Standard value 0.035-0.07mm
Exhaust
Limit value 0.09mm
Intake 17°
Inclination angle Standard value
Exhaust 16°
Intake 75 ± 0.2mm
Valve stem length Standard value
Exhaust 74 ± 0.2mm
010. 553-10. 568

Valve guide pipe bore diameter Standard value mm(enlarged, altogether
6 levels, 0.05 for each)
Standard value Total length 87.45mm

Intake
Limit value —
Valve height
Standard value 87mm
Exhaust
Limit value —
Tappet thickness
No. Grade No. No. Thickness (mm)
1 310 Standard value 3.10


EG

Outside diameter of tappet 27.959~27.975mm

Standard value
Internal diameter of cylinder head tappet hole 28-28.021 mm

Cylinder head
Limit value 0.1mm
EG
Torque requirement
Cylinder block
Limit of deformation of large plane of cylinder head
Limit of deformation of intake flange surface Standard value 0.05mm
Limit of deformation of exhaust flange surface

Standard value 74~74.02mm
Internal diameter of cylinder jacket
Limit value 74.06mm
Roundness and cylindricity of cylinder jacket 0.01mm EG
Limit value
Conicity and ovality of cylinder jacket 0.02mm
Clearance between piston and cylinder Standard value 0.025-0.045mm
Piston
Clearance between piston ring and piston ring groove
First gas ring
Limit value 0.12mm
Standard value 0.03~0.07mm
Second gas ring
Limit value 0.1mm
Oil ring 0.04-0.16mm
Standard value
Piston diameter 73.965-73.975mm
Clearance of piston pin
Limit value 0.05mm
Bore diameter of connecting rod small end Standard value 18.003-18.011mm
Axial backlash of connecting rod big end
Limit value 0.4mm
Piston pin bore diameter 18.006~18.012mm
Standard value
Piston pin diameter 17.996-18.000mm
First gas ring
Limit value 0.7mm
Piston ring end clearance Second gas ring
Limit value 1.0mm
Oil ring
Limit value 1.2mm
Piston pin 17.996-18.000mm
Piston pin hole Standard value 18.006~18.012mm
Clearance between piston pinhole and piston pin 0.006~0.016mm
Cylinder block
Clearance between connecting rod and piston pin Standard value 0.003~0.015mm

Clearance of connecting rod bush
Limit value 0.075mm
Backlash of connecting rod big end
Limit value 0.4mm
Crankshaft
Axial clearance Standard value 0.11-0.31mm
Fit clearance between main shaft neck and bush
EG Limit value 0.056mm
Flywheel disk
Flywheel disk end face runout Limit value 0.2mm
Engine assembly
Overview
The DAM15R engine is a water-cooled in-line horizontal 4-cylinder & 4-stroke gasoline engine, and is
provided with 16-valve double overhead camshaft mechanism which is driven by the crankshaft via the
timing chain to directly drive the valves. The DAM15R Dongan double-VVT engine is widely applied in
cars, being one of the engine models of the largest torque among those engines with the same
displacement and technical features in China, providing the driver a better feeling of control whilst
Technical Characteristics EG
• “Intake and exhaust control + antifriction” technical route and the impact light-weight &
low-cost design concept are applied;
• The VVT system ( continuously variable intake valve timing control) is applied, and the
VVT structure is provided with an internal circulation gas path to realize the functions of
EGR (Exhaust Gas Recirculation);
• The snail shell type extra-long plastic intake manifold is applied to optimize the intake;
• The eccentric crankshaft, narrow connecting rod bush, light-weight graphite-coated piston,
super-thin low-tension piston ring and low-elasticity valve spring and other anti-wear
techniques have been used;
• The aluminum alloy cylinder block ( cast-in cylinder liner ) and plastic intake manifold and
other light-weight design schemes are applied;
• The silent chain timing drive system is applied to improve the engine NVH characteristics;
• Excellent power performance: power per liter L 56.1kW/L, torque per liter L 98.8N•m/L;
• The fuel consumption complies with the passenger vehicle fuel consumption evaluation
method and the standard GB27999-2011;
• The emission complies with the Stage IV emission limits ( GB18352.3-2005 ), and can be
upgraded to the Euro V level.
Replacement
Caution
• Before removal and refitting of the engine assembly, all oils and liquids in the engine must
be fully discharged, and wiring harness, pipeline joints and connections between the
engine and the body must be disconnected.
• Before disconnecting all wiring harness and pipeline, they must be bonded with marks to
avoid wrong or missing connection in the refitting operation.
• After the pipeline joint is disconnected, the pipeline nozzle must be wrapped and sealed to
EG avoid entry of foreign matters.
• The discharged oils and liquids must be collected and disposed as specified to keep the
working ground clean.
1. Release the fuel system pressure (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Fuel system -Release of fuel system pressure, Fuel system”)
2. Disconnect the negative cable of the battery. (Refer to “Chapter EL Electric System -
Electric Devices - Battery - Battery bracket, Replacement”)
3. Drain the coolant. (Refer to “Chapter EG Engine Part - Engine (DAM15R) - Cooling
System - Coolant, Replacement”)
4. Discharge the engine oil (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Lubricating system - Change, Engine oil”)
5. Recycle the air conditioner refrigerant (Refer to “Chapter EL Electric System - Electric
Devices - Heating and Air Conditioning System - Refrigerant, Replacement”)
6. Remove the driver's seat. (Refer to Section BW: Vehicle body- Seat- Driver's seat,
Replacement".)
7. Remove the assistant seat. (Refer to Section BW: Vehicle body- Seat- Assistant seat,
Replacement".)
8. Remove the dashboard . (Refer to "Section BW: Vehicle body- Dashboard/ Combination
instrument/ Ash tray- Dashboard, Replacement".)
9. Remove the gear shifting mechanism (Refer to "Section TR: Shift and control mechanism -
Manual transmission - Transmission assembly - Shift control mechanism, Replacement".)
10. Remove the air filter assembly and the throttle intake pipe (Refer to “Chapter EG Engine
part - Engine - Intake system -Air filter assembly, Replacement”)
11. Remove the middle connecting plate of the

console.
a. Remove the wiring harness grommet and move
aside the wiring harness.
b. Remove the fixing nut of parking brake control
cable, and remove and move aside the parking
brake control cable.
c. Remove these 4 fixing bolts of the console middle
connecting plate, and take out the middle
connecting plate assembly.
12. Loosen the throttle cable locking nut, take down

the cable from the pendulum block, and move it
aside.
13. Remove the intake pipe clamp from the canister EG

solenoid valve, disconnect the intake pipeline,
and move the intake hard pipe into an area free
from interference.
14. Remove these 2 clamps, and disconnect the

brake booster vacuum pipe and the crankshaft
positive vent hose as shown in the figure.
15. Press the locking blocks on both sides of the

fuel quick connector, and disconnect the fuel
pipeline from the fuel guide rail.
16. Disconnect the starter connector, remove the

starter positive terminal locking nut, take down
the starter wiring harness and move it aside.
17. Remove the connecting nut between the

exhaust manifold and the exhaust pipe, and
disconnect the exhaust pipe.
EG 18. Remove the engine water outlet pipe clamp, and

disconnect the engine water outlet pipe.
19. Disconnect the ECU connector.
20. Remove the fixing bolt of earthing wire of the

engine wiring harness
21. Remove the fixing bolts of the A/C compressor

eccentric tensioning wheel, and take down the
A/C compressor belt.
22. Remove the fixing bolt of the compressor
assembly, take down the compressor assembly,
and move it into an area free from interference.
Caution
Take down the compressor assembly, store it properly
and prevent the pipeline from being loaded.
23. Install the engine equalizer and fix the engine firmly.
Caution
After the equalizer is installed, check whether the engine is installed firmly.
24. Lift the vehicle and remove the transmission assembly (Refer to “Chapter TR
Transmission and control mechanism -Manual transmission (T15R)–Replacement,
Transmission assembly ” )
25. Remove the air heater water outlet pipe clamp
and disconnect the outlet pipe.
26. Remove the engine water inlet hose clamp, and EG
disconnect the engine water inlet hose.
27. Remove the fixing bolts of the engine lower

bracket on right side of the body.
28. Remove the fixing bolt of the earthing wire on

the exhaust manifold, and move aside the
earthing wiring harness.
29. Remove the fixing bolts of the engine lower
bracket on left side of the body, and take down
the engine lower bracket.
30. Remove all fixing bolts of the engine mounting.
31. Lift the vehicle, have the operator inside the cab to operate the engine equalizer, and
slowly lower the engine assembly.
32. Lower the engine to a certain height, and use the hydraulic lifting assembly to lift and
lower the engine.
Danger
Carefully operate the engine equalizer, hydraulic lifter and hanger, and take care to avoid any
personal injuries in the operation.
33. Use the engine hanger to lower the engine assembly and place it properly.
Caution
• Cautiously lower the powertrain assembly, and pay attention to various parts to avoid
collision and scratching.
• If the engine is yet connected to the remaining parts, timely disconnect or remove them.
• Ensure that the engine hanger, hydraulic lifter and hanger are connected or tied up onto
the powertrain assembly reliably; otherwise the personal injuries may be caused.
34. Connect or tie up the engine onto the hanger reliably, and hoist it onto the hydraulic lifter.
35. Correctly move the hydraulic lifter and the engine assembly onto the body mounting
EG position, operate the hydraulic lifter, and lift the engine to the mounting position.
36. Connect or tie up the engine onto the equalizer reliably, and adjust it to its correct
position.
Danger
Carefully operate the engine equalizer, hydraulic lifter and hanger, and take care to avoid any
personal injuries in the operation.
Caution
• Cautiously hoist the engine assembly, and pay attention to various parts to avoid collision
and scratching.
• If the engine still interferes with the remaining parts, timely disconnect or remove them.
• Ensure that the engine hanger, hydraulic lifter and hanger are connected or tied up onto
the powertrain assembly reliably; otherwise the personal injuries may be caused.
37. Install the engine mounting onto the body

reasonably, install the fixing bolts of the
mounting on both sides and tighten them.
Torque: 40~50N·m
38. Install the engine lower bracket onto the
mounting on both sides, fit the left fixing bolts
and tighten them.
Torque: 21~25N·m
39. Refit the earthing wiring harness onto the
exhaust manifold, fit the fixing bolts and tighten
them.
40. Fit the fixing bolts of the engine lower bracket
on the right side of the body, and tighten them.
Torque: 21~25N·m
41. Fit the engine water inlet hose onto the hard
pipe, and fix the clamp at its proper position.
42. Fit the air heater water outlet hose onto the
engine water inlet pipe, and fix the hoop.
43. Refit the transmission assembly onto the designated positions on the engine and the body. EG
(Refer to “Chapter TR Transmission and control mechanism -Manual transmission
–Replacement, Transmission assembly ” )
44. Lower the vehicle.
45. Remove the engine equalizer.
46. Refit the compressor onto the engine assembly,
fit the fixing bolts and tighten them.
47. Refit the compressor belt onto the correct
position of the gear train, adjust the tensioning
wheel, and tighten bolts.
Caution
After the tensioning wheel is installed, check the
conformity of the tension; if necessary, readjust the
tension.
48. Refit the engine earthing wire onto the frame, fit
the fixing bolts and tighten them.
49. Straighten out the engine ECU wiring harness

and correctly install the wiring harness plug
onto ECU.
50. Refit the engine water outlet hose onto the

water outlet and fix the clamp at its proper
position.
EG 51. Refit the exhaust pipeline onto the exhaust

manifold, fit the fixing nuts and tighten them.
Torque: 22~25N·m
52. Reconnect the oxygen sensor connector.
53. Reconnect the starter connector onto the starter

assembly.
54. Refit the positive terminal wiring harness onto
the terminal, fit the nut and tighten it.
55. Refit the fuel pipeline quick connector onto the

fuel guide rail.
Caution
When installing the connector, a clear click shall be
heard; otherwise it is necessary to check whether the
pipeline connector is connected reliably to avoid
occurrence of any accident.
56. Reconnect the brake booster vacuum pipe onto

the upper connector as shown in the figure, and
reconnect the crankcase positive vent hose
onto the lower connector as shown in the figure.
Install various hose clamps onto their
respective positions.
57. Reconnect the canister solenoid valve hose

onto the fuel steam pipe, and fit the clamp at its
proper position.
58. Reconnect the throttle cable onto the pendulum EG

block, then fit the cable fixer onto the bracket,
and then tighten the nut.
59. Refit the middle connecting plate of the console.

a. Place the console middle connecting plate at
the cab mounting position, fit the fixing bolts
and tighten them.
b. Refit the wiring harness rubber grommet onto
the connecting plate.
c. Refit the parking brake cable, fit the fixing nuts
and tighten them.
60. Refit the air filter assembly and the throttle intake pipe (Refer to “Chapter EG Engine part -
Engine - Intake system -Air filter assembly, Replacement”).
61. Add the coolant. (Refer to “Chapter EG Engine Part - Engine (DAM15R) - Cooling System
- Coolant, Replacement”)
62. Fill the engine oil (Refer to “Chapter EG Engine part - Engine (DAM15R)- Lubricating
system - Change, Engine oil”).
63. Refit the gear shifting mechanism (Refer to "Section TR: Shift and control mechanism -
64. Install the dashboard . (Refer to "Section BW: Vehicle body- Dashboard/ Combination
65. Install the assistant seat. (Refer to Section BW: Vehicle body- Seat- Assistant seat,
Replacement".)
66. Install the driver's seat. (Refer to Section BW: Vehicle body- Seat- Driver's seat,
Replacement".)
67. Connect the negative cable of the battery. (Refer to “Chapter EL Electric System -
Electric Devices - Battery - Battery bracket, Replacement”)
Engine accessories
Overview
The mounting system is used to connect the powertrain assembly and the body. The mounting system
for this vehicle consists of the left mounting assembly, right mounting assembly, rear mounting bracket
and transmission mounting cushion. It is mainly used to support the powertrain assembly, reduce the
influences of powertrain vibration on the vehicle and restrict the dithering of powertrain assembly. It is
very crucial for the NVH performance of the vehicle.
EG
Part Diagram
EG
1 Right suspension bracket 3 Round girder weldment assembly
2 Hexagon flange bolt 4 Left suspension bracket

Replacement
1. Remove the driver's seat. (Refer to Section BW: Vehicle body- Seat- Driver's seat,
Replacement".)
2. Remove the assistant seat. (Refer to Section BW: Vehicle body- Seat- Assistant seat,
Replacement".)
3. Remove the dashboard . (Refer to "Section BW: Vehicle body- Dashboard/ Combination
4. Remove the gear shifting mechanism (Refer to "Section TR: Shift and control mechanism -
EG 5. Remove the middle connecting plate of the console.
6. Install the engine equalizer and fix the engine firmly.
Caution
After the equalizer is installed, check whether the engine is installed firmly.
7. Elevate the vehicle.

8. Remove all fixing bolts of the engine left
mounting, then remove the connecting bolts
between the mounting and the bracket, and take
down the engine left mounting assembly.
9. Remove the fixing bolts of the engine right

mounting on the body.
10. Remove connecting bolts between the
mounting and the bracket, and take down the
engine right mounting assembly.
Danger
Take care to remove the mounting, and prevent the
powertrain assembly from moving, thus to avoid
injuries and damages.
11. Refit the engine right mounting onto the engine
mounting bracket, fit the fixing bolts and tighten
them.
Torque: 40~50N·m
12. Refit the right mounting onto the body, fit the
fixing bolts and tighten them.
Torque: 40~50N·m
13. Refit the left mounting onto the mounting

bracket, fit the connecting bolts and tighten
them.
Torque: 40~50N·m
14. Refit the left mounting onto the body, fit the
fixing bolts and tighten them: 40~50N•m
15. Lower the vehicle. EG

16. Remove the engine eqalizer.
17. Refit the middle connecting plate of the console.
18. Refit the gear shifting mechanism (Refer to "Section TR: Shift and control mechanism -
19. Install the dashboard. (Refer to "Section BW: Vehicle body- Dashboard/ Combination
20. Install the assistant seat. (Refer to Section BW: Vehicle body- Seat- Assistant seat,
Replacement".)
21. Install the driver's seat. (Refer to Section BW: Vehicle body- Seat- Driver's seat,
Replacement".)
Timing toothed pulley, toothed chain

Overview
The engine synchronizing chain is mainly intended to drive the valve gear mechanism of the engine, and
open or close the intake and exhaust valves at the correct time to ensure that the engine cylinder can
intake and exhaust the air normally.
EG
Part Diagram
EG
1 Synchronizing chain assembly 7 Hydraulic tensioner assembly
2 Movable rail sliding groove 8 Tensioner fixing bolt
3 Movable rail pad 9 Fixed rail sliding block
4 Movable rail assembly 10 Fixed rail assembly
Remove the fixing screws of fixed

5 Movable rail fixing pad 11
rail assembly
6 Movable rail fixing bolt

Check and repair

1. Remove the engine assembly (Refer to “Chapter EG Engine part - Engine DAM15R)
(DAM15R) - Engine mechanic part - Replacement, Engine assembly”)
2. Remove the valve chamber casing.
3. Remove the generator assembly (Refer to “Chapter EG Engine part - Engine
(DAM15R)-Starting and charging - Replacement, Generator assembly”)
4. Remove the compressor assembly (Refer to “Chapter EL Electric system - Electric parts -
Air heating and conditioning - Replacement, Air conditioner compressor”)
5. Remove the engine oil pan and oil collector (Refer to “Chapter EG Engine part - Engine
EG DAM15R) (DAM15R) - Lubricating system - Inspection, engine oil pump”)
6. Remove the synchronizing chain casing (Refer to “Chapter EG Engine part - Engine
DAM15R) (DAM15R) - Engine mechanic part - Replacement of synchronizing chain casing,
Synchronizing chain”)
7. Rotate the crankshaft to respectively align the
timing chain wheel “○” mark (2) of the intake
camshaft and exhaust camshaft with the boss
(3) on the cylinder head, and align the woodruff
key (6) of the driving synchronizing chain wheel
with the slot (5) on the cylinder block.
8. Insert the cotter pin into the locking hole on the

automatic tensioner and confirm that there is no
tension.
9. Remove the automatic tensioner bolt and take

down the tensioner. Tool: 10mm socket
10. Check the automatic tensioner.

a. Measure the projection of automatic tensioner
mandril, and if it is non-compliant, replace the
tensioner.
b. Decompose the tensioner, check various parts for EG

wear or damages, and if necessary, replace them.
11. Remove the synchronizing chain.

a. Remove the movable rail assembly (9) bolt, and
take down t he movable rail assembly.
b. Remove these 2 bolts of the fixed rail assembly (4) ,
and take down the fixed rail assembly.
c. Remove the synchronizing chain, and check it for
wear.
d. When servicing a car having a mileage over
50,000km, measure the length of the timing chain,
and if the chain is beyond its service limit, replace it.
Caution
After the timing chain is removed, do not rotate the crankshaft and crankshaft, to avoid mutual
collision between the piston and the valve which may otherwise damage parts.
12. Take down the driving synchronizing chain

wheel.
EG 13. Check the synchronizing chain wheel for wear, damages, broke tooth, deformation and the
like; if any, replace the wheel.
14. Refit the automatic tensioner
a. Screw in the plunger (1) in the direction indicated by
the arrow.
b. Fit one positioning pin (3) to fix the plunger.
15. Refit the driving synchronizing chain wheel.

a. Check whether the mating mark “○” (2) on the
intake and exhaust cam phaser is aligned with the
boss (3) on the cylinder head.
b. Rotate the crankshaft to the position where the
woodruff key (6) is aligned with the slot (5) on the
cylinder block.
c. Refit the driving synchronizing chain wheel, with the
marked side pointing outward.
16. Refit the synchronizing chain assembly.

a. To refit the synchronizing chain assembly, align the
blue chain link (1) on the synchronizing chain with
the triangular mark “△” (2) on the cam phaser chain
wheel.
b. Align the blue chain link (4) on the synchronizing EG

chain with the circular mark “○” (3) on the driving
chain wheel, and refit the synchronizing chain.
Caution
When refitting the timing chain, the timing mark shall
not be moved, and these 3 marking points of the
timing chain shall be mutually aligned with the
camshaft driving wheel and crankshaft driving
synchronizing chain wheel.
17. Refit the fixed rail assembly.
a. Firstly, apply engine lubricating oil onto the sliding
surface of the fixed rail assembly (4), then refit the
fixed rail assembly (4), and tighten these 2 bolts.
Tool: 10mm socket
Torque: 10~12N•m
18. Refit the movable rail assembly.
a. Apply engine lubricating oil onto the sliding surface
of the movable rail assembly (9), then refit the
movable rail assembly (9), and tighten 1 bolt.
Tool: 13mm socket
Torque: 21~25N·m
Caution
In the refitting process, ensure that there is no teeth disorder between the synchronizing chain
assembly and the chain wheel.
19. Check again and ensure the compliance.

a. The triangular mating mark “△” (2) on the cam
phaser shall be fully aligned with the blue chain link
(1) on the synchronizing chain assembly.
b. The mating mark “○” (3) on the driving
synchronizing chain wheel shall be aligned with the
blue chain link (4) on the synchronizing chain
assembly.
EG
20. Refit the tensioner assembly.

a. Refit the tensioner assembly, and tighten these 2
bolts.
b. After the tensioner is installed, remove the
positioning pin, and the plunger will rest against the
movable rail under the spring force to tension the
synchronizing chain.
Tool: 10mm socket
Torque: 10~12N•m
Caution
With the fixed rail chain and the chain between both chain wheels tensioned, swing the movable
rail assembly from side to side, and turn the machine, and the tensioner shall allow for a certain
expansion without getting stuck.
21. Inspection
a. Apply engine oil onto the synchronizing chain, turn the crankshaft clockwise by 2 turns, and check
whether the circular mark “O” on the driven chain wheel is aligned with the convex slot “口” on the
cylinder head and whether the woodruff key is aligned with the concave slot “ 口” on the cylinder
block.
b. After the timing mechanism is refitted, do not have the driven timing chain wheel to drive the
crankshaft, nor reverse the timing mechanism.
22. Refit the synchronizing chain casing (Refer to “Chapter EG Engine part - Engine DAM15R)
(DAM15R) - Engine mechanic part - Replacement of synchronizing chain casing,
23. Refit the engine oil pan and oil collector (Refer to “Chapter EG Engine part - Engine
DAM15R) (DAM15R) - Lubricating system - Inspection, engine oil pump”)
24. Refit the generator assembly (Refer to “Chapter EG Engine part - Engine
25. Refit the compressor assembly (Refer to “Chapter EL Electric system - Electric parts - Air
heating and conditioning - Replacement, Air conditioner compressor”)
26. Refit the valve chamber casing.
27. Refit the engine assembly (Refer to “Chapter EG Engine part - Engine DAM15R) (DAM15R)
- Engine mechanic part - Replacement, Engine assembly”)
Replacement (synchronizing chain casing)

1. Remove the engine assembly (Refer to “Chapter EG Engine part - Engine DAM15R)
(DAM15R) - Engine mechanic part - Replacement, Engine assembly”)
3. Remove the compressor assembly (Refer to “Chapter EL Electric system - Electric parts -
Air heating and conditioning - Replacement, Air conditioner compressor”)
4. Remove the valve chamber casing assembly.
a. Remove the rubber pipe clamp at the PVC valve
EG
(A), and disconnect the PVC rubber pipe assembly
(B).
b. Disconnect the connecting pipeline at (C) from the
valve chamber cover.
c. In the digital sequence shown in the figure (from
both sides to the middle), remove the valve
chamber cover mounting screws starting from the
smallest one.
5. Taken down the valve chamber cover assembly.
a. Remove the valve chamber cover (13) together with
the sealing rubber pad (15) and spark plug sleeve
seal ring (14).
smallest one.
6. Remove the engine oil pan assembly.
a. Remove these 16 bolts of the engine oil pan
assembly.
Tool: 10mm socket
b. Fit two M6 screws having a length over 25mm into

the screw holes as shown in the figure, slowly
increase the force applied, jack the engine oil pan,
and then remove it.
EG 7. Remove the oil collector and rubber grommet

screws (2) and (7), as well as the oil collector
and grommet (8).
Tool: 10mm socket
8. Remove these 4 bolts of the water pump pulley,

and take down the water pump pulley.
Tool: 10mm socket
9. Remove the generator tensioner bolts, and take

down the tensioner.
Tool: 17mm socket
10. Remove the bracket assembly

a. Remove these 2 bolts of the tensioner & bracket
assembly, and take down the tensioner & bracket
assembly and the tensioner.
b. Remove the compressor bracket fixing bolt (25),
and take down the compressor bracket (24).
Tool: 13mm socket
11. Remove the crankshaft pulley screw, and take

down the crankshaft pulley.
Tool: 17mm socket
Caution
After the flywheel disk assembly is locked, remove the
crankshaft pulley with much care, for the screw torque
here is high.
12. Remove the bolts of the synchronizing chain EG

casing.
13. Ensure that after the synchronizing chain bolts

are fully removed, fit two M6 screws having a
length over 16mm into the screw holes as
shown in the figure, slowly increase the force
applied, jack the synchronizing chain casing
and then remove it.
14. Clean the synchronizing chain casing, cylinder block and the sealing surface on the
cylinder head, and clear the engine oil, sealant and dust on the sealing surface.
15. Check the synchronizing chain casing
assembly.
a. Check the oil seal (1) lip for any fault or other
damages. If necessary, replace the oil seal in the
way described below.
b. Use the specialized tool to press the new oil seal (1)
onto the synchronizing chain casing (2).
Caution
• The oil seal end face shall be flush with the
casing end face, with the permissible set-in of
0～0.3mm.
• Before pressing the oil seal, apply lubricating
grease onto the mating surface between the
synchronizing chain casing and the oil seal.
c. Fit a new O-shaped ring (3) onto the engine oil

pump rear cover (4).
EG d. Fit the positioning pin (16) onto the cylinder block.
e. Apply sealant at A on the mounting surface of the

synchronizing chain casing.
Silicone sealant: Loctite 5699 sealant or Beijing
Tianshan 1596 sealant or Keruida MF-G5699 or
Abnen 5998
Specifications for sealant application : Width:
3mm Height: 2mm
f. Check the position (4), and make sure that the rotor
can rotate freely. Apply engine oil onto the oil seal
edge, check (3) to ensure that the synchronizing
chain casing rubber ring is seated in the slot, and
check whether its inner surface is damaged; if
damaged, replace the rubber ring. Then refit the
synchronizing chain casing (1).
16. Refit the bolts of the synchronizing chain
casing.
Tool: 13mm socket
Torque: 21~25N·m
Tool: 17mm socket
Torque: 45~55N·m
17. Refit the crankshaft pulley, and tighten the

crankshaft pulley screw.
18. Refit the tensioner & bracket assembly, and EG

tighten these 2 bolts.
a. Refit the tensioner & bracket assembly, and tighten
these 2 bolts.
b. Refit the compressor bracket assembly, and tighten
these 4 bolts.
Tool: 13mm socket
Torque: 21~25N·m
19. Refit the generator tensioner, and tighten bolts.

Tool: 17mm socket
Torque: 21~25N·m
20. Refit the oil collector.

a. Clean the oil collector strainer.
b. Refit the oil collector. Firstly tighten the oil collector
screw (2), and then tighten the oil collector
supporting screw (7).
Tool: 10mm socket
Torque: 10~12N•m
21. Refit the engine oil pan assembly, and tighten

these 16 bolts of the engine oil pan assembly.
Tool: 10mm socket
Torque: 10~12N•m
22. Refit the valve chamber cover onto the cylinder

head. Tighten the valve chamber casing
mounting screw using the way described below.
a. Tighten the screw to 3～5N·m in the descending
order as shown in the figure (starting from the
middle).
b. Tighten screws to 10 ～ 12N·m in the sequence
specified in Step (a).
c. Refit the PCV rubber pipe assembly (B) onto the
EG PVC valve (A).
d. Refit the ventilating hose assembly at (C).
Caution
• The end marked with a white dot shall be connected to the PVC valve, with the dot pointing
upward, and the other end shall be connected to the intake manifold nozzle.
• The end marked with a white dot shall be connected to the nozzle on the valve chamber
cover casing, and the clamp shall be opened to the engine front end.
24. Refit the compressor assembly (Refer to “Chapter EL Electric system - Electric parts - Air
heating and conditioning - Replacement, Air conditioner compressor”)
Rocker arm, rocker arm shaft, tappet

Overview
The tappet is another major component of the valve train next to the camshaft. The tappet is a follower of
the cam, and is intended to transfer the motion and force from the cam to the push rod or valve, and
receive the lateral force from the cam and transfer it to the engine body or cylinder head.
EG
Check and repair

(B).
EG
smallest one.
2. Use the open-end wrench at the position (5)
shown in the figure to rotate the camshaft
clockwise (viewed from the engine front end) till
the triangular mark on the cam phaser chain
wheel points upward.
3. At the position (1) as shown, mark the chain link

corresponding to the triangular mark, and then
rotate the crankshaft to completely relax the
4. In the sequence as shown, undo the cam

bearing cap screws in the ascending order, and
then remove the cam bearing cap.

down the tensioner.
Tool: 17mm socket
6. Remove the crankshaft pulley screw (5), and EG

take down the crankshaft pulley (4).
Tool: 17mm socket
7. Remove the synchronizing chain casing front
cap screw (1) and the synchronizing chain
casing front cap (2).
8. Remove the tensioner (3) to relax the
9. After the chain is relaxed, slightly pull up the synchronizing chain, raise one camshaft
from the phase wheel end to separate the cam phaser chain wheel from the synchronizing
chain, and then remove the camshaft assembly and camshaft phaser assembly.
Caution
After the camshaft is removed, it is not allowed to rotate the crankshaft separately.
10. Fix the camshaft at the position (7) as shown

using the open-end wrench, then remove the
cam phaser screw (6) and take down the
camshaft phaser.
11. Remove the valve tappet and mark it.

Caution
If it is unnecessary to replace the camshaft, record the
tappet thickness grade corresponding to each tappet
hole, or mark the tappet, in order to ensure the
one-to-one correspondence during removal and
refitting.
12. Check the valve tappet.

a. Check the valve tappet clearance according to the
internal mark of the tappet.
b. Check the tappet internal diameter, and if any
scratch or other damages are found, replace the
valve tappet.
EG 13. Check and clean the valve tappet, and if any pitting corrosion, scratch or damages or any
other defects are found on the tappet, replace the tappet.
Caution
• The valve tappet is a precision part. Its surface shall be free from any dust or foreign
matters.
• There is a mark on the inner surface of the valve tappet. Take care of it in refitting
operation.
• Use clean diesel oil to clean the valve tappet.
14. Use the micrometer to measure the tappet

external diameter.
a. Measure the diameter in three directions, A, B and
C, and record the average value among them.
Standard value: 27.959~27.975mm
b. Use the micrometer to measure the internal
diameter of cylinder head tappet hole.
Standard value: 28~28.021mm
c. Calculate the tappet clearance. If the clearance
exceeds the limit, replace the tappet or the cylinder
head.
Clearance between cylinder head tappet hole and
tappet:
Limit: 0. 1mm
15. Check and clean the valve tappet, and if any
damages are found on the tappet, replace it.
a. Prepare one vessel and the diesel oil. Fill the vessel
with sufficient diesel oil such that the valve tappet
can be fully submerged.
b. Put the tappet in the vessel and clean its external
surface.
Caution
Use a nylon brush to remove any hard adhesion.
16. Refit the valve tappet as marked at removal.

Caution
Apply lubricating oil onto the outer wall of the tappet.
17. Refit the camshaft phaser. EG

Intake phase
Exhaust phase
a. Refit the camshaft phaser and camshaft phaser
wheel
wheel
screw, with the phaser mounting pin aligned with

the pin hole on the camshaft.
b. Align the mark △ on the intake & exhaust side
cam phaser assembly with the marked chain link
respectively according to Steps 2 and 3.
Caution
• The exhaust cam phaser has a return spring,
and it shall not be confused with the intake cam
phaser.
• Apply engine lubricating oil onto the sliding
surface of the camshaft and the camshaft
journal.
18. Check whether the camshaft bearing cap

positioning sleeve (1) is installed properly.
19. Refit the cam bearing cap as marked and in the

specified sequence.
a. I: Intake cam bearing cap.
E: Exhaust cam bearing cap.
b. The third camshaft journal, when counted from the
cam phaser chain wheel end.
c. The arrow points to the cam phaser chain wheel.
20. Apply lubricating oil onto the screws of the cam

bearing cap, and tighten them according to the
digital sequence as shown, in the descending
order.
Tool: 10mm socket
Torque: 10~12N•m
Caution
• Before installation of the camshaft assembly,
ensure that the camshaft hole and camshaft bolt
EG hole are clean and free from aluminum
chippings etc.
• The intake camshaft rear end has a step surface
to accommodate the sensing wheel, while the
exhaust camshaft rear end has a ring slot to
accommodate the sensing wheel. Do not
confuse them.
21. Confirm the valve clearance. Avoid a too large

or too small valve clearance. If there is any
difference, adjust the valve clearance. There is a
mark number on the backside of the valve
tappet. At adjustment, select the tappet with the
correct mark number.
22. Refit the tensioner, and tighten these 2 bolts.

23. Refit the synchronizing chain casing front cap
screw (1) and the synchronizing chain casing
front cap (2).
Tool: 10mm socket
Torque: 10~12N•m
24. Refit the crankshaft pulley (6).

a. Align the key slot on the crankshaft pulley (6) with the woodruff key on the crankshaft, and fit the
pulley onto the crankshaft.
b. Evenly apply the plane sealant onto the sealing slot on the crankshaft pulley (6). Before
application, ensure that the sealing slot surface is dry and clean, and free from scratches.
c. Within 5 minutes after application of sealant, and before the sealant is dried, refit the crankshaft
pulley in place via the woodruff key.
d. Tighten the crankshaft pulley screw (5).
Tool: 17mm socket
Torque: 145~155N·m

Tool: 13mm socket
Torque: 21~25N·m
26. Refit the valve chamber cover onto the cylinder EG

middle).
b. In the sequence specified in Step a, tighten screws
to 10~12N·m.
PVC valve (A).
Camshaft, gear train

Overview
The dual overhead camshaft (DOHC) is a kind of two-camshaft valve arrangement in the cylinder head.
These two camshafts are intended to control the intake valve and exhaust valve respectively, and the
gas distribution using the dual overhead camshaft will be more accurate, in addition to a higher fuel
utilization rate.
EG
Check and repair

(B).
EG
smallest one.
2. Use the open-end wrench at the position (5)
shown in the figure to rotate the camshaft
clockwise (viewed from the engine front end) till
the triangular mark on the cam phaser chain
wheel points upward.
3. At the position (1) as shown, mark the chain link

corresponding to the triangular mark, and then
rotate the crankshaft to completely relax the
4. In the sequence as shown, undo the cam

bearing cap screws in the ascending order, and
then remove the cam bearing cap.

down the tensioner.
Tool : 17mm socket
EG 6. Remove the crankshaft pulley screw (5), and

take down the crankshaft pulley (4).
Tool: 17mm socket
7. Remove the synchronizing chain casing front
cap screw (1) and the synchronizing chain
casing front cap (2).
8. Remove the tensioner (3) to relax the
9. After the chain is relaxed, slightly pull up the synchronizing chain, raise one camshaft
from the phase wheel end to separate the cam phaser chain wheel from the synchronizing
chain, and then remove the camshaft assembly and camshaft phaser assembly.
Caution
After the camshaft is removed, it is not allowed to rotate the crankshaft separately.
10. Check the wear of the camshaft boss.

a. Use the micrometer to measure the camshaft boss
height. If the measured height is lower than its limit
value, replace the camshaft.
Cam height of the camshaft Standard value Limit value
Intake side 45.421~45.581mm 45.32mm
Exhaust side 44.659~44.819mm 44.56mm
11. Check the clearance between the camshaft journal and the cylinder head camshaft hole.
a. Check the camshaft journal and cylinder head cam bearing hole for pitting corrosion, scratch or
damages; if any defect is found, replace the camshaft, or replace both the cylinder head and the
cam bearing cap. It is absolutely not allowed to only replace the cylinder head without replacing
the cam bearing cap.
b. Clean the camshaft bearing hole and camshaft journal.
c. Use the micrometer to measure the camshaft

journal in two directions 1’ and 2’, and record the
average value.
Camshaft journal Standard value
Ⅰ Journal 29.434~29.455mm
Ⅱ~Ⅴ Journal 22.934~22.955mm
Caution EG
“I” is counted from the engine front end (synchronizing chain wheel end).
d. After the camshaft is removed, fit the cam bearing cap onto the cylinder head, and tighten it using
the standard torque.
e. Use the micrometer to measure the cam bearing
hole in three directions A, B and C, and record the
average value.
Camshaft journal Standard value
Ⅰ Journal 32.5~3.515mm
Ⅱ~Ⅴ Journal 23~23.021m
f. Calculate the camshaft journal clearance, and it exceeds the limit, replace the camshaft or the
cylinder head assembly. Camshaft journal clearance:
Standard value Limit value
0.045~0.087mm 0.1mm
12. Check the camshaft bush.

a. Check the bush for pitting corrosion, scratches, wear or damages. If any defect is found, replace
the bush.
13. Refit the camshaft phaser.
a. Refit the camshaft phaser and camshaft phaser
screw, with the phaser mounting pin aligned with
the pin hole on the camshaft.
Torque: 60~70N·m
b. Align the mark △ on the intake & exhaust side
cam phaser assembly with the marked chain link
respectively according to Steps 2 and 3.
14. Check whether the camshaft bearing cap

positioning sleeve (1) is installed properly.
EG 15. Refit the cam bearing cap as marked and in the

specified sequence.
a. I: Intake cam bearing cap.
E: Exhaust cam bearing cap.
b. The third camshaft journal, when counted from the
cam phaser chain wheel end.
c. The arrow points to the cam phaser chain wheel.
16. Apply lubricating oil onto the screws of the cam

bearing cap, and tighten them according to the
digital sequence as shown, in the descending
order.
Tool: 10mm socket
Torque: 10~12N•m
17. Refit the tensioner, and tighten these 2 bolts.

18. Refit the synchronizing chain casing front cap
screw (1) and the synchronizing chain casing
front cap (2).
Tool: 10mm socket
Torque: 10~12N•m
19. Refit the crankshaft pulley.

a. Align the key slot on the crankshaft pulley with the woodruff key on the crankshaft, and fit the
pulley onto the crankshaft.
b. Evenly apply the plane sealant onto the sealing slot on the crankshaft pulley. Before application,
ensure that the sealing slot surface is dry and clean, and free from scratches.
c. Within 5 minutes after application of sealant, and before the sealant is dried, refit the crankshaft
pulley in place via the woodruff key.
d. Tighten the crankshaft pulley screw.
Torque: 150±5N·m

Tool: 13m socket
Torque: 21~25N·m
21. Refit the valve chamber cover onto the cylinder EG

middle).
b. Tighten screws to 10 ～ 12N·m in the sequence
specified in Step (a).
PVC valve (A).
Cylinder head and valves

Overview
The cylinder head is intended to seal the cylinder, constitute a combustion space together with the piston,
and bear the high-temperature & high-pressure fuel gas. The cylinder head bears the gas force and
mechanic load resulted from the tightening of the cylinder bolts, as well as very high thermal load arising
out of contact with the hot fuel gas. To ensure the good sealing of the cylinder, neither damages nor
deformation of the cylinder head can be tolerated. Therefore, the cylinder head shall have sufficient
strength and rigidity. The valve is used to deliver air into the engine and to discharge the exhaust gas
EG after combustion. From the perspective of engine structure, there are intake valves and exhaust valves.
The intake valve is intended to suction air into the engine for mixing with the fuel for combustion, and the
exhaust valve is intended to discharge the exhaust gas after combustion and also to disperse the heat.
Part Diagram
Valve chamber cover
EG
1 Cylinder head assembly 12 Wiring harness bracket
2 Throttling nozzle 13 Wiring harness bracket
3 Camshaft bush 14 Bolt
4 Engine oil dipstick assembly 15 Rubber grommet
5 Bolt 16 Camshaft position sensor (intake)
6 Retaining sleeve 17 Bolt
7 PCV valve assembly 18 Cylinder head screw assembly
8 PCV rubber sleeve 19 Camshaft position sensor (exhaust)
9 Filler cap assembly 20 Valve chamber cover subassembly
10 Bolt 21 Sealing rubber pad
11 Wiring harness bracket

Cylinder head and valves
EG
1 Valve circlip × 32 7 Intake valve ×8
2 Valve spring retainer× 16 8 Exhaust valve ×8
3 Valve spring ×16 9 Throttling nozzle
4 Valve oil seal assembly × 16 10 Cylinder head screw assembly ×10
5 Cylinder liner 11 Retaining sleeve×2
6 Valve spring washer ×16

Inspection and repair of cylinder head

1. Remove the synchronizing chain (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Engine mechanic part - Inspection and repair, Synchronizing chain”)
2. Remove the camshaft (Refer to “Chapter EG Engine part - Engine (DAM15R)- Engine
mechanic part - Inspection and repair, Camshaft”)
3. Remove the valve tappet (Refer to “Chapter EG Engine part - Engine (DAM15R)- Engine
mechanic part - Inspection and repair, Tappet”)
4. Remove these 10 bolts of the cylinder head in
the digital sequence as shown, and take down
the cylinder head. EG
Caution
When undoing the cylinder head bolts, increase the
force applied gradually to have the cylinder head
loaded evenly.
5. Take down and check the cylinder head gasket.

6. Clean the cylinder head subassembly and check the cylinder head for crack or serious
damages; if necessary, replace it.
7. Use the ruler and thickness gauge to check the
planeness of the cylinder head bottom surface.
If any deformation is found, rectify the surface
via grinding (both the cylinder head and
cylinder block need to be ground ) or change
the cylinder head.
Limit of planeness of the bottom surface: 0. 05
(0. 03) mm
Limit of planeness of front end face: 0. 08 (0. 05)
mm
Limit of planeness of exhaust surface: 0. 05 (0.
05) mm
Limit of planeness of intake surface: 0. 05 (0. 05)
mm
8. Check the cylinder head height and if it is non-compliant, replace the cylinder head.
9. Fit a new cylinder head gasket.
Danger
The cylinder gasket must be fitted correctly, and the hole on the cylinder gasket must be aligned
with the hole on the upper plane of the cylinder block; otherwise it may cause serious damages
of the engine.
10. Refit the cylinder head subassembly.

Caution
The positioning pin can only fix the cylinder head subassembly after it is correctly installed.
11. Use the micrometer caliper to measure the

thread diameter at the cylinder head bolts A and
B. Then calculate the different between these
two diameter values (B-A). If the difference
Cylinder head exceeds the limit, replace the cylinder head
screw
screw assembly. Limit of diameter difference of
cylinder head bolt: 0. 2mm
Micrometer caliper
EG 12. Tighten the cylinder head screw assembly using

the way described below.
a. Apply engine oil into the cylinder head screw
assembly.
b. Tighten the cylinder head bolt to 20±1N·m at the
revolution of 20rpm in the ascending digital
sequence (1～10).
c. Tighten the bolt to 40±1N·m at the revolution of
8rpm in the sequence indicated in the previous
step.
d. Rotate the bolt by 60° at the revolution of 8rpm in
the sequence indicated in the previous step.
e. Repeat the procedure of (d), and rotate the bolt by
another 60°.
Caution
• To facilitate tightening, apply engine oil onto the cylinder head bolt threads and the
washer.
• If the bolt is excessively tightened, fully loosen the bolt and then tighten it again.
13. Refit the valve tappet (Refer to “Chapter EG Engine part - Engine (DAM15R)- Engine
mechanic part - Inspection and repair, Tappet”)
14. Refit the camshaft (Refer to “Chapter EG Engine part - Engine (DAM15R)- Engine mechanic
part - Inspection and repair, Camshaft”)
15. Refit the synchronizing chain (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Engine mechanic part - Inspection and repair, Synchronizing chain”)
Inspection and repair of valves

1. Remove the cylinder head (Refer to “Chapter EG Engine part - Engine (DAM15R)- Engine
mechanic part - Inspection and repair, of cylinder head, Cylinder head & valves”)
Caution
Hang tags, indicating the cylinder number and mounting position, onto the valve, valve spring
and other parts, and keep them under good conditions to facilitate the correct refitting.
2. Use tools to remove the valve lock spring, and

take down the valve spring upper seat, valve
EG
spring and valve spring gasket respectively.
3. Remove the valve oil seal and take down the

valve.
Caution
Repeated use of the valve oil seal is prohibited.
4. Check the valve spring

a. Check the free height of the valve spring; if it is
lower than the limit value, replace the spring.
Limit value: 39.08mm
b. Compress the valve spring to 29.9mm, and then
measure the valve spring pre-tightening torque.
Standard pre-tightening torque of the valve
spring: 110~126N•m
5. Check the valve
a. Check whether the valve working surface is in good contact with the valve sea; if the contact is
poor, polish the valve using the polishing machine. The valve seat contact surface must be
consistent with the center of the valve working surface.
b. Use the micrometer to measure the diameter of the

valve stem and guide sleeve, and check the
clearance between t he valve stem and the guide
sleeve. Readings at a multiple of positions between
each valve stem and the valve guide sleeve must
be taken.
Clearance between valve stem and valve guide
sleeve:
EG 6. Check the valve appearance.

a. Check the valve appearance.
b. Remove all carbon on the valve.
c. Check the surface of each valve and the end of valve stem for wear, burn marks or deformation; if
necessary, replace the valve.
7. Check the valve for leakage.
a. Remove the intake and exhaust manifolds and other peripheral parts of the cylinder head, except
for the intake valve and exhaust valve. Fit the valve spring, valve spring seat, valve spring washer
and valve circlip.
b. Pour the kerosene into the intake passages of cylinders Nos.1, 2, 3 and 4 and the exhaust
passages of cylinders Nos.1, 2, 3 and 4, and check the sealing conditions of valves and valve
seats of all cylinders.
c. In the case of any leakage, replace the valve and use the valve seat reamer to polish the valve
seat, as appropriate, till no leakage occurs, and if necessary, replace the cylinder head.
8. To replace the valve guide pipe, use the inside micrometer to measure the diameter of the
valve guide pipe, and if it is non-compliant, execute following steps:
Bore diameter of valve guide pipe: (enlarged, altogether 6 levels, 0.05 for each)
Caution
The valve guide pipe which has the same size with the removed valve guide pipe shall not be
used.
a. Heat the cylinder head and take down the valve seat.
b. Use the tool to press out the valve guide pipe toward the cylinder head lower plane.
c. Process the valve guide pipe hole on the cylinder head to have the hole diameter suitable for the
valve guide pipe of an increased size.
d. Fit a new valve guide pipe, press down the guide
pipe from the cylinder head top surface till its
projection is satisfactory.
Caution
• Press down the valve guide pipe from the top
surface of the cylinder head.
• The length of intake valve guide pipe is different
from that of the exhaust valve guide pipe.
9. Assemble the valve, and measure the projection height of the valve stem between the
valve stem end and the valve spring seat face.
10. Refinish the valve seat.
a. Before refinishing the valve seat, check the clearance between the valve guide pipe and the valve
stem, and if necessary, refinish the seat after the valve guide pipe is replaced.
b. Use the polishing machine to rectify the valve seat width and angle to specified values.
c. After the valve seat is refinished, use the polishing paste to polish the valve and valve seat in
pairs. Then check the projection height of the valve stem.
11. Refit the valves as marked at removal.
12. Refit the valve spring gasket. EG
13. Use the tools to fit a new valve oil seal.
14. Refit the valve spring (when installing the valve spring, note that the color-marked end
shall point to the valve spring upper seat).
15. Refit the valve spring upper seat.
16. Use the tools to refit the valve clamp.
17. Refit the cylinder head (Refer to “Chapter EG Engine part - Engine (DAM15R)- Engine
mechanic part - Inspection and repair, of cylinder head, Cylinder head & valves”)
Piston and connecting rod

Overview
The piston connecting rod unit is intended to transform the reciprocating motion of the piston into the
rotational motion of the crankshaft, and also transform the force acting upon the piston into the output
torque of the crankshaft to drive the vehicle wheels to rotate. It belongs to the engine transmission
system, designed to transfer the pressure of the combustion gas to the crankshaft to rotate it and output
power. The piston connecting rod unit mainly comprises the piston, piston ring, piston pin, connecting
rod and connecting rod bush.
EG
Part Diagram
EG
1 First piston ring 7 Connecting rod bush
2 Second piston ring 8 Connecting rod bush
3 Piston oil ring assembly 9 Connecting rod nut X2
4 Piston pin circlip ><2 10 Connecting rod cover
5 Piston 11 Piston pin
6 Connecting rod
Check and repair

1. Mark the cylinder number on the side face of the
connecting rod big end to ensure the correct
refitting.
Caution
Place the connecting rod, connecting rod cover and
connecting rod bearing in the sequence of cylinder
number to avoid confusion at refitting.
EG
2. Remove these 8 bolts of the connecting rod
cover in the digital sequence as shown.
Tool: 12mm socket
3. Use a wooden or plastic stick to knock out the

piston and the connecting rod assembly.
4. Use a special tool to remove the piston pin.

Caution
Place the piston, piston pin and connecting rod in the
sequence of cylinder number to avoid confusion at
refitting.
a. Use a special tool to remove pins at both ends of
the piston.
b. With the piston forward-pointing mark upward, fit
the piston connecting rod unit onto the base of the
piston pin installer.
c. Press out the piston pin under the pressure.
5. Remove the first gas ring, second gas ring and EG

oil ring.
Caution
• Remove the carbon on the piston surface and in
the gas ring, and clear the oil in the oil ring.
• Take care not to scratch the piston surface.
6. Check appearance of the piston.

a. Check the piston ring for damages, excessive wear and breakage, and if any, replace it. If the
piston is to be replaced, the piston ring must be also replaced.
b. The piston top is marked. The digital or color represents the piston skirt dimension grade, and the
letter represents the piston weight grade. One engine must be provided with pistons of the same
weight grade.
Piston weight grading Piston dimension grading
A, B or E, F 1, 2 or yellow (Grade 1), blue (Grade 2)
7. Check the lateral clearance between the piston

ring and the piston ring groove. If the clearance
is too large, replace the piston ring, or replace
the piston and piston ring.
Standard value
of clearance
between piston Limit value
ring and piston
ring groove
First ring 0.03-0.07 5mm 0.12mm
Second ring 0.03〜0.07 mm 0.1mm
Oil ring 0.04〜0.16 mm
8. Insert the piston ring into the cylinder, and

measure the clearance using the thickness
gauge. If the clearance is out of tolerance,
replace the piston ring. Before inserting the
piston ring, clean the cylinder bore and piston
ring, and remove the deposit carbon. Piston ring
end clearance:
Item Criteria Limit
First ring 0.15~0.30mm 0.7mm

EG Piston ring
end Second ring 0.35~0.50mm 1.0mm
clearance
Oil ring 0.20~0.70mm 1.2mm
9. Measure the clearance between piston and cylinder which is obtained by calculating the
difference between the cylinder barrel diameter and the piston diameter. The clearance
between piston and cylinder shall be within the specified range given below.
Standard value Limit value
Clearance between piston and

0.025~0.045mm 0.085mm
cylinder
10. Check the clearance of piston pin

a. Check the clearance between the piston pin and the connecting rod small end hole. If the
connecting rod small end hole is seriously worn or damaged, or the measured clearance is out of
tolerance, replace the connecting rod.
Item Criteria Limit
Clearance of piston pin 0.003~0.015mm 0.05mm
Bore diameter of connecting rod

18.003~18.011mm -
small end
Piston pin bore diameter 18.006~18.012mm -
Piston pin diameter 17.996~18.000mm -
11. Check the connecting rod

a. Axial clearance of connecting rod big end.
Item Criteria Limit
Axial lateral clearance of big end 0.15~0.35mm 0.4mm

b. Check the connecting rod screw. If the connecting

rod is further used, check whether the connecting
rod screw is damaged, and if damaged, replace the
connecting rod.
Caution
After the connecting rod bolt is pressed into the bolt
hole, it shall not be detached from the connecting rod
body.
12. Check the connecting rod bush. EG

a. Check the bush for fusion, cave-in, ablation and scaling, and observe the contact way. If the
connecting rod bush is defective, it must be replaced.
Item Criteria Limit
Clearance of connecting rod

0.039~0.065mm 0.075mm
bush
b. Clearance of connecting rod bush

Tighten the connecting rod with bush to the
standard torque, measure the connecting rod big
end hole diameter A and the connecting rod journal
B, and calculate the clearance A-B. If the clearance
is out of limit, fit a new bush of a standard size, and
measure the said clearance again. If this clearance
remains out of limit, use the bush of a higher
thickness grade.
13. If the connecting rod bush is under poor conditions or the bush clearance is out of limit,
select a new bush in accordance with the following procedure.
a. Firstly, check the diameter of the connecting rod journal in accordance with following procedure.
The fourth crank has 4 digits which represent the size grade of the first to fourth crankshaft
connecting rod journals.
Digital mark Crankshaft connecting rod journal diameter
1 41.994-42.000mm
2 41.988-41.994mm
3 41.982〜41 .988mm
b. Thereafter, check the connecting rod big end hole diameter without connecting rod bush. Digitals
and letters are marked on the intake side of the connecting rod big end. The digitals represent the
connecting rod bearing hole size grade, while the letters represent the connecting rod weight
grade.
Digital mark Connecting rod big end diameter
1 45.000〜45.006mm
2 45.006〜45.012mm
3 45.012〜45.018mm
Caution
The weight grade of connecting rods of the same engine must be identical.
14. Use a plastic wire clearance gauge to measure

the oil clearance of the crankpin.
a. Remove the engine oil on the connecting rod
journal and the connecting rod bearing.
b. Cut the plastic wire clearance gauge into the length
equal to the bearing width, and put it on the
EG crankpin such that it is parallel with the shaft central
line.
c. Fit the connecting rod cap carefully and tighten the
nut to the specified torque.
d. Remove the connecting rod cap with much care.
e. Measure the width of the widest part of the flattened
plastic wire using the measuring scale printed on
the package of the plastic wire clearance gauge,
and calculate the clearance value.
15. Refit the piston pin.

a. Assemble the pin with the piston forward-pointing mark and connecting rod forward-pointing mark
in the same direction.
b. Apply engine oil onto the outer diameter of the piston pin.
c. Insert the piston pin, pressure rod and guide pipe unit into the piston pin hole from the
forward-pointing side.
d. With the piston forward-pointing mark upward, fit
the piston connecting rod unit onto the base of the
piston pin installer, and press it into the piston pin.
e. Refit the snap pins on both sides of the piston pin.
16. After the piston pin is installed, check whether

the free movement between the piston and
connecting rod is allowed.
17. Refit the oil ring. EG

Caution
Either face of the oil ring scraper and main ring can be
top or bottom surface.
a. Put in the upper scraper. When installing the

scraper, press one end of the scraper into the piston
oil ring groove, and then press the remaining part of
the scraper into the oil ring groove using the thumb.
Caution
It is not allowed to install the oil ring scraper using the
piston ring pliers, for the scraper may be broken if it is
expanded using the piston ring pliers.
b. It is not allowed to install the oil ring scraper using
the piston ring pliers, for the scraper may be broken
if it is expanded using the piston ring pliers.
c. Check whether the installed oil ring can move
freely.
18. Refit the first gas ring and second gas ring.
a. Use the piston ring pliers to fit the second gas ring,
and then the first one.
Caution
When installing piston rings, keep in mind that the
marks must face upward and point to the piston top.
b. The identification marks are provided at the gas ring

open end: first gas ring: A1; second gas ring: A2.
EG 19. Adjust the opening direction of the gas ring and

oil ring (apply clean engine oil onto the piston
ring groove, gas ring and oil ring).
a. Adjust the opening position of the gas ring and oil
ring to the position as shown in the figure.
1 Opening of oil ring upper scraper
2 Position of piston pin
3 Opening of oil ring lower scraper
4 Opening of lining ring and second gas ring
5 Opening of first gas ring
6 Crankshaft pulley side
20. Rotate the crankshaft to locate the crankpin at the cylinder middle.
21. Before inserting the piston and connecting rod unit into the cylinder block, apply
appropriate thread protection onto the connecting rod bolt. Take care not to damage the
crankpin.
22. When installing the piston and connecting rod
Valve pit assembly, ensure that the manufacturer’s mark
printed on the connecting rod points to the
Engine intake end
engine front end, and the piston top pit or arrow
Fuel injection
orifice mark points to the engine front end, with the
Engine front
connecting rod injection hole pointing to the

Engine rear
end
end
engine intake side.

23. Use a proper piston ring compression tool to fit

the piston and connecting rod assembly.
Caution
• When installing the piston and connecting rod
assembly into the cylinder, avoid damages of
the crankpin due to collision with the
connecting rod cap bolt.
• When installing the piston and connecting rod
assembly, use a wooden or plastic tool to lightly
press the assembly, but never press it EG
downward forcibly; otherwise it may cause
breakage of the piston ring or crankpin.
24. Refit the connecting rod cap against the

assembly marks provided in the course of
breakdown.
a. If the connecting rod is a new product and is
provided with no assembly mark, then the grooves
on both the upper connecting rod bearing and the
lower connecting rod bearing shall be located on
the same side, as shown in the figure below.
25. Use the thickness gauge to measure the axial

clearance of the connecting rod big end.
26. Refit the connecting rod nut.

a. The connecting rod bolts and nuts shall be tightened using the plastic zone tightening method.
Before reusing this bolt, check whether the bolt is tensioned.
b. Before tightening the nut, apply engine oil onto the nut threads and seat face.
c. Use the finger to tighten the nut onto the bolt, and then alternatively tighten nut to correctly fit the
connecting rod cap.
d. Tighten the connecting rod nut.
Tool: 12mm socket
Torque: 37±3N·m
Crankshaft and flywheel

Overview
The crankshaft is the most important component of the engine. It receives the force from the connecting
rod, transforms it into the torque and output it to drive other accessories of the engine. The crankshaft is
intended to bear the bending torque under the centrifugal force of the rotating mass, periodical gas
inertia and reciprocating inertial force. Therefore, the crankshaft is required to have sufficient strength
and rigidity, and the journal surface must be wear-resistant, and provided with sound uniformity and
balance in operation. The flywheel is fitted at rear end of the engine, and is provided with rotational
EG inertia. It is intended to store the engine energy and overcome the resistance of other components to
enable the crankshaft to rotate uniformly, to connect the engine to the vehicle transmission system via
the clutch on the flywheel, and to start the engine through engagement with the latter.
Part Diagram
EG
1 Main bearing cap screw ×10 11 Clutch driven plate assembly
Clutch pressure plate & shell

2 Main bearing cap ×5 12
assembly
3 Lower main bearing bush ×5 13 Screw assembly X 6
4 Woodruff key 14 Flywheel disk screw ×6
5 Upper main bearing bush ×5 15 Locating pin ×3
6 Retaining sleeve 16 Flywheel disk & gear ring assembly
7 Pin 17 Pin
8 Crankshaft rear oil seal cover 18 Crankshaft
9 Crankshaft rear oil seal assembly 19 Cylinder block
10 Bolt
Check and repair

1. Remove these 6 bolts of the flywheel in the
digital sequence and take down the flywheel.
Tool: 13mm socket
EG
2. Remove these 6 bolts of the crankshaft rear seal
and take down the crankshaft rear oil seal bolt.
Tool: 10mm socket
3. Remove these 10 bolts of the crankshaft main

bearing cap in the digital sequence, and take
down the crankshaft.
Tool: 15mm socket
4. Take down the crankshaft, and use the

micrometer gauge to measure the middle
runouts of various main journals. Slowly rotate
the crankshaft. If the runout is out of limit,
replace the crankshaft.
Limit of runout: 0.04mm
5. Check the axial movement of crankshaft.

a. Refit the crankshaft, and tighten the main bearing
cap screw as required.
b. Use the micrometer gauge to measure the axial
movement of the crankshaft.
c. If out of limit, replace the thrust gasket.
d. If, with a new thrust plate, the clearance remains
out of limit, replace the crankshaft.
Item Criteria Limit
EG
Axial movement
0.11~0.3mm 0.35mm
of crankshaft
Thickness of
2.470~2.520mm -
thrust plate
6. Check the roundness and conicity of the main journal.
a. The uneven wear of the main journal may result in diameter deviation of the cross section or the
diameter deviation of other parts. Such deviation can be measured using the micrometer.
b. If any main journal is seriously or unevenly worn to exceed the limits, the crankshaft shall be
replaced.
Limits of roundness and conicity: 0. 009 mm
7. Check the appearance of the main bush.
a. Check the bus for pitting corrosion, scratches, wear or damages. If any defect is found, replace
both upper and lower bushes (it is not allowed to replace only one bush).
b. If any main journal is seriously or unevenly worn to exceed the limits, the crankshaft shall be
replaced.
8. Check the main bush clearance:
a. Before checking the main bush clearance, clean the
main bush, crankshaft and cylinder block.
b. Tighten the connecting rod with bush to the
standard torque, measure the main shaft hole
diameter A.
c. Measure the main journal diameter B.
d. Calculate the clearance A-B. If the clearance is out
of limit, fit a new bush of a standard size, and
measure the said clearance again.
e. If, with a new standard bush, this clearance remains
out of limit, use the bush of a higher thickness
grade.
Main bush Criteria Limit

clearance
0.026~0.0 46mm 0.056mm
9. If the main bush is under poor conditions or the bush clearance is out of limit, select a new
bush in accordance with the following procedure.
a. Firstly, check the diameter of the main journal in accordance with following procedure. As shown
in the figure, the fifth crank has 5 digits which represent the size grades of the first to fifth main
journals.
b. There are 3 grades (“1”, “2” and “3”) and they represent the following main journal diameters
respectively:
Digital mark Main journal diameter
1 48.000~48.006mm
EG
2 47.994~48.000mm
3 47.988~47.994mm
c. Next, check the main bearing hole diameter without bush. 5 digits are marked on intake side of
lower end face of the cylinder block. There are 3 grades (“1”, “2” and “3”) and they represent the
following main bearing hole diameters respectively.
Digital mark Main bearing hole diameter (without bush )
1 52.000~52.006mm
2 52.006~52.012mm
3 52.012~52.018mm
d. The main bush has 5 grades depending on its

thickness. The grade marks are located on back
side of the bush, as shown in the figure. Each grade
digital mark listed in the table below represents the
central thickness of the main bush.
Grading criteria Main bush thickness
5 1.990~1.994mm
4 1.993~1.997mm
3 1.996~2.00mm
2 1.999~2.003mm
1 2.002~2.006mm
e. Determine the grade of the new main bush in accordance with the digits marked on the 3rd
cylinder crank and the main bearing hole grade digit marked on the cylinder block as shown in the
table below. For example, given the digit “1” on the crank and the digit “2” on the cylinder block, a
grade 4 main bush shall be selected.
Digital mark on the crank (main journal diameter)
1 2 3
1 5 4 3
Digital mark on the
mating surface 2 4 3 2
(main bearing hole
diameter) 3 3 2 1
10. Refit the thrust bearing in accordance with

following procedure. EG
a. Fit the grooved bearing on the cylinder block side.
b. Fit the non-grooved bearing on the main bearing
cap side.
c. Fit the crankshaft thrust bearing at the 3rd main
bearing hole of the cylinder block. To facilitate the
installation, apply a little of engine oil onto the thrust
bearing surface.
11. Refit the crankshaft main bearing cap bolt in
accordance with following procedure.
a. Before tightening the crankshaft main bearing cap
bolt, measure the bolt length.
b. Apply a little of engine oil onto the thread parts and
seat face of the bolt.
c. Tighten these ten bolts of the crankshaft main

bearing cap in the digital sequence.
Tool: 15mm socket
Torque: 65±3N·m
12. After the crankshaft main bearing cap is

installed, check whether the crankshaft can
rotate freely and check whether the axial
clearance conforms to standard value.
13. Refit the crankshaft rear end cap to the correct

position and tighten these 6 bolts.
Tool: 10mm socket
Torque: 10~12N•m
Caution
• Remove foreign matters on the rear end cap
before refitting it, and take care not to scratch
the contact surface.
• Apply sealant onto the oil seal cap contact
EG surface.
• Quickly install the rear end cap before the
sealant is dried (≤15 minutes).
• After refitting, keep the sealing zone far from t
he lubricating oil and coolant for about 1h.
14. Refit the flywheel in place, and tighten these 6

bolts in the digital sequence.
Tool: 13mm socket
Torque: 82~87N·m
Cylinder block, flywheel housing

Part Diagram
EG
1 Cylinder block assembly 10 Retaining sleeve
2 Main bearing ca 11 Wiring harness bracket
3 Retaining sleeve 12 Pin
4 Main bearing cap screw 13 Bolt
5 Engine oil filter adapter gasket 14 Knock sensor
6 Oil filter pipe nozzle 15 Oil pressure sensor assembly
7 Engine oil filter adapter assembly 16 Oil injection nozzle
8 Engine oil filter assembly 17 Compressor bracket
9 Screw 18 Screw
Check and repair

1. Remove these 6 bolts of the flywheel in the
digital sequence and take down the flywheel.
Tool: 13mm socket
EG
2. Remove these 6 bolts of the crankshaft rear seal

and take down the crankshaft rear oil seal bolt.
Tool: 10mm socket
3. Remove these 10 bolts of the crankshaft main

bearing cap in the digital sequence, and take
down the crankshaft.
Tool: 15mm socket
4. Remove the crankshaft, and use the plastic gauge to measure the crankshaft oil film
clearance.
a. Evaluate the cylindricity of the main journal and
connecting rod journal by measuring diameters at
different points on the same profile and diameters at
different points in the length direction and
calculating their difference. This cylindricity can
reflect the uneven wear of the crankshaft. If any
journal is seriously or unevenly worn to exceed the
cylindricity limit, the journal shall be ground or the
crankshaft shall be replaced.
Imit of crankshaft main journal cylindricity: 0.
007 (0. 005) mm
b. Refit the crankshaft.

c. Cut off a piece of plastic gauge material having a
equal length to the bearing width, and place it on
the crankshaft journal in parallel with the latter.
d. Carefully refit the crankshaft main bearing cap and
tighten the bolt to the tightening torque.
e. Remove fixing bolts of the crankshaft main bearing
cap and take down the crankshaft main bearing cap
with much care.
f. Measure the flattened part of the plastic gauge EG
material using the measuring scale printed on the
plastic gauge package.
5. Check the cylinder block assembly
a. Visually check the cylinder block for scratches, rusting and other corrosion signs, or use the flaw
detection agent to check for cracking. If there is an obvious defect, repair or replace the cylinder
block.
b. Use the testing panel and thickness gauge to
measure the planeness of the top plane, bottom
plane and front end face of the cylinder block, and
make sure that no gasket chippings and foreign
matters are left on the surface.
Limit of planeness of the top plane: 0.05 (0.03)
mm
Limit of planeness of the front end face and
bottom plane: 0.08 (0.05) mm
c. If the planeness of the top surface of the cylinder
block is too large, rectify or replace the cylinder
block.
d. Check the cylinder wall for scratches or other
damages. If the scratch is noticeable, rectify or
replace the cylinder wall.
e. Use the cylinder gauge to check the cylinder bore
diameer and cylindricity. If the cylinder is seriously
worn, rectify the cylinder to a higher size and
replace the piston and piston ring to a suitable new
size.
Cylinder bore Standard
Item
inner diameter value (M)
Cylinder bore 69.7 (+0.01/ 8.5 (+0.01/

inner diameter +0.02) mm +0.02) mm
f. Measure the outer diameter of the piston to be used

in the direction of thrust as shown in the figure.
g. Calculate the reboring size of the cylinder bore
according to the measured outer diameter of the
piston. Reboring size = piston outer diameter +
(clearance between piston and cylinder) - 0.02mm
(honing size)
EG Caution
If reboring is required, all four cylinders must be rebored to the same size.
h. Rebore all cylinder bores to the required reboring size.

Caution
When reboring the cylinder, to avoid any error due to temperature rise, execute following
processing procedure: No. 2→No. 4→No. 1→No. 3
i. Hone the cylinder to the final cylinder bore (piston bore diameter + clearance between piston and
cylinder ).
j. Check the clearance between piston and cylinder.
6. Refit the thrust bearing in accordance with
following procedure.
a. Fit the grooved bearing on the cylinder block side.
b. Fit the non-grooved bearing on the main bearing
cap side.
c. Fit the crankshaft thrust bearing at the 3rd main
bearing hole of the cylinder block. To facilitate the
installation, apply a little of engine oil onto the thrust
bearing surface.
7. Refit the crankshaft main bearing cap bolt in
accordance with following procedure.
a. Before tightening the crankshaft main bearing cap
bolt, measure the bolt length.
b. Apply a little of engine oil onto the thread parts and
seat face of the bolt.
c. Tighten these ten bolts of the crankshaft main

bearing cap in the digital sequence.
Tool: 15mm socket
Torque: 65±3N·m
8. After the crankshaft main bearing cap is

EG
installed, check whether the crankshaft can
rotate freely and check whether the axial
clearance conforms to standard value.
9. Refit the crankshaft rear end cap to the correct

position and tighten these 6 bolts.
Tool: 10mm socket
Torque: 10±2N·m
Caution
• Remove foreign matters on the rear end cap before refitting it, and take care not to scratch
the contact surface.
• Apply sealant onto the oil seal cap contact surface.
• Quickly install the rear end cap before the sealant is dried (≤15 minutes).
• After refitting, keep the sealing zone far from t he lubricating oil and coolant for about 1h.
10. Refit the flywheel in place, and tighten these 6

bolts in the digital sequence.
Tool: 13mm socket
Torque: 55±5N·m
Fuel system
Fuel system
Overview
The fuel system comprises the electronic gasoline injection system, fuel supply system (fuel tank,
gasoline filter, electric fuel pump, canister, fuel pipe and other auxiliary devices). When demanded by the
engine working conditions, the fuel system will supply a certain quantity of clean and well-atomized
gasoline into the engine for mixing with a certain quantity of air to produce a flammable gas mixture.
Meanwhile, the fuel system also requires the storage of a considerable quantity of gasoline to ensure a
EG
very long driving range of the vehicle.
• The filler of this vehicle is located on the right rear side of the vehicle, and the fuel is filled
into the fuel tank via the filler. At ignition, the fuel will be supercharged via the fuel pump,
constantly pumped into the fuel pipeline, and after being filtered by the filter to remove
impurities, delivered into the fuel rail, and finally injected into the cylinder via the injector
to ignite the engine. When the car is running or stopped, the gasoline steam in the fuel
tank will go to the upper portion of the charcoal canister via the pipeline, while the fresh air
will enter into the charcoal canister via the lower portion of the charcoal canister.
• Activated carbon canister After the engine is shut down, the gasoline steam will be mixed
with the fresh air in the canister and the mixture will stay in the canister. After the engine is
started, the electromagnetic valve of the fuel evaporation purifier between the charcoal
canister and the intake manifold will be opened, and in this way, the gasoline steam in the
canister will be suctioned into the intake manifold to take part in the combustion.
Part Diagram
EG
1 Fuel tank assembly 6 Filler hose
2 Filler vent hose 2 7 Fuel tank rear fixing strap assembly
3 Fuel tank filler 8 Gasoline filter bracket
4 Filler vent hose 1 9 Canister bracket
5 Fuel tank body

EG
10 Gasoline filter 15 Vent hose from canister to engine
11 Front fuel delivery pipe assembly 16 Canister assembly
Gasoline filter - engine fuel delivery

12 17 Wiring harness clamp
pipe assembly
13 Electric fuel pump assembly 18 Vent hose
14 Vent hose from hard pipe to canister 19 Double pipe clamp

Precautions
1. Before inspection and servicing of fuel system, disconnect the battery negative cable.
2. When removing the fuel pipeline, use a proper vessel to receive the discharged fuel.
3. The fuel is flammable. The fuel system can be operated only after the vehicle parts are
cooled down to the ambient temperature, and the cigarette, flame, indicator lamps, electric
arc equipment and switches shall be kept far from the working area. The working area
shall be also equipped with ventilation device to avoid personal injuries or even death.
4. The fuel pump high-pressure fuel pipeline and fuel rail contain high-pressure fuel. To
avoid personal injuries, never loosen any fuel pipe joint when the engine is running.
5. Keep the fuel far from the rubber or leather parts. EG
6. After the engine is shut down, the residual fuel pressure in the fuel system will last for a
long period of time. Before servicing the fuel system, the fuel pressure must be released.
Failure to comply with such requirements may lead to injuries.
7. Before disconnecting the fuel system pipeline, check the fuel pipe joint area for dirt or
foreign matters; if any, remove them, for the dirt or foreign matters may damage the fuel
system or engine.
8. Avoid the contact between the cleaner and the fuel system rubber or plastic seals, for the
cleaner may damage the fuel system.
9. Do not bend or distort the fuel system pipe forcibly.
10. Before reconnecting various pipelines of the fuel system, ensure that the pipe joint is not
damaged. If damaged or cracked, replace the fuel pipe assembly and ensure that the pipe
connection surface is clean.
Release of the fuel system pressure

1. Turn off the ignition switch.
2. Open the cover of the engine.
3. Remove the fuel pump fuse in the fuse box ( the
fuse box is located on left side in the engine
compartment).
EG
4. Start the engine and keep it running at the idle speed till it is shut down.
5. Restart the engine, wait for 5s, and confirm that the pressure in the fuel injector is fully
released.
6. Turn off the ignition switch, and insert the fuel pump fuse.
7. Close the engine hood.
Empting of fuel tank/ cleaning of fuel pipeline

1. Check the fuel level on the fuel gauge.
2. Empty the fuel tank.
a. Turn off the ignition switch.
b. Insert the hose with a diameter smaller than that of the filler into the fuel filler pipe via the filler,
and extract fuel from the filler pipe.
c. Fully discharge the fuel in the filler pipe, and disconnect the filler pipe from the fuel tank inlet pipe.
d. Insert the hose into the fuel tank via the inlet pipe nozzle to extract fuel.
3. Use the fuel system cleaner approved by Foton to clean the fuel system.
EG
4. Use the fuel additive approved by Foton to clean the fuel system.

The table below can assist you to find the failure. The number represents the sequence of occurrence of
possible failures. Check each part as per this sequence, and provide replacement if necessary.
Fault symptom Cause Troubleshooting
“Chapter EG Engine part - Engine (DAM

1. Electric fuel pump (damaged) 15R)- Fuel system -Replacement, Electric
fuel pump”)
“Chapter EG Engine part - Engine

2. Fuel pipeline (clogged) (DAM15R)- Fuel system -Empting of fuel
EG
tank/ cleaning of fuel pipeline, Fuel system”
The engine can’t be 3. The fuel pressure regulator is

started damaged (the fuel pressure is Replacement
too low)
4. Fuel tank (no fuel) Add fuel
5. Fuel pump relay (damaged) Replacement

6. Fuel injector (damaged) (DAM15R)- Fuel system -Replacement,
Fuel rail assembly”)
1. Fuel pipe pipeline (clogged) Clean the fuel pipeline
2. The fuel pressure regulator is “Chapter EG Engine part - Engine

inoperative (the fuel pressure is (DAM15)- Fuel system -Replacement,
too low) Electric fuel pump”)

3. Injector (oil leakage or
(DAM15R)- Fuel system -Replacement,
clogging)
Fuel injector”
Difficult start of the
engine “Chapter EG Engine part - Engine (DAM
4. Electric fuel pump (poor
15)- Fuel system -Replacement, Electric
operation)
fuel pump”)
5. Injection control system

-
(faulted)
6. Fuel pressure regulator return

valve port or fuel pump check -
valve (leakage)
1. The fuel pressure regulator is “Chapter EG Engine part - Engine (DAM

inoperative (the fuel pressure is 15R)- Fuel system -Replacement, Electric
too low) fuel pump”)

2. Injector (poor atomization,
(DAM15R)- Fuel system -Replacement,
leakage or clogging)
Fuel injector”
Poor idling of engine
3. Fuel pipe pipeline (clogged) Clean the fuel pipeline
“Chapter EG Engine part - Engine (DAM

4. Electric fuel pump (poor
15R)- Fuel system -Replacement, Electric
operation)
fuel pump”)
5. Fuel quality (poor quality ) Replacement

Recommended tools
Illustration Name Purpose
Long-nose pliers Fuel pressure regulator
EG
Fuel injector, fuel pump plug or

Digital multi-meter
fuel pump wiring harness
Torque wrench Fuel filter assembly
Lifting type hydraulic jack Fuel tank assembly
Equipment
Injector leakage testing bench
Consumables
Item Quantity Specifications
Lubricating grease - -
Maintenance data
1. Fuel rail assembly (see Table)
The fuel rail assembly is composed of the fuel guide rail and the injector, and is fitted between upper
body and lower body of the intake manifold. The fuel rail assembly is intended to distribute fuel among
various cylinders. When distributing fuel, the ECM will control the time of opening of the injector to
realize accurate fuel supply.
EG
Figure
Working temperature: -40-120℃: Maximum leakage (assembly): 2

Working parameters
mm/min
Turn on the ignition switch 396〜400KPa

Fuel pressure of the gasoline
Engine idling 407〜409KPa
engine
Turn off the ignition switch. 359〜367KPa
2. Fuel injector (see Table)

The injector will timely and accurately inject a proper quantity of fuel into the intake manifold in response
to the ECM signal of the gasoline engine. ECM will control the fuel injection quantity depending on the
engine revolution, coolant temperature, intake quantity (intake pressure) and the oxygen content of the
exhaust.
Figure
Min. working voltage: 6v Working temperature: -40°-110℃ System fuel

Working parameters pressure: 4bar Number of fuel injection holes: 4 Fuel injection cone
angle: 20° Static winding resistance: 12Ω
Peak current 1.167A

Electric parameters of fuel
Holding current -
injector
Resistance 12±5%Ω
Fuel injector
Replacement
2. Disconnect the battery negative cable.
3. Remove the fuel rail assembly “Chapter EG Engine part - Engine (DAM15R)- Fuel system
-Replacement, Fuel rail ”)
4. Remove the injector
a. Remove the clamp from the injector clamp groove. EG
b. Rotate the injector and pull it out.
5. Check the fuel injector

a. Use the multi-meter to measure the resistance
between two pins of the injection nozzle.
Standard resistance: 13～16Ω
b. Check the injection orifice for carbon deposit or
clogging. Remove the clogging if any.
c. Fit the injector to be tested onto the pressure testing

bench and check the injector for leakage.
6. Refit the fuel injector.

a. Fit a new O-ring onto each fuel injector.
Caution
• O-rings on upper and lower ends of the injector are different. Do not confuse them.
• Apply lubricating oil or gasoline onto each new O-ring. Do not use engine oil, gear oil and
brake liquid.
b. Refit the injector onto the fuel guide rail.

Caution
Try to stretch the injector outward to make sure that
the injector is locked in place by the clamp.
EG
7. Refit the fuel rail assembly “Chapter EG Engine part - Engine (DAM15R)- Fuel system
-Replacement, Fuel rail ”)
8. Reconnect the battery negative cable.
9. Check after refitting.
a. Turn on the ignition switch, enable the fuel pipeline to apply the fuel pressure and check the
connection for leakage.
b. Start the engine and speed it up. Make sure that the fuel pipeline joint has no fuel leakage.
Fuel rail
Purpose
The fuel rail is generally composed of the fuel rail assembly, injector, injector clamp and the like. It is
mainly intended to fix the injector at its accurate position, supply a sufficient and closed fuel chamber to
inhibit the fuel pressure impulses of the fuel supply system, and after the injector receives ECM
commands, deliver fuel to the engine pursuant to constant requirements.
EG
Replacement
3. Remove the injector assembly.
a. Disconnect the injector connector.
EG
b. Press the fuel pipe joint locking pin, and disconnect

the nylon delivery pipe assembly from gasoline filter
to the fuel rail.
c. Remove these two fixing bolts of the fuel rail
assembly.
Tool: 13mm socket
d. Slightly shake the rail, pull it upward in the direction

as indicated by the arrow, and take out the fuel rail
assembly.
4. Check the external surface of the fuel rail assembly for deformation, cracking and leakage,
and if necessary, replace the assembly.
5. Refit the fuel rail assembly.
a. Refit the fuel rail assembly, and tighten these 2
bolts.
b. Reconnect the nylon fuel delivery pipe assembly
from the gasoline filter to the fuel rail, till you hear a
clear click.
Tool: 13mm socket
Torque: 21~25N·m
c. Reconnect the injector connector.
6. Reconnect the battery negative cable. EG

Fuel system pipeline

Replacement
3. Discharge the fuel tank if necessary (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Fuel system -Emptying of fuel tank, Fuel system”)
4. Raise the vehicle.
EG 5. Remove the fuel tank assembly. (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Fuel system -Replacement, Fuel tank assembly”)
6. Remove the fuel pump-gasoline filter delivery pipe assembly, return pipe assembly and
fuel tank-hard pipe vent hose.
8. Disconnect the gasoline filter - engine fuel

delivery pipe assembly
a. Press the fuel pipe connector lock pin, and
disconnect the gasoline filter - engine fuel delivery
pipe and fuel tank pipe.
b. Press the fuel pipe connector lock pin, and

disconnect and take down the gasoline filter -
engine fuel delivery pipe.
9. Remove the canister connecting pipe.

a. Remove the fixing clamp of the canister - solenoid
valve hose, and disconnect the vent hose.
b. Remove the hard pipe-canister vent hose.

c. Pull down the canister - engine vent hose, and
remove the canister - engine vent hose.
10. Raise the vehicle. EG

11. Remove the hard pipe-canister vent hose from the double pipe clamp.
12. Check various fuel pipes for cracking, damages or aging, and if necessary, replace the
pipe.
Caution
• When disconnecting the fuel pipe, check the hose for cracking, damages or aging, and if
necessary, replace the hose.
• Keep the connection clean, and fully cover it with plastic bag or similar object to avoid
damages and entry of foreign matters.
13. Reconnect the hard pipe-canister vent hose onto the double-pipe clamp, and fix them.
15. Reconnect the gasoline filter - engine fuel
delivery pipe assembly
a. Reconnect the gasoline filter onto the fuel rail
delivery pipe and the fuel tank pipeline till you hear
a clear click.
b. Reconnect the gasoline filter - engine fuel delivery

pipe onto the fuel rail assembly till you hear a clear
click.
16. Reconnect the canister connecting pipe.

a. Reconnect the hose-canister vent hose.
b. Reconnect the canister - engine vent hose.
EG c. Refit the connecting hose between the canister and

the solenoid valve, and install the fixing clamp.
17. Refit the fuel pump-gasoline filter delivery pipe assembly, return pipe assembly and fuel
tank-hard pipe vent hose.
18. Refit the fuel tank assembly (Refer to “Chapter EG Engine part - Engine (DAM15R)- Fuel
system -Replacement, Fuel tank assembly”)
Fuel tank
Replacement
4. Lift the vehicle to a proper position.
5. Remove the fuel tank. EG
a. Disconnect the fuel pump wiring harness connector.
b. Disconnect the quick connector between fuel tank
and engine oil pipe.
c. Disconnect the fuel tank evaporation vent hose.
d. Remove these 2 clamps of the fuel tank filler vent
hose, and disconnect the filler vent hose.
e. Disconnect the quick connector between fuel tank
and engine oil pipe.
f. Remove the fuel tank filler pipe clamp, and disconnect the hose from the fuel tank.
Caution
• When disconnecting the fuel tank filler hose, check the fuel inlet hose nozzle rubber cover
for cracking, damages or aging, and if necessary, replace the hose.
• Keep the connection clean, and fully cover it with plastic bag or similar object to avoid
g. Use the approrite tool to lift the fuel tank assembly, remove all fixing points of the fuel tank, and
take down the fuel tank assembly.
6. Check the surface of fuel tank assembly for scratches, deformation and corrosion, and
check the welding joint for cracking; if necessary, make a replacement.
7. Refit the fuel tank assembly.
a. Use the tool to lift the fuel tank assembly, align the
tank with the mounting position, install the strap and
fixing nut, and tighten them.
b. Reconnect the fuel pump wiring harness connector.
c. Reconnect the quick connector of fuel pipe between
the fuel tank and the engine till you hear a clear click.
d. Reconnect the fuel tank evaporation vent hose.
e. Refit the fuel tank filler vent hose onto the
corresponding connection, fit these two clamps and
tighten them.
10. Check the fuel pipeline
Electric fuel pump

Overview
The electric fuel pump of this vehicle is installed in the fuel tank and submerged in the fuel. It is intended
to supercharge the gasoline and continuously pump it into the fuel supply pipeline, ensuring a constant
fuel supply to the injector.
EG
Working principle
The electric fuel pump is composed of the pump body, permanent magnet motor and housing. The
permanent magnet motor, once electrified, will drive the pump to rotate and suction the fuel from the fuel
inlet. The fuel will flow through the electric fuel pump and then leave the fuel outlet to reach fuel system.
The fuel will pass through the electric fuel pump to cool down the armature of the permanent magnet
motor. So this kind of fuel pump is also called “wet type fuel pump”.
The motor of electric fuel pump comprises the permanent magnet attached onto the housing, the
armature intended to generate electromagnetic torque and the electric brush fitted on the housing. The
electric brush will contact the commutator on the armature, and its lead wire is connected to the terminal
EG
on the housing to lead the voltage to the armature winding. Both ends of the housing of the electric fuel
pump are crimped and riveted to accommodate various parts as an irremovable assembly.
Additional functions of the fuel pump are fulfilled by the relief valve and check valve. The relief valve is
provided to prevent the excessive increase of the pressure when the fuel pipeline is clogged, which may
otherwise cause the bursting of fuel pipe or damages of the fuel pump. The check valve is provided to
seal the pipeline when the fuel pump stops working, in order to maintain a certain residual pressure in
the fuel system to facilitate the easy next start of the engine.
Replacement
4. Remove the cargo box assembly (Refer to “Chapter BW Body-Cargo box - Replacement,
Cargo box”)
5. Remove the electric fuel pump assembly.
EG
a. Disconnect the fuel pump connector and the fuel
pump output pipe quick connector.
b. Remove the gland of the electric fuel pump
assembly.
Caution
After the fuel pump gland is removed, timely mark the
relative positions of the fuel pump and the fuel tank.
c. Remove the electric fuel pump.

Caution
Take much care when removing the electric fuel pump,
and never bend the crank excessively.
6. Remove the fuel level sensor.

a. Disconnect the sensor wiring harness connector.
b. Press fasteners on both sides of the sensor, and
take out them in the arrow direction.
c. Check the sensor and float.

Caution
Check the contact surface of the copper plate for dirt
and foreign matters, and keep both in good contact
and the float undamaged.
7. Refit the fuel level sensor.

a. Refit the fuel level sensor in the arrow direction till
you hear a click, and stretch the sensor forcibly to
make sure that it is connected reliably.
b. Reconnect the sensor wiring harness connector.
8. Identify the sound conditions of the electric fuel pump using the following methods EG
a. Before the electric fuel pump goes to be damaged, its noise will be noticeably increased
compared with the normal operation, and this can be judged through listening.
b. Measure the resistance of the winding of armature of the electric fuel pump, and generally, it is
10~20Ω. If the resistance is too high or too low, it indicates that the said winding is in short circuit,
the electric brush is in poor contact, or the winding is in open circuit, etc.
Caution
The electric fuel pump is irreparable; when it is judged to be damaged, it must be replaced.
9. Refit the electric fuel pump assembly.

a. Refit the electric fuel pump assembly.
Caution
• When positioning the electric fuel pump
assembly, make sure that its positioning mark
is aligned with the mark on the fuel tank.
• If a new fuel pump is to be fitted, make sure that
the part number of the fuel pump is the same
with that of the old one.
b. Refit the gland of electric fuel pump, and tighten it.

c. Reconnect the fuel pump outlet pipe onto the fuel
pump till a clear click is heard.
Cargo box”)
connection for leakage. Check whether the fuel level indicated on the fuel gauge of the instrument
cluster is normal.
b. To avoid damages of the fuel pump, do not run it when it is dry.
c. Start the engine and speed it up. Make sure that the fuel pipeline joint has no fuel leakage and
that the fuel pump works normally.
EG
Fuel delivery pipe

Replacement
Cargo box”)
4. Remove the fuel delivery pipe assembly.
a. Remove the connecting hoop between the fuel EG
delivery pipe vent hose and fuel tank, and
disconnect the vent hose.
b. Remove the fixing hoop of the connecting hose
between the fuel delivery pipe and fuel tank, and
disconnect the fuel delivery pipe.
c. Remove these 2 fixing bolts of the bracket of the
fuel delivery pipe assembly, and take down the fuel
delivery pipe assembly.
Caution
• Keep the connection clean, and fully cover it
with plastic bag or similar object to avoid
• When disconnecting the fuel pipe, check the
hose for cracking, damages or aging, and if
necessary, replace the hose.
5. Refit the fuel delivery pipe assembly

a. Refit the clean fuel delivery pipe onto the body, fit
b. Reconnect the fuel delivery pipe onto the fuel tank,
refit the fuel delivery hose hoop and tighten it.
c. Reconnect the vent hose of the fuel delivery pipe
assembly onto the fuel tank connection, refit the
hoop and tighten it.
6. Fill the fuel tank as appropriate, and check whether fueling is smooth and whether there is
any fuel leakage.
7. Refit the cargo box assembly (Refer to “Chapter BW Body-Cargo box - Replacement,
Cargo box”)
Gasoline filter
Overview
The gasoline filter is in serial connection with the pipeline between the fuel pump and fuel rail. It is
located on the vehicle underside and can be visible after the vehicle is raised up. The gasoline filter is
intended to remove the iron oxide, dust and other solid matters contained in the fuel to prevent clogging
of fuel system (especially the injector), so as to reduce the mechanical wear, ensure the steady
operation of the engine, and thus improve the reliability.
EG
Replacement
3. Lift the vehicle to a proper height.
4. Remove the gasoline filter assembly.
a. Remove the fixing bolt of the earthing wire of the
gasoline filter, and move aside the earthing wire.
EG
b. Disconnect the quick connectors of the oil inlet and
outlet pipes of the gasoline filter.
Caution
• When disconnecting the inlet and outlet pipes
of the gasoline filter assembly, check the pipes
for cracking, damages or aging, and if
necessary, replace them.
• Keep the connection clean, and fully cover it
with plastic bag or similar object to avoid
c. Remove the gasoline filter fixing screw, and take
down the gasoline filter .
5. Refit the gasoline filter assembly
a. Refit the gasoline filter at the fixing position, and
install and tighten the fixing screw.
Caution
The gasoline filter assembly shall be installed in the
arrow direction indicated on the filter.
b. Reconnect the inlet and outlet pipes onto the filter
till you hear a clear click.
6. Check the fuel pipeline

Canister
Overview
The canister is generally located between the fuel tank and the engine. The canister of this vehicle is
located at the right front end of the vehicle, and can be visible after the front bumper assembly is
removed. of the As the gasoline is kind of volatile liquid, the fuel tank is usually filled up with steam at the
normal temperature. The fuel evaporative emission control system is designed to lead the steam into
combustion and prevent its evaporation into the atmosphere. Such a process is primarily fulfilled by the
charcoal canister.
EG The charcoal is adsorbent. When the car is running or stopped, the gasoline steam in the fuel tank will go
to the upper portion of the charcoal canister via the pipeline, while the fresh air will enter into the
charcoal canister via the lower portion of the charcoal canister. After the engine is shut down, the
gasoline steam will be mixed with the fresh air in the canister and the mixture will stay in the canister.
After the engine is started, the electromagnetic valve of the fuel evaporation purifier between the
charcoal canister and the intake manifold will be opened, and in this way, the gasoline steam in the
canister will be suctioned into the intake manifold to take part in the combustion.
Replacement
1. Raise the vehicle.
2. Remove the canister.
a. Remove the fixing clamp of the canister connecting
vent pipe, and disconnect the canister vent pipe
from the canister.
b. Take down the canister in the direction as shown in
the figure.
Caution
EG
Keep the connection clean, and fully cover it with
plastic bag or similar object to avoid damages and
entry of foreign matters.
3. Refit the canister.

a. Refit the canister onto the bracket in the arrow
direction.
Caution
After the canister is installed, check whether it is fixed
in place.
b. Refit the canister vent hose onto the corresponding
connection on the canister, and fix the clamp at its
proper position.
Lubricating system
Lubricating system
Overview
1. The lubricating system is composed of the oil collector, engine oil pump, engine oil filter,
engine oil dipstick and various pipelines.
2. As various moving parts of the engine work under different conditions, their respective
lubrication intensity as required also differs from each other significantly; therefore, the
EG lubrication methods are also diverse. There are three methods of lubrication: pressure
lubrication, splash lubrication and gravity lubrication.
a. The pressure lubrication is to deliver the lubricating oil to various friction surfaces via the engine
oil pump in a mandatory way. Generally, members which are heavily loaded and has a high
speed of relative movement are provided with pressure lubrication. Examples include the
crankshaft main bearing, connecting rod bearing and wheel bearing. In addition, although the
valve rocker arm shaft, for example, is not heavily loaded, it must be also provided with pressure
lubrication, for it is located on the cylinder head.
b. The splash lubrication is to provide lubrication by utilizing the oil mist from the lubricating oil
thrown off during rotation of connecting rod journal and main journal and also from the lubricating
oil injected from the injection orifices. Generally, members which are insignificantly loaded or
have a low speed of relative movement, for example, the concave wheel working surface and
tappet, are provided with splash lubrication. In addition, although the cylinder wall receives a high
working load, it should not be excessively lubricated; otherwise this may cause the entry of engine
oil into the combustion chamber to worsen working conditions of the engine; therefore, it is
provided with splash lubrication.
c. The gravity lubrication is to provide lubrication via the gravity of the lubricating oil itself. For
example, the rocker arm lubricates the valve and push rod by shaking itself under the gravity of
the lubricating oil.
3. The nomenclature of engine oil is lubricating oil, and it plays a crucial role in the normal
operation of the engine.
a. Lubrication: lubricate the surface of moving parts, decrease the friction resistance and wear, and
reduce the power consumption of the engine.
b. Washing: the engine oil will be continuously circulated in the lubricating system to wash the
friction surface and carry away wear debris and other foreign matters.
c. Cooling: the engine oil will be continuously circulated in the lubricating system to carry away the
heat generated from mutual friction for cooling down the system.
d. Sealing: an oil film will be built between moving parts to improve sealing performance to prevent
leakage of gas or oil.
e. Prevention of corrosion: the oil film is built on the surface of the parts for protection, thus
preventing corrosion and rusting.
f. Hydraulic action: the lubricating oil can also be used as the hydraulic oil, for example, the
hydraulic tappet, to fulfill hydraulic actions.
g. Damping and buffering: an oil film will be formed on the surface of moving parts to absorb impacts
and diminish the vibration, thus attaining the damping and buffering effects.
4. The engine oil pump of this engine is an internal meshing cycloid gear pump which is
integrated on the synchronizing chain casing and directly driven by the crankshaft front
end. The engine oil is delivered into the oil collector guide pipe via the collector strainer,
and then it flows into the engine oil pump via the pipe orifice, and finally into the cylinder
body. The engine oil pump outlet pressure is controlled by the pressure-regulating flap.
When the outlet oil pressure is higher than the opening pressure of the said flap, the flap
will overcome the spring elasticity to be opened, and the oil will return into the engine oil
pan via the drain hole. The oil orifice on the cylinder block which corresponds to the
engine oil pump outlet will pump the high-pressure engine oil into the engine oil filter, and
then deliver the oil into the main oil passage via the filter pipe nozzle.
5. Five inclined oil passages are provided on one side of these 5 main bearing seats of the
cylinder block and they are interconnected with the main passage. The high-pressure oil in EG
the main passage will flow through the said inclined passage and then enter into various
main bearing friction pairs via round holes on the upper main bush. Direct oil passages
which are through in the diameter direction are provided on the 1st, 2nd, 4th and 5th main
journals of the crankshaft. One direct oil passage hole interconnecting the main oil
passage and directing to the top surface of cylinder block is made on the front end of the
cylinder block, and a cross slot is provided at the position where the cylinder head is
opposite to the said direct oil passage; through this slot, two inclined upward oil passage
holes are provided. Furthermore, three vertical oil passage holes directing to the phase
control valve on the synchronizing chain casing are respectively made on the cylinder
head and synchronizing chain casing. Two of these oil passage holes are interconnected
with both inclined upward oil passage holes , and the engine will enter into the phase
control valve via this passage.
6. Four vertical oil passage holes are provided on top surface of the cylinder head and they
are interconnected with these four oil passage holes directing to the phase control valve.
Two of these holes are intake & exhaust cam phaser oil inlet holes, and the other two are
oil return holes. The engine oil will enter or leave the camshaft phaser via the first
camshaft journal, and the oil passage hole interconnecting the intake phase control valve
inlet hole is directed to the second camshaft journal in the inclined upward direction.
Thereafter, the engine oil will enter the intake and exhaust camshaft cavities via the direct
oil holes on the camshaft second journal respectively. All camshaft journals are provided
with oil holes interconnecting the cavities, thus to effectively lubricate various journals of
the camshaft. The phase control valve will control its motion via the command from the
engine control module (ECM) and select the oil passage directing to the phaser. The phase
control valve mounting hole on the synchronizing chain casing is interconnected with the
crankcase for oil drainage.
7. The first main bearing seat will deliver oil to the tensioner via one inclined oil passage
hole.
8. The first bearing seat will deliver oil to the injection nozzle via the one upward direct oil
passage hole to splash the driving synchronizing chain wheel. Meanwhile, a square oil
hole is forged on the front end of the cylinder head, and the engine oil splashed from
above the cylinder head will splash the oil onto the synchronizing chain transmission
system at the engine front end via this hole, thus to lubricate the chain transmission unit.
9. A inclined oil passage is provided between the main journal and connecting rod journal,
and the engine oil intended to lubricate the main journal will lubricate the connecting rod
journal via the said incline passage. The lubrication of the piston and cylinder jacket is
realized by engine oil splash. The oil passage hole is made in the connecting rod big end
and the engine oil intended to lubricate the connecting rod journal is sprayed onto the
cylinder wall via this hole to ensure the reliable lubrication between the piston skirt and
cylinder jacket. The connecting rod small end and piston pin are lubricated by the engine
oil splashed from these two oil receiving holes made on the connecting rod end. The
lubrication between the piston and piston pin is realized by the splashed engine oil
received by the slot in the piston pin hole.
EG
Precautions
Caution
• Long-time and repeated contact with the mineral oil may remove the grease on the skin,
leading to dryness, irritability and dermatitis of the skin.
• Furthermore, the used engine oil contains potential hazardous pollutants which may lead
to skin cancer. Therefore, the appropriate skin protection measures and cleaning
equipment must be provided.
1. Avoid long-term and repeated contact with the engine oil, especially the old oil.
2. Wear protection clothes, inclusive of the waterproof working gloves. EG
3. Avoid contamination of clothes, especially the underwear contaminated by engine oil.
4. Never put the cleaning cloth dipped with engine oil in your pockets.
5. Never wear seriously contaminated clothes and the oil-dipped socks. Wok pants must be
cleaned regularly and separated from personal clothes.
6. Wear goggles, i.e., chemical goggles or face mask, to avoid contact with engine oil. In
addition, prepare the eye washing equipment.
7. Any wound must be disposed immediately and wrapped.
8. Often wash your exposed skin using soap and clean water, especially before eating, and
make sure that all engine oil has been removed (you can also use the skin cleaner and nail
brush ). After cleaning, apply lanolin cream onto the skin to act as the natural skin grease.
9. Never use gasoline, kerosene, diesel oil, thinner or solvent to clean the skin.
10. Before working, apply the sunscreen cream onto the skin to assist cleaning after working.
11. If you skin becomes abnormal, see the doctor immediately.
Part Diagram
EG
1 Engine oil pan assembly 6 Bolt
2 Washer 7 O-ring
engine oil oil collector & rubber

3 Drain plug 8
grommet assembly
4 Bolt 9 Rubber grommet
5 Bolt 10 Engine oil dipstick assembly

Preparations
Recommended tools
Engine oil pan, engine oil pump,

Torque wrench engine oil filter, engine oil
pressure sensor
EG
Rubber hammer Engine oil pan
Clearance gauge Engine oil pan, engine oil filter
Torque requirement
Fasteners Torque (N.m)
Drain plug 35 ±3
Oil pan 10-12
Engine oil filter bolt 10-12
After the engine oil filter comes into contact with the
Engine oil filter cylinder block bonding surface, further tighten it by
3/4~1 turn.
Oil pan
Replacement
1. Turn over the driver seat, and pull out the engine oil dipstick.
3. Remove the engine protection panel assembly.
4. Remove the drain plug, and fully discharge the engine oil.
5. Refit the drain plug and washer.
Caution
EG Check the drain plug washer for damages, and if necessary, replace it.
6. Remove the oil pan

a. Remove these 10 fixing bolts and 2 fixing nuts of
the oil pan assembly beneath the engine assembly.
b. Use the oil pan remover to pry up and take down
the oil pan assembly.
7. Remove the oil collector.

a. Remove the oil collector bracket bolt (7) and oil port
bolt (2), and take down the oil collector and rubber
ring (8).
8. Refit the oil collector onto the engine cylinder

block, install and tighten the oil port bolt (2) and
bracket bolt (7), and then tighten them to the
specified torque.
Tool: 10mm socket
Torque: 10~12N•m
9. Clean the contact surface between the engine oil pan and the engine cylinder block.
10. Apply Loctite 5699 sealant or Beijing Tianshan 1596 sealant or Keruida MF MF-G5699 or
Abnen 5998 onto the engine oil pan surface evenly.
Specifications for sealant application : 3mm wide, 2mm thick
11. Refit the oil pan.

a. After the engine oil pan is installed onto the cylinder
block, tighten the engine oil pan bolts in the
diagonal tightening way.
Tool: 10mm socket
Torque: 10~12N•m
12. Refit the engine protection panel assembly. EG

14. Fill the engine with a suitable quantity of engine oil as per the mark indicated on the engine
oil dipstick (round holes at upper and lower limits).
15. Recover the driver seat, and check the engine for oil leakage.
Engine oil pump

Check and repair
Caution
The engine oil pump of this engine is an internal meshing cycloid gear pump which is integrated
on the synchronizing chain. Nobody other than the specialized personnel, is allowed to remove
the engine oil pump; if the pump is damaged, it must be replaced together with the synchronizing
chain casing assembly.
EG 1. Remove the engine assembly (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Engine mechanic part - Engine assembly, Replacement”)
2. Remove the synchronizing chain casing assembly (Refer to “Chapter EG Engine part -
Engine DAM15R) (DAM15R) - Engine mechanic part - Replacement of synchronizing chain
casing, Synchronizing chain”)
3. Remove the bolts used to attach the engine oil
pump assembly onto the synchronizing chain
casing, and then take down the engine oil pump.
4. Check the engine oil pump assembly.

a. Check the oil hole and passage for clogging, and if any, clear off it.
b. Check the front cover for cracking or other damages, and if necessary, replace it.
c. Check the oil seal lip for wear or damages, and if necessary, replace it.
d. Check whether the engine oil pump can rotate freely.
e. Check the engine oil pump bolt for loose thread etc., and if necessary, replace the bolt.
5. Refit the engine oil pump and tighten the bolt.
EG
6. Refit the synchronizing chain casing assembly (Refer to “Chapter EG Engine part - Engine
DAM15R) (DAM15R) - Engine mechanic part - Replacement of synchronizing chain casing,
8. Refit the drain plug and washer.
Caution
Check the drain plug washer for damages, and if necessary, replace it.
10. Start the engine and check for leakage.
Engine oil filter

Replacement
1. Start the engine and warm it up.
2. Turn over the driver seat.
3. Screw off the engine oil filler cap.
5. Discharge the engine oil (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Lubricating system - Change, Engine oil”)
EG Caution
Unless otherwise specified, the engine oil filter shall be replaced together with the engine oil, to
avoid contamination of engine oil which may otherwise influence the engine operation.
6. Use a special tool to remove the engine oil filter.

7. Remove foreign matters on the mounting
surface of the engine oil filter.
8. Apply engine oil onto the oil seal surface of the

new engine oil filter.
9. Screw in the engine oil filter by hand till it

contacts the mounting surface, and then tighten
the bolt by 2/3 turn or use a tool to tighten the
filter to the specified torque.
Torque: 20~25N·m
10. Refit the drain plug.

12. Screw off the engine oil filler cap and fill the engine oil to the specified level.
13. Refit the engine oil filler cap.
14. Park the car on a horizontal ground, start the engine and warm it up.
15. Check the engine oil filter and make sure that it has no leakage.
16. Shut down the engine and wait for 10 minutes.
17. Remove the engine oil dipstick and check whether the engine oil level is within the
specified range.
18. Restore the driver seat.
EG
Oil dipstick
Replacement
1. Turn over the assistant driver seat.
2. Pull out the engine oil dipstick.
Caution
Check the engine oil dipstick scale for damages, and if
damaged, replace it.
EG
3. Remove the engine oil dipstick tube.

a. Remove the fixing bolt of engine oil dipstick tube,
and pull out the engine oil dipstick tube.
4. Refit the engine oil dipstick tube.

a. Refit the engine oil dipstick tube, install the bolt, and
tighten it.
5. Insert the engine oil dipstick.

6. Restore the assistant driver seat.
Engine Oil Level

Replacement
1. Start the engine and warm it up.
4. Screw off the engine oil filler cap.
EG
6. Remove the engine oil pan drain bolt and discharge

the engine oil.
Tool: 16mm socket
Caution
• The engine oil is very hot, and take care of it to
avoid scald injury.
• Long-time and repeated contact with the old
engine oil may lead to skin cancer; therefore,
the direct exposure of the skin to the old engine
oil shall be avoided. If such exposure happens,
wash the skin using the soap or cleaner
immediately.
• The old oil shall be collected in a specified
vessel and disposed as required.
7. Replace the drain bolt pad and tighten the bolt.

Tool: 16mm socket
Torque: 20~25N·m

10. Refit the filler cap onto the engine cylinder head
cover.
EG 11. Park the car on a horizontal ground, start the engine and warm it up. Check the drain bolt
and engine oil filter for oil leakage.
13. Check the engine oil level.
a. Pull out the engine oil dipstick and wipe it clean.
b. Insert the dipstick, and make sure that the engine
oil level is within the range as shown in the figure.

Cooling system
Cooling system
Overview
The cooling system is a device intended to carry away the heat absorbed by hot parts when the engine is
working, in order to keep them within the normal temperature range. It mainly comprises the radiator &
electronic fan assembly, connecting water pipe and expansion tank.
The cooling water in the radiator will be pressurized by the water pump and then delivered into the
cylinder block jacket and cylinder head jacket via the water distribution pipe. After the absorption of
EG
massive heat, the cooling water will flow back into the radiator via the water outlet hole on the cylinder
head. Due to strong suction by the fan, the air flow will pass through the radiator backward and at a high
speed. Therefore, the heat will be continuously dissipated into the atmosphere when the heated cooling
water flows through the radiator core, while the cooled water will flow into the radiator bottom and then it
will be pumped out by the water pump again and delivered into the engine water jacket again. By
repeating such a cycle, the heat is thus constantly delivered into the atmosphere to cool down the engine
ceaselessly.
Minor circulation
Water
supply pipe
Cylinder block water passage

Water valve
Thermostat
Cylinder Fan
block Reservoir
water
passage
Blower
Air heater tank

Water tank
Water
pump
Minor circulation
Drain pipe
Major circulation
Water
supply pipe
Cylinder block water passage

Water valve
EG
Thermostat
Cylinder
Fan
block
Reservoir
water
passage
Blower
Water tank
Air heater tank

Water
pump
Major circulation
Drain pipe
Precautions
1. When disconnecting the cooling system pipeline, use a dedicated vessel to collect the
residual coolant. If no further use is required, dispose the coolant as specified.
2. When disconnecting the cooling system pipeline, avoid the entry of debris into the cooling
system pipeline, for this may damage the cooling system and engine.
3. When disconnecting the cooling system pipeline joint, seal the pipe nozzle using the
dedicated plug to avoid entry of dirt or debris.
4. The coolant is poisonous. If no further use is required, keep it out of reach of children and
pets, and dispose the coolant as specified.
EG
5. Do not open the radiator cover from a hot engine. The pressure cover can be removed only
after the coolant temperature is reduced to below 50℃[120℉]. Otherwise, the hot coolant
or steam may be injected to cause personal injuries.
6. After the coolant filling is finished, do release air in the engine cooling system; otherwise it
may cause overheating of the engine.
7. Use the coolant designated by Foton, but do not only use the water as the coolant. Only
using the water as the coolant may damage the engine due to corrosion.
8. Frequently clean the outside surface of the radiator to prevent the accumulation of slurry
or dust which may influence the working efficiency of the radiator.


1. Lack or leakage of coolant (DAM15R)- Cooling system -
Change, Coolant”
2. Non-compliance of coolant (DAM15R)- Cooling system -
EG Change, Coolant”
(DAM15R)- Cooling system -
3. Fault of thermostat
Inspection and repair,
Thermostat”
The engine water temperature is Improve the operation conditions
4. Rough operation of engine
too high of the engine
(DAM15R)- Cooling
5. Poor radiation of radiator
system-Precautions, Cooling
system”
6. Failure of electronic fan
Inspection and repair, Electronic
fan assembly”
Repair or replace the cooling
7. Clogging of cooling pipeline
pipeline
1. Damages of radiator (DAM15R)- Cooling system
-Replacement, Radiator”
2. Breakage or disconnection of Repair or replace the cooling
cooling pipeline pipeline
Engine coolant leakage “Chapter EG Engine part - Engine

3. Poor sealing of water pump, (DAM15R)- Cooling system -
breakage of shell Inspection and repair, Water
pump”
4. Breakage or damages of
(DAM15R)- Cooling system
expansion tank
-Replacement, Expansion tank”
1. Damages of electronic fan
Inspection and repair, Electronic
fan assembly”
Abnormal noise in the engine
2. Damages of water pump
Inspection and repair, Water
pump”
Repair or replace the cooling
3. Clogging of cooling pipeline
pipeline
Part Diagram
EG
1 Fan cowl assembly 7 Water filler cap
2 Lower fixing bracket, fan cowl 8 Rubber pipe
3 Support bracket 9 Filler hose
4 Support bracket 10 Connecting hose
5 Expansion tank assembly 11 Gasket
6 Rubber pipe
EG
1 Water inlet hose, engine 7 Pipe clip
2 Engine water outlet hose 8 Bracket
3 Radiator & electronic fan assembly 9 Radiator bushing
4 Bracket 10 Electronic fan
5 Radiator cushion 11 Radiator
6 Bracket
Preparations
Recommended tools
High-pressure air gun Clean the water tank
EG
Thermometer Check the thermostat
Remove/refit the water tank and

Torque wrench
thermostat
Cooling system test kit Inspection of radiator coolant
Equipment consumables
Steam washer
Specialist sealant designated by

Sealant -
Foton
Fill the coolant till the level is

Specialist coolant designated by
Coolant between MIN and MAX marked
Foton
on the coolant tank
Maintenance data
Thermostat valve opening temperature 88 °C
Thermostat valve lift ≥8mm
Torque requirement
Fasteners Torque (N.m)
Thermostat housing bolt 13-17
EG Electronic fan fixing bolt 3-5
Water pump pulley bolt 10-12
Water pump fixing bolt 21-25

Onboard inspection
1. Check the coolant level.
2. If the coolant level is too low, check the cooling system for leakage.
Caution
To avoid scald injury, do not open the expansion tank pressure cover when the engine and
radiator are still hot, for the liquid and steam will be injected under the pressure.
a. Fill the anti-freezing liquid into the radiator and fit a

radiator cover tester.
EG
b. Start the engine and warm it up.
c. Increase the pressure to the standard value and
then check whether the pressure drops.
Caution
If the pressure drops, check the hose, radiator or
water pump for leakage. If no external leakage is
found, check the heater core, cylinder head and
cylinder block.
3. Check the engine coolant level of the expansion

tank.
a. When the engine is cold, visually check whether the
coolant level of the expansion tank is located
between LOW (MIN) and FULL (MAX).
b. If the engine coolant level is too low, check the
cooling system for leakage and add “Foton
specialized long-life coolant” or the similar
high-quality ethylene glycol coolant which contains
no silicate, amine, nitrite and borate and is based
on the long-life mixed organic acid technology to
the FULL (MAX) line.
Caution
Never only use the water as the coolant.
4. Check the engine coolant quality.

Danger
Never open the pressure cover when the engine is hot. Only do this when the coolant
temperature is reduced to below 50℃; otherwise, the hot coolant or steam may be injected to
cause personal injuries.
a. Open the expansion tank cover.
b. Place a vessel beneath the radiator drain valve to receive the discharged coolant.
c. Loosen the radiator drain valve to discharge a little of engine coolant, and check the drain valve
for excessive rusting or fouling. Keep in mind that the coolant shall not contain any engine oil. In
the case of excessive fouling, clean the cooling system and change the coolant.
d. Refit the radiator drain valve, check the expansion tank coolant level, and if necessary, add the
coolant to the specified level. Check the radiator fin for clogging.
5. If the radiator fin is clogged, use the high-pressure water gun or steam washer to flush it
and then dry it with the compressed air.
Caution
• If the steam washer or high-pressure water gun is located too close to the radiator core,
the radiator fin may be damaged; therefore, an appropriate washing distance shall be kept.
• Take care not to directly spray water onto the electronic elements.
6. Check the cooling fan.

EG a. Disconnect the electronic fan connector.
b. Connect the battery and amperemeter to the connector.
c. Check whether the electronic fan rotates freely, and then check the reading on the amperemeter.
d. Reconnect the electronic fan connector.
e. The fan shall not produce abnormal noise except for the air noise of the fan itself when it works at
high speed.
Water pump
Check and repair
Danger
1. Discharge the coolant (Refer to “Chapter EG Engine part - Engine (DAM15R)- Cooling
system - Change, Coolant”) EG
3. Disconnect from negative cable of battery
5. Take down the water pump belt.
and take down the pulley.
Tool: 10mm socket
7. Remove the water pump assembly.

a. Remove these 2 nuts of the generator adjusting
arm.
b. Remove these 4 bolts of the water pump assembly.
Tool: 13mm socket
8. Take down the water pump.

Caution
Use a scraper to clean the contact surface between
the water pump and engine cylinder block, and
remove the adhesion carefully to avoid damaging the
said contact surface.
9. Check the water pump

a. Rotate the water pump and it shall move freely.
b. The pump rotating shaft shall have no clearance and shall not produce any noise when it is
rotating.
c. There shall be no leakage of coolant around the water pump.
10. Refit the water pump
a. Refit the water pump, and apply the engine oil pan sealant onto the contact surface to prevent
coolant leakage.
Caution
After the pump is refitted using the sealant, wait for at least 15 minutes before filling any coolant.
b. Refit the water pump in place, and tighten these 4

EG fixing bolts.
c. Refit the generator adjusting arm and tighten these
2 nuts.
Tool: 13mm socket
Torque: 21~25N·m
11. Refit the water pump pulley and tighten these 4

fixing bolts.
Tool: 10mm socket
Torque: 10～12N·m
12. Refit the water pump belt.

15. Fill the coolant (Refer to “Chapter EG Engine part - Engine (DAM15R)- Cooling system -
Change, Coolant”)
17. After the water pump is replaced, warm the engine till the electronic fan works at a high
speed, and check various connecting parts for coolant leakage.
Thermostat
Check and repair
Danger

2. Discharge the coolant (Refer to “Chapter EG Engine part - Engine (DAM15R)- Cooling EG
system - Change, Coolant”)
3. Remove the thermostat
a. Remove the radiator water inlet pipe clamp to
disconnect the pipe.
b. Remove the thermostat cover fixing bolt , and take
down the thermostat cover.
Tool: 10mm socket
Caution
Discard the thermostat cover gasket.
4. Check the thermostat

a. The thermostat is marked with the valve opening
temperature.
b. Put the thermostat in water and gradually heat the

water.
c. Check the valve opening temperature.
Valve opening temperature: 87℃
d. Check the valve lift.

Standard value of valve lift: 8mm
Caution
If the valve lift is abnormal, replace the thermostat.
• Check whether the valve can be fully closed
when the thermostat is at a low temperature
(lower than 87℃).
• If the valve is not fully closed, replace the
thermostat.
EG
5. Refit the thermostat
a. Refit the thermostat gasket.
Caution
Each time the thermostat is removed, a new
thermostat gasket shall be installed at refitting.
b. Refit the thermostat in place.
Caution
When refitting the thermostat, ensure that the gasket
is correctly engaged with the thermostat and is in
close contact with the thermostat seat plane.
c. Refit the thermostat shell at its correct position and

tighten these 2 fixing bolts.
Tool: 10mm socket
Torque: 10±2N·m
d. Refit the radiator water inlet pipe onto the
thermostat cover, and fit the clamp correctly.
Change, Coolant”)
7. After the thermostat is refitted, warm the engine till the electronic fan works at a high
Radiator
Overview
Purpose: increase the cooling area to accelerate the cooling of water. After the cooling water passes
through the radiator, its temperature may be reduced by 10~15℃. To carry away the heat from the
radiator as soon as possible, a fan is fitted behind the radiator.
Minor circulation: The thermostat will control the engine coolant in the engine to only flow inside the
engine in a cycle and carry the heat around the cylinder wall to other engine parts to increase the engine
temperature quickly. The water pump will circulate the engine coolant in the cylinder block. Thereafter,
the engine coolant will be circulated in the engine jacket, throttle unit assembly, oil cooler and cylinder EG
head. Such a circulation is called “minor circulation”.
Major circulation: When the engine runs to its normal temperature, the engine coolant will be pumped
into the engine jacket, cylinder head and radiator by the water pump, and such a circulation is called
“major circulation”.
Replacement
Danger
EG 3. Disconnect the electronic fan assembly
connector.
4. Remove the radiator water outlet pipe clamp

and disconnect the pipe.
Caution
Check the water pipe for cracking or aging, and if
necessary, replace the pipe.
5. Disconnect the radiator upper water pipe.

a. Loosen the radiator water outlet pipe clamp and
disconnect the water inlet pipe.
6. Remove the radiator.
a. Remove the fixing bolts on both sides of the radiator
and expansion tank assembly, and take down
various brackets.
7. Take down the radiator & expansion tank assembly.

a. Incline the upper radiator toward the rear end of the body, and take down the radiator &
expansion tank assembly.
Caution
Never miss the radiator lower rubber gasket, check the radiator bracket rubber gasket and
radiator lower gasket for damages, and if necessary, replace them.
b. Remove the fixing bolt of the expansion tank, and take down the expansion tank.
8. Separate the radiator & electronic fan assembly.
a. Remove the fixing bolt of the electronic fan assembly.

b. Separate the radiator & electronic fan assembly.
9. Refit the radiator & electronic fan assembly.
a. Refit the electronic fan onto the radiator assembly.
b. Refit and tighten the fixing bolt of the electronic fan assembly.
c. Fit the expansion tank onto the tank assembly.
10. Refit the radiator assembly.
a. Refit the radiator & electronic fan and expansion
tank assembly onto the mounting position.
Caution EG
Before refitting the radiator, make sure that the
radiator lower rubber gasket is installed in place.
b. Refit all brackets on both sides of the radiator
assembly, and tighten bolts.
Tool: 10mm socket
Torque: 10±1N·m
11. Refit the radiator water inlet pipe onto the water
inlet, and install the clamp correctly.
12. Refit the lower water outlet hose of the radiator
onto the water outlet and fix the clamp at its
proper position.
13. Reconnect the electronic fan connector.

Change, Coolant”)
Caution
After the engine coolant is filled, check for leakage; if any, find out and eliminate the fault.
Cooling fan
Check and repair
4. Remove the radiator assembly, and remove the electronic fan assembly from the radiator
(Refer to “Chapter EG Engine part - Engine (DAM15R)- Cooling system -Replacement,
Radiator”).
EG 5. Remove the electronic fan motor.
a. Remove the electronic fan motor wire and
connector from the electronic fan assembly.
b. Remove these 3 fixing bolts of the electronic fan
motor, and take down the electronic fan motor
assembly.
6. Remove the fan blade from the motor.

7. Check the electronic fan.
a. Use the ohmmeter to measure the resistance between two pins of the electronic fan connector.
b. Visually check the electronic fan blades for lack or damages.
c. Rotate the electronic fan by hand, and the fan blade shall rotate freely.
8. Refit the fan blade onto the electronic fan motor.
9. Refit the electronic fan motor onto the
electronic fan, and install and tighten these 3
fixing bolts.
Tool: 10mm socket
Torque: 10±1N·m
10. Refit the electronic fan wiring harness and
connector at their fixing position on the fan
assembly.
11. Refit the electronic fan assembly onto the radiator, and then refit the radiator assembly
(“Refer to Chapter EG Engine part - Engine (DAM15R)- Cooling system -Replacement,
Radiator”).
Expansion tank
Replacement
2. Discharge the engine coolant (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Cooling system - Change, Coolant”)
3. Remove the radiator assembly( Refer to “Chapter EG Engine part - Engine (DAM15R)-
Cooling system -Replacement, Radiator” )
4. Remove the expansion tank assembly
a. Slowly open the expansion tank pressure cover to EG
release the pressure.
Caution
Never open the pressure cover when the engine is hot.
Only do this when the coolant temperature is reduced
to below 50℃; otherwise, the hot coolant or steam
may be injected to cause personal injuries.
b. Remove the expansion tank - radiator water filling
pipe clamp, and disconnect the pipe.
c. Remove the radiator - expansion tank vent hose
clamp, and disconnect the hose.
d. Remove the fixing bolt of the expansion tank
assembly, and take down the expansion tank
assembly.
Caution
Check the expansion tank connecting pipe for cracking or aging, and if necessary, replace the
pipe.
5. Refit the expansion tank assembly.

a. Refit the compressor onto the engine assembly, fit
b. Refit the radiator - expansion tank vent hose, and fit
the clamp correctly.
c. Refit the radiator - expansion tank water filling pipe
at its fixing position, and fit the clamp correctly.
6. Refit the radiator assembly ( Refer to “Chapter EG Engine part - Engine (DAM15R)- Cooling
system -Replacement, Radiator”)
7. Fill the engine coolant (Refer to “Chapter EG Engine part - Engine (DAM15R)- Cooling
Coolant
Replacement
Danger
1. Cool down the engine to the normal room temperature.

EG 2. Turn over the driver seat.
3. Screw off the expansion tank pressure cover to
release the pressure.
Danger
Wrap the expansion tank pressure cover with a piece
of thick cloth and screw it off with much care.
Firstly, rotate the cover by 1/4 turn to release the
pressure in the expansion tank. Then fully screw off
this cover.

5. Remove the engine protection panel.
6. Remove the engine water inlet hose clamp,
disconnect the hose, and discharge the coolant.
Danger
The coolant is corrosive, and the residual coolant must be
collected in a dedicated vessel. If no further use is
required, dispose the coolant as specified.
7. Check the coolant

a. Check the discharged engine coolant for rusting, corrosion or discoloration.
b. Flush the engine cooling system if it is contaminated.
8. Flush the cooling system.
a. Reconnect the radiator water inlet hose, and fit the
clamp correctly.
b. Add water into the expansion tank to a normal level.
c. Run the engine and warm it up to its normal working
temperature.
d. Increase the engine revolution for two or three
times at zero load.
e. Shut down the engine and cool it down.
f. Discharge water from the cooling system.
g. Repeat the above-mentioned steps till the water
discharged from the radiator is clean.

10. Add the engine coolant
a. Slowly inject Foton long-life coolant into the expansion tank.
b. Press the radiator inlet hose and outlet hose by hand for several times and check the coolant level.
If the coolant level is low, add coolant.
c. Refit the expansion tank pressure cover.
d. Start the engine and warm it up till the fan works at a high speed.
e. Stop the engine, and wait for the engine coolant to cool down.
f. Check whether the expansion tank coolant level is at its specified position. If necessary, fill the
coolant to the specified level. EG
Cooling pipeline
Replacement
Danger
EG system - Change, Coolant”)
4. Remove the radiator water inlet pipe clamp and
take down the radiator inlet pipe.
5. Remove the radiator water outlet pipe clamp

and disconnect the radiator water outlet pipe
from the radiator.
6. Remove the radiator water outlet pipe clamp,

disconnect the pipe form the engine, and take
down the hose.
7. Refit the radiator water outlet hose onto the

radiator water outlet and fix the clamp correctly.
8. Refit the radiator water outlet hose onto the EG

engine water inlet, and fit the clamp correctly.
9. Refit the radiator water inlet pipe correctly, and

refit clamps at both ends correctly.

Change, Coolant”)
Caution
After the cooling pipeline is replaced, warm up the engine till the electronic fan works at a high

Drive belt
Replacement
2. Remove the compressor belt.
a. Tighten the fixing bolt of the tensioner assembly.
b. Move the tensioning wheel assembly upward.
c. Take down the compressor belt.
EG
3. Remove the water pump belt.

a. Loosen the tightening bolt of the generator.
b. Rotate the generator adjusting bolt to incline the
generator to the cylinder block.
c. Remove the generator belt.
4. Take down the belt and check it. If following

damages are found, replace the belt.
a. The backside rubber is aged to reflect light, and
there is no mark left on the surface when it is
scratched by the nail.
b. Cracking and plucking of the canvas.

c. Cracking on the backside rubber.
d. Cracking on the toothed bottom.
e. Cracking on the toothed side face.
f. Abnormal wear on the side face of the belt. If the

toothed side face looks regular as if it is cut by a
sharp blade, this is normal.
g. Abnormal wear of belt.

EG
h. Missing teeth.
5. Refit the water pump belt.

a. Refit the generator belt, and rotate the generator
adjusting bolt to regulate the generator belt to its
appropriate tension.
b. Tight the locking bolt of the generator adjusting
block.
Torque: 21~25N·m
6. Refit the compressor belt.

a. Refit the generator belt, and adjust the tensioning
wheel to regulate the belt to its appropriate tension.
b. Tighten the tensioner assembly tensioning bolt.

Pulley
Replacement
2. Remove the water pump belt (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Cooling system -Replacement, Drive belt”
and take down the pulley.
Tool: 10mm socket
EG Caution
Check the water pump pulley for cracking, wear and
other serious defects, and if necessary, replace it.
4. Refit the water pump pulley and tighten these 4

fixing bolts.
Tool: 10mm socket
Torque: 10~12N•m
5. Refit the water pump belt (Refer to “Chapter EG Engine part - Engine (DAM15R)- Cooling
system -Replacement, Drive belt”
Intake system
Intake system
Overview
The intake system is located at the front end of the engine. The intake system is composed of the air
filter, throttle unit, intake manifold, intake pressure and temperature sensor, air flowmeter, resonant
cavity and intake pipeline etc. The air filter assembly can eliminate part of noise from the engine to
improve the comfort level.
Purposes of intake system: it is used for following purposes: remove the impurities and dust in the air
EG
thus to filter the gas, so as to deliver the clean, fresh and dry gas into the engine cylinder steadily, thus
protecting the engine and prolonging its service life; supply the gas mixture of the appropriate
concentration; evenly and sufficiently distribute the air-fuel gas mixture or clean air into various cylinders;
and reduce the noise from the engine intake.
Part Diagram
EG
1 Air filter inlet pipe 4 Retaining clip, harness
2 Engine intake rubber tube 5 Air filter assembly
3 Crankcase exhaust rubber tube 6 Main element

Precautions
1. The engine intake must be filtered to prevent the entry of dirt and chippings into the
engine. If the intake pipe is damaged or loosened, the introduction of unfiltered air into the
engine will accelerate the wear of the engine.
2. The intake pipeline connection shall be firm and reliable without leakage.
3. The intake pipe shall be connected to the bracket reliably, and its surface shall have no
cracking, without air leakage at its connection with the rubber intake pipe.
4. Various cushions shall be bonded onto the intake pipe bracket reliably.
EG

Check the pipeline, and replace it

1. Air leakage of pipeline
if necessary
Shaking of the engine
2. Intake temperature & pressure
Replace the sensor
sensor
EG 1. Clogging of intake pipeline Clean intake pipeline.

Replace the sensor
Difficult start of the engine sensor

3. Leakage of intake pipeline
if necessary
1. Clogging of intake pipeline Clean intake pipeline.

Replace the sensor
Poor idling of engine sensor

3. Leakage of intake pipeline
if necessary
Recommended tools
Clearance gauge Intake manifold
EG
High-pressure air gun Air filter element
Torque wrench Remove/refit the fixing bolt

Auxiliary material
Specialized sealant designated

Sealant -
by Foton
EG
Maintenance data
Torque requirement
Fasteners Nym
Intake manifold fixing bolt 21-25
Throttle fixing bolt 10-12
EG
Intake manifold
Replacement
3. Remove the air filter outlet pipe (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Intake system - Replacement, Intake pipeline”)
Caution
For vehicles which have a high mileage, when disconnecting the hose, firstly screw off the hose,
EG and continue only when it is confirmed that the hose is loosened.
4. Remove the throttle unit assembly (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Engine control system -Replacement, Throttle unit”)
5. Disconnect the intake manifold vacuum pipe.
a. Remove these 2 clamps, and disconnect the brake
booster vacuum pipe and the crankshaft positive
vent hose as shown in the figure.
b. Move aside the pipeline into an area free from
interference.
6. Remove the intake temperature sensor.
a. Disconnect the intake temperature sensor
connector.
b. Remove the fixing bolt of intake temperature sensor
and take down the sensor.
Tool: 10mm spanner
7. Remove the fixing clamp, and disconnect the
fuel steam hose.
8. Remove the intake manifold.

a. Remove all fixing bolts and fixing nuts of the intake
manifold.
b. Take down the intake manifold.
Caution
After the intake manifold is removed, stop the cylinder
head intake using clean plastic cloth or other clean
lint-free objects to prevent the entry of foreign matters
into the cylinder.
9. Install inlet manifold.

a. Refit the intake manifold at its correct position.
b. Refit fixing bolts and nuts of the intake manifold,
and tighten them.
Tool: 12mm socket, 13mm socket
Torque: 21~25N·m
c. Refit various pipelines and wiring harness brackets
onto the fixing positions on the intake manifold.
Caution
EG
• Before refitting, check the intake manifold sealing ring for damages; if damaged, replace it.
• If the intake manifold sealing ring is removed, it shall be squarely refitted into the slot on
flange face of the intake manifold.
10. Reconnect the fuel steam hose onto the intake

manifold, and refit the clamp correctly.
11. Refit the intake temperature sensor.

a. Refit the intake temperature sensor at its mounting
position on the intake manifold, refit the fixing bolt
and tighten it.
Tool: 10mm socket
Torque: 10±1N·m
b. Reconnect the intake manifold wiring harness
connector onto the sensor.
12. Reconnect the intake manifold vacuum pipe.
a. Reconnect the brake booster vacuum pipe as
shown in the figure, and reconnect the crankcase
positive vent hose onto the corresponding
connection as shown in the figure. Install various
clamps correctly.
13. Refit the throttle unit assembly (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Engine control system -Replacement, Throttle unit”)
14. Refit the air filter outlet pipe (Refer to “Chapter EG Engine part - Engine (DAM15R)- Intake
system - Replacement, Intake pipeline”)
Intake pipeline
Replacement
2. Remove the crankcase exhaust rubber tube
from the air filter outlet pipe.
3. Remove the hoops at both ends of the throttle
intake pipe, and take down the intake pipe.
Caution
EG • For vehicles which have a high mileage, when
disconnecting the hose, firstly screw off the
hose, and continue only when it is confirmed
that the hose is loosened.
• Check the air filter outlet pipe for corrosion and
leakage; if any, rpelace the pipe.
4. Refit the air filter outlet pipe.

a. Refit the air filter outlet pipe correctly.
b. Refit the air filter outlet pipe hoop, and tighten the
hoop bolt.
5. Reconnect the crankcase exhaust rubber tube
from the air filter outlet pipe, and refit and
tighten the hoop.

Air filter
Overview
The air filter is intended to remove particles in the air. When the engine is working, if the intake air
contains dust or other foreign matters, the wear of parts will be worsened, so an air filter must be
provided. The air filter is composed of the filter element and the shell. The air filter primarily requires high
filtering efficiency, low flowing resistance and long-time & maintenance-free continuous operation.
EG
Replacement
2. Remove upper cover of air filter.
a. Remove the clamp between the air filter outlet pipe
and air filter upper cover.
b. Disconnect the air filter outlet pipe.
c. Remove the fixing screw of the air filter upper cover.
EG
3. Take down the air filter upper cover and remove

the air filter element.
Caution
The air filter element is made of paper, and if necessary, it can be purged using the high-pressure
air gun from inside. It is not allowed to clean the element using water.
4. Remove the air filter assembly.

a. Remove the fixing bolt of air filter assembly bolt and
take down the filter lower assembly.
Tool: 10mm socket
5. Remove the intake duct bolt, and take down the

air filter intake duct.
6. Refit the air filter assembly

a. Refit the lower air filter assembly at its correct
position, refit the fixing bolt and tighten it.
Tool: 10mm socket
7. Refit the intake duct at its mounting position, EG

refit the fixing bolt and tighten it.
8. Refit the air filter element into the air filter.

9. Refit the air filter upper cover.
a. Reconnect the air filter upper cover and the lower
body correctly, and refit and tighten the screw.
b. Refit the air filter outlet pipe onto the air filter upper
shell, refit the hoop bolt correctly and tighten it. .

Exhaust system
Exhaust system
Overview
1. The exhaust system is mainly intended to discharge as much as possible
post-combustion exhaust gas in the cylinder block and process the hazardous emission.
2. The hazardous exhaust gas will be transformed by the three-way catalyzer into harmless
gas, and delivered through the muffler to reduce its noise and finally discharged into the
EG atmosphere. The exhaust gas will be emitted in conformity with emission standards after it
is catalytically converted and muffled by the exhaust system.
3. Major components of the exhaust system include:
a. Exhaust manifold
b. Three-element catalyzer
c. Heating type oxygen sensor
d. Exhaust pipe and muffler
Precautions
1. When the engine is hot, the exhaust system temperature is very high; therefore, the
exhaust system can be only serviced after the engine is cooled down, in order to avoid
injuries.
2. When refitting the exhaust pipeline, note that the heating elements of the exhaust pipeline
shall maintain a sufficient distance from the body and other body parts; otherwise the
friction noise may be caused or other parts may be damaged.
3. The exhaust pipeline connection shall be firm and reliable without leakage.
4. Various exhaust pipes shall be free from cracking and abnormal noise.
EG
Preparations
Recommended tools
Figure Name Applicable scope
Feeler gauge Check the exhaust manifold
EG
Measurement of the oxygen

Digital multimeter
sensor
Tighten the bolts of the exhaust

Torque wrench
pipe assembly
Technical data
Required tightening torques
Fasteners N .m
M8: 22-26
Muffler mounting bolt
M10: 41-51
Connecting bolt between muffler and three-way catalyzer 41-51
Fixing bolt, exhaust manifold 45-55
Fixing bolt, exhaust manifold upper/lower heat shield 10-12 EG

Fixing bolt, engine rear lifting lug 45-55
Fault diagnosis
Symptom Malfunction cause Troubleshooting
The exhaust temperature is too Three-way catalytic converter is Clean or replace the three-way
high blocked catalyzer
The fuel quality is too poor to Clean the fuel system or replace
block the three-way catalyzer the three-way catalyzer
Three-way catalytic converter is
EG blocked
The engine burns engine oil to
Check the engine for mechanic
fault and replace the three-way
block the three-way catalyzer
catalyzer
The exhaust pipe joint bolt is Tighten the bolt to the specified
loosened torque
The exhaust pipe graphite seal

Replace the graphite seal ring
ring is deformed
The exhaust manifold gasket is Replace the exhaust manifold

Gas leakage of exhaust pipe
broken gasket
The exhaust manifold is cracked

Replace the exhaust manifold
or broken
The exhaust pipe or muffler is Replace the exhaust pipe or

burnt out or corroded muffler
The exhaust pipe lifting lug is Replace the exhaust pipe lifting
damaged lug
The hanger rod and mounting

Adjust or replace relevant parts
Abnormal noise in the exhaust holder are bent or damaged
pipe
The exhaust pipe is disconnected Tighten all loose fasteners to the
or loosened specified torque
The internal structure of the

Replace the exhaust pipe
exhaust pipe is damaged
Onboard inspection
1. Check the exhaust system
a. After the engine is started, check various components of the exhaust system for leakage, welding
failure or damages; if any, repair or replace the faulted component.
Caution
As the exhaust pipeline is very hot when the engine is running or immediately after the engine is
stopped, the exhaust system can be only operated after the engine is naturally cooled down;
otherwise the scald injury may occur.
b. After the engine is started, check the exhaust system for shrill exhaust noise or other abnormal EG
noise. If any, diagnose and service the system as per the fault diagnosis procedure.
Exhaust manifold
Part Diagram
EG
1 Ground wire 8 Heat shield, exhaust manifold
2 Bolt 9 Bolt
3 Exhaust manifold upper heat shield 10 Nut
4 Exhaust manifold gasket assembly 11 Stud
5 Oxygen sensor 12 Bolt
6 Screw 13 Exhaust manifold assembly
7 Engine rear lifting lug

Replacement
1. Lift the vehicle, or place the vehicle in the ground pit.
2. Remove the exhaust manifold assembly.
a. Disconnect the front oxygen sensor connector of
the exhaust pipe , remove the fixing nut of the front
oxygen sensor probe, and take down the front
oxygen sensor.
EG
b. Remove the fixing bolt of the engine rear lug on the

exhaust manifold, and take down the engine rear
lifting lug.
c. Disconnect the rear oxygen sensor connector,
remove the front and rear fixing bolts and nuts of
the three-way catalyzer, and take down the
three-way catalyzer assembly. (Refer to “Chapter
EG Engine part - Exhaust purifier- Three-way
catalyzer - Replacement, Three-way catalyzer”)
d. Remove these fixing bolts of earthing wiring
harness on the exhaust manifold, and disconnect
the earthing wiring harness.
e. Remove the upper and lower fixing bolts of the

exhaust manifold heat shield, and take down the
heat shield.
f. Remove the fixing bolt ① and nut ② of the

exhaust manifold, and take down the exhaust
manifold assembly ③.
Caution
After the exhaust manifold is removed, stop the
cylinder head exhaust port using clean plastic cloth or
other clean lint-free materials to prevent the entry of
foreign matters into the cylinder.
EG 3. Refit the exhaust manifold assembly.

a. Refit the exhaust manifold assembly ③ onto the
engine, refit the fixing bolt ① and nut ②, and
tighten them.
Torque: 45~55N·m
b. Refit the exhaust manifold upper/lower heat shield,

refit the fixing bolt and tighten it.
Torque: 10~12N•m
c. Reconnect the earthing wiring harness of the

exhaust manifold, refit the fixing bolt and tighten it.
d. Refit the engine rear lifting lug, refit the fixing bolt
and tighten it.
Torque: 45~55N·m
e. Refit the three-way catalyzer assembly, refit the
front and rear fixing bolts and nuts, and reconnect
the rear oxygen sensor connector. (Refer to
“Chapter EG Engine part - Exhaust purifier-
Three-way catalyzer - Replacement, Three-way
catalyzer”)
f. Refit the front oxygen sensor probe, and tighten the EG
fixing nut.
g. Reconnect the front sensor connector of exhaust
pipe.
4. Start the engine and check fthe exhaust system for leakage.
Exhaust pipe and muffler assembly

Part Diagram
EG
1 Mounting cushion 4 Hanger plate
2 Muffler assembly 5 Muffler body assembly
3 Hanger plate
Replacement
1. Remove the muffler assembly.
a. Remove the connecting bolt and nut between
muffler and three-way catalyzer.
EG
b. Remove the fixing bolt of the muffler mounting, and
take down the muffler assembly and mounting
cushion.
c. Remove the fixing bolt of hanger plate of the muffler

assembly, and take down the muffler hanger plate.
2. Refit the muffler assembly.

a. Refit the muffler hanger plate, and tighten the fixing
bolt.
Torque: 22~26N·m
b. Refit the muffler assembly and mounting cushion,

refit the muffler mounting bolt and tighten it.
Torque: 41~51N·m
EG c. Refit the connecting bolt and nut between muffler

and three-way catalyzer, and tighten them.
Torque: 41~51N·m
Starting and charging

Starting and charging
Overview
The starting and charging unit mainly comprises the starter assembly and generator assembly. The
starter is also called a motor, and is intended to transform the battery electric energy into mechanic
energy and drive the engine flywheel to rotate to realize the engine startup. The generator is a mechanic
device designed to transform other types of energy into the electric energy.
EG
Precautions
1. When the engine is running, do not disconnect the battery positive terminal or the
generator B+ terminal wiring harness; otherwise the vehicle electric circuit will generate a
very high instant voltage, and the generator will be prevented from acquiring accurate
voltage signals to result in a too high generator voltage which may cause burnout of
electric elements of the vehicle electric circuit.
2. The generator is provided with negative earthing, so the battery earthing terminal must be
also provided with negative earthing; otherwise the battery will be discharged via the
silicon diode to damage it.
EG
3. After the generator starts to work, do not check whether the generator is discharged using
the spark test, but test it using the bulb or multi-meter to avoid damages of the diode.
4. It is absolutely not allowed to test the generator silicon rectifier cell using the megameter
or to test the insulation conditions of the generator using the 220V AC current; otherwise
the diode may be penetrated.
5. After the generator is replaced, the generator belt shall not be over-tensioned; otherwise
the service life of the generator bearing will be shortened.
6. When the engine revolution is low, avoid over-loading for a long period of time; otherwise
it may cause the low voltage of the battery. When the engine revolution is low, the
generator will generate a little of electricity, and the long-time overloading may cause the
low voltage of the battery.
7. The starter will work for short time at a high current, but it shall not work for long time.
Each start shall be finished within 5s, and there shall be an interval of at least 30s between
two consecutive starts. After the engine is started, the reveres dragging by the starter
shall not last for more than 30s. Otherwise, the starter may be burnt out due to the
temperature rise.
8. After engine is started, quickly turn the ignition key from the ON position, and cut off the
power supply of the starter. Never depress the accelerator pedal with the ignition key at
ON, for this will lead to quick rise of the engine revolution to make the starter inoperative.
9. The starter is designed to start the engine, so never move the car by using the starter as
the power source.

Symptom Possible cause Refer to
The starter doesn’t 1. Control circuits of the starter switch Check the electric circuit for reliable
work etc. (broken wire) connection

2. Carbon brush and commutator (poor
(DAM15RL)-Starting and charging -
contact)
Inspection and repair, Starter”
EG
3. Internal circuit of the starter (open or
short circuit)
The starter works Check the electric circuit for reliable

1. Lead wire (poor contact)
ineffectively and connection
can’t start the engine
2. Commutator (surface burnout or
contamination by oil)
3. Carbon brush (excessive wear) or “Chapter EG Engine part - Engine

carbon brush spring (insufficient (DAM15RL)-Starting and charging -
elasticity to cause poor contact with Inspection and repair, Starter”
the commutator)

4. Electromagnetic switch (main
contact burnout, poor contact )

5. Bearing (wear), armature (friction
with the shell)
After the engine is 1. Starter relay (the internal copper “Chapter EG Engine part - Engine
started, the starter contact disc is adhered with two (DAM15RL)-Starting and charging -
continues to rotate contacts) Inspection and repair, Starter”
and produces shrill
noises “Chapter EG Engine part - Engine
2. Starter armature (broken or bent) (DAM15RL)-Starting and charging -

3. Starter contact toothed surface
(roughening or getting stuck)
Preparations
Recommended tools
Digital multimeter Check the generator and starter
EG
Test the lead wire group Check the generator and starter
Remove/refit the generator and

Torque wrench
starter
Dial indicator Test the starter.
Thickness gauge Test the starter.
Maintenance data
Starter
Rated voltage 12V
Output power 1.2kw
Rated time 30S

Starter
Clockwise rotation when

Rotating direction viewed from the direction of
transmission output
Initial pull-in voltage ≤8V

Initial pull-in voltage
（20°C）
Release voltage Release

Release voltage
voltage ≤4.8V(20°C)
Unloaded (20°C) 11V ≤90A-2500r/min EG

Loaded (20°C) 7. 7V, 300A ≤9.1N .m≥850r-min
Braking (20°) 4V ≤650A≥15.6N . m
Circumference of
commutator of starter Maximum value 0.008mm
assembly (radial runout)
Diameter of commutator Standard value 028.3mm

of starter assembly
Minimum value 028.1mm
Electric brush Effective working length 5mm
Generator
Working method Continuous
Rated output 85A, 14V
Revolution at zero load 1000r/miN . max
Working revolution 1000-18000r/min
Ambient working temperature -40°C~105。C
Earthing method Negative
Mass
Electromagnetic polarity 12-pole
Clockwise when viewed from

Rotating direction
the driving end
Output current (A)

Voltage (V) Generator revolution ( r/min)
Cold state Hot
28min 15min 1300
70min 60min 2000
82min 65min 2500

13.5
88min 70min 3000
95min 78min 5000
100min 85min 6000

Starter assembly
Check and repair
5. Dismantle the starter assembly
a. Disconnect the starter wiring harness connector.
EG b. Remove the starter power wire fixing nut, and
disconnect the starter positive terminal wiring
harness.
Tool: 13mm socket
c. Remove the starter fixing bolt, and take down the

starter.
d. Take down the starter.
6. Test the starter.

a. Adjustment of pinion clearance
• Separate out the magnetic field coil wire from the
terminal M of the electromagnetic switch.
• Connect a 12V battery between the terminal S and
the terminal M.
Caution
• This test must be quickly done (within 10s) to avoid burnout of the coil.
• When connecting a 12V voltage between the terminal S and the terminal M, the pinion will
bounce up. If the pinion doesn’t eject out, replace the electromagnetic switch.
• When electrified, use the thickness gauge to

measure the clearance from the pinion to the
stopper (pinion clearance).
EG
• When diselectrified, use the vernier caliper to

measure the clearance from the pinion to the
stopper (pinion clearance).
b. Electromagnetic switch test

• Separate out the magnetic field coil wire from the
terminal M of the electromagnetic switch.
• Connect a 12V battery between the terminal S and
the terminal M.
Caution
• This test must be quickly done (within 10s) to
avoid burnout of the coil.
• When connecting a 12V instant voltage between

the terminal S and the terminal M, the pinion will
bounce up. If the pinion doesn’t eject out, replace
the electromagnetic switch.
• If the pinion remains at its ejected position when the
power supply is maintained , the system works
normally. If the pinion doesn’t bounce back, replace
the electromagnetic switch.
• After the power supply is interrupted, if the pinion
bounces back timely, the system works normally. If
the pinion doesn’t bounce back, replace the
electromagnetic switch.
7. Separate out the magnetic field coil wire from

the terminal of the electromagnetic switch.
Tool: 12mm socket
EG 8. Remove these 2 fixing screws of the

9. Remove these 2 fixing bolts of the starter shell.
Tool: 8mm socket
10. Clean the starter parts.

• Parts shall not be washed by submerging it in the cleaning liquid, for submerging the magnet yoke,
excitation coil subassembly or armature in the cleaning liquid will destroy their insulativity.
• These parts shall be cleaned using cloth.
• Driving parts shall not be submerged in the cleaning liquid. The overrun clutch has been oiled
before delivery and submerging it in the cleaning liquid will wash off the lubricating oil in the
clutch.
• Driving parts can be cleaned using the brush dipped with cleaning liquid and then dried with a
piece of cloth.
11. Check the armature.
a. Use a group of V-shaped blocks to support the
armature, and rotate the armature using the
micrometer gauge to measure the out-of-roundness
of the surface, provided that the armature doesn’t
come into friction with the carbon brush.
Standard value: 0. 004 mm
Limit value: 0.008mm
b. Measure the armature diameter.

Standard value: 45.5mm
Limit value: 45.46~45.54mm
12. Check the electric brush and the electric brush holder. EG
a. Check whether the electric brush holder plate is electrically connected to the electric brush holder;
if not, this is normal.
b. Check whether the contact surface between various carbon brushes of the armature is very rough.
If the wear of carbon brush exceeds its limit, replace the brush.
Limit value: To the remaining length of 2mm from the electric brush lead wire.
c. If the carbon brush contact surface is rectified, or the brush holder is replaced, refinish the contact
surface around the armature using the emery paper.
13. Check the overrunning clutch.
a. Make sure that the pinion can’t rotate
counterclockwise, but it can rotate clockwise.
b. Check the wear and damages of the pinion, and
make sure that there is no missing tooth, burnout or
deformation.
14. Check the armature coil.

a. Place the rotor on the coil short circuit tester.
b. Put a thin iron plate above the rotor, keep it parallel
with the rotor central axis, slowly rotate the rotor
and observe the thin plate. If the iron plate is not
pulled in and doesn’t vibrate, the rotor works
normally.
Caution
Before conducting this test, thoroughly clean the
armature surface.
c. Check the insulation between the commutator lug

and rotor iron core. If they are not electrically
conducted, it is normal.
EG d. Check the electric conduction between various

commutator lugs. If they are electrically conducted,
it is normal.
15. Check the electromagnetic switch.

a. Coil open circuit test
• Check the electric conduction between the terminal
M and the body A.
• If they are not electrically conducted, replace the
b. Check the contact point.

• Check the electric conduction between the terminal
B and the terminal M.
• If they are electrically conducted, replace the
c. Check of switch contact

• Forcibly push down the indicated end of the
electromagnetic switch to close the internal contact.
With the switch end not released, check the electric
conduction between the terminal B and the terminal
M.
• If they are not electrically conducted, replace the
16. Reassemble the starter.

a. Refit the starter shell and tighten these 2 fixing
bolts.
Tool: 8mm socket
Torque: 9~11N·m
b. Refit the electromagnetic switch and tighten these 2
fixing screws.
c. Refit the magnetic field coil wire onto the terminal of EG

the electromagnetic switch, and tighten the nut.
Tool: 13mm socket
Torque: 9~11N·m
17. Install starter assembly

a. Refit the starter at its mounting position and tighten
the fixing bolt.
Tool: 15mm socket
Torque: 50±5N·m
b. Refit the starter wiring harness connector.

c. Refit the starter power wire and tighten the nut.
Tool: 13mm socket

Generator assembly
Replacement
4. Dismantle the generator assembly.
a. Disconnect the generator connector.
b. Remove the fixing nut of the generator output
EG terminal, and take down the output wiring harness.
c. Loosen the generator fixing bolt and nut.

Tool: 16mm socket, 13mm socket
d. Loosen the generator adjusting screw to incline the

generator to the cylinder block, and remove the
generator belt.
e. Remove the central bolt of the generator.
Tool: 16mm socket
f. Take down the generator assembly.
5. Check the generator.

a. Check the generator for cracking and wear, and check whether it can rotate freely.
b. Check the generator inside for open and short circuit, and check the terminal for corrosion,
burnout and other defects.
c. Connect the red probe of the multi-meter to the “armature” terminal of the generator, and connect
the black probe to the shell. Run the engine at the medium speed or above. The standard voltage
of the 12V electric system shall be about 14V; if the measured voltage is the battery voltage, the
generator is not working.
6. Install the generator assembly.
a. Refit the generator at its correct position, and fit
these 2 fixing bolts and the one adjusting bolt of the
generator, but do not tighten them. EG
b. Adjust the generator position and refit the generator

belt.
Caution
Before fitting, check the generator belt, and if
cracking, breakage, aging or other defects of the belt
are found, replace it.
c. Tighten the generator adjusting bolt, and tension

the generator belt properly.
d. Tighten the generator fixing bolt.
Torque: 21~25N·m
Caution
Note that the generator belt shall not be over-tensioned;
otherwise the service life of the generator bearing will be
shortened.
e. Reconnect the engine connector.

f. Refit the generator output terminal onto the wiring
terminal, fit an tighten the nut.

Ignition system
Ignition system
Overview
The ignition system is a key component of the gasoline engine, and its performance has a direct bearing
on the power, fuel consumption and exhaust emission of the engine. Any equipment which can generate
electric spark between both electrodes of the spark plug is called the engine “ignition system”. It is
generally composed of the battery, generator, distributor, ignition coil and spark plug.
EG
Precautions
3. Before removal and refitting of electric elements, turn off all electric loads and ignition
switch, and disconnect the battery negative cable; otherwise the electric elements or
control unit may be damaged.
4. When servicing the ignition system, use the fault diagnoser to carry out the fault diagnosis
EG
of the engine, and record the results of diagnosis. After all service is finished, read the
fault code again and delete it.
5. When starting or running the engine, check the ignition system. Wear insulation gloves to
avoid electric shock.
6. Before checking the sparking of spark plug, disconnect the power supply of the injector,
and ensure that there is no fuel or other flammables around the spark plug.

Name Common fault Refer to
Failed start, unstable idling, poor

acceleration (movement),
Spark plug (DAM15R)- Ignition system -
unexpected shutdown,
Inspection and repair, Spark plug”
out-of-limits emission etc.
Failed start, unstable idling, poor “Chapter EG Engine part - Engine

acceleration (movement), (DAM15R)- Ignition system
High-voltage damping wire
unexpected shutdown, -Inspection and repair,
EG out-of-limits emission etc. High-voltage damping wire”
Failed start, unstable idling, poor “Chapter EG Engine part - Engine

acceleration (movement), (DAM15R)- Ignition
Ignition coil
unexpected shutdown, system-Inspection and repair,
out-of-limits emission etc. Ignition coil”
Part Diagram
EG
1 High-voltage damping wire 4 Spark plug assembly
2 High-voltage damping wire 5 Bolt
3 Ignition coil assembly

Maintenance data
Ignition coil parameters
Secondary resistance 8±0.8KΩ
Primary resistance 0.62±0.06Ω
Working voltage range 6-18V
Primary charging time 3.2 ± 0.025ms
Primary operating current peak 8.6A

EG
Minimum ignition energy 50mJ
Working temperature -40-125 °C
Spark plug parameters
Electrode gap 0.9±0.1mm
Resistance between wiring screw and central electrode 3-7.5KΩ
Common specification
Application Specification
Ignition type Dual-cylinder concurrent firing
Firing sequence 1-4 or 2-3

Preparations
Recommended tools
Remove/refit the fixing bolt and

Torque wrench
nut
EG
T-shaped universal spark plug

Remove/refit the spark plug
sleeve
Spark plug
Check and repair
4. Remove the ignition coil.
a. Disconnect the ignition coil connector.
EG
b. Remove these 2 fixing bolts of the ignition coil.

Tool: 10mm socket
c. Remove the ignition coil and high-voltage damping

wire.
Caution
Before pulling out the high-voltage damping wire,
make sure that the high-voltage damping wire of each
cylinder is located at the corresponding position on
the ignition coil and is properly marked.
5. Remove the spark plug.

a. Use a specialized socket tool to remove the spark
plug.
b. Take out the spark plug.
6. Check the spark plug.

• Check the external surface of the spark plug
insulation for cracking.
• Check the sparking position of spark plug for
deposit carbon.
• Check the spark plug positive and negative
terminals for burnout. Check the spark gap of the
spark plug.
Standard value: 0.9±0.1mm
7. Identify the faulted parts using the following methods: EG
a. Onboard inspection method.
• Touching: start the engine, run it at the idle speed, touch the insulation ceramic of the spark plug
by hand; if the temperature rises abruptly and quickly, the spark plug works normally.
• Short circuit method: start the engine, run it at the idle speed, use the screwdriver to short circuit
the spark plug in each cylinder, and judge the engine revolution and noise changes by listening. If
the revolution and noise changes are noticeable, the spark plug works normally.
• Sparking method: screw off the spark plug, put it on the cylinder block, and spark it using the
high-voltage wire; if no spark is generated or the spark is weak, the spark plug has electric
leakage or it fails.
b. Color observation method.
• Remove the spark plug for observation. If the spark plug is russet or rusty, it is normal; if the spark
plug is oily, its clearance is incorrect or the fuel supply is excessive, or the high-voltage line is in
short circuit or open circuit; if the spark plug is smoky black, its cold/hot type is incorrectly
selected and the engine oil flows upward; if any oily deposit is found between the top end and the
electrode, the leakage of engine oil into the cylinder is irrelevant to the spark plug, or if any black
deposit is found, the carbon deposit is found on the spark plug to cause bypassing, or if the grey
deposit is found, the electrode is covered by the additive in the gasoline to cause misfiring; if there
is any serious ablation, such as scarring on the top end, breakage of black pattern and smelting of
electrode, the spark plug is damaged.
8. Refit the spark plug.
Use a specialized socket tool to tighten the spark
plug.
Torque: 20~25N·m
Caution
When refitting the spark plug, the tightening torque
shall meet technical requirements of Foton. The spark
plug shall not be too loose or too tight, to avoid
leakage or damages of the spark plug and spark plug
hole.
9. Refit the ignition coil and high-voltage damping

wire
a. Refit the ignition coil and high-voltage damping wire
into the cylinder head.
EG b. Refit and tighten these two fixing bolts of the ignition

coil.
Tool: 10mm socket
Torque: 6~10N·m
c. Reconnect the ignition coil connector.

12. Start the engine and check whether it works normally.
High-voltage cable
Check and repair
4. Remove the high-voltage damping wire.
a. Disconnect the high-voltage damping wire from
the ignition coil.
EG
b. Lightly rotate the high-voltage damping wire and

pull it out.
Caution
c. Take down the high-voltage damping wire.
5. Check the high-voltage damping wire.

a. Check the high-voltage damping wire for breakdown signs, and in the case of breakdown, replace
the wire.
6. Refit the high-voltage damping wire.
a. Refit the high-voltage damping wire onto the
cylinder block.
b. Reconnect the high-voltage damping wire to the

ignition coil.
EG 7. Reconnect the battery negative cable.

Ignition coil
Check and repair
4. Remove the ignition coil.
a. Disconnect the ignition coil connector.
EG
b. Remove these 2 fixing bolts of the ignition coil.

Tool: 10mm socket
c. Remove the ignition coil and high-voltage damping

wire.
Caution
d. Take down the ignition coil.

5. Check the ignition coil

• Check the ignition coil for cracking.
• Test the ignition coil.
a. Use a fault diagnoser to confirm that no fault code is stored. If any fault code exists, record the
code number. Even if the stored code is not related to the ignition system, this code shall be
diagnosed to solve the problem.
b. Pull out the fuel pump fuse.
c. Remove the ignition wire and the spark plug.
d. Connect a new spark plug to the high-voltage damping wire, and connect the spark plug negative
EG terminal to the cylinder block.
e. Start the engine, and check whether there is sparking between spark plug electrodes.
f. If the spark is weak or doesn’t exist, use a new ignition coil to repeat the test. If the spark is strong
with a new ignition coil, the problem lies with the ignition coil. In such a case, replace the ignition
coil. If the spark doesn’t exist with a new ignition coil, the ignition circuit is defective, and requires
an inspection. Use a proper tool to remove the spark plug and test it.
g. Use a fault diagnoser to confirm that no fault code exists after the above-mentioned inspection.
Except for the code stored in the step a, all codes must be cleared. Then carry out
troubleshooting against all recorded codes.
6. Refit the ignition coil and high-voltage damping
wire
a. Reconnect the ignition coil and high-voltage
damping wire
b. Refit the ignition coil and high-voltage damping wire

c. Refit and tighten these two fixing bolts of the ignition

coil.
Tool: 10mm socket
Torque: 6~10N·m
d. Reconnect the ignition coil connector.

EG

Engine control system

Engine control system
Precautions
• To prevent injuries or vehicle damages, before removal or refitting of any electric device,
disconnect the battery negative cable, and finally reconnect the battery negative cable.
• Unless otherwise specified, the ignition switch must be turned off.
EG
Danger
Before connecting or disconnecting the battery negative cable, do turn off the ignition switch
and illumination switch. (Failure to do so may damage the semiconductor element).
2. When servicing, perform adjustment, removal & refitting and testing in accordance
with various requirements stipulated in this manual.
3. Parts of the electronic injection system has a high reliability. When the vehicle or engine
works abnormally, firstly check relevant mechanic parts, system connectors and wiring
harness, earthing wire, spark plug high-voltage wire connector and fuel pressure regulator
vacuum pipe etc.
4. Before refitting, use the sealant scraper or steel wire brush to remove foreign matters on
the mounting surface, and make sure that the sealing surface is flat and smooth, and free
from oil. Do not forget to remove sealant in the mounting hole and threaded hole and on
the threads.
5. When refitting the sensor and actuator, tighten bolts as per the specified torque.
6. Unless otherwise specified in the test, do not use the pointer type multi-meter to test the
ECM and sensor, but use the high-impedance digital multi-meter to do this.
7. When refitting and handling the sensor, take much care to avoid any impact and drop, for
this may cause substantial damages.
8. In the case of low battery voltage or starter fault, do not start the engine for long to avoid
damages of the three-way catalyzer.
9. Do not check the system electric signal by puncturing the wiring harness using a needle.
10. When removing and replacing the oxygen sensor, prevent the sensor from contacting
water or other liquid.
11. Do not run the fuel pump for long when it carries no gasoline. Nor run it in the air with
gasoline in it.
12. Most of electronic injector parts are unrepairable. Once any part is damaged, it should be
replaced.
13. The system shall be provided with anti-interference spark plug and high-voltage wire, for t
he non-impedance type spark plug and high-voltage wire will not only release the
interference wave, but will also impair the functioning of ignition coil drive module in ECM.
14. Do not remove the ECM cover.
System overview
1. Overview
DAM15R is a kind of electronic multi-point injection (MPI) engine control system which utilizes
various sensors installed at different positions of the engine to measure various working
parameters of the engine, and accurately control the injection quantity by controlling the injector
via the preset control program in the computer to enable the engine to obtain the gas mixture of
the best concentration under all working conditions. In addition, the electronic gasoline injection
system can also realize cranking enrichment, warm-up enrichment, acceleration enrichment,
full-load enrichment, deceleration enrichment, forced idling cut-off, automatic idling speed control
EG
and other functions via the control program in ECM, thus to satisfy gas mixture requirements
under special engine conditions to enable the engine to obtain good fuel economy and emission
level with improved working performance of the vehicle. Furthermore, ECM is also provided with
several fault diagnosis modes to simplify the troubleshooting work.
2. The engine control system mainly comprises following features:
• Knock control
• Mileage memory
• Overvoltage protection
• Injection quantity
• Injection timing
• Ignition control
Features of the engine control system • Vehicle master power supply relay control
include
• Idle speed control
• Fuel pump control
• Exhaust after-treatment
• System control
• Realization of OBD functions
• Fault diagnosis
• Canister solenoid valve control

3. ECM control structure diagram
Normal power supply of

Fuel injector 1
battery
IG power Fuel injector 2
Ignition switch Fuel injector 3
Front oxygen sensor Fuel injector 4

EG
Rear oxygen sensor Ignition coil 1
Water temperature Ignition coil 2

sensor
Crankshaft position Throttle motor

sensor Engine control module (ECM)
Intake camshaft position Intake VVT valve
Exhaust camshaft
sensor Exhaust VVT valve
Intake temperature
sensor Front oxygen sensor
heater
Intake air pressure Rear oxygen sensor

sensor heater
Accelerator pedal
sensor Starter relay
Crankshaft position
Air conditioner
sensor
compressor relay
Knock sensor
Oil pump relay
Clutch switch
Low-speed fan relay
Brake switch
High-speed fan relay
A/C pressure switch

Main relay
Collision signal
Blower switch signal

High load signal
CAN communication OBD diagnosis interface

4. Engine control system diagram
EG
1 Intake 13 Fuel pressure sensor

2 Air filter 14 Crankshaft position sensor
3 Electronic throttle unit 15 Front oxygen sensor
Intake manifold pressure/temperature Exhaust manifold & three-way
4 16
sensor catalyzer assembly
5 ECM 17 Rear oxygen sensor
6 Accelerator pedal 18 Camshaft position sensor (intake)
7 Ignition coil assembly 19 Injector
8 To fuel filter 20 Spark plug
9 OCV valve assembly 21 Coolant temperature sensor
10 Fuel rail assembly 22 Knock sensor
11 PCV valve assembly 23 Canister solenoid valve
12 Camshaft position sensor (exhaust) 24 Canister
Introduction to system functions

1. Idling control
The idling control is to control the engine revolution when the accelerator pedal is depressed. The
idling control also includes the steady engine revolution control in the idling operation of the car.
Furthermore, this control also addresses the idling speed regulation when the load is increased,
for example, activation of air conditioner, power steering system and headlamp. The system is
provided with a stepping motor (integrated in the electronic throttle ) to automatically regulate the
throttle openness and realize the high-precision idling speed control.
2. Ignition timing control system
EG
Electronic injection system of the DAM15R engine is a direct ignition control system which is
provided with automatic ECM ignition timing control and charging time setting control. The ignition
system utilizes the advanced distributor-free direct ignition technology which outputs ignition
signals to the primary winding of the dual ignition coils via the built-in ignition driving circuit in the
engine electronic control module, to supply the ignition signal current to coils of the cylinders No.1
& No.4 and the cylinders No.2 and No.3 respectively and ignite both spark plugs respectively
connected to ignition coils of the cylinders No.1 & No.4 and the cylinders No.2 and No.3. In
normal operation, except for the replacement of spark plug as appropriate, other parts of this
ignition system require no maintenance. In the operation of gasoline engine, the electronic
controller will determine the set value of ignition advance angle depending on the load information
and revolution signal, and rectify it in response to the coolant temperature signal and so on, to
obtain the accurate ignition advance angle and thus determine the ignition timing.
3. Warm-up and three-way catalyzer heating control
After the engine is started at a low temperature, the quantity of air in the cylinder, fuel injection
and ignition will be adjusted to compensate the higher torque requirement of the engine. This
process will go on till the engine temperature rises to a certain threshold value (the engine
temperature is similar to the engine coolant temperature).
As the working temperature of the three-way catalyzer is above 300℃, the most essential issue of
the warm-up process is the quick heating of the three-way catalyzer. Under such a working
condition, the exhaust gas is utilized to heat the three-way catalyzer by appropriately postponing
4. Closed-loop control
The system adopts the closed-loop control of fuel supply and idling. The advantage of the
closed-loop control is that the system is capable of eliminating the difference arising out of
manufacturing and wear of the system and relevant mechanical parts to improve the
comprehensive consistence and reduce emission of the car.
5. Evaporative emission control
Due to the external radiation heat and the heat transferred by the return fuel, the fuel in the tank
will be heated to produce fuel steam. As limited by the evaporative emission regulations, such
steam containing massive HC components is not allowed to e directly discharged into the
atmosphere. The fuel steam in the system is collected in a charcoal canister via the guide pipe
and washed into the engine to take part in the combustion in good time.
The flushing gas flow rate is regulated by the canister solenoid valve which is controlled by ECM.
Such a control will only work when the λ closed-loop control system is working in the closed-loop
mode.
6. Fault diagnosis
The gasoline engine control system is capable of fault self-diagnosis. When any system
component is in trouble, ECM will turn on the fault indicator lamp to remind the driver of servicing
the car. At this moment, the system will enable the user to drive the car to the service station
provided that the gasoline engine is properly protected.
a. The system fault self-diagnosis is an indispensable of the engine control system. When one or
more system components work abnormally, the system will timely remind of the user of
performing necessary inspection and repair by illuminating the fault indicator lamp. When any
fault occurs, the system will also apply a temporary emergency program to control the engine
operation to ensure that the user can drive the car to the service station. EG
b. When the abnormal operation of certain sensor and actuator is detected, the engine fault indicator
lamp will illuminate to remind the driver.
c. When the abnormal operation of certain sensor and actuator is detected, the fault code
corresponding to the fault will be output.
d. The RAM data in the ECM related to the sensor and actuator can be read via the fault diagnoser.
Furthermore, in a certain case, the actuator can be driven forcibly.
7. Overvoltage protection
When a failure of the charging system leads to a high voltage, the system will activate the
protection mode to limit the engine revolution and thus avoid ECM damages.
8. Three-way catalyzer.
The three-way catalytic converter is also called “catalytic cleaner”. This device is fitted in the
exhaust system and is intended to eliminate most of exhaust pollutants from the engine. The
three-way catalytic converter is composed of a metallic shell, a bottom net and a catalyst layer
(containing platinum, rhodium and other precious metals) to eliminate 90% of three major
pollutants, i.e., HC (hydrocarbon), CO ( carbon monoxide ) and NOx( oxynitride) (the so-called
“three-way” refers to the chemical reaction generated in the elimination of these three
compounds).
When the exhaust gas flows through the cleaner, the platinum catalyst will oxidize HC and CO to
generate water steam and carbon dioxide, and the rhodium catalyst will reduce NOx into nitrogen
and oxygen. Such oxidization reaction and reduction reaction will be only commenced when the
temperature reaches 250℃. If the improper gasoline or lubricating oil additive is selected, or the
leaded fuel additive or the engine oil containing out-of-limit sulfur, phosphor and zinc is used, the
catalyst layer surface of the three-way catalytic converter will be covered by phosphor, lead and
other substances to prevent it from contacting the harmful components in the exhaust gas thus to
defeat its catalytic action. This is so-called “poisoning” of the three-way catalytic converter.
9. Cooling fan control
a. The car is equipped with an electric dual-speed engine cooling fan.
b. Electric fan control function: ECM will decide whether to turn on the fan or switch to the high or
low speed to reduce the internal power consumption of the engine, by judging the engine coolant
temperature and whether conditions to start the air conditioner are met.
10. Cooling fan control
a. After the air conditioner switch is turned on, ECM will receive a signal called “air conditioner
request”, prepare for loading of air conditioner depending on the current working conditions of the
engine, and then turn on the air conditioner compressor.
b. ECM will turn on or off the air conditioner provided that the air conditioner itself is properly
protected. To ensure the power output and protect the engine, the system will interrupt the air
conditioner under certain working conditions.
11. Knock control
a. The system will detect the characteristic vibration induced by knock via the knock sensor installed
between the No.2 cylinder and No.3 cylinder, and convert it into the electronic signal and transfer
it to ECM for processing.
b. The ECM utilizes a special processing algorithm to detect the knock in each combustion cycle of
each cylinder. Once any knock is detected, the knock closed-loop control will be activated. After
the knock danger disappears, the influenced cylinder will be advanced to its preset ignition
EG advance angle again.
Basic principle
1. Startup control principle
a. After the ignition switch is turned on, the fuel pump will run for 1.5s and then stop.
b. When the engine starts to run, ECM will detect two valid 58X signals, and the fuel pump will being
to work.
c. 0.8s after the revolution signal disappears (the analog signal is liable to be disturbed) , the fuel
pump will stop working.
d. Pre-injection: the pre-injection process will only give one injection in a normal start (if the fuel is
absorbed by the deposit carbon, the gas mixture will be thinned to cause the engine difficult to be
EG
started).
e. At beginning of start: the internal pressure of the intake manifold is indicated as the ambient
atmospheric pressure. The throttle is closed, and ECM designates a fixed parameter which varies
with the starting temperature.
f. In the course of start: the fuel injection quantity will vary with the coolant temperature, and the
ignition angle also changes all the time along with the engine coolant temperature, intake
temperature and engine revolution.
g. At ending of the start: the starting mode will be ended when the engine revolution exceeds
600rpm.
2. Fuel injection control principle
a. ECM will control the injector driving time and injection timing to provide the engine with the gas
mixture of the best air-fuel ratio under all working conditions.
b. The intake of each cylinder is provided with an injector. The fuel pump in the fuel tank will pump
out the fuel and deliver it into the high-pressure fuel rail. The fuel pressure regulator will keep the
injection pressure stable and the injector will directly inject the fuel into the gas passage of each
cylinder. In each working cycle (consisting of two turns of crankshaft) of the engine, each cylinder
will inject fuel once (injection sequence: 1-3-4-2), and such an injection method is called
“sequential injection”.
c. When the engine works when it is cold or at a high load, to maintain good performance, ECM will
activate the open-loop control to provide thicker gas mixture. When the engine works under
normal conditions (medium to low load), ECM will execute the closed-loop control via the
feedback signal from the oxygen sensor to obtain the best air-fuel ratio and also the best
purification efficiency of the three-way catalytic converter.
d. Fuel injection pulse width control.
Signal input ECM Control output
Air-fuel ratio correction
Closed-loop feedback correction
Intake manifold pressure

Injection quantity Fuel injection pulse
Inflating temperature
calculation width
Self-learning correction
Power voltage correction
Acceleration enrichment
Signal input ECM Control output
Deceleration dilution
Deceleration cut-off
Injector parameter
Explanation on control signals:
Correction item Contents
Air-fuel ratio at start

EG Air-fuel ratio at engine working
Air-fuel ratio at low engine coolant temperature
Composition of air-fuel ratio Air-fuel ratio at normal engine coolant temperature
Air-fuel ratio in power enrichment mode Theoretical
air-fuel ratio
Air-fuel ratio at overheat protection
Control the actual air-fuel ratio close to the

Closed-loop feedback correction theoretical air-fuel ratio via the feedback signal of
the oxygen sensor
Intake manifold pressure Directly read from MAP fitted on the intake manifold
Correct the inside slow changes due to long-term

Self-learning
operation of the engine
When the battery voltage changes, the voltage

Power voltage correction can ensure the correct fuel injection
quantity
When ECM detects the intake manifold pressure

and the throttle openness is largely increased, the
Acceleration enrichment fuel injection quantity will be increased to avoid
instant thinning of the engine gas mixture, in order to
improve the power performance
When ECM detects the intake manifold pressure

and the throttle openness is largely decreased, the
Deceleration dilution fuel injection quantity will be decreased to avoid
instant thickening of the engine gas mixture, in order
to improve the emission and driving performance.
When the system detects the car deceleration, it will

cut off the fuel supply, in order to reduce the
emission and fuel consumption. When the engine
Deceleration cut-off
revolution is higher than the set value, the system
will cut off the fuel supply. When the ignition system
is in trouble, the system will cut off the fuel supply.
Provide the relation between engine and fuel

Fuel injection parameters
injection quantity
e. Correction of engine gas mixture
• When the engine works at the normal temperature, its part of load control is closed-lop fuel
control. At this moment, the system will make real-time correction of the injection quantity
via ECM to approximate the mixture concentration to the theoretical air-fuel ratio via ECM,
thus ensuring the three-way catalytic converter can convert the harmful exhaust gas at its
best efficiency whilst maintaining a good fuel economy.

• When the engine works within its normal temperature range, it will be under the open-loop
fuel control when it works at full load. At this moment, to ensure the best power output of
the engine, the system will control the injection quantity at a high air-fuel ratio, and properly
increase the ignition advance angle without knock in the engine. The system will also
utilize the exhaust temperature mathematical model built at calibration to control the
exhaust temperature to protect the engine itself and the three-way catalytic converter.
• The system will judge the full-load conditions of the engine according to the signal provided
by the throttle position sensor, and when t he throttle openness reaches 80%～90%, the
system will deem that the engine works at its full load. When the driver depresses the EG
accelerator pedal, the system will properly increase the injection quantity to satisfy the
engine’s power demand at acceleration. The increment of injection quantity is in direct
proportion to the changing ratio of the throttle openness. At acceleration, ECM will firstly
postpone the ignition advance angle, and then gradually recover it, with the purpose to
avoid impacting the driveline due to the torque increment arising out of the fast
acceleration of the engine.
• When the load in the acceleration mode approaches the engine full load, the system will
temporarily disconnect the air conditioning system to ensure the power output at
acceleration. In all cases, when the engine revolution exceeds the maximum revolution set
by the engine overdrive system, the system will cut off the fuel supply to inhibit the
unlimited rising of revolution thus to protect the engine and avoid “loss of control”. When
the revolution drops to below the maximum revolution limit, the system will recover the fuel
supply immediately.
3. Ignition control principle
a. Start: When the engine is started, a fixed ignition advance angle will be applied to ignite the gas in
the cylinder and provide a positive torque. After the engine revolution rises to a certain speed,
ECM will calculate the ignition advance angle according to the input signal.
b. Ignition advance angle control
Correction signal ECM Output control
Correction of coolant temperature
Correction of intake temperature
Altitude correction
Idling speed correction

Calculation of ignition advance
Main ignition angle Ignition advance angle
angle
Deceleration cut-off correction
Acceleration correction
Power enrichment correction
Air conditioner correction
c. Main ignition advance angle: after the engine temperature reaches its normal value, the main
ignition angle at which the throttle is opened is the minimum ignition angle at the best torque point.
When the throttle is closed, the ignition angle shall be decreased to obtain a steady idling speed.
d. Ignition advance angle correction

• Acceleration correction: If ECM will detects a knock signal in car acceleration, it will correct
the ignition angle till no knock occurs. It will also relive the engine revolution fluctuation
arising out of the torsional shock of the driveline.
• Power enrichment correction: In the vicinity of external characteristic point, to obtain better
power and torque, the air-fuel ratio will be increased to the Leanest Mixture That Gives
Best Torque.
• Deceleration cut-off correction: When exiting the deceleration cut-off, the system will
correct the ignition advance angle to realize a smooth transition.
EG • Air conditioner control correction: When the engine is idling, the system will deactivate the
air conditioner and correct the ignition advance angle to realize a smooth transition.
4. Idling control principle
a. Idling control
• The idling control is to control the throttle openness according to idling conditions and the
engine load change at idling, to maintain the idling speed at the best revolution. ECM will
drive the throttle stepping motor to run the engine at the target idling speed depending on
the engine coolant temperature and air conditioner load. In addition, when the engine is
idling, if the air conditioner switch is turned on or off, the idling stepping motor will adjust
the throttle openness depending on the engine load to avoid unstable idling speed.
b. Calculation of target idling speed
Input ECM Output control
Basic target idling speed
Voltage compensation
Vehicle speed compensation
Fan compensation Calculation of target idling speed Target idling speed
Headlamp compensation
Air conditioner compensation
Deceleration adjustment
• Voltage compensation when the voltage is lower than 12V, the system will automatically
increase the target idling speed to increase the power generation of the generator.
• Air conditioner compensation: when the car is stopped and the engine is idling with the air
conditioner turned on, the target idling speed will be increased to 50rpm to compensate for
power consumption of the compressor.
• Headlamp compensation: when the low beam lamp is turned on, the target idling speed will
be increased to 50rpm to compensate for its power consumption.
• Fan compensation: when the coolant temperature rises and the fan runs, the target idling
speed will be increased to 50rpm to compensate for the power consumption of the fan.
c. Idling control parameters
• Idling air quantity control
• Fuel injection quantity control
• Ignition timing control
d. Design of idling control time
• Calibration of idling stability

• Calibration of acceleration mode
• Calibration of deceleration mode
• Deceleration cut-off
• Calibration of fuel supply in engine instant transition mode
• Calibration of constant-speed driving
• Calibration of increase/decrease of mechanic & electric load
e. Decisive factors of target idling speed
• When the engine water temperature is low, the system will give a high target idling speed
to accelerate the warm-up. EG
• When any xternal load (for example, headlamp, air conditioner, cooling fan and other
electric loads) is turned on, the system will increase the idling speed to compensate for the
increased load and maintain the idling stability.
5. Knock control principle
a. Introduction to knock sensor
• The knock sensor is a kind of shock acceleration sensor which is fitted on the engine
cylinder block. Generally, it is fitted between No.2 cylinder and No.3 cylinder to benefit the
knock balance. ECM will utilize the shock frequency signal from the sensor to judge
whether any shock occurs in the engine through wave filtering inside ECM. When any
knock signal is detected, ECM will correct the ignition angle till no knock occurs.
b. Knock control conditions
• The vehicle is equipped with a knock sensor.
• The engine revolution is higher than 800rpm.
• MAP is greater than 40kpa.
c. Knock control mode
• Steady control When the engine works normally, ECM will collect and analyze the noise
generated in the engine combustion process via the knock sensor, and detect any knock
through filtering. Once the knock strength is out of limit, the system will postpone the
ignition advance angle of the cylinder which is reported to experience a knock, to eliminate
the knock.
• Instant control: The knock is liable to occur in the case of fast acceleration or abrupt
change of engine revolution. After the system forecasts the possibility of knock, it will
automatically postpone the ignition advance angle to avoid the occurrence of out-of-limit
(strong) knock.
• Quick postponing of ignition angle: After the system detects any knock, it will quickly
postpone the ignition advance angle depending on the engine revolution, and recover the
normal operation within the subsequent 2 to 3 seconds.
• Adaptive adjustment of ignition angle: The engine may have become different or been
changed due to the manufacturing error and the wear after long-term operation (belt, pulley,
cam and the like which may influence the phase angle). During the initial operation of the
system and engine or re-electrification of the ECM, the knock may occur when the engine
is working, and it will be recorded by the system. After running-in, the system will
automatically generate an adaptive ignition adjustment correction value (self-learning
value). When the engine operates to the same working condition, the system will
automatically make an adaptive adjustment to the ignition advance angle. This is to
prevent the occurrence of any strong knock. The adaptive learning of the system will be
continuously updated in the course of engine operation.
6. Canister solenoid valve control principle
a. It is intended to control the canister purging flow rate. The canister solenoid valve is controlled by
ECM based on the duration and frequency (duty ratio) of the electric pulse which are calculated
from the engine load, engine coolant temperature, revolution and other signals. The excessive
accumulation of gasoline steam in the charcoal canister will lead to leakage of gasoline to cause
environmental contamination; therefore, the canister solenoid valve is provided and it will be
turned on at the good time to fully mix the steam with the air and deliver the mixture into the intake
EG pipe to take part in the combustion.
b. The canister will not take part in the work in following cases:
• Where the engine works for some time after cold start and the coolant water temperature is
very high;
• Where the engine is working on the idling phase;
• Where the engine is working on the high-load phase;
• Where any important sensor is in trouble.

Component Overview Quantity Purpose
ECM will optimize the control system

depending on the signal derived from
ECM 16-bit CPU 1
the sensor to adapt it to the engine
working conditions.
Detect the oxygen concentration of the

Front oxygen sensor Heater type 1
exhaust gas
Detect the oxygen concentration of the EG

Front oxygen sensor Heater type 1
exhaust gas
ECM will compare signals from front

and rear oxygen sensors and judge
Rear oxygen sensor Heater type 1
whether the three-way catalytic
converter works normally
Intake manifold Detect the temperature and flow rate of

Piezoelectric,
pressure/temperature 1 air entering the cylinder and execute
thermistor type
sensor pressure control
Crankshaft position Magnetoelectric Detect the rotating position and

1
sensor induction coil type revolution of the engine crankshaft
Frequency response Detect whether there is any knock in the

Knock sensor 1
type engine
Fuel injector Multi-hole type 4 Inject fuel via the ECM signal
Detect the engine oil pressure when the

Fuel pressure sensor Piezoelectric type 1
engine is working
Control the emission via the digital

Canister solenoid valve Electromagnetic type 1
pulse square wave of ECM
3-wire carbon film

Crankshaft position
resistor sliding pointer 1 Detect the throttle openness
sensor
type
Negative temperature
Coolant temperature
coefficient thermistor 1 Detect the engine coolant temperature
sensor
type
Vehicle speed sensor Hall effect type 1 Detect the vehicle speed
Electromagnetic coil
Ignition coil 1 Ignite the gas mixture
type
Turbine type
Supply the fuel of a sufficient pressure
Gasoline pump single-stage electric 1
to the system
pump
Provide the crankshaft and camshaft

position information to ECM, i.e., the
Sensor for camshaft information needed to distinguish the
Hall effect type 2
position sensor compression top dead center and
exhaust top dead center of the
crankshaft
Component Overview Quantity Purpose
Regulate the opening/closing angle of

Stepping motor
Electronic throttle unit 1 the throttle via the stepping motor to
regulation type
control the engine revolution
Control the engine oil flow to the

OCV valve assembly Electromagnetic type 2 camshaft position actuator to change
the intake phase
EG
Engine control module (ECU, ECM)

Overview
1. ECM (both ECU and ECM mentioned in this manual refer to the engine control module, and
they are different designations for the same component ) is an electric engine control
center which is centered by the microprocessor and provided with a sensor signal input
interface and actuator drive circuit. It is intended to receive and process engine status
signals derived from various sensors and to send the control signal to the actuator, to
enable the engine work under its best conditions as per the preset program, and maintain
the satisfactory power performance, fuel economy and emission level. EG
2. ECM is provided with a self-protection feature.
Failure of start may occur in service, but after
the ECM is replaced, all will be ok. This seems
that the ECM is in trouble, but indeed ECM is ok,
and it just works in the self-protection mode
and will recover the normal operation after a
while.
Normal operating voltage: 9～16V
Working temperature: -40~105℃
Overvoltage protection: -14~24V
Replacement
Caution
Before connecting or disconnecting the battery negative cable, do turn off the ignition switch
and illumination switch. Fully loosen the battery negative terminal nut. When performing such
operation, do not pry up the cable terminal.
3. Remove ECM.
EG a. Disconnect the ECM connector.
b. Move aside the ECM connector.
Caution
After the connector is removed, ensure that the
connecting part of the connector is not contaminated
by dirt, water or other foreign matters.
c. Remove these 4 fixing bolts of the ECM.

Tool: 10mm socket
d. Remove the ECM module.
Caution
• Take care to avoid collision when removing
ECM.
• Take care to protect the removed ECM against
water.
• Pay attention to the protection of the plug pins.
4. Refit ECM.
a. Refit these 4 fixing bolts of the ECM.
Torque: 10±1N·m
Tool: 10mm socket
Caution
Pay attention to static protection in refitting operation.
b. Refit the ECM connector.

Caution
Pull down the ECM connector by hand to make sure
that it is installed in place.

Accelerator pedal
Overview
The accelerator pedal is also called ”throttle pedal”, and is mainly intended to control the throttle
openness thus to control the power output of the engine. The accelerator pedal installed in this vehicle is
linked to the throttle via the throttle control cable or lever.
EG
Replacement
3. Remove the throttle pedal

a. Disconnect the throttle pedal control cable.
EG
b. Take down the fixing screw of throttle pedal

assembly.
c. Take down the throttle pedal assembly.
4. Refit the throttle pedal

a. Refit the throttle pedal at its mounting position on
the body, install and tighten the throttle pedal fixing
screw.
Torque: 9~11N·m
b. Reconnect the throttle pedal control cable onto the

pedal.


Overview
1. The coolant temperature sensor (WTS) is
located on the rear water outlet adapter in the
rear end of the engine, and it is used to detect
the engine working temperature. ECM will
provide the best control program to the engine
depending on the temperature.
2. This coolant temperature sensor is of the EG
two-wire type. The single-wire sensor is usually
provided to supply the coolant temperature
signal to the instrument.
3. The engine coolant temperature sensor is a
negative temperature coefficient resistor. When
the engine coolant temperature rises, the
resistance of this sensor will diminish.
4. When the resistance increases, the output
voltage of the engine coolant temperature
sensor will increase, and when the resistance
decreases, the said output voltage will also
decrease.
Performance parameters and technical specifications

Type Technical specifications
Maximum measuring current of

5mA
the sensor
20℃: Nominal resistance 2.5kQ
Working temperature -30°C~130°C
Working response time About 153

EG
Corresponding resistance (45.313±9.7)
-40℃
kΩ

-30℃
kΩ

-10℃
kΩ

0
kΩ

10
kΩ

30
Resistance-temperature kΩ
characteristics
50
kΩ

70
kΩ

90
kΩ

110
kΩ
Corresponding resistance (0. 0712±10.

130
3) kΩ
Corresponding resistance (0. 0712±10.

140
3) kΩ
Check and repair

2. Discharge the engine coolant (Refer to “Chapter EG Engine part - Engine (DAM15R)-
Cooling system - Change, Coolant”)
3. Remove the engine coolant temperature sensor.
a. Disconnect the coolant temperature sensor
connector.
b. Remove the coolant temperature sensor.
Caution
• After removal, clean the mounting surface.
EG
• After removal, clean the mounting hole threads.
• After removal, clean the sensor mounting
threads.
4. Check the coolant temperature sensor

a. Dip the temperature sensing part of the coolant
temperature sensor in the hot water, and use a
multi-meter to measure the resistance between
terminals of the coolant temperature sensor.
b. If the results of measurement is non-compliant,
replace the coolant temperature sensor.
Caution
When testing the coolant temperature sensor by
dipping it in water, avoid the entry of water into the
terminal. After testing, dry the sensor.
5. Refit the coolant temperature sensor

a. Apply sealant onto the threads.
Sealant: 3MNUTLOCKINGPART or the
equivalent product.
b. Tighten the water temperature sensor using the

spanner and reconnect the WTS sensor connector.
Torque: 15~20N·m
6. Fill the coolant (Refer to “Chapter EG Engine - Cooling system - Change, Coolant”)
7. Start the engine and check for coolant leakage.
EG
Throttle unit
Overview
The electronic throttle unit is composed of the idle speed control valve, throttle position sensor and
throttle. It is fitted on the intake manifold, and is intended to adjust the throttle openness, and to measure
the throttle openness at real time via the throttle position sensor and feed it back to ECM, thus to satisfy
the intake demand of the engine under various working conditions.
Technical data
Item Parameter EG
Working temperature -40~+140℃
Flow rate at mechanic bottom dead center ≤2.5Kg/h
Throat diameter Φ44mm
Default flow rate at the idling position (25±6) Kg/h
Crankshaft position sensor resistance 70-100Ω

Replacement
4. Remove the intake pipeline (Refer to “Chapter EG Engine part - Engine (DAM15R)- Intake
system - Replacement, Intake pipeline”)
5. Remove the throttle assembly.
a. Remove the fixing bolt of the throttle control cable,
and take down the throttle control cable.
EG
b. Disconnect the throttle position sensor connector.

c. Disconnect the idle speed control valve connector.
d. Disconnect the idle speed control valve connector.
e. Remove these 4 fixing bolts of the throttle
assembly, and take down the throttle assembly.
Tool: 10mm spanner
6. Refit the throttle unit.

a. Refit the throttle unit onto the intake manifold, refit
these four fixing bolts and tighten them.
Torque: 10N·m
b. Reconnect the throttle position sensor connector.
c. Reconnect the idle speed control valve connector.
Caution
Check the throttle unit and intake manifold gasket for
damages and if necessary, replace it.
7. Reconnect the throttle control cable

a. Reconnect the throttle control cable onto the
throttle, fit the locking nut and tighten it.

Intake manifold pressure/temperature sensor

Overview
1. The intake manifold pressure/temperature sensor is
a combination between the intake pipe absolute
pressure sensor and the intake pipe absolute
temperature sensor, intended to feed back both the
intake pipe absolute pressure and temperature at
the same time. It is located on the top of the intake
manifold. EG
2. The absolute pressure sensor is intended to measure the engine intake air quantity, being
a key element of the speed & density type air flow metering method. This sensor can
directly sense the absolute pressure in the engine intake manifold, and based on this
reference signal, the engine electronic control module will adjust the basic fuel flow
injected into the engine.
3. The temperature sensor is provided with a negative temperature coefficient thermistor
sensing element, and the engine electronic control module can measure the temperature
of the air flowing into the engine cylinder via this sensor to correct the fuel supply to the
engine.
Working pressure range: 10~115kPa
Working temperature range: -40～130℃
System power voltage: 5V
Max. working current: 10mA
System output voltage: 0.3~4.8V
Performance parameters and technical specifications

Type Temperature Technical specifications
0℃ 5.671～6.118KΩ
20℃ 2.416～2.583KΩ
Resistance of intake temperature
sensor
40℃ 1.139～1.209KΩ
80℃ 0.315～0.3299KΩ
Replacement
3. Disconnect the wiring harness of battery positive terminal.
4. Remove the intake manifold
pressure/temperature sensor
a. Disconnect the intake manifold
pressure/temperature sensor connector.
b. Remove the one fixing bolt of the intake manifold
EG pressure/temperature sensor.
Tool: 10mm socket
c. Remove the intake manifold pressure/temperature

sensor.
Caution
After removal, clean the mounting surface.
5. Refit the intake manifold pressure/temperature

sensor.
a. Refit the intake manifold pressure/temperature
sensor onto the intake manifold.
b. Tighten the one fixing bolt of the intake manifold
pressure/temperature sensor.
Tool: 10mm socket
Torque: 8~12N•m
c. Reconnect the intake manifold
pressure/temperature sensor connector.
Caution
• Press the sensor into the mounting hole. It is
not allowed to use any impacting tool (for
example, the hammer) to knock the sensor into
its mounting hole.
• Apply engine oil onto the outer ring surface of
the O-ring.

Knock sensor
Overview
The knock sensor is a kind of vibration acceleration
sensor, and is fitted on the engine cylinder, generally
between the No.2 cylinder and No.3 cylinder, in order to
benefit the knock balance of the engine. The ECM will
judge whether any knock occurs in the engine via ECM
filtering by utilizing the vibration frequency signal from the
knock sensor. When any knock signal is detected, ECM EG
will gradually decrease the ignition advance angle till no
knock occurs, and then gradually recover the angle till the
knock is imminent. Such a cycle will be repeated.
Working temperature range -40℃~+150℃
Capacitance 800～1600pF
Sensitivity 26±8mV/g (at 5KHz )
Insulation resistance >1MohM（500VDC）
Capacitance of sensor probe C=1150±200pF

Onboard inspection
1. Start the engine and run it to its normal working temperature.
3. Connect the diagnoser.
4. Turn the digital multi-meter to millivolt position, and measure the signal voltage of No.1
and No.2 terminals.
5. Use a small hammer to knock the immediate area of the knock sensor; at this moment,
there shall be a voltage signal output.
6. Use the oscilloscope to test the sensor signal.
EG 7. Use a small hammer to knock the immediate area of the knock sensor; at this moment,
there shall be a wave signal output.
8. If the results are abnormal, replace the knock sensor.
Replacement
4. Remove the intake manifold (Refer to “Chapter EG Engine part - Engine (DAM15R)- Intake
system - Replacement, Intake manifold”)
5. Remove the knock sensor.
a. Disconnect the knock sensor connector.
b. Remove the knock sensor fixing bolt and take down
EG
the sensor assembly.
Tool: 13mm socket
Caution
• After removal, clean the mounting surface.
• After removal, avoid contact with any liquid, for
example, engine oil, coolant, and brake liquid.
Long-time contact with such liquids may cause
corrosion of the sensor.
6. Refit the knock sensor

a. Refit the knock sensor at its mounting position, refit
the fixing bolt and tighten it.
Torque: 17~23N·m
Caution
• Ensure that the knock sensor is in its correct
direction.
its mounting hole.
• The sensor must be mounted such that its metal
face rests against the cylinder block, and it is
not allowed to use any type of washer.
• The sensor signal cable shall be installed such
that it will not be exposed to resonance to avoid
breakage.
b. Reconnect the knock sensor connector.
7. Refit the intake manifold (Refer to “Chapter EG Engine part - Engine (DAM15R)- Intake
system - Replacement, Intake manifold”)
9. Reconnect the battery negative wiring harness.

Overview
1. The crankshaft position sensor is the magnetic
induction coil type revolution sensor which
utilizes the rotary magnetic line cutting to
generate the alternating current and voltage
signals. After shaping, ECM will convert such
signals into the digital signals which can be
EG identified by ECM to realize the engine system
control. The flywheel ring gear is integrated with
the signal wheel which is of the 58X teeth type
to provide revolution, rotating angle and top
dead center to ECM. The continuous gap is the
top dead center of the first cylinder. The sensor
is located on right front shell of the
transmission.
2. This sensor is used in the electronic fuel
injector to monitor the engine crankshaft
revolution and output the voltage-frequency
signal to the electronic controller to judge
working conditions of the engine. Meanwhile, in
combination with the lacking tooth position of
the signal wheel, the engine crankshaft
position can be detected to judge the position
of the top dead center of the first cylinder which
will be utilized as one of parameters to calculate
Performance parameters
Resistance of electromagnetic coil at 20℃ 860Ω±10%
Coil inductance at 1kHz 370±60mH
Working temperature range -40~120℃
Polarity of output signal Sinusoidal signal output
EG
Check and repair

4. Remove the crankshaft position sensor.
a. Disconnect the crankshaft position sensor
connector.
EG
b. Remove the crankshaft position sensor fixing bolt

and take down the crankshaft position sensor.
Caution
After removal, clean the mounting surface to ensure
that it is free from oil.
5. Check the crankshaft position sensor

a. Working temperature: -40~120℃
Polarity of output signal: Sinusoidal signal
output Resistance of electromagnetic coil at 20
℃
Resistance: 1000Ω±10%
Coil inductance at 1kHz: 370±60mH
b. If the resistance is non-compliant, replace the
sensor.
6. Refit the crankshaft position sensor
Caution
• Apply a thin layer of engine oil onto the O-ring
of the crankshaft position sensor.
its mounting hole.
a. Screw the crankshaft position sensor into the

mounting hole.
b. Tighten the one fixing bolt.
Torque: 6~10N·m
c. Reconnect the crankshaft position sensor EG

connector.

Front oxygen sensor

Overview
1. The front oxygen sensor is intended to measure
the oxygen content of the exhaust gas thus to
determine the concentration of the engine gas
mixture and send a signal to the engine control
unit which will change the fuel injection time
according to this signal. The final purpose is to
EG control the emission in a better way whilst
saving fuel. The front oxygen sensor is located
on the top of the exhaust manifold, close to the
engine side.
2. The sensitive material of the oxygen sensor is
zirconia, and the sensor structure has a hollow
part and external sensing part. After the zirconia
element is heated (>300℃) and activated, the
reference air will be delivered into the hollow
part of the zirconia element, and its exhaust gas
will pass through the external electrode of the
zirconia, with the oxygen ions moving from the
zirconia center to the external electrode, thus
constituting a simple atomic battery to generate
a voltage between both electrodes. The zirconia
can change this output voltage via the oxygen
concentration in the exhaust gas thus to judge
the oxygen content of the exhaust. Generally,
the oxygen sensor is designed to generate a
voltage leap when the exhaust gas has an
air-fuel ratio approaching the theoretical value
(14.6:1), which will help ECM judge the air-fuel
ratio accurately.
Voltage signal at thick air-fuel ratio (λ=0.97) min800mV
Voltage signal at thin air-fuel ratio (λ=1.10) max100mV
Time elapsed from a thick air-fuel ratio to a thin one max250ms
Time elapsed from a thin air-fuel ratio to a thick one max150ms
Resistance of heater element (at room temperature) 5.4～6.6Ω

EG
Resistance 350℃≤5kΩ
Voltage 14±0.1V
Size of mounting threaded hole M18×1.5-6e
Tightening torque 35~45N·m
Ordinary working temperature range ≤900℃ (temperature of zirconium tube)
Requirement on sensor signal transmission wire diameter Min. bending radius of 20mm
Replacement
3. Remove the front oxygen sensor
a. Disconnect the front oxygen sensor connector.
b. Screw off the front oxygen sensor using the wrench.
Caution
The exhaust pipe is a high-temperature part, and it can
be operated only after it is fully cooled down.
EG
4. Refit the front oxygen sensor

a. Put the front oxygen sensor at its mounting position
and tighten the sensor.
Tool: Specialist remover of oxygen sensor
Torque: 35~45N·m
Caution
Before refitting, apply the anti-rust oil onto the threads
to exclude the possibility that the sensor can’t be
removed due to rusting.
b. Reconnect the front oxygen sensor connector.
Rear oxygen sensor

Overview
1. The rear oxygen sensor is intended to measure
the oxygen content in the exhaust gas
converted by the three-way catalytic converter,
and transform this signal into the point signal
and send it to ECM which will compare signals
from front and rear oxygen sensors to judge
whether the three-way catalytic converter works EG
normally.
2. The rear oxygen sensor can be only used in the
electronic injection system provided with OBD
functions, and is intended to detect out-of-limit
of the exhaust gas. Technical and physical
conditions of the rear oxygen sensor are totally
the same with the front oxygen sensor, except
for the mounting position. Remove the front
oxygen sensor from the exhaust manifold &
three-way catalyzer assembly
Voltage signal at thick air-fuel ratio (λ=0.97) min800mV
Voltage signal at thin air-fuel ratio (λ=1.10) max100mV
Time elapsed from a thick air-fuel ratio to a thin one at 350℃ max250ms
Time elapsed from a thin air-fuel ratio to a thick one at 350℃ max150ms
EG Resistance of heater element (at room temperature) 5.4～6.6Ω
Internal resistance 350℃≤5kΩ
External voltage 14±0.1V
Size of mounting threaded hole M18×1.5-6e
Tightening torque 35~45N·m
Ordinary working temperature range ≤900℃ (temperature of zirconium tube)

Replacement
4. Remove the rear oxygen sensor.
a. Disconnect the rear oxygen sensor connector.
b. Screw off the rear oxygen sensor using the wrench.
Caution
The exhaust pipe is a high-temperature part, and it can
be operated only after it is fully cooled down.
EG
5. Refit the rear oxygen sensor.

a. Refit and tighten the rear oxygen sensor.
Torque: 35~45N·m
Caution
Before refitting, apply the anti-rust oil onto the threads
to exclude the possibility that the sensor can’t be
removed due to rusting.
b. Refit the rear oxygen sensor connector.


Overview
1. The canister solenoid valve is composed of the
electromagnetic coil, armature and valve, with a
strainer provided at the inlet. The canister
solenoid valve is located at rear end of the
intake manifold.
2. The gas flow passing through the canister
EG solenoid valve is correlated to the duty ratio of
the electric pulse output to the canister
solenoid valve by ECM, and also to the pressure
difference between inlet and outlet of the
canister solenoid valve. Where no electric pulse
is provided, the canister solenoid valve will be
closed.
3. After the engine is started at a low temperature,
the solenoid valve fitted between the charcoal
canister and intake manifold will be opened, and
the gasoline steam in the canister will be carried
into the cylinder under the vacuum action of the
intake pipe to take part in the combustion. This
is to reduce the emission and fuel consumption.
Flow at full openness 2ml/h（-20kPa）
Airtightness ≤0.002ml/h（∆P=-40kPa）
Control frequency 30Hz
Working voltage 9~16V
Rated working voltage 13.5V EG

Resistance 19～22Ω
Working temperature –30~+120℃

Onboard inspection
1. Start the engine and run it to its normal working temperature.
3. Connect the diagnoser to the fault diagnosis connector (16-pin) below the co-driver seat.
4. Turn on the ignition switch, and start the diagnoser. Use the latest software version.
5. Test the action of the canister solenoid valve.
a. Set the diagnoser in “Action test” mode.
• Touch the canister solenoid valve of the fuel evaporative emission control system by hand.
• Set the diagnoser in “Action test” mode, and conduct the action test of the canister
EG solenoid valve.
• The canister solenoid valve should vibrate slightly. If the canister solenoid valve doesn’t
vibrate slightly, check the solenoid valve, wiring harness and ECM.
b. Vacuum method.
• Remove the vacuum hose on the charcoal canister, and check whether there is vacuum
suction in the vacuum hose. When the engine is idling, if the canister solenoid valve works
normally, the solenoid valve should be closed and there should be no vacuum suction in
the vacuum hose.
• If, at this moment, there is vacuum suction in the hose, remove the solenoid valve
connector, and use a multi-meter to measure the voltage at terminals Nos.1 & 2 of the
canister solenoid valve connector; if the voltage exists, the ECM is in trouble, and if there is
no voltage, the canister solenoid valve is stuck at its opened position.
• Depress the accelerator pedal to increase the engine revolution to above 2000rpm and
check whether there is vacuum suction in the vacuum hose. If the vacuum suction exists,
the canister solenoid valve works normally; if there is no vacuum suction and the voltage of
the canister solenoid valve connector terminal is normal, the canister solenoid valve is in
trouble; and if the voltage is abnormal, the ECM or wiring harness is in trouble.
Check and repair

4. Remove the canister solenoid valve.
a. Disconnect the canister solenoid valve connector.
b. Loosen the clamps of canister inlet & outlet
hoses, and disconnect these hoses from the
solenoid valve.
EG
c. Take down the canister solenoid valve.
Caution
For vehicles which have a high mileage, when
disconnecting the hose, firstly screw off the hose, and
continue only when it is confirmed that the hose is
loosened.
5. Check the canister solenoid valve
a. Connect the canister solenoid valve to the battery
power supply, and the solenoid valve should
generate a click when it is connected to or
disconnected from the power supply; at this
moment, blow air into the inlet (connected to the
canister).
• If air flows from the gas outlet (connected to
the intake manifold), the canister solenoid
valve works normally. Otherwise replace the
solenoid valve.
• If the solenoid valve is not electrified, the
solenoid valve should keep closed to hold
back the air flow.
b. Check the resistance of the canister solenoid valve.
Impedance: 19～22Ω
6. Refit the canister solenoid valve.

a. Refit the canister solenoid valve onto the bracket.
b. Refit the clamps between the canister inlet &
outlet hoses and the solenoid valve.
c. Reconnect the canister solenoid valve connector.
EG 7. Reconnect the battery negative cable.

Vehicle speed sensor

Replacement
4. Remove the vehicle speed sensor.
a. Disconnect the vehicle speed sensor connector.
b. Use the spanner to remove the vehicle speed
sensor. EG
5. Refit the vehicle speed sensor.

a. Refit the vehicle speed sensor onto the
transmission, and tighten it using the spanner.
b. Reconnect the vehicle speed sensor connector.

Camshaft position sensor

Overview
Camshaft position sensor (intake)
The camshaft position sensor is intended to collect the
position signal of the gas distribution camshaft, and input it
into ECM to enable ECM to identify the cylinder
compressor TDC thus to execute the sequential injection
control, ignition time control and knock control. In addition,
EG the camshaft position signal is also intended to identify the
first ignition time when the engine is started. The camshaft
position sensor can identify which cylinder piston is about
to reach the TDC, so it is also called “cylinder identification
sensor”. The intake camshaft position sensor is located at
left rear end of the cylinder head.
Camshaft position sensor (exhaust)
The exhaust camshaft position sensor is located above the
left rear end of the cylinder head.
Technical specifications
Intake camshaft position sensor
System input voltage 5.0V
Output signal Digital level (switch signal)
The crest inductor shall output low level, while the bottom
Output signal characteristic
inductor shall output high level.
Working temperature range -40~150℃ EG

Low level output 0~0.5V
Exhaust camshaft position sensor
Output signal Output signal characteristic
Low level output Technical specifications
5.0V Digital level (switch signal)
The crest inductor shall output low level, while the

0.5V（max）
bottom inductor shall output high level.
Parameter
Intake camshaft position sensor
Minimum Maximum
Parameter Symbol Typical value Unit
value value
Revolution range n 0 _ 4000 rpm
Air gap AG 0.5 _ 1.5 mm
Power supply
Us 4.75 5 5.25 V
voltage range
EG Power supply
Is - - 10 mA
current
Output current lo - - 20 mA
Output low
Vol _ _ 0.5 V
voltage
Output signal high

Voh _ 4.5 - V
voltage
Exhaust camshaft position sensor
Minimum Maximum
Parameter Symbol Typical value Unit
value value
Revolution range n 0 - 4000 rpm
Air gap AG 0.5 - 1.5 mm
Power supply
Us 4.75 5 5.25 V
voltage range
Power supply
Is - - 7.5 mA
current
Output signal
Uso 0 - 16 V
power voltage
Output current lo 0 - 20 mA
Output low
Vol - - 0.5 V
voltage
Output signal high

Voh 0.9 - - V
voltage
Replacement
4. Camshaft position sensor
a. Disconnect the camshaft position sensor connector.
EG
b. Remove these 2 fixing bolts of the camshaft

position sensor.
c. Remove the camshaft position sensor.
Tool: 10mm socket
Caution
After removal, clean the mounting surface to ensure
that it is free from oil.
5. Refit the camshaft position sensor

a. Fit the camshaft position sensor.
b. Tighten these 2 fixing bolts of the camshaft position
sensor.
Torque: 8~12N•m
c. Reconnect the camshaft position sensor connector.

Caution
The sensor shall be pressed into its mounting hole,
but shall not be knocked using the hammer.
EG

Engine oil pressure sensor

Overview
The engine oil pressure sensor is fitted at the middle of the
cylinder block on engine exhaust side. The pressure
sensor is provided with the membrane and contact which
will act under the oil pressure. When the oil pressure is
lower than the specified value, the membrane will not push
the spring, and the contact is closed with the indicator
lamp lit; when the oil pressure is higher than the specified EG
value, the membrane will push up the spring and the
contact will be separated with the indicator lamp
extinguished. At this moment, the driver should have
known that the oil pressure has reached its specified
value.
Replacement
4. Remove the engine oil pressure sensor.
a. Disconnect the engine oil pressure sensor
connector.
b. Use the spanner to remove the engine oil pressure
sensor.
EG
Caution
• After the engine oil pressure sensor is removed,
timely block the mounting hole to avoid
excessive leakage of engine oil.
• Clean various surfaces of the removed parts,
and block the engine oil pressure sensor
mounting hole to prevent entry of dust into the
engine.
5. Refit the engine oil pressure sensor.

a. Refit the engine oil pressure sensor into the engine
and tighten it.
b. Reconnect the engine oil pressure sensor
connector.

8. Turn on the ignition switch and make sure that the engine oil pressure warning lamp of the
instrument is extinguished normally.
Engine harness
Engine harness
EG
E Connectors between engine wiring harness and electric elements

E003 Fuel injector 3 E016 Reversing lamp switch
Intake pressure & temperature

E007 Ignition coil 2 E019
sensor
E011 Ignition coil 1 E021 Starter coil
E012 Coolant temperature sensor E022 Crankshaft position sensor

E Connectors between engine wiring harness and wiring harness
E006 To rear wall wiring harness E009 To frame wiring harness 1
E008 To frame wiring harness 2
E Engine wiring harness -Earthing point
G301 Engine earthing point 1 G302 Engine earthing point 2
EG
OCV valve
Overview
1. The working power supply of OCV (oil control
valve) is provided by the main relay, and ECM
controls the earthing system via the pulse width
modulating signal.
In this way, it controls the engine oil flow to the
camshaft position actuator. The engine oil
pressure will actuate one safety sliding valve in EG
the camshaft position actuator at front end of
the camshaft to act. When the safety sliding
valve acts, the engine oil will be delivered into
the camshaft position actuator to rotate the
camshaft. This can realize the continuous
change of the phase between camshaft and
crankshaft to further realize the control over
valve timing. OCV is located on top of the
synchronizing chain casing at front end of the
engine.
2. ECM will determine the camshaft phase as
needed depending on the engine revolution,
load and cooling water temperature to send the
duty ratio signal to OCV. OCV is a dual-direction
four-channel pulse width modulating solenoid
valve, and can change the axial displacement of
the sliding valve according to the ECM control
signal to execute control over the engine oil
flow rate and direction of the camshaft position
actuator.
Working conditions
Item Parameter
Oil used SAE 5W20/5W30
Extreme ambient temperature -40~150℃
Working oil pressure 0～1MPa
EG
Major parameters
Coil resistance 8.5±4%Ω
Current at central point 0.5~0.6A
Leakage at central point Lower than 0.2L/min
Max. flow Higher than 3.5L/min
Working voltage range 9～16V power supply

EG
Power supply PWM250HZ
Duty ratio 10%~99%

Replacement
4. Take down OCV assembly.
a. Disconnect the phase control valve assembly
connector.
EG
b. Remove these 2 fixing bolts of the phase control

valve assembly.
c. Take down the phase control valve assembly.
Caution
• The valve can be cleaned using the clean engine
oil, but it is not allowed to use the strong
solvent type oil (for example, gasoline), nor can
be purged using the compressed air. If the OCV
valve is contaminated by non-engine-oil type
oil, such oil shall be immediately removed.
• The OCV valve shall be kept clean and protected
against iron chippings and aluminum
chippings.
5. Refit the oil control valve assembly

a. Refit the phase control valve into the engine.
b. Tighten these 2 fixing bolts of the phase control
valve assembly.
c. Reconnect the phase control valve assembly

connector.
Caution
• In the course of refitting, avoid collision. Before
refitting, check whether the strainer is clean and
intact, and free from noticeable particles, and
whether the O-ring is intact and the sealing ring
is serious scratched; if there is any defect, no
refitting is allowed.
• When refitting the valve, apply engine oil onto EG
the outer ring surface of the O-ring.

Positive crankcase ventilation valve (PCV)

Overview
1. PCV is composed of the valve body, valve, valve
cover and spring, and it is undecomposable. It
is primarily used to deliver the gas from the
crankcase into the intake manifold, and directly
deliver a little of air from air filter into the intake
manifold via PVC, thus to avoid icing at the
EG throttle, insufficient combustion, worsening of
emission etc. This can prevent the gas leakage
from being discharged into the atmosphere and
prevent the engine oil from being degraded.
2. PCV is a metering control valve. It is located
between the engine crankcase ventilation
system and the intake system. PCV is controlled
by the vacuum degree, used to regulate the flow
rate of fume generated from the crankcase
ventilation system into the intake system. The
flow rate during high-speed operation of the
engine is higher than that during the low-speed
operation. In the event of engine backfire, PVC
shall be able to cut off the ventilation system to
prevent explosion of crankcase.
Replacement
3. Remove the crankcase positive ventilation
valve.
a. Loosen the fixing clamp of the PCV rubber pipe
assembly.
b. Pull out the PCV rubber tube assembly.
c. Remove the crankcase positive ventilation valve.
EG
4. Check the crankcase positive ventilation valve

assembly.
a. Run the engine at the idle speed, remove PCV from
the cylinder head hose, and check PVC valve for
clogging. If the handle is located at the PVC valve
connection, the finger can feel the violent vacuum
pull.
b. Refit PVC, remove the crankcase air inlet pipe from
the air filter, cover the pipe orifice using a piece of
thin paper, and when the pressure in the crankcase
is reduced (about 1min later), the paper will be
suctioned toward the pipe orifice. In addition, after
the engine is stopped, remove PCV and shake it by
hand. If a click is heard, PCV is operative.
5. Refit the crankcase positive ventilation valve
assembly.
a. Refit the crankcase positive ventilation valve.
b. Refit the PCV rubber pipe assembly.
c. Refit the PCV rubber pipe clamp at its fixing
position.

EG-274 Engine part - Exhaust gas purifier
Exhaust gas purifier
Three-element catalyzer
Three-element catalyzer
Overview
The three-way catalyzer is the most important external purifier in the exhaust system, and it is intended
to convert the harmful gases in the exhaust, including CO, HC and NOx, into the harmless CO2, water
and nitrogen. As such a catalyzer can convert these three major harmful substances in the exhaust gas
into the harmless substances, it is called “three-way catalyzer”.
EG
Engine part - Exhaust gas purifier EG-275
Working principle
1. The working principle of the three-way catalyzer is as follows: When the high-temperature
exhaust gas passes through the purifier, the purifying agent in the three-way catalyzer will
strengthen the activity of CO, HC and NOx to cause them to carry out certain
oxidization-reduction chemical reactions, where CO will be oxidized into colorless and
nontoxic CO2 gas at high temperature, HC is oxidized into water and CO2 at high
temperature, and NOx is reduced into nitrogen and oxygen. These three harmful gases are
converted into harmless ones to purify the exhaust gas.
2. The carrier of three-way catalyzer is a piece of porous ceramic material which is fitted in
EG
the specially manufactured exhaust pipe. The reason why it is called a carrier is that itself
will not take part in the catalytic reaction, but it is covered by a layer of precious metals
like platinum, rhodium ad palladium. It can convert HC and CO in the exhaust gas into
water and CO2, and also decompose NOx into nitrogen and oxygen. HC and CO are
poisonous gases, and excessive inhalation may lead to deaths, while NOX will directly
cause the generation of photochemical smoke. The study discloses that the three-way
catalyzer is the most effective way to reduce such emissions. Through oxidization and
reduction actions, CO is oxidized into CO2, HC is oxidized into water and CO2, and NOx is
reduced into nitrogen and oxygen. Thus, these three harmful gases are converted into
harmless ones. The three-way catalyst can only react when the temperature is at least
350°C. If the temperature is too low, the conversion efficiency will drop dramatically; the
activation temperature of the catalyst (best working temperature) is between 400℃ and
800℃, and a too high temperature may worsen the aging of the catalyst. The catalytic
conversion will reach its best efficiency at the ideal air-fuel ratio of 14.7 (14.7：1).
Maintenance data
Torque requirement
Fasteners N.M
Connecting nut between three-way catalyzer assembly and exhaust manifold M10:41~51
Connecting bolt and nut between three-way catalyzer assembly and muffler M10:41~51
EG
Precautions
1. Never use leaded gasoline.
2. Never run the engine at a high speed for long time (in open-loop control mode).
3. Do not run the engine at a low speed and high speed alternatively.
4. The ignition time shall not be too late.
5. Avoid long-time trial of startup.
6. Do not remove the high-voltage wire for spark test for a long period of time.
7. When measuring the cylinder pressure, the central control joint of the fuel pump shall be
removed to stop the fuel injection into the cylinder by the injector.
8. If the cylinder works improperly, stop the vehicle timely to solve the problem. EG
9. Avoid various factors which may cause the gas mixture too thick, for example, improperly
closed injector, inoperative fuel pressure regulator (too high oil pressure), inoperative
oxygen sensor, and inoperative air flow sensor.
10. The catalytic converter generally requires no maintenance once it is correctly installed, so
do not remove it when unnecessary, and if it is to be replaced, the one matching the
engine must be used.
Part Diagram
EG
1 2-way catalytic reactor assy

Catalyzer mark
EG
Manufacturer code of three-element catalyzer

Production batch number of three-way catalyzer
assembly
Serial number of three-way catalyzer assembly
FT52003/ Foton Motor Group Model/manufacturer name of three-way
catalyzer
Encapsulation: Foton Motor Group
Name of encapsulation manufacturer
Carrier: Corning
Name of carrier manufacturer
Coating: Headway Group, Zhucheng
Name of coating manufacturer
Replacement
Danger
The three-way catalyzer is a high-temperature part, and it can be operated only after it is fully
cooled down.
1. Lift the vehicle, or place the vehicle over the ground pit.
2. Remove the rear oxygen sensor.
a. Disconnect the rear oxygen sensor connector.
EG
b. Remove the rear oxygen sensor locking nut, and

screw off the rear oxygen sensor probe.
3. Remove the three-way catalyzer assembly.

a. Remove the front fixing nut of the three-way
catalyzer.
b. Remove the connecting bolt and nut between the

three-way catalyzer and the rear muffler.
c. Disconnect the fixing rubber block of the three-way
catalyzer assembly, move aside the rear muffler,
and take down the three-way catalyzer assembly.
4. Check the three-way catalyzer.

a. Check the three-way catalyzer surface for pits; if noticeable pits and scratches are found, the
catalyzer carrier may have been damaged. Check the three-way catalyzer surface for serious
faded spots or light cyan and purple marks, and check whether there is any noticeable dark grey
spot at the center of the catalyzer protection cover; if any, the three-way catalyzer is once
overheated.
b. Knock and shake the three-way catalyzer by hand; if you can hear the object moving sound, its
internal catalyst carrier is broken and the catalyzer needs to be replaced. Meanwhile, check the
three-way catalyzer for cracking, looseness and leakage; if any, deal with them immediately.
5. Refit the three-way catalyzer assembly. EG
a. Reif the three-way catalyzer assembly between the
exhaust manifold and the rear muffler, and refit the
fixing rubber block onto the hook.
b. Refit the fixing bolt and nut between the three-way
catalyzer and the rear muffler, and tighten them.
Torque: M10:41~51N·m
6. Refit the front fixing nut of the three-way

catalyzer and tighten it.
Torque: M10 41~51N·m
7. Refit the rear oxygen sensor.

a. Refit the rear oxygen sensor probe onto the exhaust
pipe, and tighten the locking nut of rear oxygen
sensor.
b. Reconnect the rear oxygen sensor connector.


a. When the engine is working, check the exhaust manifold connection for leakage and abnormal
noise.
EG
TR shift and control mechanism
Clutch ....................................................................... TR-1
Clutch system ........................................................ TR-1
Air bleeding of clutch system ................................ TR-9
Clutch pressure disc and driven disc .................. TR-11
Clutch oil pot ....................................................... TR-16

TR
Clutch components ............................................. TR-20
Clutch slave cylinder ........................................... TR-23
Clutch master cylinder......................................... TR-25
Clutch pedal ........................................................ TR-28
Manual transmission ............................................ TR-36
Transmission assembly ....................................... TR-36

Shift and Control Mechanism - Clutch TR-1
Clutch
Clutch system
Overview
1. Clutch is installed in the clutch shell between engine and transmission, use bolt to fix the
clutch assembly on the rear surface of flywheel, clutch consists of clutch driven plate
assembly and clutch pressure plate assembly.
2. The clutch assembled on this car is of diaphragm-spring clutch, single-plate dry friction
clutch, the diaphragm compresses spring, tortional absorber and vibration absorbing
damper are installed on clutch driven plate assembly, clutch driven plate is compounded
by high quality environmental friendly non-asbestos friction materials.
3. Clutch device is the control mechanism to transfer power and separate power, it transfers
TR
the power output by engine to transmission, so as to stably connect or temporarily
separate engine power and transmission, and for ease of vehicle start, stop and shift, etc.
4. When vehicle starts, clutch driven plate assembly and clutch pressure plate assembly
combines gradually, engine power is transferred by the friction force among flywheel,
clutch driven plate assembly and clutch pressure plate assembly to vehicle power train, so
that the vehicle can start stably.
5. During vehicle driving, driver can depress or release clutch pedal as needed, so as to
temporarily separate and gradually connect clutch driven plate assembly and clutch
pressure plate assembly, cut or transfer the power from engine to transmission.
6. Clutch can temporarily cut the power transfer between driving system and engine when
shift gear, to reduce the collision impact of gears, and realize stable shift.
7. The clutch is composed of following components:
a. Clutch pedal assembly
b. Clutch pressure disc and driven disc assembly
c. Clutch master cylinder
d. Clutch slave cylinder
TR-2 Shift and Control Mechanism - Clutch
Precautions
1. The discharged brake fluid can’t be used continuously.
2. Special brake fluid must be used, because other brake fluid may cause corrosion, and
shorten the service life of clutch system.
3. Don’t splatter the brake fluid on vehicle, or it may damage paint. If the brake fluid is
splattered on the paint coat, clean it immediately with water.
4. Clutch pressure plate can’t be cleaned with gasoline！
5. There is lubricating grease filled in release bearing, don’t clean with oil or liquid
substance.
6. When installing clutch, temperature-resistant and pressure-resistant lubricating grease
TR shall be used to properly lubricate friction plate spline and transmission input axis spline,
ensure that the friction plate can move freely on transmission input axis spline. Excessive
lubricating grease will cause friction plate sliding.
7. When friction plate is worn to specified wear limit, replace the friction plate assembly
timely, in order to avoid clutch sliding, pressure plate and flywheel surface scratch.
8. When repairing clutch components, it is not allowed to use sanding or dry brush or clean
with compressed air, in order to avoid powder. Water-dampened cloth shall be used to
wipe or dust cleaner shall be used for cleaning.
Preparations
Recommended tools
Flywheel fixer Fix the flywheel
TR
Clutch locating shaft clutch positioning
Measure end surface of flywheel

Dial indicator and measure end surface of
driven plate
Diaphragm spring
Vernier calliper
Depth of rivet
Circlip pliers Clutch master cylinder
Torque wrench Fastening bolt

Technical data
Maintenance data
Clutch pedal travel 125~130mm
The free travel of clutch pedal 5~10mm
Thickness from driven plate surface to Standard value 1.5mm

rivet head Limit value 0.5mm
Check run-out tolerance of clutch driven Standard value 0~0.15mm

plate assembly Limit value 0.8mm
TR Planeness of clutch pressure plate Limit value 0.3mm
Torque requirements
Fasteners N·m
Clutch pedal mounting bolt 21~25
Clutch pressure plate mounting bolt 20~28
Clutch wheel cylinder mounting bolt 28~36
Clutch master cylinder mounting bolt 22~28


The clutch pedal bush is

Change clutch pedal
damaged.
The internal parts of clutch is

Repair
loose
The release bearing is worn or

Replace release bearing
damaged.
TR
Check for clutch noise. Release fork or connecting piece Change release shifting fork or
is damaged connector
Damper spring is broken Replace driven plate

excessively worn.
The release bearing is loose. Change of release bearing
The clutch pedal is distorted. Repair or change clutch pedal
The clutch pedal bush lacks

lubricating oil.
Clutch oil performance decreases Replace clutch oil
The clutch master cylinder is Repair or change clutch master

defective. cylinder
The clutch pedal is heavy to
operate. The clutch slave cylinder is Repair or change clutch wheel
defective. cylinder
The clutch pressure disc Repair or change clutch pressure

assembly is defective. plate
The clutch release fork is not well Repair or change clutch release
lubricated. shifting fork

Adjust free travel of pedal
too large.
The input shaft spline or spline of

Remove the oil dirt or change
clutch driven plate assembly is
driven plate of clutch
polluted by oil dirt.
The clutch is not released The clutch pressure disc Replace the clutch plate
completely. assembly is defective. assembly
The driven disc assembly is worn

abnormally.
The clutch pressure disc with cap

assembly is deformed.
The release bearing is worn

Replace release bearing
excessively.
The clutch release fork is worn is Change release shifting fork of

abnormally. clutch
Clutch driven plate assembly is

Inspect or change clutch driven
polluted by oil or worn
plate assembly
excessively
The clutch pressure disc

assembly is damaged.
TR The release fork is seized. Check the release fork
Clutch slips The free travel of clutch pedal is

Adjust free travel of pedal
too small.

excessively worn.
The flywheel warps Replace the flywheel
Clutch driven plate assembly is Inspect or change clutch driven

polluted by oil or damaged plate assembly
The clutch pressure disc Replace the clutch plate

assembly is damaged. assembly
Torsional spring of clutch driven

plate assembly is deformed or Change clutch driven plate
The clutch is not engaged broken
smoothly
Torsional spring of clutch driven
plate assembly is deformed or Change clutch driven plate
broken
The mounting point of engine is

Tighten engine anchoring points
loose
The flywheel is worn abnormally. Replace the flywheel

Onboard inspection
1. Check if the clutch is slippery.
Activate the parking brake, shift the transmission lever to low speed gears, start the engine,
depress the acceleration pedal and slowly release the clutch pedal. If the vehicle fails to move
and the engine does not flame out, it can be called clutch slippery failure.
2. Check if the clutch shakes.
Shift the transmission lever to low speed gears, slowly release the clutch pedal to move the
vehicle. If the vehicle shakes, it can be called clutch shaking failure.
3. Check the travel of clutch pedal.
a. Check the distance L from clutch pedal to front floor.
Standard value: 203mm
TR
b. Depress the pedal and then measure the distance
D from pedal to front floor and calculate the clutch
pedal travel: L-d.
Standard value: 125~130mm
Caution
If the pedal travel is not acceptable, adjust it:
4. Check the free travel of clutch pedal

a. Gently push the clutch pedal till it is hard to push it
further. Check the free travel a of clutch pedal.
Caution
If the free travel of pedal is not acceptable, adjust it.
5. Check if the brake liquid is polluted.

a. Check if the brake liquid contains water.
b. Check if the brake liquid is polluted by dust or debris.
c. Check if the brake liquid is polluted.
Caution
If the brake liquid is polluted, change brake liquid and damaged parts and clean hydraulic pipe of
clutch.
6. Check if the clutch is separated completely

a. Any of following description indicates the clutch is not separated completely when the engine is
running idly and it is necessary to find out the cause and repair:
• Depress the clutch pedal to the end to separate the clutch completely.
• Depress the clutch pedal and feel it is difficult to engage the gear.
• Depress clutch pedal, the transmission gear makes sharp impact noise.
• Depress clutch pedal, the vehicle starts to move without releasing the clutch pedal.
Caution
Refer to failure diagnosis to solve the problem if the clutch is not separated completely.
7. Check if the clutch makes abnormal noise when it is working.

TR a. Depress and release the clutch pedal to engage and separate the clutch to check if it makes
abnormal noise.
Caution
Refer to failure diagnosis to solve the problem if the clutch is not separated completely.
8. Check if the vehicle shakes when it starts to move.

a. Start the vehicle at low speed gear, release the clutch pedal and slowly depress accelerator pedal
to check if the clutch is engaged smoothly.
Caution
If the vehicle’s shake is caused by the clutch, which fails to engage smoothly, refer to failure
diagnosis to solve the problem.
9. Check if the clutch is slippery.

a. Start the vehicle at low speed gear, if any of following descriptions appears, it indicates abnormal
slippery clutch:
• When the clutch pedal is released, the vehicle fails to start to move at once or difficult to
move.
• When depress the accelerator pedal, the vehicle fails to speed up along with the engine
rpm.
• The engine is powerless and even produces smelly smoke.
Caution
In case of abnormal slippery clutch, refer to failure diagnosis to solve the problem.
10. Check clutch shifting fork shaft

a. Shake the clutch shifting fork shaft to check if the clearance between clutch shifting fork shaft and
lining is large; if so, change the clutch shifting fork shaft lining.
Air bleeding of clutch system

Air bleeding
Caution
When the clutch pipeline, clutch master cylinder and clutch wheel cylinder are removed or when
the clutch pedal becomes soft, it is necessary to release air in the brake hydraulic system. The
operation requires two operators.
1. Causes
If air exists in the clutch pipeline, it may block the clutch; therefore the air shall be
released.
TR
2. When it is necessary to release air?
a. In case of oil leak during repairing, it indicates low brake liquid of clutch oil reservoir.
b. Clutch pipeline is removed when repairing the clutch.
c. Remove wheel cylinder, oil reservoir and clutch master cylinder.
3. Release air in the hydraulic system of clutch
a. Remove filler cover plate of brake liquid.
b. Check brake liquid and ensure the brake liquid is

above the MAX position.
Caution
Add brake liquid to the fluid reservoir to specified level
and keep adding the brake liquid during air releasing
to maintain the level.
Danger
Never drop any brake fluid onto the paint or skin;

otherwise, the paint or skin polluted with brake fluid
shall be cleaned immediately.
c. Remove the dust cap of air bolt of clutch wheel

cylinder.
d. Install a transparent hose on the head of air screw
and put the other end of the hose in a glass cup.
e. Depress the clutch pedal till you feel it is difficult to

depress further and keep the pedal being
depressed.
TR
f. While keeping the clutch pedal being depressed,

tighten the air screw on the wheel cylinder. When
brake liquid is to stop flowing out, lock the air screw.
g. Repeat (e) and (f) for several times and observe the
transparent hose if the brake fluid flowing out from
the hose contains bubble and foreign matters.
Repeat the operation till no bubble comes out.
h. Add brake liquid to MAX position.
Clutch pressure disc and driven disc

Part diagram
TR
Clutch pressure plate assembly with

1 4 Dowel pin
cover
2 Clutch driven disc 5 Hexagon flange bolt
3 Dowel pin 4 Dowel pin

Check and repair

1. Remove the transmission assembly. (Refer to "Section TR: Shift and control mechanism -
Manual transmission - Transmission assembly - Transmission assembly, Replacement".)
2. Remove clutch pressure plate and driven plate
assembly
a. Use clutch locating tool to install on the clutch
pressure plate and central hole of driven plate.
b. Make marks on clutch pressure plate and flywheel
to maintain dynamic balance when assembling.
c. Lock the flywheel with special tool.
TR
d. Loosen clutch pressure plate mounting bolts evenly
and separately till the pressure from the spring has
been completely eliminated.
e. Remove clutch pressure plate mounting bolt,

remove the clutch pressure plate and driven plate.
Caution
Do not drop the pressure plate and driven plate;
otherwise it may cause damage to the pressure plate
and driven plate and even cause human injury.
Warning
Keep the components clean. Keep the surface of

clutch pressure plate and driven plate flywheel away
from dust and oil.
3. Install clutch pressure plate and driven plate

assembly
a. Use clutch locating tool ③ to install clutch pressure
plate ① and driven plate ② with the assembly
marks aligned. Install clutch pressure plate
mounting bolt.
Caution
The clutch driven plate shall not be installed in
reversed direction. Before assembling the driven plate
of clutch, apply grease on the spline and brush the
grease to the groove.
TR
b. Tighten the mounting bolts of clutch pressure plate

in several steps.
Torque: 20~28N•m
c. Remove clutch lock tool and flywheel lock tool.
4. Install the transmission assembly. (Refer to "Section TR: Shift and control mechanism -
Manual transmission- Transmission assembly - Transmission assembly, Replacement".)
Check and repair

1. Test the planeness of clutch pressure plate
a. Use a precision straight edge ① and feeler gauge
② to measure the planeness of pressure plate ③.
Limit value: 0.3mm
Caution
• At least measure at three different angles on a
same plane.
• Lay the precision straight edge and pressure
plate flat.
TR • If the planeness is above the service limit,
change the pressure plate.
2. Test the diaphragm spring of pressure plate.

a. Check the end of diaphragm spring for wear and
height difference. In case of obvious wear or if the
wear is above the limit, change the pressure plate.
3. Check the driven plate of clutch

a. Check if the damper spring and corrugate sheet are
worn seriously or corroded. If so, change the clutch
driven plate.
b. Use vernier caliper to measure the thickness a of
clutch driven plate. If it is less than the service limit,
change the clutch pressure plate and driven plate.
c. Use vernier caliper to measure the depth a of rivets

on the friction lining. If it is less than the service
limit, change clutch driven plate.
Standard value: 1.5mm
Limit value: 0.5mm
d. Use a dialgauge to measure the end run-out of

driven plate.
Standard value: 0~0.15mm
Limit value: 0.8mm
TR
Clutch oil pot

Oil discharge
Caution
It is required to discharge the oil before removing the clutch master cylinder, clutch wheel
cylinder and clutch pipeline or when the brake liquid is dirty due to long period of operation.
1. Drain the brake fluid.

a. Remove the sleeve of drain screw on the clutch
wheel cylinder.
TR b. Slight loose the exhaust screw on the clutch wheel
cylinder and connect a transparent hose to the
screw head and put the other end of the hose in a
glass cup.
c. Screw off the exhaust screw.
d. Depress the clutch pedal repeatedly till no oil flows
out from the transparent hose.
Caution
To better clean the clutch pipeline, add fresh brake
liquid into the clutch the fluid reservoir and then drain
off again.
Fill
Caution
Use specified brake liquid and never mix brake liquid of different grades.
1. Fill the brake liquid

a. Remove the brake fluid filler cap.
TR
b. Screw off fluid reservoir cap.

c. Add fresh or clean brake liquid.
Caution
Pay attention to the scale marks on the fluid reservoir
when adding the brake liquid.
d. Tighten the fluid reservoir cap.
e. Install filler cap of brake liquid.
2. Discharge the air in the clutch system (refer "Section TR: Shift and control mechanism-
clutch- air bleeding of clutch system".)
Replacement
1. Discharge brake liquid (Refer to “Chapter TR Transmission and Control Mechanism -
Clutch - Clutch Fluid Reservoir, Drainage”)
2. Remove the fluid reservoir
a. Remove the fluid reservoir mounting screw.
b. Remove the dashboard. (Refer to “Chapter BW
Body - Dashboard, Combination Instrument, and
Ashtray - Dashboard, Replacement")
TR
c. Disconnect from the fluid reservoir level alarm.

d. Remove the hose hoop connected to the oil pipe of
fluid reservoir, remove the oil pipe and remove the
fluid reservoir assembly.
3. Install the fluid reservoir

a. Connect the oil pipe to fluid reservoir and install
hose hoop.
b. Connect to the fluid reservoir level alarm.
c. Install the dashboard (Refer to "Section BW:

Vehicle body- Dashboard/ Combination instrument/
Cigar lighter/ Ash tray- Dashboard, Replacement".)
d. Install the fluid reservoir mounting screw and
tightening.
4. Add brake liquid. (Refer to “Chapter TR Transmission and Control Mechanism - Clutch -
Clutch Fluid Reservoir, Drainage”)
TR
Clutch components
Check and repair
1. Remove the transmission assembly. (Refer to "Section TR: Shift and control mechanism -
Manual transmission - Transmission assembly - Transmission assembly, Replacement".)
2. Dismantle the release bearing and release
support arm.
a. Remove the release bearing and release support
arm.
b. Dismantle the bearing clip, and remove the release
bearing.
TR c. Dismantle the support arm clip.
d. Remove the front stud of support arm.

3. Check the clutch release bearing.

a. Check the bearing for seizure, damage, noise or
abnormal rotation. Check the bearing surface in
contact with clutch diaphragm spring for damage.
Caution
• Before installation, check the interior and
exterior surfaces of bearing; in case of
deformation or damage, replace the bearing.
• If the contact surfaces of release bearing and
release support arm are worn, check the release
support arm and release bearing, and renew the
release support arm and release bearing when
TR
necessary.
• The bearing is lubricated permanently and does
not need cleaning or lubricating.
4. Check the clutch release support arm.

a. Check the release support arm for deformation,
breakage or crack, check the release support arm
surface in contact with the release bearing for
damage, and replace the release support arm when
necessary.
5. Install the release bearing and release support

arm.
a. Install the front stud of support arm.
b. Install the support arm clip.

c. Install the release bearing and release bearing clip.
d. Install the release bearing and release support arm
onto the transmission.
TR
6. Install the transmission assembly. (Refer to "Section TR: Shift and control mechanism -
Manual transmission- Transmission assembly - Transmission assembly, Replacement".)
Clutch slave cylinder

Part diagram
TR
1 Clutch master cylinder assembly 6 Clutch hose assembly
Oil pipe assembly, clutch master Oil pipe assembly, clutch slave
2 7
cylinder cylinder
3 Oil pipe assembly, clutch 8 Clutch salve cylinder assembly
4 Clutch oil pipe clamp 9 Support, clutch hose
5 Rear crossbeam wire grommet

Replacement
2. Remove the clutch slave cylinder.
a. Remove oil inlet pipe connector nut of clutch wheel
cylinder.
b. Remove clutch wheel cylinder assembly mounting
bolt.
c. Remove the clutch wheel cylinder assembly.
Caution
The residual brake liquid shall be collected in a
specified container and the hose shall be closed to
TR
avoid foreign matter from getting in.
3. Check clutch wheel cylinder assembly

a. Check the dust cap of clutch slave cylinder for aging or crack. If any, replace the dust cap timely.
b. Check if the clutch slave cylinder leaks oil, the push rod has a high moving resistance or is seized;
if yes, repair or replace the clutch slave cylinder.
4. Install the clutch salve cylinder.
a. Install clutch wheel cylinder assembly, install
mounting bolt and tighten the bolt.
Torque: 28~36N•m
b. Install oil pipe of clutch wheel cylinder and tighten
the nut of pipe connector.
5. Add brake liquid (Refer to “Chapter TR Transmission and Control Mechanism - Clutch -
Clutch master cylinder

Check and repair
2. Remove the dashboard. (Refer to "Section BW: Vehicle body- Dashboard/ Combination
3. Remove the clutch master cylinder.
a. Remove the hose hoop of clutch master cylinder
inlet pipe.
b. Unplug the clutch master cylinder inlet pipe.
Caution
TR
Close the oil pipe with a cover to avoid foreign matters
from getting in.
c. Loosen the connector nut of clutch master cylinder
outlet pipe.
d. Move away the clutch master cylinder outlet pipe.
e. Remove the split pin and washer at the connection

of clutch master cylinder push rod and clutch pedal
and remove the clutch push rod.
f. Remove the clutch mounting bolt and remove the

clutch master cylinder.
TR
4. Check if the clutch slave cylinder leaks oil, the push rod has a high moving resistance or is
seized; if yes, repair or replace the clutch slave cylinder.
5. Install the clutch master cylinder.
a. Install clutch master cylinder onto the clutch pedal
and install mounting bolt and tightening.
Torque: 22~28N•m
b. Install clutch master cylinder push rod on clutch

pedal and install the split pin and washer and lock
the split pin.
c. Install the clutch master cylinder outlet pipe to the

outlet port of clutch master cylinder and tighten the
outlet pipe connector nut.
d. Connect the oil inlet hose of clutch master cylinder
to oil inlet of clutch master cylinder and tighten the
hose hoop.
TR
6. Install the dashboard (Refer to "Section BW: Vehicle body- Dashboard/ Combination
instrument/ Cigar lighter/ Ash tray- Dashboard, Replacement".)
7. Add brake liquid (Refer to “Chapter TR Transmission and Control Mechanism - Clutch -
Clutch pedal
Part diagram
TR
Hydraulic brake and clutch pedal

1 2 Connecting plate
assembly
Adjustment
1. Adjust the height of clutch pedal.
a. Loose the locking bolts and nuts of clutch pedal.
b. Turn the lock bolt of clutch pedal to adjust pedal
height to reach the specified value, then tighten the
lock bolt and nut of clutch pedal.
Distance from central position of clutch pedal to
base plate: 120±5mm
TR
2. Adjust free travel of pedal.

a. Loose the lock nut of fork of master cylinder of
clutch.
Caution
To adjust the free travel of clutch pedal, it’s necessary
to remove the dashboard assembly (Refer to Chapter
BW Body - Dashboard, Combination Instrument, and
Ashtray - Dashboard, Replacement”).
b. Turn the rod to extend or retract to adjust the free

travel of pedal.
Replacement
2. Remove the dashboard (Refer to "Section BW: Vehicle body- Dashboard/ Combination
instrument/ Cigar lighter- Dashboard, Replacement".)
3. Remove the steering column (Refer to "Chapter ST Steering system - Steering mechanism
- Steering wheel, Inspection and repair".)
4. Remove the dashboard framework (Refer to "Section BW: Vehicle body- Dashboard/
Combination instrument/ Cigar lighter- Dashboard framework, Replacement".)
5. Remove clutch pedal assembly

TR a. Remove the split pin and washer at the connection
of push rod of clutch master cylinder and clutch
pedal and remove the push rod.
b. Remove the mounting bolt of clutch master cylinder,

disconnect from oil pipe and remove the master
cylinder.
c. Disconnect from brake pedal switch.

d. Remove brake switch lock nut and remove the

brake switch.
TR
e. Remove the fixed split pin at the connection of push

rod of brake vacuum booster and pedal and remove
the pin shaft connected to the push rod.
f. Remove the hoop of vacuum pipe of brake vacuum

booster and remove the pipe.
g. Disconnect from oil inlet and oil outlet pipes of

master cylinder of brake.
h. Remove mounting bolt of brake vacuum booster
and remove the brake vacuum booster with brake
master cylinder assembly.
i. Remove the mounting bolt of connection board of

brake clutch pedal assembly and remove the
connection board.
TR
j. Remove the mounting bolt of vacuum pipe from the

brake pedal and move the vacuum pipe.
k. Remove mounting bolt on the brake pedal.
l. Remove the bottom mounting bolts of clutch pedal

and bottom mounting nuts of brake pedal to remove
the brake clutch pedal assembly.
6. Refit the clutch pedal assembly.

a. Install brake clutch pedal assembly in the cab,
install top bolts of clutch pedal and bottom nuts of
brake pedal and tightening.
21~25N•m
b. Install upper mounting bolts of brake pedal and

tighten.
21~25N•m TR
c. Install the vacuum pipe bracket on brake pedal and

install the mounting bolt and tightening.
d. Install connection board of brake clutch pedal

assembly and install the mounting bolts and
tightening.
21~25N•m
e. Install brake vacuum booster with brake master

cylinder assembly and install mounting bolt and
tightening.
f. Connect the oil inlet and outlet pipes of brake
master cylinder.
g. Install connection pin shaft of brake vacuum booster

push rod and brake pedal and install the washer
TR and split pin.
h. Install vacuum pipe of brake vacuum booster and

install the clamp and tightening.
i. Install brake switch, adjust pedal height and tighten

the lock nut.
j. Connect the brake pedal switch connector.
k. Install clutch master cylinder on the pedal and

install mounting bolts and tightening.
l. Install oil inlet and outlet pipes of clutch master TR
cylinder.
m. Install clutch master cylinder push rod on clutch

pedal and install the washer and split pin and lock.
7. Install the dashboard framework (Refer to "Section BW: Vehicle body- Dashboard/
Combination instrument/ Cigar lighter- Dashboard framework, Replacement".)
instrument/ Cigar lighter- Dashboard, Replacement".)
9. Install the steering column (Refer to "Chapter ST Steering system - Steering mechanism -
Steering wheel, Inspection and repair".)
10. Drain the clutch oil (Refer to “Chapter TR Transmission and Control Mechanism - Clutch -
TR-36 Shift and Control Mechanism - Manual transmission
Manual transmission
Transmission assembly
Transmission assembly
Overview
DAT18R transmission is composed of five forward driving gears and one reverse gear via three groups
of synchronizers, three shafts—input shaft, countershaft and output shaft.
All speed gears are engaged in regular ways.
The low speed synchronizer is installed on output shaft, engaged with the 1st and 2nd speed gears while
high speed synchronizer is installed on output shaft, engaged with the 3rd and 4th speed gears. The
reverse gear and the 5th speed gear synchronizer is installed on the output shaft, engaged with reverse
th
TR gear and the 5 speed gear.
Shift and Control Mechanism - Manual transmission TR-37
Precautions
1. Operation precautions
a. Adjust the clutch correctly to separate it or engage it completely.
b. Cargo shall never above the specified load limit.
c. Perform initial maintenance and regular maintenance according to the operation manual.
d. Never drive the vehicle when the coolant has not reached the specified temperature and when the
pressure has not reached the specified value.
e. It is prohibited to shift low speed gears of high speed or high speed of low speed gears.
f. Never impact the gear shifting, never knock, push or hit the gear shifting rod when shifting gears.
g. Before shift to reverse gear, stop the vehicle.
h. Never slide at neutral gear when running downhill. TR
2. Cautions
a. Before removing the transmission, park the vehicle on even and safe place, shift the transmission
to neutral gear of low speed gears, power off the vehicle and wedge the front and rear wheels.
b. Before disassembling the transmission assembly, clean the housing of transmission.
c. The transmission shall be disassembled in a clean place to avoid the dust or other matter from
getting into the transmission, which may intensify wear and damage the bearing.
d. The bearing shall be removed with special tool, which makes the removal easier and will not hurt
the bearing. The removed bearing shall be washed carefully.
e. When disassembling each sub-assembly, all parts shall be placed on clean table in the sequence
of removal to avoid part from missing and make the assembly easier.
f. Use circlip plier to remove the circlip, which makes the removal easier and will not hurt the circlip.
g. When removing parts when tools, be careful that the force exerted on shaft or housing shall not
hurt the part. Some parts shall never be removed. Never exert force on moving driven parts. Use
soft hammer and rod during removal.
3. Cautions for assembling
a. All parts shall be cleaned completely before assembling. Dust and other foreign matters shall not
enter the transmission case.
b. Paper pad and sealant on engagement surface shall be removed.
c. When assembling the parts, ensure the gears, thrust washer and bearing are placed in right
direction.
d. All thrust washer, needle bearing and cone of synchronizer shall be applied with clean grease to
protect the parts against friction.
e. When assembling the output shaft assembly, check axial clearance of each speed gear.
f. When assembling the synchronous ring and taper ring of synchronizer, be careful with the
position and orientation and ensure the mounting position and orientation are not changed.
g. When recover the installation, ensure the lubrication hole is not blocked and working surface of
each gear is free from rust, crack and bump. Clean the taper ring of synchronizer, apply clean
lubrication oil on taper ring, oil seal and working surface of bearing.
h. All bolts, screw plugs, nuts and speed gear switches shall be tightened to specified torque.
i. When installing the countershaft gear, apply lubrication oil on outer surface of countershaft.
j. When assembling the oil seal and bearing, never knock the bearing with a hammer, instead, use
special tool.
k. Inspect each lip for damage. If so, change it.
l. If it is necessary to change the part, use new part of same specification of the transmission.
Preparations
Recommended tools
Puller Pull out the bearing and gear
TR
Check the run out of shaft and

Dial indicator
bearing
Check the run out of shaft and

Magnetic bracket
bearing with a dial indicator
bearing erector Install bearing
Remover of elastic pin Remove elastic pin
Oil seal installer Install oil seal
Torque wrench Measure the tightening torque

Collecting the liquid waste,

Oil basin
cleaning the transmission parts;
Hammer Knock
TR
Copper bar For removing the components
Remove and install the bolts and

Speed wrench
nuts
Circlip pliers Remove the circlip
Removing or installing the lock

Elastic clamp pliers
pin
Measure the inner and outer

Vernier calliper
diameter
Drum processor Punch out the parts

Feeler gauge Measure the clearance
Remover of oil seal Remove the oil seal
TR
Scraper knife Clean away the sealant

Technical data
Maintenance data
GL-5 85W/90 (in summer), GL-5
Specification
80W/90 (in winter)
Transmission oil
Qty 1.5L
1st gear 4.81
2nd gear 2.577
3rd gear 1.513

Transmission speed ratio
4th gear 1 TR
5th gear 0.871
Reverse gear 4.457
Torque requirements
Fasteners N·m
Oil drainage plug 30~40
Screw plug of oil filler 35~40
Front case bearing

10~14
pressure plate mounting bolt
Middle case mounting bolt of middle 18~22
Gear shifting cable shaft guide housing mounting bolt 18~22
Check screw of speed gear locking piece 18~22
Middle case bearing pressure plate mounting bolt 18~22
Rear case housing mounting bolt 30~35
Rearview lamp switch 24~28
Reverse gear bolt 24~28
Speedometer sensor mounting bolt 10~14

Part diagram (I)
TR
1 Oil seal of output shaft 17 Locking nut
2 Rear case assembly 18 Bearing
3 Speedometer assembly 19 Gasket
4 Locking nut 20 Driven gear of the 5th speed gear
Synchronous ring of the 5th speed

5 Bearing 21
gear
Synchronizer of reverse gear and

6 Driving gear of speed 5 gear 22
the 5th speed gear
7 Reverse gear bolt 23 Reverse driven gear

TR
8 Spacer sleeve 24 Driven gear of the 1st speed gear
Intermediate gear shaft of reverse gear

9 25 Low-speed synchronizer
assembly
10 Driving gear of reverse gear 26 Driven gear of the 2nd speed gear
11 Rear case bearing pressure plate 27 Middle case housing
12 Countershaft adjust washer 28 Driven gear of the 3rd speed gear
13 Spacer sleeve 29 High-speed synchronizer
14 Countershaft assembly 30 Front case bearing press plate
15 Front case 31 Input shaft
16 Speedometer drive gear

Part diagram (II)
TR
1 input shaft collar 23 5th gear needle roller bearing
Driven gear assembly of the 5th

2 Input shaft bearing 24
speed gear
3 Input shaft subassembly 25 Gasket
4 Input and output needle bearing 26 Output shaft rear bearing
Synchronizer collar of speed 3 and

5 27 Locking nut
speed 4 gears
6 High-speed synchronizer ring 28 Cirlip
7 High-speed synchronizer assembly 29 Steel ball
8 3rd gear needle roller bearing 30 Speedometer drive gear
9 Driven gear assembly of speed 3 gear 31 Cone bearing
10 Output shaft 32 Countershaft
11 1st/2nd gear needle roller bearing 33 Spacer sleeve

12 Driven gear assembly of speed 2 gear 34 Driving gear of reverse gear
13 low speed synchronous ring 35 Spacer sleeve
14 Low-speed synchronizer assembly 36 Driving gear of the 5th speed gear
15 Lining of the 1st speed gear 37 Counter shaft rear bearing
Driven gear assembly of the first speed

16 38 Locking nut
gear
Intermediate gear shaft of reverse

17 Double row angular contact bearing 39
gear
18 reverse gear lining 40 Needle bearing of reverse gear

TR
19 Needle bearing of reverse gear 41 Intermediate gear for reverse gear
20 Reverse driven gear assembly 42 Gasket
Synchronizer assembly of the reverse

21 43 Cirlip
gear and the 5th speed gear
22 Lining of the 5th speed gear

Part diagram (III)
Reverse gear
Gear
selecting
TR
direction
Gear shifting
direction
Reverse gear
Return spring of reverse gear lock

1 Gear shifting housing assembly 8
block
Shifting fork assembly of speed 1

2 Gear shifting arm assembly 9
and speed 2 gears
Shifting fork assembly of speed 3

3 Gear selecting arm assembly 10
and speed 4 gears
Shifting fork of reverse gear and the

4 Gear shifting handle 11
5th speed gear
Shifting fork shaft of reverse gear of

5 Lock block of reverse gear 12
speed 5 gear
Return spring of reverse gear and Gear shifting arm of reverse gear
6 13
speed 5 gear and the 5th speed gear
Return spring of speed 1 gear and

7
speed 2 gear

1. The shifting declutch shift shaft is worn out. Replacement
2. Gear shifting fork and outer ring of

Replacement
Wrong engagement of synchronizer is worn.
gears
3. Input and output bearings are worn Replacement
4. Gear sleeve and gear chamfering are worn. Change the gear or sleeve TR
1. The lubricant is insufficient Replacement
2. Wrong free travel of clutch pedal Replacement
3. Clutch driven plate is damaged or broken Replacement
Difficult gear shifting 4. Clutch pressure plate is damaged Replacement
5. The synchronizer is worn Replacement
6. Gear and sleeve chamfering are worn. Change gear or sleeve
7. Gear shifting shaft is damaged Replacement
1. The lubricant is insufficient Add lubrication oil
2. Bearing is worn or damaged Replacement

Noise
4. Gear is worn or damaged Replacement
5. The synchronizer is worn or damaged Replacement

Transmission oil
1. Discharge the transmission oil.
a. Before changing and checking transmission gear
oil, stop the engine and park the vehicle on even
ground.
b. Lift the vehicle. Remove drain plug to discharge
transmission oil.
c. Drain off the transmission and install the drain plug.
Torque: 30~40N•m
Caution
Apply sealant on threads of drain plug.
TR
2. Add transmission oil

a. Remove oil filler plug, fill the transmission with gear
oil.
Specification: GL-5 85W/90 (summer) or GL-5
80W/90 (winter), amount: 1.5L
b. Install filler plug
Torque: 35~40N•m
Caution
Apply sealant on threads of filler plug.
Change transmission assembly

1. Discharge the transmission oil. (Refer to “Chapter TR Transmission and control
mechanism -Manual transmission -Transmission assembly - transmission oil,
Replacement ” )
2. Remove the transmission shaft. (Refer to "Section AX: Axle and transmission shaft-
Transmission shaft- Transmission shaft, Replacement".)
3. Remove clutch wheel cylinder (refer to “Chapter TR Transmission and Operation
Mechanism-clutch -clutch wheel cylinder, Change ”)
4. Remove the transmission assembly.
a. Disconnect from speedometer sensor connector
b. Remove the mounting bolts of ground connection
TR
wire of transmission assembly and remove the wire
of transmission assembly.
c. Disconnect from connector of reverse gear switch.
d. Disconnect from connector of crankshaft position

sensor, remove the mounting bolts of the senor and
remove the sensor.
e. Disconnect from all harness fixing clips.
f. Remove E-type gear selecting cable shaft type E

locking piece ①.
g. Remove the split pin ② of gear selecting cable shaft
and remove the gear selecting cable shaft.
h. Remove gear shifting cable shaft type E locking
piece ③.
i. Remove the split pin ④ of gear shifting cable shaft
and remove the gear shifting cable shaft.
j. Use a jack to lift the transmission assembly till the

jack is slightly stressed.
k. Remove the mounting bolts at the connection of
rear suspension of transmission assembly and
frame and then remove the fuel filter ground
connection wire.
l. Remove the mounting bolts at the connection of
transmission assembly and engine assembly and
then remove the transmission assembly.
5. Install the transmission assembly
a. Move the transmission assembly to installation
TR position with a jack.
b. Install the mounting bolts at the connection of
transmission assembly and engine assembly
transmission assembly and tighten the bolts.
c. Install the mounting bolts at the connection of rear
suspension of transmission assembly and frame
and tighten the bolts.
Caution
Do not forget the fuel filter ground connection wire.
d. Install gear selecting and gear shifting cable shaft

on installation position.
e. Install gear selecting cable shaft type E locking
piece ①
f. Install the split pin ② of gear selecting cable shaft.
g. Install gear shifting cable shaft type E locking piece
③.
h. Install the split pin ④ of gear shifting cable shaft.
i. Install the crankshaft position sensor on installation

position and install crankshaft position sensor
mounting bolts and tighten the bolts.
j. Connect the crankshaft position sensor connector.
k. Connect the reverse gear switch connector.
l. Connect the speedometer sensor connector.

m. Install transmission assembly ground connection
wire and tighten the mounting bolts. TR
n. Install all fixing clips of harness.
o. Install clutch wheel cylinder (refer to “Chapter TR Transmission and Operation Mechanism-clutch
-clutch wheel cylinder, Change ”)
p. Install the transmission shaft. (Refer to "Section AX: Axle and transmission shaft- Transmission
shaft- Transmission shaft, Replacement".)
q. Fill the transmission oil. (Refer to “Chapter TR Transmission and control mechanism -Manual
transmission – Transmission assembly - transmission oil, Replacement ” )
Disassembly of transmission
1. Remove rear case housing
a. Remove reverse light switch ①.
b. Remove speedometer mounting bolt ④ and
remove the speedometer ③.
c. Remove reverse gear bolt ⑥.
d. Remove rear case housing mounting bolt ⑤ and
remove rear case housing ②.
TR 2. Dismantle the liner.

a. use special tool to Remove lining ①.
3. Remove speedometer driving gear

a. use special tool to pull out driving gear ① of
speedometer.
Caution
Before removing the collar below the gear, it is
necessary to remove the collar above the gear and
then remove the driving gear of speedometer (steel
ball inside the gear).
4. Remove lock nut

a. Remove output shaft and countershaft lock nut ①.
5. Remove the rear bearing output shaft rear

bearing
a. Remove output shaft rear bearing ① with a puller.
6. Remove countershaft rear bearing and driving

gear of the 5th speed gear
a. Use a special tool to pull out the countershaft rear
bearing ② and driving gear of the 5th speed gear
①.
7. Remove countershaft rear bearing and driving

gear of the 5th speed gear.
a. Remove spacer ③, lining ① and driving gear ② TR
of reverse gear.
8. Remove elastic pin

a. Use special tool to knock out the elastic pin ①.
9. Remove washer, driven gear assembly of the 5th

speed gear, needle bearing, high speed
synchronous ring, shifting fork of reverse gear
and the 5th speed gear and outer gear ring of
high speed (synchronizer assembly of reverse
gear and the 5th speed gear) and sliding block.
a. Remove the washer ⑦, driven gear assembly ⑥
of the 5th speed gear, needle bearing ⑤ and high
speed synchronous ring ④.
b. Hold the shifting fork ① of reverse gear and the
5th speed gear as well as high speed outer gear
TR ring ③ with your hands and slowly pull up the
shifting fork ① of reverse gear and the 5th speed
gear as well as high speed outer gear ring ③ and
sliding block ②.
Caution
• When pulling out the shifting fork of reverse
gear and the 5th speed gear and high speed
outer gear ring, three sliding blocks will drop,
so you shall be slow to avoid the sliding blocks
from dropping or missing.
• To install the sliding blocks, the installation
position among the three sliding blocks shall be
interchangeable and the positive side and
negative side shall also be interchangeable.
10. Remove the spacer, washer, transfer coupling

of the reverse gear and the 5th speed gear,
driven gear assembly of the reverse speed gear
and needle bearing.
a. Use a special tool to pull out the spacer ⑤, washer
④, transfer coupling ③ of the reverse gear and the
5th speed gear and driven gear assembly ② of the
reverse gear and remove the needle bearing ①.
11. Remove Intermediate gear shaft of reverse gear

assembly
a. Remove the intermediate gear shaft of reverse gear
assembly ①.
12. Remove the cover plate of middle case and

adjust washer of countershaft.
a. Use a special tool to remove the bolt ② and then
remove the cover plate ① of middle case and
adjust washer ③ of countershaft.
13. Remove gear selecting and shifting lever

housing assembly, two-row ball bearing circlip
and screw of reverse gear locking piece and TR
check screw of reverse gear locking piece.
a. Use special tool to remove two-row ball bearing
collar ②, bolt ④ and check screw ① of reverse
gear locking piece and then remove the gear
shifting level housing assembly ③.
14. Remove middle case bolt

a. Remove two middle case bolts ① from the
external side of housing and remove 7middle case
bolt s ① from the housing of clutch.
15. Remove middle case

a. Remove two middle case bolts ① from the
external side of housing and remove 7middle case
bolt s ① from the housing of clutch.
b. Knock the boss of middle case housing with a

special tool to separate the middle case from the
front case and remove the middle case housing
①.
16. Remove shifting fork shaft and gear shifting arm

of reverse gear and the 5th speed gear.
a. Use a special tool to remove the elastic pin.
b. Pull out the shifting fork shaft ② and remove gear

shifting arm ① of reverse gear and the 5th speed
TR gear.
17. Remove shifting fork assembly of speed gear

1/2 and shifting fork assembly of speed gear 3/4
a. Remove the shifting fork assembly of speed gear
1/2 and shifting fork assembly of speed gear 3/4.
18. Remove input shaft, countershaft and output

shaft assembly.
a. Remove the bearing pressure plate mounting bolt
① of front case and remove the bearing pressure
plate ②.
b. Remove the input shaft, countershaft and output

shaft assembly.
Caution
Hold the countershaft and output shaft assembly with
two hands and knock the non-matching end face of
front case.
Assembling of transmission
1. Install input shaft ①, countershaft ③ and output
shaft ②assembly
a. Insert the end of output shaft with needle into the
input shaft assembly, and knock the countershaft
and housing of front case housing assembly with a
rubber hammer.
Caution
Do not scratch the oil seal of input shaft.
b. Install front case bearing pressure plate ② (with the TR

even face downward), install mounting bolt ① and
tightening.
Torque: 10~14N•m
2. Install shifting fork assembly of speed gear 1/2,

shifting fork assembly of speed gear 3/4
a. Install shifting fork assembly of speed gear 1/2,
shifting fork assembly of speed gear 3/4 on
installation position.
3. Install shifting fork shaft and gear shifting arm

of reverse gear and the 5th speed gear.
a. Thread the shifting fork shaft ② through the hole
on the shifting fork assembly of speed gear 1/2 as
shown in the picture.
b. Place the gear shifting arm ① of reverse gear and
the 5th speed gear to close to shifting arm of the 3rd
and 4th speed gears. Thread the shifting fork shaft
② through the gear shifting arm of reverse gear
and the 5th speed gear and shifting fork of the 3rd
and 4th speed gears.
c. Insert the shifting fork shaft into front case housing
and check if it works well.
d. Install spring pin ①.
4. Install middle case housing

a. Lift the output shaft while turning the output shaft
TR and countershaft bearing, which shall turn
smoothly. If they are blocked when turning, use a
special tool to separate the high speed synchronous
ring from output shaft.
b. Clean the matching face of front case and middle

case and apply sealant on the matching face of
front case and then engage the middle case ①.
Sealant: Oil-resistant silicone sealant
(HZ-1213Q/320222 YAP02-92)
c. Install two middle case bolts on the external side of

housing and tighten with specified torque and install
7 middle case bolts on the housing of front case
clutch.
Torque: 18~22N·m
5. Install gear shifting selecting shaft guide

housing assembly
a. Apply sealant on the matching face of middle case,
install gear shifting selecting guide housing
assembly ③mounting bolt ④and tightening.
Torque: 18~22N·m
b. Install two-row ball bearing collar ②, install check
screw ① of speed gear locking piece and
tightening.
Torque: 18~22N·m
(HZ-1213Q/320222 YAP02-92) TR
6. Install middle case bearing pressure plate and
adjust washer of countershaft.
a. Place adjust washer ③ of countershaft, install
middle case bearing pressure plate ① and tighten
with bolt ②.
Torque: 18~22N·m
7. Install spacer, washer, reverse gear and the 5th

speed gear transfer coupling of reverse gear
and the 5th speed gear, driven gear assembly of
reverse gear and needle bearing
a. Place the needle bearing ①, reverse gear driven
gear assembly ②, washer ④, reverse gear and
the 5th speed gear transfer coupling ③, spacer ⑤.
b. Use special tool to press the spacer ⑤.
Caution
Slide block boss ① shall face the reverse gear.
8. Install washer, driven gear assembly of the 5th

speed gear, needle bearing, high speed
synchronous ring, shifting fork of the reverse
gear and the 5th speed gear and high speed
outer ring and slide block.
a. Hold the shifting fork ① of reverse gear and the
5th speed gear and high speed outer ring ③
(synchronizer assembly of the reverse gear and the
5th speed gear) to install on gear shifting shaft and
then install slide block ② in synchronizer.
b. Install high speed synchronous ring ④ , needle
TR bearing ⑤, driven gear assembly ⑥ of the 5th
speed gear and washer ⑦.
c. Lift the shifting fork shaft to align the pin hole with
the pin hole on the shifting fork of reverse gear and
the 5th speed gear and use a special tool to install
gear shifting pin ①.
9. Install lining, driving gear of reverse gear and

spacer
a. Install lining ①, driving gear of reverse gear ②,
spacer ③on installation position.
10. Install countershaft rear bearing, driving gear of

the 5th speed gear
a. Install driving gear of the 5th speed gear ①，use
special tool to press into countershaft rear bearing
②.
11. Install output shaft rear bearing

a. Use special tool to press into output shaft rear
bearing ①.
b. Install lock nut ①.

Caution
Rivet two positions for small lock nut or one position
TR
for large lock nut.
12. Install speedometer driving gear

a. Use special tool to knock the collar ② into the
groove on the lower end of output shaft, then install
the driving gear ① of speedometer (place the steel
ball in the groove of output shaft) and then use a
special tool to knock the collar into the groove on
the higher end of output shaft.
b. Use special tool to press into the lining ①.

13. Install rear case housing assembly

a. Apply sealant on matching faces of middle case and
engage the rear case housing assembly ②.
(HZ-1213Q/320222 YAP02-92)
b. Install rear case housing mounting bolt and
tightening.
Torque: 30~35N•m
c. Install reverse light switch assembly ① and washer
and tightening.
Torque: 24~28N•m
TR d. Install reverse gear bolt ⑥ and washer and
tightening.
Torque: 24~28N•m
e. Tighten the mounting bolt ④ of speedometer
assembly ③ with specified tightening torque.
Torque: 10~14N•m
Transmission control mechanism

Part diagram (I)
TR
Transmission control mechanism

1 5 Control lever sleeve assembly
assembly
2 Transmission lever sleeve assembly 6 Ball knob assembly
3 Dust cap 7 Dust cap washer
4 Pressure plate
Part diagram (II)
TR
1 Gear selecting cable shaft assembly 4 Locking plate
2 Gear shifting cable shaft assembly 5 Locating block
3 Lock plate 1
Check and repair

1. Remove the dashboard (Refer to "Section BW: Vehicle body- Dashboard/ Combination
2. Remove the transmission control mechanism
assembly
a. Remove the split pin of gear shifting cable shaft.
TR
b. Remove the split pin of gear selecting cable shaft.
c. Remove the locking piece of gear selecting and

shifting cable shaft and remove gear selecting and
shifting cable shaft.
d. Remove transmission operation mechanism

assembly mounting bolt and remove transmission
mechanism assembly.
3. Remove gear selecting and shifting cable shaft

assembly
a. Remove gear selecting cable shaft type E locking
piece ①.
b. Remove the split pin ② of gear selecting cable
shaft and remove gear selecting cable shaft.
c. Remove gear shifting cable shaft type E locking
piece ③.
d. Remove the split pin ④ of gear shifting cable shaft
and remove gear shifting cable shaft.
e. Remove gear selecting and shifting cable shaft
TR assembly.
4. Install gear selecting and shifting cable shaft
assembly
a. Install gear selecting and shifting cable shaft on
b. Install gear selecting cable shaft type E locking
piece ①
c. Install the split pin ② of gear selecting cable shaft.
d. Install gear shifting cable shaft type E locking piece
③.
e. Install the split pin ④gear shifting cable shaft.
5. Install transmission operation mechanism
assembly
a. Install transmission operation mechanism assembly
on installation position .
b. Install transmission operation mechanism assembly
mounting bolt and tightening.
c. Install the lock plate of gear selecting and gear

shifting cable shaft.
d. Install the split pin of gear selecting cable shaft.
e. Install the split pin of gear shifting cable shaft.
TR
Input shaft module

Check and repair
Caution
All parts shall be cleaned completely before testing and change any part if it is unacceptable.
1. Remove input shaft assembly of transmission (refer to “Chapter TR Transmission and

Operation Mechanism-manual transmission -transmission assembly -transmission
assembly, disassembly of transmission”)
2. Disassemble the input shaft assembly.
a. Remove bearing collar ② with circlip plier.
TR b. Remove input shaft bearing ③ and cover plate ④
of front case.
Caution
• Check if the bearing turns smoothly.
• Check if the bearing moves seriously. If so,
change the bearing.
• Check if the gear and spline are hurt or broken.
If so, change input shaft ①.
3. Assemble the input shaft

a. Place the input shaft sub-assembly ③ on the press
machine as shown in the left picture ⑤ and install
front case cover plate ④ (put the cover plate on
synchronous gear ring), press the bearing ② into
input shaft sub-assembly with bearing erector ①
and press machine, inspect if the bearing is welled
pressed into the position (bearing is pressed on the
retaining shoulder of input shaft).
Caution
• The bearing erector shall be pressed on the
inner ring of bearing. Never press the outer ring,
retainer and steel ball of the bearing.
• When the opening length of front case cover plate is
larger than the outer diameter of input shaft gear,
install the cover plate later.
b. Place the collar ② and collar erector ③ as shown in

the picture and knock the collar erector with
hammer to knock the collar into the groove.
Caution
The collar erector and collar shall be placed in parallel.
4. Install input shaft assembly of transmission (refer to “Chapter TR Transmission and

Operation Mechanism-manual transmission -transmission assembly - Transmission
assembly, disassembly of transmission assembly”)
TR
Output shaft assembly

Check and repair
Caution
All parts shall be washed completely before testing. Any unacceptable part shall be changed.
1. Remove the output shaft assembly (refer to “Chapter TR Transmission and Operation
Mechanism-manual transmission -transmission assembly -transmission assembly,
disassembly of transmission”)
2. Disassemble the output shaft assembly.
a. Manually remove the output needle bearing ①, high
TR speed synchronizer collar ②, then remove high
speed synchronizer assembly ③ , high speed
synchronous ring ④, driven gear assembly ⑤ of
the 3rd speed gear and 挡 needle bearing of the 3rd
speed gear.
b. Check if the gear is hurt or broken, if the needle
bearing has missed its needle, if the needle is worn
seriously, if the retainer is damaged; change if
necessary;
c. Use special tool to place the output shaft ① as

shown in the picture, get stuck the driven gear
assembly of the 1st speed gear, press out the
driven gear assembly of the 1st speed gear, double
row angular contact bearing ③ (hold the bearing
inner ring and outer ring with two hands as the
bearing may easily disperse) and reverse gear
lining ②. Remove the needle bearing of the 1st
speed gear and low speed synchronous ring.
d. Check if the gear is hurt or broken, if the needle
bearing has missed the needle, if the needle is worn
seriously, if the retainer is damaged, if the bearing
turns smoothly and if the lining and output shaft are
worn seriously, and change if necessary.
e. Place the output shaft ① as shown in the picture,

get stuck the driven gear assembly of the 2nd
speed gear, press out the driven gear assembly of
the 2nd speed gear ⑤, low speed synchronous ring
④, low speed synchronizer assembly ③ and lining
② of the 1st speed gear, remove the needle bearing
of the 2nd speed gear with hands (unmarked in the
picture, it is between the driven gear of the 2nd
speed gear and output shaft).
f. Check if the gear is hurt or broken, if the needle
seriously, if the retainer is damaged, if the bearing TR
g. Place the output shaft ① as shown in the picture to
get stuck the driven gear assembly of the 2nd
speed gear, press out the driven gear assembly of
the 2nd speed gear ⑤, low speed synchronous ring
④, low speed synchronizer assembly ③ and lining
② of the 1st speed gear, remove the needle bearing
of the 2nd speed gear with hands (unmarked in the
picture, it is between the driven gear of the 2nd
speed gear and output shaft).
h. Check if the gear is hurt or broken, if the needle
seriously, if the retainer is damaged, if the bearing
3. Assemble the output shaft assembly.

a. Place the output shaft as shown in the picture,
install needle bearing ②, driven gear assembly of
the 2nd speed gear ③, low speed simultaneous
ring ④ and low speed synchronizer assembly ⑤
manually one by one (if the synchronizer assembly
has dispersed, refer to below picture for
installation).
Caution
• When installing the needle bearing and low
speed tri-cone synchronous ring, apply
TR lubrication oil on the matching face.
• Place the gear ring of driven gear assembly of
the 2nd speed gear upward.
• Install low speed tri-cone synchronous ring and
ensure the middle ring boss is located in the
groove of driven gear of the 2nd speed gear.
• When installing the low speed synchronizer
assembly, hold the outer ring low speed
transfer coupling of synchronizer with hands
and place into the output shaft slowly.
• Ensure the slide block on synchronizer
assembly is aligned with the groove on outer
ring of synchronous ring.
b. Assemble the low speed synchronizer assembly,

place the transfer coupling and assemble the sliding
block assembly as shown in the picture.
①: Inner ring of low speed synchronous ring
②: Middle ring of low speed synchronous ring
③: Outer ring of low speed synchronous ring
④: Low speed outer gear ring
⑤: Low speed slide block assembly
⑥: Low speed transfer coupling
c. Place the lining of the 1st speed gear and lining

erector as shown in the picture, press the lining onto
the output shaft with a press machine.
①: lining erector
②: Lining of the 1st speed gear
③: Low speed synchronizer assembly
④: Low speed tri-cone synchronous ring
⑤: Driven gear assembly of the 2nd speed gear
⑥: Output shaft
TR
d. The output shaft is placed as shown in the picture,

install needle bearing, low speed tri-cone
synchronous ring and driven gear assembly of the
1st speed gear one by one.
①: Driven gear assembly of the 1st speed gear
②: Low speed tri-cone synchronous ring
③: Needle bearing
④: Lining of the 1st speed gear
⑤: Low speed synchronizer assembly
⑥: Low speed tri-cone synchronous ring
⑦: Driven gear assembly of the 2nd speed gear
⑧: Output shaft
e. Install double row angular contact bearing, bearing

erector and press the bearing onto the output shaft
with a press machine.
①: Bearing erector
②: Double row angular contact bearing
③: Driven gear assembly of the 1st speed gear
④: Low speed tri-cone synchronous ring
⑤: Low speed synchronizer assembly
⑥: Low speed tri-cone synchronous ring
⑦: Driven gear assembly of the 2nd speed gear
⑧: Output shaft
f. Reverse the output shaft and place the lining and

lining erector as shown in the picture, press the
lining onto the output shaft with a press machine.
①: Lining erector
②: Reverse gear lining
③: Double row angular contact bearing
④: Driven gear assembly of the 1st speed gear
⑤: Low speed synchronous ring
⑥: Low speed synchronizer assembly
⑦: Low speed synchronous ring
⑧: Driven gear assembly of the 2nd speed gear
TR ⑨: Output shaft
g. Output shaft is placed as shown in the picture.

Manually install the needle bearing, driven gear
assembly of the 3rd speed gear, high speed
synchronous ring and high speed synchronizer
assembly one by one.
①: High speed synchronizer assembly
②: High speed synchronous ring
③: Driven gear assembly of the 3rd speed gear
④: Needle bearing
⑤: Driven gear assembly of the 2nd speed gear
⑥: Low speed synchronous ring
⑦: Low speed synchronizer assembly
⑧: Low speed synchronous ring
⑨: Driven gear assembly of the 1st speed gear
⑩: Double row angular contact bearing
⑪ Reverse gear lining
⑫ output shaft
Caution
• When installing the needle bearing and high
speed synchronous ring, apply lubrication oil
on the contacting face.
• Gear ring of driven gear assembly of the 3rd
speed gear shall face forward.
• When installing the high speed synchronous
ring, ensure the slide block groove of
synchronous ring is aligned with the slide block
on synchronizer assembly.
• When installing high speed synchronizer
assembly, the long end of retainer shoulder of
transfer coupling shall be downward.
h. Place the collar and collar erector as shown in the

picture. Knock the collar erector with a hammer to
knock the collar into the groove and place a needle
bearing.
①: Collar erector
②: Collar
③: High speed synchronizer assembly
④: High speed synchronous ring
⑤: Driven gear assembly of the 3rd speed gear
⑥: Driven gear assembly of the 2nd speed gear
⑦: Low speed synchronous ring
⑧: Low speed synchronizer assembly TR
⑨: Low speed synchronous ring
⑩: Driven gear assembly of the 1st speed gear
11. Double row angular contact bearing
12. Reverse gear lining
13. Output shaft
14. Needle bearing
4. Install output shaft assembly (refer to “Chapter TR Transmission operation
mechanism-manual transmission -transmission assembly -transmission assembly,
Counter shaft components

Check and repair
Caution
Wash every removed part, inspect and test each part. Change the part if it is defected or
unacceptable.
1. Remove countershaft assembly (refer to “Chapter TR Transmission and Operation

disassemble the transmission”)
2. Disassemble the counter shaft assembly.
TR a. Use a puller to pull out the countershaft bearing ②.
3. Assemble the counter shaft assembly.

a. Use bearing erector ① and pressure machine to
press the countershaft bearing ② into countershaft
①.
4. Install countershaft assembly (refer to “Chapter TR Transmission and Operation

AX Axle and drive shaft
Drive shaft ......................................................... AX-1
Drive shaft assembly ............................................ AX-1
Drive shaft ............................................................ AX-9
Universal joint ...................................................... AX-11
Sliding yoke ........................................................ AX-16
Rear axle .......................................................... AX-17
Rear axle (A2125) .............................................. AX-17 AX

Axle and drive shaft - Drive shaft AX-1
Drive shaft
Drive shaft assembly

General
1. The intersection position between axis of transmission output shaft and axis of rear axle
drive gear changes frequently and the universal drive device must be used for the power
transmission between these two parts. The drive system is composed of universal joint
and drive shaft with sliding yoke and is functioned to transmit the outputted torque of
engine and transmission to the drive axle.
2. This vehicle is assembled with tubular open drive shaft, which is composed of one drive
shaft and two universal joints.
AX
AX-2 Axle and drive shaft - Drive shaft
Precautions
1. The drive shaft must have good balance performance. Therefore, at the time of
disassembling, add assembling markings on the universal joints and do not disassemble
any counterbalance at will.
2. The drive shaft is internal hollow. Handle the drive shaft with caution to prevent
bending/deformation of the drive shaft.
3. Before disassembling and detaching the drive shaft, hoist the drive shaft by a crane or
other metal wires or ropes to ensure safety.
4. Before disassembling this assembly, park the vehicle on a level ground, shift the
transmission to neutral gear, cut off the power supply, and block both front and rear
wheels.
5. After the breakup of drive shaft, clean all parts by kerosene or diesel, check the parts one
AX by one, and take corresponding repair and service measures.
6. Before reassembling the drive shaft assembly, thoroughly clean all parts and apply
automotive all-purpose lithium-base lubricating grease to the bearings, oil seals, and
fitting surfaces of all parts.
7. After reassembling the drive shaft assembly, inspect and adjust the drive shaft by a
dynamic balance tester. Before the dynamic balance test, measure the radial run-out at
any point in full length of the shaft tube. The measurement shall be no higher than 1mm for
the drive shaft. After the dynamic balance test, no more than 2 counterbalances for each
end can be welded by two welding points to the corresponding locations on two ends of
shaft tube. After the welding, repeat the dynamic balance test.
8. Do not start up the vehicle in high speed gear, release the clutch pedal fiercely, overload
the vehicle, or drive the vehicle over-speed, otherwise it will result in deformation or
damage of drive shaft.
Preparations
Recommended tools
For disassembling of
Circlip pliers
crossing shaft circlip
For disassembling of AX
Copper bar crossing shaft needle
bearings
Dial indicator For checking of drive shaft
For checking of gaps of

Feeler gauge universal joints and
crossing shaft
Equipment
Drive shaft dynamic balance For test of drive shaft dynamic

-
tester balance
Technical data
Maintenance data
Axial clearance of crossing shaft ＜0.1mm
Static run-out of drive shaft ≤1mm
Filling volume of lubricating grease for universal joint assembly 5.6~7.2g
Torque requirements
Fasteners N·m
Connecting bolts and nuts between drive shaft and rear axle main
58~70
reducer
AX
Part diagram
AX
1 Propeller shaft assembly 2 Drive shaft bolt


1. Universal joint yoke

(Inconsistent assembling Reinstall.
direction)
Swing of drive shaft or vibration of
2. Drive shaft is twisted or bent Repair or replace.
vehicle during driving
3. Any part (Looseness or
Repair, perform dynamic balance
excessive dynamic
test, or replace.
unbalance)
AX
1. Telescoping spline (Excessive
Replace the transmission shaft.
wear)
Abnormal sound of transmission
2. Universal joint bearings Replace crossing shaft or
shaft
(Wear, seizure, and damage) bearings.
3. Fasteners (Looseness) Re-tighten.
1. Universal joint bearings (Oil

Add lubricating oil
shortage)
Heating of universal joints Run in at low speed and add oil to
2. Oil seals (Over-tightness)
the lips.
Onboard inspection
The repairs of the drive shaft are mainly to check the vibration symptom of drive shaft, find out the
vibration cause, and correct the cause.
1. Check the drive shaft flange for secure connection.
a. Check whether the fastening bolts and nuts between drive shaft flange and rear axle are
tightened to the specified torque.
Torque: 58~70N•m
2. Check whether the universal joints are
assembled as per the markings.
a. If the universal joints are not assembled as per
markings, it will probably result in unbalanced drive
shaft and serious vibration.
AX
3. Check drive shaft for bending deformation.

a. The visually observed bending of the drive shaft is
incorrect. Measure the bending by a special
measurement gauge. (Refer to Chapter AX Axles
and Drive Shafts - Drive Shaft - Drive Shaft,
Checking and Repair)
4. Check the axial clearance of crossing shaft.

a. Shake the flange yoke vertically and longitudinally
to check the axial clearance of crossing shaft. If the
clearance is beyond the limit, replace the crossing
shaft assembly.
Axial clearance of crossing shaft: ＜0.1mm.
5. Perform the dynamic balance test for the drive

shaft.
a. The dynamic balance testing shall be conducted
after the checking, repair, or replacement of parts
each time. The dynamic balance test shall be
performed by a professional drive shaft dynamic
balance tester. Based on the indication of the tester,
no more than 2 counterbalances for each
unbalanced end can be welded by two welding
points on two ends of shaft tube. After the welding,
repeat the dynamic balance test. The permissible
unbalance for the inter-axle drive shaft is 20g•cm
(Measurement speed at 3,200r/min).
AX
b. An unbalanced drive shaft of the vehicle will
generate a periodical sound during the traveling.
The higher the driving speed is, the higher the
sound is. In serious cases, it can result in jitter of
vehicle body, vibration of cab, and numb hand
feeling on the steering wheel. The jitter of vehicle
body will result in the looseness of vehicle parts and
the accident of vehicle.
Caution
Before the dynamic balance test, check the run-out of
drive shaft to minimize the dynamic balance
measurement error.
Drive shaft
Check and repair
1. Disassemble the drive shaft.
a. Disassemble the fastening bolts and nuts between
rear drive shaft and rear axle.
Caution
During disassembling, support the drive shaft
assembly by supports to prevent the falloff during
disassembling from causing harms.
b. Pull out the drive shaft from the transmission end. AX
2. Check the drive shaft.

a. Check the radial run-out of drive shaft.
Caution
Before the dynamic balance test, check the run-out of
drive shaft to minimize the dynamic balance
measurement error.
b. Check the intermediate drive shaft universal joint for

damage.
Caution
Check the intermediate drive shaft universal joint for
clear damage. Upon detection of serious damage,
replace it directly.
3. Install the drive shaft.

a. Insert the drive shaft spline into the transmission
spline bore.
Caution
During installation, support the drive shaft assembly
by supports to prevent the falloff during installation
from causing harms.
b. Install the rear end of drive shaft onto the rear axle
main reducer and install and tighten the connecting
bolts and nuts.
Torque: 58~70N•m
AX
Universal joint
Check and repair
Caution
The checking and repair method is same for the drive shaft universal joints. This section
describes by taking the checking and repair method for the universal joint on one end of the
drive shaft for instance.
1. Disassemble the drive shaft assembly. (Please refer to Chapter AX Axle, Drive Shaft –
Drive Shaft – Drive Shaft, Inspection)
2. Add the assembling markings.
a. Add assembling markings on the drive shaft flange
yoke and universal yoke.
Caution AX
The assembling markings shall be within one same
horizontal plane. Install as per the markings during
installation.
3. Break down the universal joint assembly.

a. Disassemble the fixing circlips from the four ends of
crossing shaft by circlip pliers.
b. Knock the flange yoke by a hammer to take out the

crossing shaft needle bearings.
Caution
Due to tight fit of bearings, knock the flange yoke
uniformly by a hammer during hammering.
c. Knock the flange yoke on the other side by a
hammer to take out the other needle bearing and
flange yoke.
d. Knock the crossing shaft in the drive shaft by a copper

bar and take out the crossing shaft needle bearings.
Caution
Due to tight fit of bearings, knock uniformly the shafts
on two sides of the crossing shaft by a copper bar
during knocking.
e. Rotate the drive shaft, knock the crossing shaft
needle bearing on the other end by a copper bar as
per same method.
f. Take down the cross shaft.
g. Disassemble the lubricating oil nozzle of crossing

shaft.
AX
4. Check the crossing shaft parts for damage.

a. Check the needles of crossing shaft needle
bearings for damage. If damaged, replace the
crossing shaft assembly.
Caution
There are many lubricating oil in the bearings. Remove
the oil firstly during checking.
b. Check the journal surfaces for flaking and check the

journal surfaces for needle indentation. If yes,
replace the crossing shaft assembly.
c. Check the fit clearance between crossing shaft and

needle bearings. If the clearance is beyond
specified value, replace the crossing shaft
assembly.
• Fix one end of crossing shaft on a vice and
install the needle bearings.
• Push the probe of a micrometer against the
middle of needle bearing surface and reset
the micrometer indicator.
• Move the needle bearing vertically and
observe whether the variation value of the
micrometer indicator is within specified
range.
AX
5. Assemble the universal joint assembly.
a. Install the lubricating oil nozzle of crossing shaft.
b. Apply an appropriate amount of lubricating oil to two

ends of drive shaft and contact surfaces of flange
yoke.
c. Apply lubricating oil uniformly to the upper, lower,

left, and right journals of the crossing shaft.
d. Install the crossing shaft into the flange yoke.
e. Apply a film of lubricating grease onto the inner

needles and outer steel sleeve of the needle
bearing.
f. Install the crossing shaft into the flange yoke, install
the crossing shaft needle bearing with oil seal into
the crossing shaft via the flange yoke, and knock it
tight by a copper bar.
g. Install the flange yoke with crossing shaft onto the

drive shaft.
AX
h. Install the crossing shaft needle bearing with oil seal

to the crossing shaft via universal joint yoke and
knock it tight by a copper bar.
i. Install the needle bearings in place by a hammer

and a copper bar in same diameter with crossing
shaft needle bearing.
j. Install the crossing shaft needle bearing circlips into

the circlip grooves.
Caution
After installation, rotate the circlips by one turn to
ensure proper installation.
6. Check the crossing shaft for flexible rotation

and check its axial clearance.
Axial clearance of crossing shaft: 0.02~0.20mm.
Limit value: 0.25mm
Caution
If the clearance is beyond the limit, replace the drive
shaft assembly.
7. Install the drive shaft assembly. (Refer to Chapter AX Axle, Drive Shaft – Drive Shaft –
Drive Shaft, Inspection)
AX
Sliding yoke
Check and repair
1. Disassemble the drive shaft assembly. (Please refer to Chapter AX Axle, Drive Shaft –
Drive Shaft – Drive Shaft, Inspection)
2. Disassemble the sliding yoke.
a. Break down the universal joint on the sliding yoke end and take out the sliding yoke.
3. Check the backlash of drive shaft sliding spline.
a. Use a feeler gauge to measure the fit clearance
between spline shaft and transmission spline bore
in normal rotation direction.
A: Spline bore B: Spline shaft
AX b. If the backlash of sliding spline is beyond limit,
replace with new drive shaft.
4. Install the sliding yoke.

a. Install the universal joint at sliding yoke.
b. Apply an appropriate amount of lubricating grease to the sliding yoke spline.
5. Checking after assembling
a. After the installation of sliding yoke, the repeated pull-out of the sliding yoke shall be free of
stagnation and there shall be free of clearance in circumferential direction. Upon detection of
above-mentioned symptoms, replace the sliding yoke.
6. Install the drive shaft assembly. (Please refer to Chapter AX Axle, Drive Shaft – Drive Shaft
– Drive Shaft, Inspection)
Axle and drive shaft - Rear axle AX-17
Rear axle
Rear axle (A2125)

Rear axle assembly
Precautions
1. Precautions for maintenance of final drive gear oil
a. Precautions for maintenance of final drive gear oil
Gear oil: 85W/90 GL-5 gear oil (Summer) and 80W/90 GL-5 gear oil (Winter)
b. Do periodically change the final drive gear oil. (Refer to Chapter AX Axle, Drive Shaft – Rear Axle
– Gear Oil Replacement)
• Ensure to replace with new gear oil at the first level II maintenance.
• Ensure to replace with new gear oil after first 40,000km mileage or first 24 months.
• Ensure to replace with new gear oil after first 80,000km mileage or first 48 months.
Afterwards, replace the gear every 50,000km. AX
c. Periodically perform the inspection, at least once every four-time level II maintenance
• Check the gear oil for color change and thinning Change with the new gear oil if needed.
(Refer to Chapter AX Axle, Drive Shaft – Gear Oil Replacement)
2. Precautions for maintenance of final drive assembly
a. Do periodically check the breather plug and remove
the dust and mud.
Caution
• At the level II maintenance, disassemble the
breather plug and clean it to make is smooth.
• Blocking the breather plug could increase the
final drive interior pressure, possibly lead to
leaking.
• Clean the breather plug and check the gear oil
level at the same time.
b. For the level III maintenance, dismantle the final
drive assembly to clean the inside chamber. The
bolts and nuts shall be tightened to the stipulated
value for assembling of the final drive.
c. Ensure to periodically check the wear status of the
brake shoes and the rear brake drums. (Refer to
Chapter BR Service Brake (Hydraulic) - Rear Drum
Brake, Checking and Repair)
3. Precautions for maintenance of final drive assembly
a. Do replace the parts in pair.
b. All the rubber parts (such as the O-ring, oil seal and washer) cannot be reused any more.
c. Check the appearances of all the parts via the visual inspection or with red lead for the following
defects:
Uneven wear Eccentric wear Scratch Cracking
Deformation Bent Loose Rust
Abnormal noise
Color change or jam Invalid or weak (spring) Going bad (brake shoes)
(bearing)
AX-18 Axle and drive shaft - Rear axle
d. Prior to assembly of final drive assembly, do make sure all the parts are clean, free of oil
contamination and iron scrap. Gear oil shall be used for lubrication unless special requirements
Gear oil: 85W/90 GL-5 gear oil (Summer) and 80W/90 GL-5 gear oil (Winter)
4. Precautions for vehicle use
a. Never be overloaded. Namely, the vehicle loaded weight shall not be more than the max.
load-bearing capacity.
b. With vehicle running, do not fast release the clutch.
Caution
Releasing the clutch quickly could impact or even damage the gear.
AX

1. Axle shaft spline (clearance

Replace half shaft.
Intermittent knocking sound too wide or wear)
(travel) 2. Foreign material gets into the
Check and repair main reducer.
final drive.
1. Vent port is blocked Smooth the vent port
2. Gear oil is excessive Check and drain gear oil.

Final drive is leaking
3. Final drive housing is cracked
Replace. AX
or has blister
1. Lack of rear axle gear oil Check and add gear oil.
Final drive overheats
2. Rear wheel brake is stuck. Check and repair rear brake.
Preparations
Recommended tools
Tire pressure gauge Tire
AX
Drive shaft, spline, drive shaft
Clearance gauge
gear
Drive shaft, universal joint,

intermediate bearing, front wheel
Hammer hub cover, rear wheel hub cover,
steering knuckle, and differential
planetary gear shaft
Drive shaft, universal joint,

intermediate bearing, front wheel
Copper bar hub cover/rear wheel hub cover,
steering knuckle, and differential
planetary gear shaft
Micrometer Drive shaft, universal joint, spider
Drive shaft, universal joint, front

wheel hub bearing, rear wheel
Dial indicator hub bearing, drive gear, driven
gear, half shaft gear, planetary
gear, and drive gear flange
Drive shaft, universal joint, rear

Circlip pliers wheel hub bearing, and main
reducer output flange
Drive shaft joint yoke, half shaft

Puller
bearing, and drive gear bearing
AX
Front wheel hub bearing, rear

Grease gun wheel hub bearing, and steering
knuckle
Lifting type hydraulic jack Final drive assembly
Torque wrench Starting torque of drive gear
Half shaft gear thrust washer,

Vernier caliper planetary gear thrust washer, and
drive gear adjustment shim
Tape Total play of rear axle

Drive gear adjustment shim, and

Spring balance starting force for rotation of rear
wheel hub
Equipment
V-shaped table —
Drive shaft dynamic balance tester —
Bench press —
AX
Bench vice —
Lubricating grease
Universal joint of drive shaft
Intermediate bearing
Universal joint
Front wheel hub — No.2 lithium-base grease
Rear wheel hub
Drive half shaft
Main reducer output flange oil
seal and drive gear oil seal
Main reducer gear oil 2.5L GL—580W/90
Sealant
Main reducer output flange bolt
Loctite 204
Bolt, driven gear
Differential bearing bolt
Balance block, propeller shaft — —

Maintenance data
Rear axle assembly
Rear wheel track 1300mm
85W/90 GL-5 gear oil (Summer) and 80W/90

Rear axle gear oil specification
GL-5 gear oil (Winter)
Rear axle gear oil volume 1.1L
Torque requirements
Fasteners N·m
Axle and drive shaft AX
Driving gear flange of final drive X drive shaft 25±3
Rear brake oil pipe assembly × rear brake slave cylinder 18±3
Steering knuckle × lower swing arm ball and socket joint 45±5
Steering gear tie rod × steering knuckle arm 40±4
Final drive drain plug 10±1
Final drive filler cap 10±1
Main reducer ventilation plug 10±1

Onboard inspection
1. Check the total play of rear axle.
a. Park the vehicle on the flat ground.
b. Shift the transmission to neutral gear and apply the parking brake handle assembly tightly.
c. Use a jack or elevator to elevate the left and right rear wheels off the ground.
d. Separate the universal joint at the rear of drive shaft from the driving gear flange assembly.
• Mark the universal joint at the rear of drive shaft and
the driving gear flange assembly.
Caution
Make sure that the installation marking is clear and
visible.
AX
• Loosen four fixing bolts.

Tools: 13mm wrench
Caution
The disassembled bolts cannot be reused.
• Put down the rear end of drive shaft.

Caution
Support the rear drive shaft using the bench or the
similar.
e. Measure the play of rear axle.

• Rotate the drive gear flange assembly
counter-clockwise by hand, till it can’t be
rotated freely further.
• Add assembling markings to the drive gear
flange assembly and main reducer housing.
Caution
Make sure that the installation mark is clear and
visible.
• Rotate the drive gear flange assembly

clockwise by hand, till it can’t be rotated
freely further.
• In such case, the distance between two
assembling markings on the drive gear
flange assembly and main reducer is the play
of rear axle.
f. Connect the drive shaft rear universal joint and

drive gear flange assembly.
• Place the rear drive shaft in place as per the
assembling markings.
AX
Caution
• Make sure that the installation marking is clear
and visible.
• As required, rotate the drive gear flange
assembly to align the assembling markings.
• Tighten 4 bolts.
Tool: 13mm wrench;
Torque: 25±3N•m
Caution
Ensure to replace with new bolts.
2. Check the gear oil level

a. Loosen the oil filler using the wrench.
Tools: 24mm wrench
b. Check the distance from the gear oil level to the

inside surface of oil filler.
Caution
• Excessive gear oil or lack of it could lead to
system failures.
• Add the gear oil into the rear axle. (Refer to
Chapter AX Axle, Drive Shaft – Rear Axle – Gear
Oil- Replacement.)
c. Tighten the oil filler using the wrench.

Tools: 24mm wrench
Torque: 25±3N•m
AX
3. Check the main reducer housing.

Check the main reducer housing for cracking and leakage and as required replace.
Rear axle housing weldment assembly

Check and repair
1. Precautions (Refer to Chapter AX Axle, Drive Shaft – Rear Axle– Rear Axle assembly,
Precautions)
3. Disassemble the rear wheel assembly. (Refer to Chapter FR Frame, suspension and
wheels - Wheels and tires - Replacement, Rear wheels and tires)
4. Remove the rear drum-type brake. (Refer to Chapter BR Service Brake (Hydraulic) – Rear
Drum Brake, Inspection)
5. Completely drain the gear oil out of the rear axle. (Refer to Chapter AX Axle, Drive Shaft –
Rear Axle – Gear Oil Replacement)
6. Remove the rear axle brake pipeline and the
AX
parking brake cable.
Caution
Drain the oil out of the service brake pipeline before
removing the rear service brake pipeline.
a. Loosen one bolt fixing the left rear control cable of
the parking brake onto the leaf spring, disassemble
the bolts fixing the cable bracket and then put the
cable away.
Tools: 13mm wrench
Caution
Removal of the right parking brake cable with the
bracket assembly has the same steps as the removal
of the left one.
b. Remove the nuts attached to left service brake pipe

joint of rear axle and the put the brake pipe away.
Tools: 10mm wrench
c. Remove the nut attached to the right service brake

pipe joint of rear axle.
Tools: 10mm wrench
d. Remove two fixing bolts attached to the upper

service brake pipe of rear axle.
Tool: 13mm socket
e. Take down and put away the service brake pipe of
rear axle.
Caution
The pipes must not be twisted or deformed for
storage.
7. Remove the wheel hubs at both sides of rear axle. (Refer to Chapter AX Axle, Drive Shaft –
Rear Axle– Rear Wheel Hub, Inspection)
8. Remove the left and right axle shaft assemblies (Refer to Chapter AX Axle, Drive Shaft –
Rear Axle– Axle Shaft Assembly, Inspection)
AX
9. Remove the final drive assembly
a. Separate the universal joint at the rear of drive shaft
from the driving gear flange assembly.
• Mark the universal joint at the rear of drive
shaft and the driving gear flange assembly.
Caution
Make sure that the installation mark is clear and
visible.
• Loosen the four fixing bolts.
Tools: 13mm wrench
Caution
The disassembled bolts cannot be reused any more.
b. Put down the rear end of drive shaft.

Caution
Support the rear drive shaft using the bench or the
similar.
c. Disconnect the connecting spring between

load-sensing proportional valve and axle.
d. Loosen the 8 fixing nuts on the final drive assembly

to take down the final drive assembly.
Tool: 13mm socket
Caution
Support the final drive assembly using the jack or
bench.
10. Remove the rear suspension assembly. (Refer to Chapter FR Frame, Suspension, Wheel –
Rear Suspension – Rear Leaf Spring Assembly, Inspection)
Caution
Support the welded axle housing assembly using the jack or bench prior to removal.
AX
11. Disassemble the rear axle housing weldment

assembly.
12. Check the rear axle housing weldment assembly.

a. Check the rear axle housing weldment assembly for presence of cracking and oil leakage and as
necessary replace.
13. Mount the rear axle housing weldment
assembly.
a. Mount the rear axle housing weldment assembly in
place using the jack or the bench.
14. Mount the rear suspension assembly. (Refer to Chapter FR Frame, Suspension, Wheel –
Rear Suspension – Rear Leaf Spring Assembly, Inspection)
15. Mount the final drive assembly

a. Mount the final drive assembly and tighten the 8
nuts on the final drive assembly.
Tool: 13mm socket
Torque: 25±3N•m
Caution
Support the final drive assembly using the jack or
bench.
b. Install the connecting spring between load-sensing

proportional valve and axle.
AX
c. Mount the rear end of rear drive shaft according to

the mounting marks and then tighten the four bolts
and nuts.
Tools: 13mm wrench
Torque: 25±3N•m
d. Remove the jack, the bench or the jacking pump.
16. Mount the left and right axle shaft assemblies (Refer to Chapter AX Axle, Drive Shaft –
Rear Axle – Axle Shaft Assembly, Inspection)
17. Mount the wheel hubs at both sides of rear axle. (Refer to Chapter AX Axle, Drive Shaft –
Rear Axle – Rear Wheel Hub, Inspection)
18. Mount the rear axle service brake pipeline and
the parking brake cable.
a. Mount two fixing bolts attached to the upper service
brake pipe of rear axle.
Tool: 13mm socket
Torque: 18±3N•m
b. Tighten the nut attached to the right service brake

Tools: 10mm wrench
Torque: 18±3N•m
c. Tighten the nut attached to the left service brake

Tools: 10mm wrench
Torque: 18±3N•m
AX
d. Tighten the one fixing bolt fixing the parking brake

left rear cable bracket onto the leaf spring.
Tools: 13mm wrench
Torque: 25±3N•m
Caution
Installation of the right parking brake cable with the
bracket assembly has the same steps as the
Installation of the left one.
19. Mount the rear drum-type brake. (Refer to Chapter BR Service Brake (Hydraulic) – Rear
Wheel Brake, Inspection)
20. Remove the rear wheel assembly. (Refer to Chapter FR Frame, suspension and wheels -
Wheels and tires - Replacement, Rear wheels and tires)
21. Add the gear oil into the rear axle.(Refer to Chapter AX Axle, Drive Shaft – Rear Axle – Gear
Oil Replacement)
22. Replenish and drain out the brake fluid. (Refer to Chapter BR Service Brake (Hydraulic) –
Brake liquid, Venting)
Rear wheel hub

Check and repair
1. Remove the left rear wheel assembly. (Refer to Chapter FR Frame, suspension and wheels
- Wheels and tires - Replacement, Rear wheels and tires)
2. Remove the rear drum-type brake. (Refer to Chapter BR Service Brake (Hydraulic) – Rear
3. Remove the left –rear wheel hub with axle shaft
assembly
a. Loosen the one bolt attaching the parking brake
rear-left cable assembly to the leaf spring, and
disassemble the cable assembly at the rear of
parking brake.
AX
Tools: 13mm wrench
Caution
Remove the bolts from the side of leaf spring.
b. Loosen the nuts at the left rear parking brake pipe

to disassemble the left rear service brake pipe.
Tools: 10mm wrench
c. Loosen 4 fastening nuts.

Tool: 17mm wrench.
d. Remove the left rear wheel hub with axle shaft

assembly and left rear brake baseplate.
4. Mount the left –rear wheel hub with axle shaft

assembly
a. Use the dial indicator to measure the rear-left wheel
hub bearing clearance. If the measured value is out
of the range, replace with the new left rear wheel
hub.
Caution
• During measurement, manually and axially push
the left rear fixing plate in place.
• Prior to measurement, the dial gauge shall be as
near the left rear wheel hub center as possible.
AX
b. Insert the left rear wheel hub with axle shaft
assembly into the rear axle housing.
Caution
Prior to assembly, coat the hex. Platform of brake
baseplate with the proper 2# lithium-base grease, not
contaminating the brake drum and the friction plate
c. Tighten the four fixing bolts.

Tools: 17mm wrench
Torque: 95±10N•m
d. Use the dial indicator to measure the left rear wheel
hub deflection.
If the measured value is out of the range, replace
with the new one.
Caution
• For measurement, manually and tangentially
rotate the left rear wheel hub.
• During the measurement, the dial gauge shall
be as near the outer edge of left rear wheel hub
as possible (outside of wheel bolt).
e. Connect the left rear brake pipe assembly and the

left rear brake slave cylinder and then tighten the
pipe joint nut.
Tools: 10mm wrench
Torque: 18±3N•m
f. Mount the parking brake left rear cable assembly

onto the brake baseplate and then tighten the one
mounting bolt.
Tools: 13mm wrench
AX
Torque: 25±3N•m
Caution
The bolts shall be mounted from the front of brake
baseplate.
5. Mount the rear drum-type brake. (Refer to Chapter BR Service Brake (Hydraulic) – Rear
6. Remove the left rear wheel assembly. (Refer to Chapter FR Frame, Suspension, Wheels
and Tires, Rear Wheel and Tire, Replacement)
8. Mount and install the right rear wheel hub.
Caution
The steps to mount/disassemble the right rear wheel hub are same as that to mount/disassemble
the left rear one.
Axle shaft assembly

Check and repair
1. Remove the left axle shaft assembly.
a. Remove the left- rear wheels (Refer to Chapter FR Frame, Suspension, Wheels and Tires, Rear
Wheel and Tire, Replacement)
b. Remove the rear drum-type brake. (Refer to Chapter BR Service Brake (Hydraulic) – Rear Wheel
Brake, Inspection)
c. Disassemble the left rear wheel hub.
Caution
Left-rear wheel hub and the left axle shaft is integrated into one part.
2. Check the axle shaft.

AX
a. Measure the axle shaft middle run-out and the
flange inside-end run-out by using the V-shaped
bench and the dial gauge.
If the run-out and the end run-out exceeds the limit,
correct it and replace it with a new one if needed.
b. Check the axle shaft is cracked or not by using the
magnetic inspection.
c. Check the spline at the end of axle shaft severely
wear, or obviously twists or cracks.
If the spline tooth wears or twists severely, replace
with the new one.
3. Install left rear wheel hub. (Refer to Chapter BR Service Brake (Hydraulic) – Rear Wheel
Brake, Inspection)
Caution
Left-rear wheel hub and the left axle shaft is integrated into one part.
4. Remove and mount the right axle shaft assembly

Caution
The steps to mount/disassemble the right axle shaft assembly are same as that to
mount/disassemble the left axle shaft assembly.
Driving gear
Inspection
1. Check the drive gear flange assembly.
a. Measure fitting end face run-out of drive gear flange
assembly by a dial indicator.
b. If the fitting end face run-out of the drive gear flange
assembly is beyond the limit range, replace with
new drive gear inner and outer bearings and
bearing spacers.
AX
c. Measure the run-out of drive gear flange spigot by a

dial indicator.
d. If the run-out of drive gear flange assembly spigot is
beyond the limit range, replace with new drive gear
flange assembly.
2. Check the differential bearing pre-tightening

force.
a. Open the lock edge of nut
b. Loosen the nut.
Tool: 30mm socket
c. Tool: 30mm socket

Tool: 30mm socket
Torque: 95±10N•m
d. Use the torque wrench to measure the starting

torque of driving gear.
Danger
Never loosen nut to reduce the starting torque of
AX
driving gear.
Caution
• If the starting torque is higher than the top limit,
replace the driving gear bearing spacer.
• If the starting torque is less than the bottom
limit, perform the following.
e. Tighten the nut.
f. Use the torque wrench to measure the starting torque of

driving gear again.
Caution
• If the starting torque is still less than the bottom
limit, repeat the above steps until the starting
torque falls in the stipulated range.
• If the nut torque exceeds the max. value but the
driving gear starting torque cannot yet fall into
the stipulated range, replace with the new
driving gear bearing spacer.
g. Lock nut
AX
Gear oil
Replacement
1. Drain the gear oil out of the rear axle
a. Loosen the vent plug
AX
b. Loosen the drain plug using the socket

Tool: 24mm socket
c. Completely drain the gear oil
Caution
Collect the gear oil using a container
d. Loosen the drain plug using the socket

Tool: 24mm socket
Torque: 25±3N•m
2. Add the gear oil.

a. Loosen the oil filler using the wrench.
Tools: 24mm wrench
b. Add the gear oil.
Gear oil: 85W/90 GL-5 gear oil (Summer) and
80W/90 GL-5 gear oil (Winter)
c. Check the gear oil level

Visually check the distance from the gear oil level to
the inside surface of oil filler.
Caution
• Excessive gear oil or lack of it could lead to
system failures.
• Add the gear oil into the rear axle. (Refer to
Chapter AX Axle, Drive Shaft – Rear Axle – Gear
Oil- Change)
d. Tighten the oil filler using the wrench.

Tools: 24mm wrench
Torque: 25±3N•m
AX
e. Tighten the breather plug

FR Frame, suspension and wheels
Front independent suspension ............................ FR-1
Front independent suspension assembly ............ FR-1
Four-wheel alignment........................................... FR-7
Shock absorber assembly (FR) ......................... FR-12
Thrust bar assembly ...........................................FR-16
Lower swing arm ................................................ FR-18
Subframe assembly ........................................... FR-20
Front wheel hub ................................................. FR-22 FR

Rear suspension .................................................. FR-24
Rear suspension assembly ................................ FR-24
Rear leaf spring assembly.................................. FR-32
Rear shock absorber assembly ......................... FR-35
Wheel and tire ...................................................... FR-36
Wheel and tire assembly .................................... FR-36
Front wheels and tires ........................................ FR-47
Rear wheels and tires ........................................ FR-49
Spare wheel and installation mechanism ........... FR-50

Frame, suspension and wheels - Front independent suspension FR-1
Front independent suspension
Front independent suspension assembly

Precautions
1. Tightening of the rubber parts shall be done with the tires unloaded and free from the
ground. As the lubricant shortens the service life of rubber, the over-flowed lubricant must
be removed away.
2. After the reinstallation of the disassembled suspension parts, check the wheels for
alignment and adjust them if needed.
3. The locknut, belonging to the disposable parts, shall be replaced with the new one every
time. The new locknut shall keep the lubricant prior to tightening them.
FR
FR-2 Frame, suspension and wheels - Front independent suspension
Onboard inspection
1. Check the front wheel bearing is loosened or not.
2. Check the front suspension is loosened or damaged or not.
3. Check if the steering linkage is loosened or not.
4. Check if each ball joint is loosened excessively.
5. Perform the standard elasticity to check the shock absorber for normal work.
6. Measure the unloaded vehicle height.
Place the vehicle on a platform for inspection and then bob the vehicle to stabilize the suspension.
Forcefully lift and press down the front bumper for 5～10 times and then loosen it so as to
measure the ground clearance of bumper center. Repeat this step again and then the difference
between two measured values shall not be more than 10mm.
FR
Part diagram
FR
1 Left lower wing arm assembly 6 Pivot
2 Right lower wing arm assembly 7 Lower swing arm pin
Left front traveler assembly with

3 Subframe assembly 8
brake
Right front traveler assembly with

4 Left thrust bar assembly 9
brake
5 Right pull rod assembly

Preparations
Recommended tools
Lifting type hydraulic jack Front suspension assembly
Torque wrench —
FR
Equipment
Four-wheel alignment tester Four wheel alignment
Tire changer Remove the tires
Tire dynamic balancing tester Tire dynamic balance
Consumable
Lubricating grease — Foton special-purpose grease

Maintenance data
14′±5′ (with difference between left and right ones
Front toe-in (one side)
not exceeding 10′)
0.77°±30′( with difference between left and right

Front wheel camber
ones not exceeding 30′)

Kingpin inclination angle

Caster of kingpin
Torque requirements
Fasteners N·m
Upper fastening nuts of front shock absorber 21~25

FR
Fastening nut between thrust bar and lower swing

78~96
arm
Fastening bolts of subframe assembly 75~92
Fastening bolts of thrust bar bracket 75~92
Adjustment nuts of thrust bar 126~154
Fastening nuts of steering tie rod ball joint 45~55
Fastening bolts and nuts between lower swing arm

73~89
and subframe assembly

Use the following table to help you to find out the reasons of malfunctions. Serial number represents the
order of possibility of fault reasons. Check each part as per this order and replace as the case may be.

1. Lubricant is excessive. Replace the absorber
Shock absorber leaks 2. Seals are invalid or damaged. Replace the absorber
1. Tires wear or is inflated Adjust tire pressure or replace
abnormally. tire.
Perform four-wheel alignment test
again.
3. The connector for steering
Tighten all loose parts.
Suspension noise system is loosened or wears
FR 4. Wear of wheel hub bearing Replace wheel hub assembly.
5. Steering gear wear or is of
Check and repair steering gear.
maladjustment.
Check and repair suspension
6. Suspension parts
parts.
1. Vehicle overloads Reduce the load.
Vehicle body sinks
abnormally. tire.
Sway / incline 2. The connector for steering Tighten loose parts and replace
system is loosened or wears worn parts.
abnormally. tire.
Perform dynamic balance test for
wheels again.
Front wheel swings
Perform four-wheel alignment test
again.
5. Wear of wheel hub bearing Replace wheel hub assembly.
6. The connector for steering Tighten loose parts and replace
system is loosened or wears worn parts.
1. Wheel alignment is not in line Perform four-wheel alignment test
with the regulations. again.
Tires wear abnormally. the regulations.
Perform dynamic balance test for
wheels again.
Four-wheel alignment
Checking
1. Checking before four-wheel alignment
a. Check and ensure that every axle uses the tires of same structure and tread, of which the tread
wears and the overall diameters are equal. Check and ensure that the radial and axial run-outs of
the wheels are within the specified tolerance. The tire pressure shall be within specified pressure
range.
b. Check the steering linkage and suspension for excessive play, check the steering tie rod ends
and ball joints for wear, check the springs for looseness, and check the swing arm and front strut
for excessive play.
c. Fully fill the fuel tank with fuel, ask all passengers to leave the vehicle, load the spare wheel, and
remove any other load.
d. Push down both front and rear ends of the vehicle for several times to ensure that the vehicle is
under normal driving height. FR
e. Check and ensure the consistent heights of corresponding positions between two sides of
vehicle.
f. When the wheels are under straight forward direction, the steering wheel must be in neutral
position. If necessary, disassemble steering wheel for adjustment.
g. Ensure that the wheel hub bearings have appropriate preload and the fastening nuts are
tightened to the specified torque.
h. Perform the dynamic balance test for the wheels. After the dynamic balance test, reinstall wheels
to the vehicle.
Caution
Do not attempt the wheel alignment by straightening the parts. Any damaged part must be
replaced.
2. Field requirements
a. The surface of the test field shall be smooth and
horizontal.
b. Place two alignment testers into the reserved pits of
same height with the alignment testers.
Caution
If no reserved pits are available, after two front wheels
are placed on the steering angle testers, cushion two
rear wheels with flat wood boards of same height with
steering angle testers.
3. Correct placement of vehicle

a. Elevate the vehicle, place two front wheels onto the steering angle testers, and ensure that the
extension line of the kingpin centerline passes through basically the center of steering angle
testers.
b. Rotate the steering wheel to place the vehicle under straight forward direction.
4. Install the apparatuses.

Caution
• Four-wheel alignment tester is a high-precision measurement apparatus functioned to
measure the wheel alignment parameters of the vehicle, compare the measurements
against the manufacturer’s design parameters, instruct the user for corresponding
adjustment of wheel alignment parameters to meet the manufacturer’s design
requirements, achieve ideal vehicle driving performance, namely handy operations and
stable and reliable driving, and reduce the wears of wheels.
• Operate as per the operation manual of the four-wheel alignment tester.
5. Check the front wheel kingpin inclination angle.

a. Apply the wheel brakes.
Caution
To prevent the rolling of front wheels during the
FR
rotation of steering wheel, brake the wheels during the
checking of kingpin inclination angle.
b. Rotate the steering wheel. At completion of
operation, the display screen of the apparatus will
display the inspection report.
Kingpin inclination angle: 12.2°±30′
Caution
The kingpin inclination angle is guaranteed by design
structure and no adjustment is required during the
operations. If this parameter is beyond specified
range, directly replace the steering knuckle.
6. Check the front wheel kingpin caster angle.

a. Apply the wheel brakes.
Forward direction of vehicle Caution
To prevent the rolling of front wheels during the
rotation of steering wheel, brake the wheels during the
checking of kingpin caster angle.
b. Rotate the steering wheel. At completion of

operation, the display screen of the apparatus will
display the inspection report.
Kingpin caster angle: 3.04°±30
Caution
The kingpin caster angle is guaranteed by design
structure and no adjustment is required during the
operations. If this parameter is beyond specified
range, directly replace the steering knuckle.
7. Check the front wheel camber angle.

a. Rotate the steering wheel to roughly horizontal
status in lateral direction.
b. Read the front wheel camber angle on the display
screen of the apparatus.
Front-wheel camber angle: 0.77°±30′
Caution
If the measurement is beyond the range, the
adjustment is required.
8. Check the front wheel toe-in.

a. Place the vehicle under straight forward direction.
b. Measure the front wheel toe-in by an apparatus.
Forward direction of vehicle
Front wheel toe-in: 14′±5′

Caution FR
Check the toe-in. If the toe-in is beyond the technical
requirement, adjust.
Adjustment
1. Adjustment sequence
a. The four-wheel alignment adjustment sequence is the rear wheels and then front wheels.
b. For the rear wheels, adjust the rear wheel camber angle and then the rear wheel toe-in.
Caution
For this vehicle model, the rear wheel alignment parameters are non-adjustable. If the parameters
are beyond the specified range, directly replace the rear axle.
2. Adjustment of front wheel camber angle

Caution
Normally, no adjustment is required for the camber
angle after the assembling of independent suspension
and wheel steering knuckle. Upon detection that the
FR wheel camber angle offsets from the specified
tolerance due to other factor, correct by the
connecting bolts between independent suspension
and steering knuckle.
a. Before correction, visually check the driving system

parts for damage and replace any damaged part.
b. Upon detection that the front wheel camber angle is
beyond the tolerance, loosen the connecting bolts
between front shock absorber and steering knuckle
and correct accordingly.
Front-wheel camber angle: 0.77°±30′
3. Adjustment of front wheel toe-in
a. Loosen the lock nut ① and elastic sleeve circlip ②
of right steering tie rod.
b. As required, rotate the toe-in adjustment rod ③ to
adjust the length, till the specified value is reached.
Front wheel toe-in: 14′±5′
c. Tighten the lock nut ①, reinstall the sleeve circlip
②, and check the lock nut ① for secure tightening
and check sleeve for correct position.
d. After the proper adjustment of front wheel toe-in,
check the steering wheel for levelness. Otherwise,
loosen the lock nut of steering wheel, adjust the
steering wheel to horizontal position, and tighten the
steering wheel lock nut to specified torque.
4. Adjustment of front wheel kingpin caster angle

a. Loosen or tighten the thrust bar lock nut to adjust
the kingpin caster angle.
Kingpin caster angle: 3.04°±30
FR
Shock absorber assembly (FR)

Check and repair
1. Disassemble the right front wheel assembly. (Refer to Chapter FR Suspension and
Wheels - Wheels and Tires, Front Wheel and Tire, Replacement)
2. Disassemble the front right shock absorber.
a. Disassemble the fastening bolts between front
shock absorber and steering knuckle.
b. Disassemble the type E clamp of right front brake
fluid pipe and move away the right front brake fluid
pipe.
FR
c. Disassemble the front passenger seat. (Refer to
Section BW: Vehicle body - Seat - Front Passenger
Seat, Replacement.)
d. Disassemble the upper fastening nuts of front shock
absorber and take out the front shock absorber.
3. Break down the right front shock absorber.

a. Fix the front shock absorber assembly on a bench vice.
b. Install the spring compressor to place the compressor claws between spring top and bottom.
c. Compress the coil spring till the spring detaches from the upper and lower spring seats.
d. Take out the dust cover of front shock absorber
assembly.
e. Disassemble the lock nuts of front shock absorber

by shock absorber nut remover/installer.
f. Take out the upper support assembly, spring upper

seat, and spring upper sleeve.
g. Take out the dust cover.
FR
h. Disassemble the spring compressor and take out

the front shock absorber coil spring.
i. Disassemble the limit block of front shock absorber.
4. Check the shock absorber.

a. Check if the shock absorber is leaking, and replace it if needed.
b. Check if the pressure bearing for damping is stuck or excessively loose or sounds abnormally,
and replace it with a new one if any.
5. Assemble the right front shock absorber.
a. Install the limit block of front shock absorber.
b. Install the spring compressor, compress the front
shock absorber coil spring, and install it to the front
shock absorber.
c. Install the dust cover of front shock absorber
assembly.
d. Install the dust cover.

e. Install the upper support assembly, spring upper
seat, and spring upper sleeve.
f. Install the lock nuts of front shock absorber by

shock absorber nut remover/installer.
FR
g. Install the dust cover of front shock absorber

assembly.
h. Disassemble the spring compressor.
6. Install the right front shock absorber.

a. Install the right front shock absorber assembly to
the installation position and install and tighten the
upper fastening nuts of right front shock absorber
assembly.
Torque: 21~28N·m
b. Install and tighten the fastening bolts and nuts

between front shock absorber assembly and
steering knuckle.
c. Install right front brake hose and fix it by type E
clamp.
7. Inspection of the installed shock absorber

a. After the shock absorber is installed, run the vehicle on the poor road for about 10km and stop it
to feel the shock absorber surface. If the temperature difference of two shock absorbers is large, it
means the two resistances also differ greatly, with the cooler one having lower resistance; if the
strut surface temperature is not higher than the air temperature, it indicates the shock absorber
becomes invalid due to lack of resistance and needs to be replaced.
b. If vehicle sharply stops when slowly running and vibrates abruptly, it could damage the shock
absorber. Disassemble it and keep it right up, then use the vise to clamp the lower end. Then
forcefully pull and press the shock absorber a few times. In such case, there should be steady
resistance, with the uplifting resistance higher than the pressing resistance. If the resistance
becomes unsteady or zero, it is possible that the inside of shock absorber lacks of oil or the valve
parts are damaged. If any, replace the shock absorber.
c. In case of any abnormal sound occurring to the front strut, check if the shock absorber, the spring,
the frame or the shaft impact with each other, if the rubber pad is damaged or comes off, if the
front strut dust jacket is deformed or if the lubricant is insufficient.
FR
8. Disassemble and install the left front shock absorber.
Caution
The steps to install/disassemble the left front shock absorber are same as that to
install/disassemble the right front one.
Thrust bar assembly

Check and repair
1. Disassemble the left thrust bar.
a. Disassemble the fastening bolts of air deflector
bracket.
b. Disassemble the fastening bolts between thrust bar

bracket and vehicle body.
FR
c. Disassemble the fastening nuts between thrust bar

and lower swing arm and take out the thrust bar
assembly.
2. Check the thrust bar rubber sleeve for damage.

3. Install the left thrust bar.
a. Install the thrust bar to the installation position and
install and tighten the fastening nuts between thrust
bar and lower swing arm.
Torque: 78~96N·m
b. Install and tighten the fastening bolts between thrust

bar bracket and vehicle body.
Torque: 75~92N·m
Caution
If it's difficult to install the fastening bolts, loosen the
lock nut of thrust bar before installation.
4. Disassemble and install right thrust bar.

Caution
The procedure to disassemble and install the right thrust bar is same with that for left and right
thrust bar.
5. Check and adjust the front wheel alignment. (Refer to Section FR: Frame, Suspension and
Wheels- Front Independent Suspension - Wheel Alignment, Adjustment.) FR
Lower swing arm

Replacement
1. Disassemble the left front wheel assembly. (Refer to Chapter FR Frame, Suspension,
Wheels and Tires, Front Wheel and Tire, Replacement.)
2. Disassemble the left lower swing arm assembly.
a. Disassemble 2 fastening nuts between thrust bar
and lower swing arm.
FR b. Disassemble fastening bolts and nuts between

lower swing arm and subframe.
c. Disassemble the lock bolts and nuts between lower

swing arm and steering knuckle.
d. Disassemble the swing arm ball joint by a ball joint
remover and take out the lower swing arm.
3. Install the left lower swing arm assembly.

a. Install the lower swing arm to installation position.
between lower swing arm and subframe.
Torque: 73~89N·m
c. Install the lower swing arm ball joint and install and
tighten the lock bolts and nuts of lower swing arm.
Torque : 45~55N·m
d. Install and tighten the fastening nuts between thrust

bar and lower swing arm.
Torque: 78~96N·m
FR
4. Install the front left wheel assembly. (Refer to Chapter FR Suspension and Wheels-
Wheels and Tires - Front Wheels and Tires, Replacement.)
5. Disassemble and install the right lower swing arm assembly
Caution
The steps to install/disassemble the right lower swing arm assembly are same as that to
install/disassemble the left –lower swing arm assembly.
6. Check and adjust the front wheel alignment. (Refer to Section FR: Frame, suspension and
wheels- Front independent suspension - Wheel alignment, Adjustment.)
Subframe assembly
Replacement
1. Disassemble the left and right lower swing arms (Refer to Chapter FR Frame, Suspensions,
and Wheels - Front Independent Suspension - Lower Swing Arm, Replacement.)
2. Drain the coolant. (Refer to Chapter EG Engine Part - Engine (DAM15DL) - Cooling
System - Coolant.)
3. Disassemble the left lower swing arm assembly.
a. Disassemble the fixing clamp of heater water inlet
and outlet pipes and unplug the heater inlet and
outlet hoses.
b. Disassemble the fastening bolts of the heater water
inlet and outlet pipes.
FR
c. Disassemble four fastening bolts of steering gear.
d. Disassemble the fastening bolts of air deflector

bracket.
e. Elevate the subframe assembly by an elevator till

the elevator is subject to slight force application,
disassemble all fastening bolts of subframe
assembly, and take out the subframe assembly.
4. Install the subframe assembly.

a. Install subframe assembly to installation position.
b. Install and tighten all fastening bolts of subframe
assembly.
Torque: 75~92N·m
c. Install and tighten fastening bolts of air deflector

bracket.
FR
d. Install and tighten four fastening bolts of steering

gear.
e. Install and tighten fastening bolts of heater inlet and

outlet pipes.
f. Install the heater water inlet and outlet hoses and fix
them by circlips.
5. Install the left and right lower swing arms (Refer to Chapter FR Frame, Suspensions, and
Wheels - Front Independent Suspension - Lower Swing Arm, Replacement.)
6. Add the coolant (Refer to Chapter EG Engine Part - Engine (DAM15DL) - Cooling System -
Coolant.)
Front wheel hub

Replacement
1. Disassemble the front wheels. (Refer to Chapter FR Frame, Suspension and Wheels -
Wheels and Tires, Front Wheel and Tire, Replacement.)
2. Disassemble the front brake. (Refer to Chapter FR Frame, Suspension, Wheels and Tires,
Front Wheel and Tire, Replacement.)
3. Disassemble the front drive wheel hub.
a. Pry open the trim cap ① of steering knuckle nut.
FR
b. Punch the lock opening of nut.
c. Disassemble the steering knuckle end nut.

d. Take out the front wheel hub ①.
4. Install the front wheel hub.

a. Install the front wheel hub ① to installation
position.
b. Install and tighten the steering knuckle end nut.
c. Lock the steering knuckle end nut by a chisel.
d. Install the trim cap ① of steering knuckle nut.
FR
5. Install the front brake. (Refer to Chapter FR Frame, Suspension, Wheels and Tires, Front
Wheel and Tire, Replacement.)
6. Install the front wheel. (Refer to Chapter FR Frame, Suspension, Wheels and Tires, Front
Wheel and Tire, Replacement.)
FR-24 Frame, suspension and wheels - Rear suspension
Rear suspension
Rear suspension assembly

Overview
1. Function of rear suspension
a. Work with the tires to absorb and mitigate all kinds of shiver, shimmy, and vibration arising from
the rough road during driving, in order to guarantee the safety of passengers and cargo and
promote the driving stability.
b. Transmit the drive force and braking force arising from the friction between ground and wheels to
the chassis and body.
c. Support the body on the axles and maintain appropriate geometrical relationship between the
body and the wheels. The suspension exerts high influence over the main operation
performances of the vehicle, including the driving smoothness, operation stability, vehicle
trafficability, fuel economy.
d. The vibration of the vehicle and the increased deformation of spring due to the factors such as
FR rugged roads and vehicle speed variation during traveling vehicle will shorten the lives of the leaf
springs, vehicle body, and frame. The shock absorbers are additionally installed to mitigate the
vibration of vehicle and improve the driving smoothness of the vehicle. The shock absorbers are
telescopic shock absorbers and are installed in paralleling connection with the leaf springs in the
suspension to absorb the vibration of vehicle during the lifting and lowering of leaf springs, rapidly
restore the leaf springs to steady status, and thus improve the driving stability of the vehicle.
2. Composition of rear suspension
a. It’s composed of leaf spring assemblies and shock absorbers. The leaf spring is laminated from
several steel plates. The middle of the leaf spring is fixed onto the leaf plate seat of rear axle
housing by rear pressure plate assembly with cushion plate, U-bolts, and U-bolt baseplates. The
shock absorber is connected to the frame and rear axle respectively by connecting pin, upper
bracket, lower bracket, and rubber sleeves.
b. The rubber cushion plate is install the above the leaf spring assembly to restrain the maximum
deformation of leaf spring and play a certain cushioning role.
Frame, suspension and wheels - Rear suspension FR-25
Precautions
1. Severe overloading, unbalance loading and uneven stress aren't allowed, otherwise, the
leaf spring camber reduces, and the flexibility weakens.
2. The emergency brake isn't allowed, especially the condition shall be treated in advance
upon the full load to avoid the emergency brake, otherwise the front leaf spring would be
damaged due to the excessive bending stress.
3. The vehicle speed shall not be excessive, especially driving on the uneven road, because
it would accelerate the deformation amplitude of leaf spring and increase the deformation
times, promoting the acceleration of bending stress and the fatigue aggravation.
4. The too quick steering isn't allowed, because the vehicle would generate the centrifugal
force upon the sharp steering, which increases the load of the outside leaf spring, the
sharper the steering is, the larger the load is, and the larger damage it would incur to
vehicle.
5. The leaf spring shall be regularly maintained. Upon the overhauling, each spring shall be
FR
painted with the graphite grease, which could avoid the fatigue damage of leaf spring,
could reduce the wear and could prevent corrosion. Therefore, the regular prevention shall
be conducted in order to lengthen the service life.
Preparations
Recommended tools
For measurement of tightening

Torque wrench
torque
Hammer For knocking
FR
For disassembling/installation of
Speed wrench
bolts and nuts
Feeler gauge For measurement of clearance
For measurement of leaf spring

Steel ruler
height
Equipment
- Elevator Elevate the rear axle.
- Steel stool For support of frame

Technical data
Clearance between inner side of
Limit value 1.0~1.5mm
circlip and two sides of leaf spring
Torque requirements
Fasteners N·m
Fastening nuts of U-bolts 78~96
Fastening nuts of rear leaf spring lifting eye pin of

126~154
rear leaf spring assembly
Fastening nuts of front leaf spring lifting eye pin of

73~79
rear leaf spring assembly
Fastening nuts of rear shock absorber 40~50

FR

1. Seals are invalid or damaged. Replace the absorber

Shock absorber leaks
1. Vehicle overloads -
2. Leaf spring has the rigidity

Vehicle body sinks Replace the leaf spring.
1. Tires wear or is inflated

Check and adjust the tires.
FR abnormally.
Tilting 2. Leaf spring has the rigidity

Replace the leaf spring.

-
Tires wear abnormally. 2. Tire pressure is not in line with

the regulations.

-
Rear wheels sway. 2. Tire pressure is not in line with

the regulations.

Part diagram
FR
1 Rear leaf spring assembly 7 Leaf spring fastening plate
2 Leaf spring rear lifting eye bushing 8 Buffer block assembly (FR)
Leaf spring rear lifting eye outer plate Shock absorber lug rubber bushing
3 9
weldment assembly washer
4 Inner panel of leaf spring rear hanger 10 Hexagon thick nut
5 Leaf spring rear lifting eye bushing 11 Rear shock absorber assembly
6 Rear U-bolt
Inspection
1. Check rear shock absorber
a. After the vehicle is driving on the relatively bad road
for a distance (Generally >10km), stop the vehicle
and check the surface temperature of both rear
shock absorbers.
Caution
Judgment method:
• If the surface temperature of the shock absorber
is higher than the ambient temperature, it
indicates that the shock absorber functions
normally.
• If the surface temperature of the shock absorber
is below the ambient temperature, it indicates
FR
that the shock absorber has no resistance and
fails for shock absorption and needs to be
disassembled and replaced.
• If there is high temperature difference between
two shock absorbers, it indicates that the one
with low temperature has much smaller
resistance than the one with high temperature
and needs to be disassembled and replaced.
2. Check the rear leaf springs.

a. The torque wrench is used to measure the
tightening torque of U bolt.
Torque: 78~96N·m
b. Measure the tightening torque of leaf spring pins
and rear lifting eye pins by a torque wrench.
c. Measure the tightening torques of shock absorber
upper and lower fastening nuts by a torque wrench.
Torque: 40~50N·m
d. Measure the clearances between inner side of
circlip and two sides of leaf spring by a feeler
gauge.
Reference clearance: 0.7~1.0mm
e. Measure the heights from the tops of leaf springs on

two sides to the bottom of longitudinal beam
respectively by a steel ruler and record the
measurements.
Caution
Judgment method:
• Compare the heights of leaf springs on two
sides.
• The smaller value indicates the problem of leaf
spring on corresponding side. Check and repair
the corresponding leaf spring.
FR
Rear leaf spring assembly

Check and repair
1. Disassemble the rear leaf spring assembly.
a. Disassemble the fastening bolts of parking brake
cable bracket and move away the parking brake
cable.
b. Disassemble the fastening nuts of rear leaf spring

U-bolts, take out the U-bolts, and take out the leaf
FR spring support plate.
c. Disassemble the fastening nuts of front leaf spring

lifting eye pin of rear leaf spring assembly.
d. Use a copper bar to punch out the leaf spring rear
lifting eye outer plate weldment assembly.
Caution
Avoid damaging the thread or leaf spring pin
cylindrical surface.
e. Take out the leaf spring inner bushing from the

frame.
f. Disassemble the fastening nuts of front leaf spring
lifting eye pin of rear leaf spring assembly.
g. Use a copper bar to knock out the leaf spring lifting
eye pin.
h. Take out the leaf spring assembly.
2. Check the leaf spring bushing.

a. Check the leaf spring bushing for wear. If yes,
replace the leaf spring bushing.
3. Break down the rear leaf spring.

a. Disassemble and take out the fastening nuts and
bolts for U-clamps of rear leaf spring assembly.
b. Take out the U-clamps ① of rear leaf spring
assembly.
FR
c. Pry open the clamp of leaf spring by a chisel.
d. Disassemble the central fastening bolts of front leaf

spring and take out the leaf spring plates and
inter-plate spacers one by one.
4. Check the rear leaf spring.

a. Check the 1st and 2nd plates of leaf spring for
presence of breakage at the coils. Upon detection
of above-mentioned symptom, the causes and
solutions are as below:
• Disqualified application of load and
overloaded driving (Replace the leaf spring
and operate vehicle correctly).
b. Check leaf spring for breakage at central hole.

Upon detection of above-mentioned symptom, the
causes and solutions are as below:
• Insufficient preload of U-bolts (Replace
damaged leaf spring and tighten U-bolts).
• Insufficient preload of central bolts (Replace
damaged leaf spring and tighten central
bolts).
c. Check leaf spring for presence of fatigue.

• Long-time overloaded operation (Replace
fatigued leaf spring).
d. Hollow bolt of leaf spring
FR
• Insufficient preload or looseness of rear
U-bolts (Replace central bolts of leaf spring).
5. Install rear leaf spring assembly in reverse sequence of the disassembling procedure and
notice the following issues.
Caution
• Before assembling the leaf spring, remove the dirt and rust from the leaf spring by a wire
brush.
• Apply suitable graphite grease onto the both sides of each steel leaf spring.
• Fix the leaf spring plate closing to the central bolts onto a bench vice and tighten the
central fastening bolts of rear leaf spring.
• Apply an appropriate amount of lubricating grease into the coil bushing hole of 1st leaf
spring plate.
a. Measure the clearances between inner side of circlip and two sides of leaf spring by a feeler
gauge after assembling.
Reference clearance: 0.7~1.0mm
Rear shock absorber assembly

Check and repair
1. Disassemble the assembly of rear shock
absorber
a. Lift up the vehicle.
b. Support the rear axle by safety supports and lower
the vehicle till the leaf springs are not subject to
force application.
c. Disassemble the fastening nuts from upper and
lower ends of rear shock absorbers and take out the
rear shock absorbers.
Caution
• Compress and stretch the shock absorber and
check the shock absorber for abnormal sound FR
and normal operating resistance.
• Check the shock absorber assembly for leakage
and damage and replace damaged shock
absorber assembly.
d. Pry out the rubber sleeve of shock absorber.
Caution
Replace worn or damaged rubber sleeve.
2. Install the rear shock absorber assembly in reverse sequence of the disassembling
procedure.
FR-36 Frame, suspension and wheels - Wheel and tire
Wheel and tire
Wheel and tire assembly

Overview
1. Wheel and tire are the running parts of car, and installed on vehicle axle. The basic
functions are as follows:
• Support car, bear the car gravity, enable the car to bear load.
• Transfer the driving force, steering force and brake force, so as to control the car
operation.
• Reduce the driving resistance and energy consumption.
• Ease the driving impact, and improve the bearing condition.
The wheel with consistent bearing capacity, size and type shall be selected for replacement. The
inconsistence of wheel size and type will influence the wheel and bearing life, brake cooling,
vehicle speed/ milometer accuracy, vehicle body ground clearance, the clearance of tire from
vehicle body and chassis.
FR 2. Wheel replacement condition:
• Wheel bends or depresses.
• Excessive radial run-out of wheel. Wear of tires.
• Exposed cords
• Tire swells.
• Deformation and open weld of wheel rim.
• Enlarged bolt hole in excess of specified diameter due to wear.
• Wheel gets serious rusty.
3. Tire is the final executor of most operation instructions on car, it not only bears the weight
of vehicle body, transfers the vehicle driving force and brake force to ground, keep car
driving direction; but also eliminates the road vibration, improve the sitting comfort,
good-quality tire can also reduce the rolling resistance, so as to improve the fuel
economic efficiency. Spare tire is the emergency tire in case of wheel fault, when the fault
is solved, normal tire shall be replaced timely. Correct tire pressure is very important to
continuously keep good vehicle performance, operability and driving economy, regular
check shall be done to tire pressure, improper tire inflation will bring negative influence to
vehicle performance, and cause the following results:
• Lower fuel economy.
• Tire overload.
• Shorter tire life.
• Serious wear of tire.
• Uneven wear of tire.
• Poor vehicle operability.
• Lower sitting comfort.
Frame, suspension and wheels - Wheel and tire FR-37
Precautions
1. Notice the periodical wheel rotation during operations, in order to reduce the offset wear
of tires, guarantee the driving performance of vehicle, and prolong the lives of tires.
2. During operations, timely flush away the mud and stones from the tires, in order to prevent
shimmy of wheels or damage of tires during high-speed traveling.
3. During checking or repair, park the vehicle on a level ground and block the wheels.
4. While blocking the wheel, place the wheel blocks on the front of the front wheels or behind
the rear wheels.
5. It’s prohibited to install the tires of different specifications and treads for one same
vehicle.
6. Operate the jack as per the operation instructions of the jack.
7. Ensure to place the jack on a level and firm ground and set up the jack at correct jacking
position.
8. Do not place any part of your body beneath the vehicle being elevated by jack, or it will
FR
probably lead to injury of personnel.
9. It’s prohibited to jack up the vehicle with any person stayed in the vehicle.
10. It’s prohibited to start the engine after the vehicle is elevated.
Part diagram
FR
1 Rim with spoke weld assembly 3 Decorative cover of wheel
2 Tire
Preparations
Recommended tools
Tire pressure gauge Measure the tire pressure
Torque wrench Dismantle the accessories FR
For checking and adjustment of

Wheel balance tester
wheel balance.
Equipment
- Jack Elevate the rear axle.
- Steel stool For support of frame
Consumable
Balance block — —
Technical data
Tire model 175R148PR
Wheel rim specifications 14×5J
Tire pressure 450±10kPa
Torque requirements
Fasteners N·m
Tire nut 120~140
FR

1. The toe-in and the camber do Adjust the wheel toe-in and the
not meet the requirements. camber

the regulations.
4. The steering mechanism is Check and repair the steering

deformed mechanism.
1. The front wheel pressures are

Adjust pressure of front tires.
different from each other. FR
Front wheels swing or shake
needed.
4. Steering mechanism wears Check and repair the steering

severely mechanism.
1. Tire pressure is too high. Adjust the tire pressure

Riding comfort is poor. needed.
3. Leaf spring (Breakage or

Check and repair the leaf spring
failure)
1. The toe-in is not in line with

Adjust the toe-in of tire.
the regulations.
Front wheel slides sideward.
the regulations.
Onboard inspection
1. Check tire
a. Check for qualified tire pressure. If not, adjust.
Caution
The tire pressure shall be no less than standard pressure by 10% under normal temperature.
b. Use soapy water to check the tire valves for air leakage.
c. Check the tires for presence of cracking and damage. If any, replace.
d. Check tire surfaces for presence of puncture by steel nail, gravel, or other foreign material. If yes,
remove.
e. Check the tires for abnormal wear. If yes, find out
the malfunction cause.
• The insufficient air pressure will result in
rapid wear of tire shoulders, deflection of
FR tires, and increased rolling resistance of
tires.
• The over-high air pressure will result in the

rapid wear in the middle of tire tread and
reduced cushioning capacity of tires.
• The penniform wear of tires is caused by

over-high (or under-low) toe-in of front and
rear wheels.
Caution
Adjust the toe-in and, depending on the wear status,
replace or swap the tires.
• One-sided wear (Camber angle problem)

Caution
Depending on the wear status, replace or swap the
tires.
f. Observe the wear indicator on the bottom of tire

tread groove. If the tire tread is worn to the wear
indicator on the bottom of tread groove, ensure to
replace with new tire.
FR
2. Check the radial and axial circular run-outs of

wheels.
a. Elevate the vehicle till the wheels are off the ground.
b. Check the wheels for clear deformation.
c. Install a dial indicator, rotate the wheel slowly, and
measure the axial circular run-out for front and rear
wheels. If the measurement is beyond the limit,
replace the wheel assembly.
Caution
Clean the wheel before checking.
d. Install a dial indicator, rotate the wheel slowly, and

measure the radial circular run-out for front and rear
wheels. If the measurement is beyond the limit,
replace the wheel.
Caution
Clean the wheel before checking.
Wheel balance
1. Preparations before checking
a. Clean the wheel to be measured to remove the mud
and sand.
b. Disassemble the used counterbalances and inflate
the tire to standard pressure.
2. Check the wheel balance.

a. Correctly install the wheel onto the balance tester.
FR
b. Fix the tire and input three parameters, namely the

width and diameter of the wheel rim and the
distance of the wheel rim outer edge from the
balance tester.
c. Lower the shield and start the balance tester to start
measurement.
d. Stop the rotation of tire, open the shield, rotate the
tire by hand, read the imbalance value from the left
and right display screens, and determine the
imbalance positions.
3. Adjust the wheel balance
a. Based on the imbalance value indicated on the
balance tester, add corresponding counterweights
to the imbalance positions.
Caution
Before installing the counterweights, ensure to
thoroughly clean the fitting surfaces of wheel.
b. While installing the counterweights on the wheel,

align the centers of counterweights with the
positions (or angles) indicated by the wheel balance
tester.
c. If the calculated counterweight weight is higher than
50g, install two counterweights on one line.
Caution
• The counterweights can’t be reused. Ensure to
use new counterweights each time.
• Always use original counterweights.
• Do not place a counterweight on another
counterweight.
d. Restart the wheel balance tester and ensure that the remaining imbalance is no higher than 10g.
If the imbalance on any side exceeds 10g, repeat the wheel balance adjustment procedure. FR
Wheel rotation
1. Wheel rotation
a. To ensure uniform wear of tires and prolong lives of
tires, it’s recommended to perform wheel rotation
once every 6,000~8,000km. However, the most
appropriate timing for wheel rotation depends on
the driver’s ordinary driving habits and road
conditions.
FR
Front wheels and tires

Replacement
1. Disassemble the front wheels.
a. Stop the vehicle steadily on a level ground and
place the parking brake handle to parking position.
b. Block by wooden triangles the wheels not to be
disassembled.
c. Loosen all wheel nuts for 1~2 turns in diagonal
manner.
Caution
The left wheel nuts are of left-hand thread and the right
wheel nuts are of right-hand thread.
d. Elevate the front axle by an elevator or jack, till the FR

front wheels are slightly off the ground by
approximately 3cm.
e. Place the steel stools.
f. Disassemble all wheel nuts in turn.
g. Take out the wheel assembly.
2. Disassemble the tires

a. Unscrew the valve cap.
b. Unscrew the valve core by valve deflation tool ①
to fully deflate the tire.
c. Install the tire on a tire changer and push out the tire
from the wheel hub groove.
Caution
• When a side press is used, do not touch the
steel rim to prevent damaging the steel rim.
• When a side press is used, keep away from the
valve position to prevent damaging the valve.
d. Overturn the tire and push out the other side of tire
from the wheel hub groove by same method.
e. Place the tire on a tire changer and properly adjust

the position.
f. Pry up the tire by a tire bar, push down the tire
sidewall on the opposite direction of the pushing
angle to engage the tire bead with the thinnest
position of wheel hub, and depress the rotation
switch.
Caution
• While installing or disassembling a tire, notice
the distance between disassembling head of tire
changer and wheel hub to prevent damaging the
surfaces of wheel hub.
• While disassembling the tire, grip securely the
wheel hub. Start after checking. It’s prohibited
FR to separate the tire by hand during rotation.
• While disassembling or installing a tire, notice
to guard the tire beads against damage to
prevent the air leakage of tire.
g. Overturn the tire, place the tire on a tire changer, pry up the tire by a tire bar, and depress the
rotation switch to take out the tire.
3. Install the wheel tire.
a. Install the wheel tire onto the wheel hub by a tire
changer.
b. Install new tire valve.
c. Loosen the valve core.
d. Inflate the tire to 100~200kPa and ensure that a
sliding sound of tire beads on the wheel rim arch
must be heard and then tighten the valve core.
e. Adjust the inflation pressure to specified value and
install the valve cap.
4. Perform dynamic balance test for wheels.
5. Install the front wheel in reverse sequence of the disassembling procedure.
Rear wheels and tires

Replacement
Caution
For the replacement of rear wheels and tires, refer to Chapter FR Frame, Suspensions, and
Wheels - Wheels and Tires - Front Wheels and Tires, Replacement.
FR
Spare wheel and installation mechanism

Replacement
Caution
Do not continue to drive the vehicle with flat tire, even for a short distance, otherwise it will cause
the damaged tire non-repairable.
1. Disassemble the spare wheel and installation

mechanism.
a. Disassemble the lock nut of spare wheel holder pull
srod.
b. Disassemble the fastening bolts of spare wheel
holder pull rod bracket and lower down the spare
wheel holder.
FR Caution
While disassembling the spare wheel, hold the spare
wheel bracket, in order to prevent the sudden falloff of
spare wheel from causing injury accident after the
disassembling of fastening bolts.
c. Disassemble the central fixing hand-wheel of spare
wheel and take out the spare wheel and spare
wheel holder.
2. Install the spare wheel and spare wheel holder in reverse sequence of disassembling
procedure.
ST Steering system
Steering mechanism ............................................... ST-1
Steering system ..................................................... ST-1
Steering wheel ....................................................... ST-7
Combination switch ............................................. ST-10
Steering column .................................................. ST-13
Steering knuckle .................................................. ST-16
Steering drive shaft ............................................. ST-18
Power steering ...................................................... ST-19
Power steering .................................................... ST-19

ST
Steering gear assembly....................................... ST-24
Steering gear reducer.......................................... ST-25
Steering motor controller .................................. ST-S27

Steering System - Steering mechanism ST-1
Steering mechanism
Steering system
General
DriveZr controls the whole vehicle’s driving direction by directly controlling the steering wheel, Steering
wheel is the first link between driver and vehicle. Steering wheel is fastened on the steering shaft of
steering column, while the steering column is connected to steering gear through steering transmission
shaft. So, the driving direction of whole car can be controlled by controlling the rotation of steering wheel.
Steering column is a component for the whole vehicle anti-theft system, the anti-theft function of steering
column mainly depends on the steering lock, ignition switch, ignition switch lock cylinder and other
components on steering column. Controlling the above component can reduce the risk of vehicle theft.
In addition to the main steering functions of vehicle, the steering wheel and steering column also install
the following components on top: horn button, steering signal control switch, light system control switch,
wiper\washer switch, steering column angle adjustment switch, etc. it will provide great convenience for
driver to control the whole car. The telescoping mechanism of steering column provide the driver a
certain safety protection. Such structure can reduce the driver's injury in case of accident.
ST
ST-2 Steering System - Steering mechanism
Precautions
3. After the installation of steering system, comprehensively check the steering handiness
and flexibility. Turn on the key switch and rotate the steering wheel. The steering system
shall be free of looseness. Measure the maximum steering angle of front wheels.
4. The bolts for various components of the steering system must be tightened to the
specified torque.
5. At completion of checking and repair of steering gear and other steering mechanisms,
check the wheel alignment.
abnormal impact frequently. The damaged parts or defective parts shall be replaced
timely.
7. If the steering wheel is locked, do not move the vehicle, in order to prevent damaging the
steering system parts.
ST
Preparations
Recommended tools
Dial indicator For inspection of steering system
Torque wrench
bolts and nuts
ST
For checking of starting torque of

Spring balance
steering wheel
For disassembling of steering tie

Ball joint remover
rod ball joint
For disassembling and

Nipper pliers
installation of split pins
For installation of steering

Steel hammer knuckle kingpins together with
copper bar
For installation of steering

Copper bar
knuckle kingpin
For measurement of steering

Feeler gauge
knuckle clearance
Accessories
ST Item Quantity Specification
Lubricating grease - 2# lithium base grease



bearings
2. Insufficient lubrication of Add lubricating grease to

steering column bearing bearings.
Heavy steering
universal joint crossing shaft universal joint crossing shaft
bearings bearings.

1. Loose fastening bolts Tighten loose bolts.
2. Excessive wear of steering ST

Replace the steering drive shaft
Excessive free clearance drive shaft spline


bearings

Steering noise or stagnation steering column bearing bearings.
steering drive shaft telescopic Add lubricating grease
joint
Part diagram
ST
Electronic steering column assembly

1 3 Steering wheel assembly
with drive shaft
2 Steering drive shaft guard

Steering wheel
General
The steering wheel converts the force applied by the driver onto the edge of steering wheel to torque,
and transfers the torque to the steering shaft. When the steering wheel with a large diameter is used, the
force applied by the driver onto the steering wheel may be lower. The steering drive shaft is used as the
connector between the steering gear and the steering shaft; it is good for the general utilization of
steering gear, and can compensate the error produced during fabrication and installation and ensure the
reasonable installation of steering gear and steering wheel on the complete vehicle.
ST
Replacement
1. Disassemble the steering wheel
a. After the stop of vehicle, push the parking brake
handle to parking position and rotate the steering
wheel to place the wheels at straight traveling
direction.
b. Pry upward the horn cover.
c. Disconnect the horn switch connector and take out
the horn cover.
d. Loosen the fastening nuts of steering wheel in such

manner that the upper ends of fastening nuts are
level with the upper end of steering column, in order
to prevent the personal harms while pulling out the
steering wheel.
ST
e. Forcibly beat downward (vibrate) the circumference

of steering wheel to loosen the steering wheel.
f. Forcibly pull up to pull out the steering wheel.
2. Install steering wheel

a. Install the steering wheel to steering column.
Caution
• If the installation markings are added during
disassembling, install as per the installation
markings.
• If no installation marking is available, ensure
that the wheels are under straight forward
direction and install the steering wheel correctly
in forward direction.
b. Install the fastening nuts of steering wheel and

tighten the nuts to specified torque.
c. Connect the connector of horn switch.

d. Align the snap joints on the horn cover and install
the horn cover.
e. At completion of installation, push the horn and
check the horn for normal sounding.
ST
Combination switch
General
The combined switch is a kind of multi-function combined switch used to control the lighting, light signal
devices, wiper and some accessories. Normally, this combined switch is a handle-type switch and
installed on the steering column under the steering wheel, in order to facilitate the driver's operation.
ST
Replacement
1. Disassemble the combination switch.
a. Disassemble the steering wheel. (Refer to Chapter
ST Steering System - Steering Mechanism -
Steering Wheel, Replacement)
b. Disassemble the fastening screws of steering
column shield, pry open two sides of the shield
lightly, and take out the upper and lower steering
column shields.
c. Disconnect the combination switch connector.
ST
d. Disassemble the fastening screws of combination

switch and take out the combination switch.
2. Install the combination switch.

a. Install the combination switch to the steering
column and install and tighten the fastening screws.
b. Connect the combination switch connector.
c. Install the steering column shields and install and

tighten the fastening screws.
d. Install the steering wheel. (Refer to Chapter ST
Steering System - Steering Mechanism - Steering
Wheel, Replacement)
ST
Steering column
General
1. The steering column is the connection device functioned to transmit the torque of steering
wheel to the steering gear and the steering wheel is fixed by nuts and spline.
2. Basic functions of steering column:
a. Transmit torque.
b. Provide energy absorption device to ensure safety.
c. Provide auxiliary functions, such as steering wheel angle adjustment, ignition switch key, steering
immobilizer lock, horn circuit, wiper, and turn signal lamp.
ST
Replacement
1. Disassemble the steering column.
a. Disassemble the steering wheel. (Refer to Chapter ST Steering System - Steering Mechanism -
b. Disassemble the combined switch. (Refer to Section ST: Steering system - Steering mechanism -
Combined switch, Replacement.)
c. Disassemble the dashboard. (Refer to Section BW: Vehicle body- Dashboard/ Combination
instrument/ Ash tray- Dashboard, Replacement.)
d. Disassemble the ignition switch. (Refer to Chapter EL Electric System - Electric Devices -
Vehicle Control System - Ignition Switch, Replacement.)
e. Disconnect the steering controller harness
connector.
ST
f. Disassemble fastening bolts on two ends of

universal joint.
g. Disassemble two fastening bolts on the upper end

of steering column.
h. Disassemble two fastening bolts on lower end of

steering column and take out the steering column.
i. Check the steering controller and steering motor for damage. If yes, replace them.
2. Install steering column
a. Install steering column to installation position.
Caution
Install the universal joint into the steering drive shaft
and steering column spline shaft, align the bolts with
the slots on the steering column and steering drive
shaft, and insert the bolts. ST
b. Install and tighten two fastening bolts on the lower
end of steering column.
c. Install and tighten two fastening bolts on the upper
end of steering column.
d. Tighten fastening bolts on two ends of universal

joint.
e. Install the ignition switch. (Refer to Chapter EL Electric System - Electric Devices - Vehicle
Control System - Ignition Switch, Replacement.)
f. Install the dashboard.(Refer to Section BW: Vehicle body- Dashboard/ Combination instrument/
Cigar lighter/ Ash tray- Dashboard, Replacement.)
g. Install the combined switch. (Refer to Section ST: Steering system - Steering mechanism -
Combined switch, Replacement.)
h. Install the steering wheel. (Refer to Chapter ST Steering System - Steering Mechanism -
Steering knuckle
Replacement
1. Disassemble the steering knuckle.
a. Disassemble the front wheels. (Refer to Chapter FR Frame, Suspension, Wheels and Tires, Front
Wheel and Tire, Replacement)
b. Disassemble the fastening bolts of front brake caliper assembly and move away and fix the front
brake caliper assembly. (Refer to Chapter BR Brake System – Service Brake (Hydraulic) – Front
Wheel Brake, Inspection and repair)
c. Disassemble the front wheel hub. (Refer to Chapter FR Frame, Suspension, and Wheels - Front
Independent Suspension - Front Wheel Hub Assembly, Replacement.)
d. Disassemble the lock bolts and nuts of lower swing
arm ball joint and disassemble the lower swing arm
ball joint by a ball joint remover.
ST
e. Disassemble the split pins and slotted nuts of

steering tie rod ball joint and disassemble the
steering tie rod ball joint by a ball joint remover.
f. Disassemble the fastening bolts and nuts between

front shock absorber and front steering knuckle and
take out the front steering knuckle assembly.
2. Install the steering knuckle.

a. Install steering knuckle to installation position.
between front shock absorber and front steering
knuckle.
c. Install and tighten the slotted nuts of steering tie rod

ball joint.
d. Install the split pins for slotted nuts of steering tie
rod ball joint.
ST
e. Install and tighten the lock bolts and nuts of lower

swing arm ball joint.
f. Install the front wheel hub. (Refer to Chapter FR Frame, Suspension, and Wheels - Front
Independent Suspension - Front Wheel Hub Assembly, Replacement.)
g. Install the fastening bolts of front brake caliper assembly and move away and fix the front brake
caliper assembly. (Refer to Section BR: Brake system - (Hydraulic) Service brake- Front wheel
brake, Inspection and repair.)
h. Mount the front wheel. (refer to 'Chapter FR Frame, Suspension, Wheels and Tires, Front Wheel
and Tire, Replacement’)
i. Complete the four-wheel alignment test. (Refer to Section FR: Frame, suspension and wheels-
Front independent suspension - Wheel alignment.)
Steering drive shaft

Replacement
1. Disassemble the steering drive shaft.
a. Disassemble fastening bolts on two ends of
universal joint and take out the universal joint.
b. Disassemble the fastening bolts on lower end of

steering drive shaft and take out the steering drive
shaft.
ST
2. Check the steering drive shaft.

a. Hold two ends of crossing shaft and then rotate in reverse direction. Upon detection of any gap,
replace the steering drive shaft.
3. Install the steering drive shaft
a. Install the steering drive shaft and universal joint to
the installation position.
b. Install the fastening bolts on lower end of steering
drive shaft and tighten them to specified torque.
Caution
Install the universal joint into the steering drive shaft
and steering column spline shaft, align the bolts with
the slots on the steering column and steering drive
shaft, and insert the bolts.
c. Tighten fastening bolts on two ends of universal

joint.
Steering System - Power steering ST-19
Power steering
Power steering
Precautions
3. After the installation of steering gear, comprehensively check the steering handiness and
flexibility. Turn on the key switch and rotate the steering wheel. The steering system shall
be free of looseness. Measure the maximum steering angle of front wheels.
4. The bolts for various components of the steering gear must be tightened to the specified
torque.
5. At completion of checking and repair of steering gear and other steering mechanisms,
check the wheel alignment.
abnormal impact frequently. The damaged parts or defective parts shall be replaced
timely.
7. If the steering wheel is locked, do not move the vehicle, in order to prevent damaging the ST
steering system parts.
ST-20 Steering System - Power steering
Preparations
Recommended tools
Dial indicator For inspection of steering system
For disassembling and installation

Torque wrench
of steering system
ST
For checking of starting torque of

Spring balance
steering wheel
For disassembling of steering tie

Ball joint remover
rod ball joint
Accessories
Lubricating grease - 2# lithium base grease


1. The fuse is damaged Replace the same type of fuse.

Failure of electronic power
steering (EPS) system and Check and repair any damaged
2. Circuit malfunction
constant turn-on of EPS warning circuit.
lamp
3. Damage of EPS control unit Replace EPS control unit.
1. Damage of steering column Replace steering column

assembly assembly.
Noise of assisting motor
2. Malfunction of assisting motor Replace assisting motor.
1. Wheel alignment is not

Four wheel alignment
accurate
2. Abnormal front shock ST

Check the front absorber.
absorber
Steering is heavy.
3. Malfunction of steering gear Replace the steering gear
4. Excessive gap of steering tie

Replace steering tie rod ball joint.
rod ball pin
1. Wheel alignment is wrong Four wheel alignment
2. Loose steering gear fastening

Tighten loose fastening bolt.
bolts

Jitter of steering wheel Replace steering tie rod ball joint.
rod ball pin
4. Malfunction of front shock

Replace front absorber
absorber

bolts

Replace steering tie rod ball joint.
rod ball pin
Excessive free play of steering
3. Malfunction of steering drive
wheel Replace the steering drive shaft
shaft
4. Wear or looseness of front

Replace wheel hub assembly.
wheel bearing
5. Malfunction of steering gear Replace the steering gear.


bolts
2. Malfunction of steering drive

Replace the steering drive shaft
Steering noise shaft
3. Malfunction of steering motor Replace steering motor.
1. Open-circuit or short-circuit of
Check and repair harness.
circuits
Occasional failure of electronic
2. Damage of electronic power
power steering Replace the steering column
steering column
ST
Part diagram
ST
1 Steering gear with linkage assembly 3 Intermediate arm
2 Steering gear reducer assembly

Steering gear assembly

Checking and repair
1. Disassemble steering gear.
a. Disassemble the subframe assembly. (Refer to Chapter FR Frame, Suspension, and Wheels -
Front Independent Suspension - Subframe Assembly, Replacement.)
b. Disassemble the split pins and slotted nuts of
steering tie rod ball joints on two ends and
disassemble the steering tie rod ball joint by a ball
joint remover.
c. Disassemble the fastening bolts between steering

ST gear and countershaft and take out the steering
gear assembly.
2. Check the steering gear.

a. Check the steering tie rod ball joints for wear and replace any worn one.
b. Check steering gear dust cover for damage and aging. If yes, replace.
3. Install the steering gear assembly.
a. Install steering gear assembly to installation
position.
b. Install and tighten the fastening bolts between
steering gear assembly and countershaft.
c. Install and tighten the slotted nuts of steering tie rod

ball joint.
d. Install the split pins for slotted nuts of steering tie
rod ball joint.
e. Install the subframe assembly. (Refer to Chapter FR Frame, Suspension, and Wheels - Front
Independent Suspension - Subframe Assembly, Replacement.)
Steering gear reducer

Checking and repair
1. Disassemble the steering reducer and
countershaft.
a. Disassemble the fastening bolts on lower end of
steering drive shaft.
b. Disassemble the fastening bolts between steering

reducer and countershaft and take out the steering
reducer.
ST
c. Disassemble the fastening bolts between

countershaft and steering gear and take out the
countershaft.
d. Disassemble the fastening bolts on lower end of

countershaft.
2. Install the steering reducer and countershaft.

a. Install countershaft to installation position.
countershaft and steering gear.
c. Install steering reducer to installation position.

d. Install and tighten the fastening bolts of steering
reducer.
ST
e. Install and tighten the fastening bolts between

steering reducer and countershaft.
f. Install and tighten the fastening bolts between

steering reducer and steering drive shaft.
Steering motor controller

Checking and repair
1. Disassemble the steering motor controller.
a. Disassemble the steering wheel. (Refer to Chapter
ST Steering System - Steering Mechanism -
b. Disassemble the fastening screws of steering
column shields and take out the steering column
shields.
c. Disconnect the steering motor controller connector.
ST
d. Disassemble the fastening bolts of steering motor

controller and take out the steering motor controller.
2. Install the steering motor controller.

a. Install steering motor controller to installation
position.
b. Install and tighten the fastening bolts of steering
motor controller.
c. Connect the steering motor controller connector.
d. Install the steering column shields and fix them by

screws.
ST
e. Install the steering wheel. (Refer to Chapter ST Steering System - Steering Mechanism -
BR Brake system
Service brake (Hydraulic) ....................................................1
Service brake system (Hydraulic) ...................................1
Vacuum booster and brake master cylinder (hydraulic)..8
Air bleeding of brake system.........................................15
Brake pedal ...................................................................17
Front wheel brake .........................................................22
Rear wheel brake ..........................................................25
Brake Pipeline (Hydraulic) ............................................30
Parking brake ......................................................................39
Parking brake system ...................................................39

BR
Parking brake handle ....................................................46
Parking brake cable ......................................................49

Brake System - Service brake (Hydraulic) BR-1
Service brake (Hydraulic)
Service brake system (Hydraulic)

Overview
1. System description
The service brake system is a series of special devices functioned to forcibly reduce the traveling
speed of the vehicle. The brake system is mainly composed of 4 parts, namely power supply
device, control device, drive device, and brake. The main application scope of the brake system is
to slow down or even stop the traveling vehicle and maintain a stable speed for the downslope
traveling vehicle. This vehicle is equipped with front disc brakes and rear drum brakes.
2. Composition
It’s composed of brake pedal, brake master cylinder, vacuum booster, brake pipeline, brake
caliper, brake drum, brake pad, and brake shoe.
3. Operating principle
When the brake pedal is depressed, the force applied onto the brake pedal by the driver is
amplified by the vacuum booster to compress the brake fluid from the brake master cylinder to the
brake pipelines of four wheels and the compressed brake fluid drives the brake pistons and brake
slave cylinders to engage the brake pads with brake discs and generate the friction force to slow
down the vehicle.
BR
4. Requirements of brake system
• Good braking efficiency: The indicators for evaluation of vehicle braking efficiency include
braking distance, braking deceleration, and braking time.
• Handy operations: Good directional stability during braking. During braking, the braking
force should be reasonably distributed between front and rear wheels and should be
basically equal between left and right wheels, in order to prevent off-tracking and sideslip.
• Good braking smoothness: Gentle and stable application and rapid and thorough release
of braking.
• Good heat dissipation and easy adjustment: The brake shoe pads require strong heat
resistance, rapid recovery capability if wetted, clearance self-adjusting capability if worn,
and dust and oil proof.
BR-2 Brake System - Service brake (Hydraulic)
Precautions
1. The performance of the service brake directly influences the driving safety. Therefore,
ensure to always maintain the good performance of the brake system.
2. Periodically check and maintain the brake system to eliminate any potential safety
problem.
3. Use recommended brake fluid and never mix brake fluid with any other trademark of brake
fluid.
4. Due to strong corrosiveness of brake fluid, guard your skin and the body paint against the
contamination of brake fluid during the repairs of brake system. In event of contamination
due to carelessness, flush with a great amount of clean water immediately.
5. If the brake pads are contaminated by oil dirt or wetted by water during repairs, the friction
coefficient will reduce sharply to cause braking failure. During the repairs, disassemble
the brake pads, clean them by gasoline, and heat and bake them by torch lamp to exude
the permeated oil from the brake pads. In event of serious oil permeation, ensure to
replace the brake pads. For water-immersed brake pads, apply the braking repeatedly to
generate the heat, in order to evaporate the sealed water and restore dryness.
6. During the disassembling of brake calipers, do not depress the brake pedal, in order to
BR prevent the ejection of piston from damaging the piston dust cover.
7. During repairs, thoroughly clean the brake slave cylinders and brake pads, in order to
minimize the harms caused by the particles and other materials contained in the air.
8. While bleeding the air, observe the level of brake fluid in the brake fluid reservoir. If the
level is below the minimum level, timely add the brake fluid.
9. After adding the brake fluid and bleeding the air, check the brake system for presence of
leakage. If yes, timely eliminate the leaks to ensure the driving safety.

1. Brake fluid (insufficient) Add the brake fluid
Check and repair the braking

2. Brake system (oil leaking)
System
The brake pedal is too low
3. Brake lining (worn) Check and repair the brake lining
or weak.
Check and repair the brake master
4. Brake master cylinder (fault)
cylinder
5. Brake system (with air) Air bleeding of brake system
1. Brake pipeline (blocked) Dredge or replace brake pipeline.

cylinder
Braking drag 3. Brake caliper (seized) Check and repair the brake caliper BR
4. Hub bearing (loose) Replace wheel hub bearing.
5. Free travel of brake pedal (too Adjust the free stroke of brake
small) pedal
1. Tires (pressure insufficient) Check the tires on the vehicle
2. Brake shoe (oily) -
3. Brake shoe (one side is worn

Check and repair the brake shoe
extremely)
4. Brake lining (oily) -
5. Brake lining (one side is worn

Check and repair the brake lining
Braking deviation extremely)
6. Brake disc (deformed) Check and repair the brake disc
7. Deformation of brake drum Check and repair the brake drum
8. Brake caliper (the left and right

braking forces differ a lot) Check and repair the brake caliper
9. Brake slave cylinder (the left and Check and repair the brake slave
right braking forces are different) cylinder
1. Brake lining (overused) Check and repair the brake lining
2. Brake caliper (fastening bolts

Check and repair the brake caliper
become loose)
Unstable braking
3. Brake caliper bracket (fastening Check and repair the brake caliper
bolts become loose) bracket
4. Brake caliper (seized) Check and repair the brake caliper


cylinder
1. Brake lining (over worn) Check and repair the brake lining
The braking force is 2. Brake shoe (over worn) Check and repair the brake shoe
insufficient.
Discharge the air in the brake
3. Brake pipeline (with air)
pipeline
BR
Preparations
Recommended tools

Torque wrench
installation of bolts
For checking of brake disc, brake

Vernier caliper
pad, brake shoe, and brake drum
BR
Dial indicator For checking of brake disc
Rear brake shoe, Brake slave

Nipper pliers
cylinder
Grease gun Rear wheel hub
Tape For measurement of pedal height

Micrometer For measurement of parts

Speed wrench
installation of bolts and nuts

Oil pipe spanner installation of oil pipe connector
nuts
Accessories
Brake fluid - DOT3/DOT4

BR
Technical data
Height of brake pedal Standard value 120~130mm
Free travel of brake pedal Standard value 5~15mm
Torque requirements
Fasteners N·m
Fastening nut of brake master cylinder 21~25
Fastening nuts of vacuum booster 21~25
Nut at oil pipe joint of brake master cylinder 19~21
Brake lamp switch lock nut 21~25
Fastening bolts of brake pedal bracket 21~25
Fastening bolts of load-sensing proportional valve 28~36
Oil inlet and outlet pipe connector nuts of load-sensing proportional BR

7~9
valve
Vacuum booster and brake master cylinder (hydraulic)

Overview
The vacuum booster is a component increasing the driver's force applied on the pedal through vacuum
(negative pressure). Normally the vacuum booster is installed between the brake pedal and the brake
master cylinder. In order to facilitate installation, it is usually combined with the master cylinder. One part
of master cylinder penetrates into the vacuum booster housing.
BR
Part diagram
BR
Vacuum booster with brake master

1 3 Vacuum pipe assembly
cylinder assembly
2 Vacuum pipe assembly

General inspection
1. Check vacuum booster.
Caution
Check the vacuum booster for good airtightness by
checking the following 3 items. In event of one or more
non-conformance, the vacuum hose or the vacuum
Third step booster is probably damaged. Replace depending on
Second step the actual situation.
First step a. Run the engine for 1~2min and then stop the
engine. Depress the brake pedal continuously. If the
travel is normal during the first depressing cycle and
becomes shorter during the second and third
depressing cycles, it indicates the normal
airtightness. If there is no change in travel, it
indicates abnormal airtightness.
b. With the engine stopped, depress the brake pedal
continuously for several times. With the brake pedal
BR depressed, start the engine. If the pedal can move
downward further, it indicates the normal
airtightness. If the pedal can’t move downward
further, it indicates the abnormal airtightness.
c. While the engine is running, depress the brake

pedal. In such case, stop the engine. If the pedal
height has no change within 30s, it indicates normal
airtightness. If the pedal rises, it indicates abnormal
airtightness.
Hold 30s
2. Check the brake master cylinder assembly.

a. Check for presence of oil leakage between brake master cylinder and booster.
b. Check the installation surfaces of brake master cylinder and brake fluid reservoir and the brake
pipe connectors for presence of leakage.
Caution
Upon detection of above problem, check the seal cup of brake master cylinder or the seal ring of
brake fluid reservoir for damage.
3. Check vacuum check valve

a. Disassemble the vacuum booster pipe clamp,
disconnect the vacuum booster pipe, and unplug
the check valve from the vacuum booster.
b. Check whether the vacuum check valve flows

through from booster to engine and doesn’t flow
through in opposite direction. Upon detection of
malfunction, replace vacuum check valve.
BR
Replacement
1. Disassemble the vacuum booster and brake
master cylinder.
a. Disassemble the dashboard. (Refer to Chapter BW
Ashtray - Dashboard, Replacement.)
b. Disassemble the steering column. (Refer to Section
ST: Steering system - Steering mechanism -
Steering wheel, Inspection and Repair.)
c. Drain the brake fluid. (Refer to Chapter BR Brake
System - Service Brake (Hydraulic) - Brake Pipeline
(Hydraulic), Brake Fluid.)
d. Loosen the fixing clamp of the vacuum hose of the
vacuum booster, unplug the vacuum hose of
vacuum booster, and seal the hose connector to
prevent the ingress of foreign materials.
e. Loosen two inlet hose fixing clamps of brake master
BR cylinder, unplug the inlet hose of brake master
cylinder, and seal the pipe connector to prevent the
ingress of foreign materials.
Caution
Ensure to recover the residual brake fluid by a special
container and do not splash any brake fluid onto the
paint surface. If your skin is contaminated by brake
fluid, flush by a great amount of water.
f. Loosen two outlet hose nuts of the brake master
cylinder by a pipe wrench, unplug the outlet pipe of
brake master cylinder, and seal by pipe connector
seal cap to prevent the ingress of foreign materials.
g. Disassemble the push rod split pin of brake vacuum
booster and take out the washer and flat-head pin.
h. Disassemble the fastening nuts of vacuum booster
assembly with brake master cylinder and take out
the vacuum booster assembly with brake master
cylinder.
2. Break down the brake master cylinder.

a. Disassemble the fastening nuts between vacuum
booster and brake master cylinder and pull out the
brake master cylinder from the brake vacuum
booster.
Caution
Disassemble the fastening nuts between vacuum
booster and brake master cylinder and pull out the
brake master cylinder from the brake vacuum booster.
3. Assemble the vacuum booster and brake

master cylinder assembly.
a. Install the brake master cylinder onto the brake
vacuum booster and install and tighten the
fastening nuts.
Torque: 21~25N•m
BR
4. Install the brake vacuum booster assembly with
brake master cylinder.
a. Install the brake vacuum booster assembly with
brake master cylinder onto the brake pedal bracket
and install and tighten the fastening nuts.
Torque: 21~25N•m
b. Install the push rod yoke flat-head pin, washer, and
split pin of brake vacuum booster and secure the
split pin.
c. Take out the pipe connector seal cap, install the
outlet pipeline of brake master cylinder into
corresponding pipe port of brake master cylinder
and tighten the pipe connector nut to the specified
torque.
Torque: 19~21N•m
d. Take out the pipe connector seal cap, install the
hose circlip to the brake hose, insert the brake hose
to the inlet pipe connector of brake master cylinder,
and fix it by clamp.
e. Take out the pipe connector seal cap, install the

hose clamp to the vacuum hose, insert the hose to
the check valve port of vacuum booster, and secure
the clamp.
f. Fill brake fluid. (Refer to Chapter BR Brake System - Service Brake (Hydraulic) - Brake Pipeline
g. Bleed the air from the brake system. (Refer to Chapter BR Brake System - Service Brake
(Hydraulic) - Air Bleeding of Brake System, Air Bleeding)
h. Install the steering column (Refer to Chapter ST Steering System - Steering Mechanism -
Steering Column, Replacement.).
i. Install the dashboard. (Refer to Section BW: Vehicle body- Dashboard/ Combination instrument/
Cigar lighter/ Ash tray- Dashboard, Replacement.)
BR
Air bleeding of brake system

Air bleeding
Caution
After the repair of brake system or upon the suspicion of air content in brake pipeline, it’s
necessary to bleed the air from the brake system.
Danger
Due to strong corrosiveness of brake fluid, guard your skin and the body paint against the
contamination of brake fluid during the repairs of brake system. In event of contamination due to
carelessness, flush with a great amount of clean water immediately.
1. Check the level of brake fluid in brake fluid

reservoir.
a. Fully fill the brake fluid before air bleeding. If the
brake fluid in the brake fluid reservoir is not full, as
the brake fluid will be drained along with the air
bubbles during the air bleeding, it will easily result in
the permeation of air from the brake fluid reservoir BR
due to insufficient level of the brake fluid and cause
ingress of new air content with the original air
content incompletely bled.
2. Bleed air in the brake pipeline
a. Air bleeding sequence: Right rear - Left rear - Right
front - Left front.
b. Open the rubber cap of air bleeding screw.
c. Attach a wrench onto the bleeding screw, insert the

transparent plastic hose of air bleeding device into
the bleeding screw of right front brake slave
cylinder, and place another end of the hose into one
transparent container.
d. Ask the assistant to depress the brake pedal
repeatedly for 5~6 times and then depress and hold
the brake pedal.
e. Loosen the brake air bleeding screw to bleed the air

from the brake system. When the brake fluid is
about to stop flowing out, tighten the brake air
bleeding screw.
Torque: 9～12N·m
f. Repeat the step d and step e continuously for
several times, till the brake fluid flowing out from the
transparent hose is free of air bubble.
Caution
While bleeding the air, always observe the level of
brake fluid and timely add the brake fluid.
BR
Brake pedal
Overview
The brake pedal is the pedal limiting the brake force, namely the pedal of foot brake (service brake). The
brake pedal aims to slow down and stop the vehicle. It is one of five control units of vehicle. It is used
frequently. The driver's control affects the running safety of vehicle directly.
BR
Part diagram
BR
1 Brake and clutch pedals assembly 2 Connecting plate

Adjustment
1. Check and adjust the brake pedal height H.
a. Move away the cab floor carpet.
b. Measure the brake pedal height H by a ruler or
equivalent measure.
Brake pedal height: 120~130mm
Caution
If the brake pedal height is disqualified, adjust the
brake pedal height.
c. Disconnect the brake lamp switch connector.
BR
d. Loosen the brake lamp switch lock nut, rotate the

brake lamp switch, and thus adjust the brake pedal
height to standard value.
e. At completion of adjustment, tighten the brake lamp
switch lock nut.
Torque: 21~25N•m
Caution
Do not rotate the brake lamp switch while tightening
the brake lamp switch lock nut.
f. Connect the brake lamp switch connector.

2. Check and adjust the brake pedal free travel L.

a. Stop the engine and depress the pedal slowly by
hand, till a small resistance is felt.
b. Measure the movement distance L of pedal from
the static status to the position a resistance is felt.
Free travel of pedal: 5~15mm
Caution
If the brake pedal free travel is disqualified, adjust the
brake pedal free travel.
BR
Replacement
Caution
To replace integrally the brake pedal and clutch pedal, follow the replacement method of brake
pedal (Refer to Chapter TR Transmission and Control Mechanism - Clutch - Clutch Pedal,
Replacement.)
BR
Front wheel brake

Overview
The caliper-disc brake is a kind of disc-type brake. Its rotating element is a metal disc operating on the
end face, and it is called as brake disc. The fastening element is the brake block composed of friction
block with small working area and its metal back plate. Each brake has 2-4 brake blocks. Those brake
blocks and their actuators are installed in the caliper-type bracket crossing both sides of brake disc. The
whole assembly is called as brake caliper. The brake disc and brake caliper together form the
caliper-disc brake.
BR
Checking and repair

1. Disassemble the front brake pad.
a. Disassemble the front wheels. (Refer to Chapter FR
Frame, Suspension, Wheels and Tires, Front Wheel
and Tire, Checking and Repair.)
b. Disassemble the lower guide bolt of brake caliper.
c. Tilt upward the brake caliper.

d. Take out the front brake pad.
BR
2. Disassemble the front wheel brake.

a. Drain the brake fluid.
b. Disassemble the brake fluid pipe connector nut and
move away the brake fluid pipe.
Caution
After disconnecting the brake pipeline, plug the brake
pipeline by plugs.
c. Disassemble the fastening bolts of front wheel
brake caliper bracket and take out the front wheel
brake caliper assembly.
d. Take out the front brake disc.
3. Check and repair various parts.

a. Check the brake pad.
• Check the front brake pad for presence of oil dirt, cracking, and falloff. If yes, replace.
• Check the thickness of front brake pad by a vernier caliper. If beyond the limit thickness,
replace.
Caution
While replacing the front brake pads, replace both inner and outer brake pads.
4. Check the front brake disc.

• Check the front brake disc for presence of oil dirt. If yes, grind clean by gauze.
• Check the brake disc for presence of cracking, corrosion, and serious scratch. If yes,
replace.
• Check the thickness of front brake disc by a vernier caliper. If beyond the limit thickness,
replace.
5. Install the front wheel brake.
a. Install the front wheel brake disc to installation
position.
BR b. Take out the brake pipeline plugs and install and

tighten the brake pipeline connector nuts.
c. Install the front wheel brake caliper assembly to
installation position and install and tighten the
fastening bolts of front wheel brake caliper bracket.
6. Install the front brake pad.

a. Tilt upward the brake caliper.
b. Install the front brake pad.
c. Tilt downward the brake caliper.
Caution
Reset the brake caliper piston by a piston resetter.
d. Install and tighten the lower guide bolt of brake

caliper.
e. Mount the front wheels. (Refer to Chapter FR
Frame, Suspension, Wheels and Tires, Front Wheel
and Tire, Check and Repair.)
Rear wheel brake

Overview
The drum-type brake presses the brake lining onto the interior of brake drum through the brake drive so
as to produce the brake force, slow down the vehicle or stop the vehicle in the shortest braking distance
according to the needs, ensure the safe running and guarantee the reliable parking of vehicle without
free slide.
The drum brake is also referred to as block brake and is functioned to realize braking by compressing
the brake drum onto the brake wheel. The mainstream drum brake is internal expanding type and its
brake block (brake shoe) is located in the inner side of the brake drum. During braking, the brake block
expands outward to come friction with the inner side of brake drum to realize the braking.
BR
Part diagram
BR
1 Left/right rear brake shoe subassembly 4 Return spring of rear brake shoe
Left/right rear brake clearance Rear brake slave cylinder assembly

2 5
self-adjusting mechanism subassembly
Left/right rear brake baseplate

3 Self-adjusting mechanism return spring 6
weldment assembly
Checking and repair

1. Disassemble the rear wheel brake.
a. Release the parking brake handle.
b. Disassemble the rear wheel assembly. (Refer to Chapter FR Frame, Suspension, Wheels and
Tires, Rear Wheel and Tire, Replacement.)
c. Take out the brake drum.
Caution
If it’s difficult to take out the brake drum, push out the brake drum by a wrench and flat-head bolt.
d. Take out the brake drum.

Caution
If it’s difficult to take out the brake drum, install
process bolts to the process holes of rear brake drum
and push out the brake drum.
BR
e. Disassemble the upper return spring ① of the
brake shoe, lower return spring ③ of brake shoe,
parking brake cable ④, and brake shoe fixing pin
② and take out the rear brake pad.
2. Check and repair the rear wheel brake.

a. Check the brake slave cylinder for presence of oil
leakage. If yes, replace the brake slave cylinder.
b. Check the brake adjustment shaft for presence of damage, such as broken gear tooth. If yes,
replace the brake adjustment shaft.
c. Check the wear thickness and remaining thickness

of brake shoe. If beyond the limit, replace.
d. Check the engagement status between brake shoe and brake drum.
• Use a white chalk to apply a film of powder onto the working surface of brake drum.
• Rotate the brake shoe against the working surface of brake drum by hand.
• The contact area between brake pad and brake drum shall be no less than 60%. If not,
repair the brake shoe.
e. The internal surface of the brake drum shall be free
of burning and scratch.
BR
f. Measure the inside diameter of rear brake drum. If

beyond the wear limit, replace the brake drum.
g. Check all return springs and tension springs for

presence of breakage and deformation and replace
any broken or deformed spring.
3. Install the rear brake.

a. Assemble the rear brake and install the rear brake
pad to the brake baseplate.
Caution
Install the parking brake cable ④, install the brake
shoe fixing pin ②, and install the lower return spring
③ and upper return spring ①.
b. Install the rear brake drum.

c. Mount the rear wheel. (Refer to Chapter FR Frame,
Suspension, Wheels and Tires, Rear Wheel and
Tire, Replacement.)
d. Adjust the brake pad clearance and test the brake
system performance.
BR
Brake Pipeline (Hydraulic)

Part diagram (Body part)
BR
Oil pipe assembly , brake master

1 Brake fluid reservoir module 8
cylinder
2 Fluid reservoir assembly 9 Multi-way unit
Preformed hydraulic brake hose

3 10 Multi-way sealing gasket
assembly

4 11 Dual-pipe clamp
assembly

5 12 Rubber plug
assembly
6 Body brake tube subassembly 13 Block cover
Oil pipe assembly , brake master

7 14 Dual-pipe clamp
cylinder
Part diagram (Chassis part I)
BR
1 Front brake tube subassembly 4 Brake hose clip
2 Left front brake tube 5 Four-way connector
3 Front brake hose assembly

Part diagram (Chassis part II)
BR
1 Rear brake tube subassembly

Part diagram (Chassis part III)
BR
Load-sensing valve fixing bracket

1 Hydraulic brake pipe assembly 3
assembly
Hydraulic load-sensing proportional

2 4 Rear ABS brake hose bracket
valve assembly
Checking and repair

1. Ensure to check the brake pipeline in event of shortage of brake fluid.
2. Check the brake pipelines for presence of cracking, indentation, and bending and replace
damaged brake pipeline.
3. The pipeline connectors shall be free of permeation or leakage of brake fluid. Otherwise
replace the related brake pipeline.
4. Ensure to use an oil pipe wrench, instead of a common open wrench, to disassemble the
brake pipeline nuts, in order to prevent damaging the brake pipelines.
5. Replace the corresponding brake pipeline as per the locations of the part diagram.
6. After replacement of brake pipeline, add brake fluid and bleed air from brake system.
BR
Brake fluid
1. Drain the brake fluid.
a. Turn off the ignition switch and apply the parking
brake.
b. Open the rubber cap of air bleeding screw.
c. Attach a wrench onto the bleeding screw, insert the

transparent plastic hose into the bleeding screw of
right front brake slave cylinder, and place another
end of the hose into one transparent container.
BR
d. Depress the brake pedal repeatedly, till the brake fluid is fully drained from the brake system.
Caution
• Drain the brake fluid depending on the actual needs during repairs. During the checking
and repair of individual brake, plug the disconnected brake pipeline only. It’s unnecessary
to drain the brake fluid.
• Due to strong corrosiveness of brake fluid, guard your skin and the body paint against the
contamination of brake fluid during the repairs of brake system. In event of contamination
due to carelessness, flush with a great amount of clean water immediately.
2. Fill the brake liquid.

a. Disassemble the brake fluid reservoir cover plate.
b. Open the filler cap of brake fluid reservoir and fill
brake fluid.
c. Bleed the air from the brake system. (Refer to
Chapter BR Brake System - Service Brake
(Hydraulic) - Air Bleeding of Brake System, Air
Bleeding)
Brake fluid reservoir

1. Disassemble the brake fluid reservoir.
a. Disassemble the dashboard. (Refer to Chapter BW Body - Dashboard, Combination Instrument,
and Ashtray - Dashboard, Replacement.)
b. Drain the brake fluid. (Refer to Chapter BR Brake System - Service Brake (Hydraulic) - Brake
Pipeline (Hydraulic), Brake Fluid.)
c. Disconnect the brake fluid reservoir connector.
d. Loosen the fixing clamp of hose, disconnect the
hose of brake fluid reservoir, and take out the brake
fluid reservoir.
2. Install the brake fluid reservoir.

a. Connect the hose of brake fluid reservoir and fix the
BR fixing clamp.
b. Connect the brake fluid reservoir connector.
c. Install the dashboard. (Refer to Chapter BW Body - Dashboard, Combination Instrument, and
Ashtray - Dashboard, Replacement.)
d. Fill brake fluid. (Refer to Chapter BR Brake System - Service Brake (Hydraulic) - Brake Pipeline
e. Bleed the air from the brake system. (Refer to Chapter BR Brake System - Service Brake
Load-sensing proportioning valve

1. Adjust load-sensing proportional valve.
a. Increase the length of load-sensing spring to reduce the pre-load of load-sensing spring and thus
reduce the pressure of rear wheel actuation pipeline. Reduce the length of load-sensing spring to
increase the pre-load of load-sensing spring and thus increase the pressure of rear wheel
actuation pipeline.
b. To ensure the smooth and rapid adjustment of load-sensing proportional valve, determine to
increase or reduce the length of spring based on the measurement of rear wheel brake pipeline
pressure before the adjustment.
c. Loosen or tighten the adjustment nut ① and adjust
the double-inlet load-sensing proportional valve.
Caution
• In event of poor braking performance, clockwise
adjust the adjustment nut ①.
• In event of poor braking drag,
counter-clockwise adjust the adjustment nut ①.
BR
2. Disassemble load-sensing proportional valve.
a. Drain the brake fluid. (Refer to Chapter BR Brake
System - Service Brake (Hydraulic) - Brake Pipeline
b. Disassemble the connector nut A of load-sensing
proportion valve inlet pipe ① and move away
load-sensing proportion valve inlet pipe ①.
c. Disassemble the connector nut C of load-sensing
proportion valve inlet pipe ② and move away
load-sensing proportion valve inlet pipe ②.
d. Disassemble the connector nut B of load-sensing
proportion valve outlet pipe ③ and move away
load-sensing proportion valve outlet pipe ③.
Caution
Disconnect the fluid pipes and plug the brake pipeline
by plugs.
e. Disconnect the control tension spring from body.
f. Disassemble the fastening bolts of load-sensing

proportional valve assembly and take out the
load-sensing proportional valve assembly.
3. Install load-sensing proportional valve.

a. Install the load-sensing proportional valve to the
fastening bolts.
Torque: 28~36N•m
BR b. Connect the control tension spring.

c. Connect the load-sensing proportional valve outlet
pipe ② and tighten the pipe nut.
d. Connect the load-sensing proportional valve return
pipe ③ and tighten the pipe nut.
e. Unplug the sealing plug.

f. Install the load-sensing proportional valve inlet pipe
① to installation position and install and tighten the
connector nut A.
Torque: 7~9N•m
g. Install the load-sensing proportional valve inlet pipe
② to installation position and install and tighten the
connector nut C.
Torque: 7~9N•m
h. Install the load-sensing proportional valve outlet
pipe ③ to installation position and install and
tighten the connector nut B.
Torque: 7~9N•m
i. Fill brake fluid. (Refer to Chapter BR Brake System - Service Brake (Hydraulic) - Brake Pipeline
j. Bleed the air from the brake system.(Refer to Chapter BR Brake System - Service Brake
Brake System - Parking brake BR-39
Parking brake
Parking brake system

Overview
1. The parking brake system can park the vehicle safely for a long time to ease the driver’s
startup on slopes. During the traveling of vehicle, if the service brake system fails, the
parking brake system can be used for emergency braking.
2. The parking brake system is composed of handle, parking brake cable, and brake.
3. To use the parking brake, pull up the parking brake handle to drive the cable and apply the
parking brake.
BR
BR-40 Brake System - Parking brake
Precautions
1. The parking brake can’t substitute the service brake. Use the parking brake to slow down
the vehicle only in event of emergency.
2. Check and adjust the parking brake only when the service brake is normal.
3. To check the parking brake system, park the vehicle on a horizontal ground and block the
wheels by wooden triangles.
4. Replace every part carefully and correctly. The incorrect installation will influence the
parking brake performance of vehicle and probably endanger the personal safety.
5. All snap joints and cable ties disassembled shall not be reused.
6. The parking braking performance must be tested for the repaired parking brake system, in
order to ensure safety and reliability.
7. Check the clutch once every 10000km as described below:
• Check the function of parking brake.
• Check the travel of parking brake handle.
• Check all connections for looseness;
• Check the parking brake system for normal functioning.
BR

Malfunction
Possible cause Troubleshooting
symptom
1. Parking brake handle (Incorrect travel) Adjust parking brake handle.
Poor parking 2. Brake shoe and brake drum (Excessive Remove oil dirt and adjust
brake clearance or oil dirt) clearance.
performance
3. Parking brake cable (Breakage, blockage, and
Replace parking brake cable.
falloff)
1. Parking brake handle (Insufficient travel) Adjust parking brake handle.
2. Parking brake return spring (Damage) Replace brake return spring.

The parking
brake drags.
3. Parking brake cable (Blockage) Smoothen parking brake cable.
4. Brake shoe gap (adjusted improperly) Adjust the brake shoe gap
BR
Preparations
Recommended tools
Vernier caliper For checking of central brake
Nipper pliers For disassembling of brake cable
BR For disassembling of fastening

Torque wrench
bolts

Screwdriver
installation of screws
Technical data
Required tightening torques
Fasteners N·m
Fastening bolts of parking brake handle 40~45
Fastening bolts of parking brake cable bracket 32~38
Fastening nuts of parking brake cable conduit 12~18
BR
Part diagram
BR
1 Parking brake handle assembly 3 Front cable fixing bracket
2 Cable assembly, hand brake

Onboard inspection
1. Travel of parking brake handle
a. Pull up the parking brake handle by a 100N force
and ensure that the ratchet is within specified
range.
Standard value: 7~9 teeth
Caution
A click sound can be heard for movement of every
ratchet tooth. Check by listening and calculating the
sounds of ratchet.
2. Braking performance of parking brake

a. Under normal status of brake, drive the vehicle to an approximately 20% slope, depress the brake
pedal, and apply the parking brake to stop the vehicle on the slope.
b. Slowly release the brake pedal. The vehicle shall hold for at least 5min without gliding. If the
vehicle glides, it’s necessary to adjust the parking brake.
3. Checking of parts
a. Verify every part for normal fastening status.
BR
b. Check the parking brake control mechanism assembly for bending, damage, and cracking. If yes,
replace.
c. Check the parking brake cable for wear and damage. If yes, replace.
4. Parking brake switch
a. Check the parking brake switch for normal functioning. If not, repair or replace.
• When the parking brake handle is pulled up, the brake malfunction warning lamp shall turn
on.
• When the parking brake handle is lowered down, the brake malfunction warning lamp shall
turn off.
Parking brake handle

Adjustment
Caution
Notice the following issues for the adjustment of parking brake:
• The rear wheel brake pads shall be free of excessive wear.
• The brake pedal travel shall meet the standard.
• Before adjustment, depress the brake pedal for several times and forcibly pull up the
parking brake handle for several times.
1. Adjust the parking brake control mechanism.

a. Disassemble the auxiliary dashboard. (Refer to
Chapter BW Body - Dashboard, Combination
Instrument, and Ashtray - Auxiliary Dashboard,
Replacement.)
b. Adjust the parking brake cable adjustment nut and
ensure that the rear wheels are completely locked
when the parking brake handle is pulled up for 7~9
BR
teeth.
Caution
After adjustment, the rear wheels shall be completely
locked when the parking brake handle is pulled up
forcibly and shall rotate freely when the parking brake
handle is completely released.
c. Check the parking brake.
Replacement
1. Disassemble the parking brake lever.
Replacement.)
b. Disconnect the connector of parking brake indicator
lamp switch.
c. Disassemble the parking brake cable adjustment

nut.
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d. Disassemble the fastening bolts of parking brake
control mechanism assembly.
e. Take out the parking brake control mechanism
assembly.
2. Install the parking brake handle.

a. Install the parking brake control mechanism
assembly to installation position.
Caution
Insert the front adjustment rod of parking brake cable
into the parking brake control mechanism assembly.
b. Install and tighten the fastening bolt of parking
brake control mechanism assembly.
Torque: 40~45 N·m
c. Install the adjustment nut A to adjust the parking

brake.
d. Connect the parking brake switch connector.

e. Install auxiliary dashboard. (Refer to Chapter BW
Ashtray - Auxiliary Dashboard, Replacement.)
BR
Parking brake cable

Replacement
1. Disassemble the front segment of parking brake
cable.
Replacement.)
b. Completely loosen the parking brake handle.
c. Disassemble the parking brake adjustment nut A.
d. Disassemble the fastening nut B of parking brake
cable conduit.
e. Disconnect the parking brake cable from parking
brake control mechanism.
Caution
If it’s difficult to disconnect the parking brake cable,
disassemble the parking brake control mechanism.
BR
f. Elevate the vehicle
g. Detach the parking brake cable dust cover A.
h. Loosen the lock nuts B of parking brake left and
right cables and loosen the lock nuts C and D of
front segment of parking brake cable.
i. Disconnect the parking brake left cable ① and
right cable ② from the front segment of cable
bracket ③.
j. Disassemble the fastening bolts between front

segment of parking brake cable and frame
crossbeam.
k. Disassemble the fastening bolts between front

segment of parking brake cable and transmission
rear suspension bracket.
l. Disassemble the fastening bolts between front

segment of parking brake cable and vehicle body.
m. Take out the front segment of parking brake cable.
2. Disassemble the left and right rear parking

brake cables.
Caution
The replacement method is same for left and right
parking brake cables. This manual describes the
replacement method by taking the left parking brake
cable for instance.
a. Disassemble the rear wheels. (Refer to Chapter FR

BR Frame, Suspension, Wheels and Tires, Rear Wheel
and Tire, Replacement.)
b. Take out the brake drum.
c. Push the parking brake arm ① along the arrow A
and take out the parking brake cable ② from the
parking brake arm ①.
d. Disassemble the circlip of parking brake cable.

e. Disassemble the fastening bolts and nuts of parking

brake cable bracket.
f. Take out the parking brake cable.
3. Install the left and right rear brake cables.

a. Install the parking brake cable to the installation
position.
b. Install and tighten the fastening bolts and nuts of
parking brake cable bracket.
c. Install the circlip of parking brake cable. BR
d. Push the parking brake arm ① along the arrow A

and take out the parking brake cable ② from the
parking brake arm ①.
e. Install the brake drum.

f. Mount the rear wheel. (Refer to Chapter FR Frame,
Suspension, Wheels and Tires, Rear Wheel and
Tire, Replacement.)
4. Install the front segment of parking brake cable.

a. Install the front segment of parking brake cable to
the installation position.
b. Install and tighten the fastening bolts between front
segment of parking brake cable and vehicle body.
Torque: 32~38N·m
c. Install and tighten the fastening bolts between front

segment of parking brake cable and transmission
rear suspension bracket.
Torque: 32~38N·m
BR d. Install and tighten the fastening bolts between front

segment of parking brake cable and frame
crossbeam.
Torque: 32~38N·m
e. Install the parking brake left cable ① and right

cable ② to the front segment of cable bracket ③.
f. Tighten the lock nuts B of parking brake left and
right cables and adjust and tighten the lock nuts C
and D of front segment of parking brake cable.
g. Install the parking brake cable dust cover A.
h. Lower the vehicle.
i. Insert the parking brake cable into the parking brake

control mechanism.
Caution
If it’s difficult to install the parking brake cable,
disassemble the parking brake control mechanism.
j. Install and tighten the fastening nuts B of parking
brake cable conduit.
Torque: 12~18N·m
k. Install the parking brake adjustment nut A.
l. Adjust the parking brake and install and tighten the
lock nut.
m. Install auxiliary dashboard. (Refer to Section BW:
Vehicle Body - Dashboard/ Combination
Instrument/Cigar Lighter/Ashtray - Auxiliary
Dashboard, Replacement.)
BR
BW Vehicle body
Body assembly ...................................................... BW-1
Body .....................................................................BW-1
Sheet Metal Parts .................................................BW-2
Painting ................................................................BW-6
Plastic parts ..........................................................BW-8
Windshield, window glass, rearview mirror

.............................................................................. BW-12
Glass and rearview mirror ..................................BW-12
Electric lifter ........................................................BW-14
Front windscreen ................................................BW-16
Rear windscreen ................................................BW-19
Exterior rearview mirror ......................................BW-22 BW

Interior rearview mirror .......................................BW-24
Door windows .....................................................BW-26
Interior/exterior trims.......................................... BW-30
Interior/exterior trims ..........................................BW-30
Inner guard panel of door ...................................BW-31
Sun visor ............................................................BW-34
Floor trim ............................................................BW-35
Front bumper ......................................................BW-38
Vehicle trim parts ................................................BW-40
Roof panel ..........................................................BW-42
Footplates...........................................................BW-43
Body logo ...........................................................BW-44
Safety handrail ...................................................BW-45
Gearshift lever shield .........................................BW-46
Boarding handrail ...............................................BW-47
Dashboard / combination instrument /ashtray BW-48

Dashboard / combination instrument /ashtray .. BW-48
Dashboard ......................................................... BW-49
Auxiliary dashboard ........................................... BW-56
Combination instrument .................................... BW-58
Dashboard framework ....................................... BW-60
Vehicle door and engine hood ........................... BW-62
Vehicle door and engine hood........................... BW-62
Front door .......................................................... BW-63
Door outer handle.............................................. BW-65
Door lock.............................................................. BW-68
Door lock ........................................................... BW-68
Front door lock .................................................. BW-70
Seat ....................................................................... BW-76
Seat assembly ................................................... BW-76

BW
Driver seat ......................................................... BW-78
Front passenger seat ........................................ BW-80
Seat belt ............................................................... BW-81
Seat belt ............................................................ BW-81
Driver/front passenger seat belt ........................ BW-83
Cargo body .......................................................... BW-87
Cargo body assembly ....................................... BW-87
Cargo body ........................................................ BW-89

Vehicle Body - Body assembly BW-1
Body assembly
Body
Overview
For this vehicle model, the vehicle body is the cab assembly, which is not only the driver’s working place,
but also an important part of the whole vehicle. Generally, the cab includes windows, doors, and cab.
The vehicle body is an important part of the vehicle, of which the design directly influences the
performance and safety of vehicle.
The vehicle cab shall provide a convenient working condition for the driver and provide a comfortable
riding condition for the passengers to protect them against the driving vibration and noise, exhaust gas
affection, and influence of external severe weathers. Some structural measures and equipment on the
vehicle cab also help safeguard the driving and mitigate the accident consequence.
The cab shall make sure the car has reasonable exterior shape, so as to effectively guide the
surrounding air flow when car driving, and reduce air resistance and fuel consumption. Besides, the cab
shall also be conducive to improve car driving stability and engine cooling condition, so as to ensure the
good ventilation inside vehicle body.
BW
BW-2 Vehicle Body - Body assembly
Sheet Metal Parts

External sheet metal trim parts
1. Sheet metal operation procedure
a. Damage confirmation. Clean the damaged area, determine the damage extent, and thus
determine the repair method.
b. Disassembling of sheet metal parts. Disassemble the damaged sheet metal parts of impacted
vehicle from the original vehicle body by cutting method.
c. Flattening of sheet metal parts. Based on the damage extent of the sheet metal parts, flatten the
depressed area by corresponding sheet metal tools. After the flattening operation, the fine
flatness adjustment is required for the surfaces of sheet metal parts.
d. Annealing treatment. The annealing treatment is functioned to eliminate the stretching and
squeezing stresses of the metal generated during the restoration to original shape and thickness
and maintain the stiffness and strength of sheet metal parts.
e. Epoxy treatment. The epoxy paint in the inside of the hammered and stretched sheet metal parts
will fall off or burn. Therefore, apply a film of epoxy paint to the inside of sheet metal parts.
The above-mentioned sheet metal operation procedure is applicable for the sheet metal parts
with minor damage extents. If the vehicle frame is damaged due to serious impact, it’s necessary
to straighten the vehicle structure on a frame straightening machine, for which the operation
difficulty will be high.
BW
Repairs of sheet metal parts
Judgment of damage scope (Selection of repair method)
Correction by hammering with

Straightening by welded washer ① hammer and anvil ②
Removal of old paint from surfaces Disassembling of sound insulation panels

of sheet metal parts from back surfaces of sheet metal parts
Repair of sheet metal parts by sheet Repair of sheet metal parts by

metal shaping machine hammer and anvil
Quenching and annealing

treatment of sheet metal parts
BW
Anti-rust treatment for back surfaces of sheet metal parts
2. Sheet metal operation standard

a. Determination of damage scope
Check the damage status of panels, judge the deformation category, and determine the
Objective
repair method.
1. Verify the appearance of vehicle.

Method and 2. Visually observe the damage status from all directions.
standard 3. Wear cotton gloves and touch the panels in longitudinal, lateral, and diagonal
directions along the curvature of the panels to feel the surface deformation status.
Tools and
materials
Labor protection
appliances and Cotton gloves
clothing
b. Removal of old paint

Objective Disassemble the old paint to ease the connection of terminals and ground.
Method and Grind away the old paint in certain inclination angle (15°~30°) by a single-action
standard grinding machine.
Tools and
Single-action grinding machine and belt grinding machine
materials
Labor protection
appliances and Cotton gloves, dustproof mask, goggles, helmet, and safety shoes.
clothing
c. Repair operation
Objective Repair the panels to restore their original shapes as far as possible.
1. Operation with manual tools: Repair with hammer, anvil, crowbar, and chisel.
2. Stretching operation with sheet metal shaping machine: Properly adjust the status of
Method and sheet metal shaping machine, prepare the welding patches, and whenever possible
standard stretch by connection and stretching method (The single-position stretching
operation can be used for small depressions).
3. Check the flatness during repairs.
Tools and Sheet metal shaping machine, sliding hammer, hammer, anvil, crowbar, chisel, and
BW materials patch.
Labor protection
clothing
d. Patching of holes
Objective Fill the panel holes due to excessive stretching to prevent panel rusting.
1. Adjust the status of sheet metal shaping machine and patch the holes with welding
Method and wires and carbon rods.
standard
2. Grind and polish by belt grinding machine.
Tools and
Sheet metal shaping machine, welding wires, and belt grinding machine.
materials
Labor protection
clothing
e. Annealing treatment.
Objective Restore the stretched sheet metal panels to original tension.
1. If the annealing area is small, the tension of sheet metal panels can be restored by
single-point or two-point annealing at the center of extension area.
2. If the extension area of the sheet metal panel is large, use the annealing method
Method and with carbon rod from outside to inside. Start from the extension center of sheet metal
standard panel and expand gradually towards circumference. The circumferential annealing
at center shall take the high spots in the extension area as main targets. Carefully
find out the circumferential high spots for annealing in turn, till the tension of the
entire extension area is completely restored.
Tools and
Sheet metal shaping machine, sliding hammer, carbon rod, and patch
materials
Labor protection
clothing
f. Removal of residual paint
Objective Disassemble the hammered old paint to ensure a solid base for the repair area.
1. Disassemble the old paint in certain inclination angle by a single-action grinding

machine.
Method and
2. Grind away the old paint of small depressions by a belt grinding machine.
standard
3. Place horizontally the single-action grinding machine and grind by P60 or P80
abrasive paper to form primary pinniform edge.
Tools and Single-action grinding machine, belt grinding machine, and P60 or P80 disc dry
materials abrasive paper.
Labor protection
clothing
g. Basic treatment (Formation of pinniform edge)

BW
Ensure the smooth transition of every paint layer in old paint to ease the checking of
Objective
panel flatness.
1. Use a double-action grinding machine with P60 or P800 abrasive paper to grind in
certain inclination (15º) every paint layer in old paint in spacing of approximately
10mm.
Method and
2. Disassemble the abrasive paper traces (P80~P120) in turn with corresponding
standard
abrasive papers.
3. Disassemble the old paint (This operation may be omitted if there is no depression
and only the paint is damaged in the repair area).
Tools and Single-action grinding machine, belt grinding machine, double-action grinding machine
materials P80~P120 discs, and P60 belt dry abrasive paper.
Labor protection
clothing
h. Intermediate checking
Objective Check the repair effect of panels.
Method and Push levelly a steel ruler in the repaired area to check the repair effect of the panel. The
standard requirement is to ensure that the repaired area is free of high spots and <1mm pits.
Tools and
Steel ruler
materials
Labor protection
appliances and Cotton gloves, helmet, and safety shoes.
clothing
Painting
Painting of body peripherals
1. Painting procedure
a. Damage confirmation.
Clean the damaged area, determine the damage extent and scope, and thus determine the repair
method.
b. Grinding to form pinniform edge.
Grind a transitional groove at the joint between damaged area and surrounding paint to ease the
better joint between new paint and old vehicle paint.
c. Application of epoxy primer
Re-clean and deoil the ground damaged area, apply the epoxy primer, bake dry, and take
anti-rust measure.
d. Application of putty
After the application of epoxy primer, slightly sand, clean, and deoil the damaged sheet metal
parts and then apply the putty. After air drying of the putty, grind and then determine the
stamping line.
e. Application of intermediate paint
After the grinding of putty, clean, deoil, and spray the intermediate paint, and bake dry. During the
spray of intermediate paint, notice to take the reverse protection for the areas requiring no paint.
BW
f. Grinding of intermediate paint
Grind the intermediate paint, till it’s level with the original paint and ensure the flatness.
g. Paint mixing.
The color of finish paint differs from the original paint after long-time use of vehicle. The manual
paint mixing is required for the painting personnel.
h. Spray of finish paint.
Fill the properly mixed finish paint into the tank of spray gun, adjust the air pressure, output rate,
and spray range of the spray gun, and start to spray finish paint uniformly to the sheet metal parts.
The spray process varies for different finish paints.
i. Polishing.
Polish the defective finish paint to remedy and enhance luster.
Identification of spray and repair quality for vehicle sheet metal

parts
1. Minor damages
If there are only small depressions or damaged paint surfaces due to minor scratch or impact of
vehicle, observe during checking the vehicle body for level repaired depression area, observe the
paint surfaces for cracking, shrink, poor covering, and abrasive paper grinding trace, and observe
the new paint surfaces for significant color difference against original paint surface.
2. Serious impact
Besides the above-mentioned checking items of vehicle body, check the doors, engine hood, and
luggage hatches for free opening and closing, check doors on two sides for consistent gaps, and
check the vehicle for off-tracking, steering wheel jitter, vehicle shimmy, and noise during driving.
BW
Plastic parts
Overview
To comply with the requirements of energy-conservation and emission-reduction, a number of plastic
parts is applied on the vehicle to reduce the body weight. The plastic parts on the vehicle body include
bumper, lamp cover, fender, intake grille, instrument panel, trim panel, fuel pipe, and door inner guard
panel. Many new reinforced plastic parts almost realize the strength and hardness equivalent to steel
parts and some plastic parts are more stable in dimension and are better than steel parts in corrosion
resistance.
The expansion of plastic part application scope demands new requirements on the repairs of collision
and it’s necessary to discuss new methods for repairs of plastic parts. The repair of plastic parts is more
economic and rapider than replacement and the damages, such as scratch, cracking, indentation, tear,
and puncture, can be repaired even without removing the related parts. Some deformed plastic parts can
be reshaped to their original shapes to save the waiting time for procurement of new parts and repair the
vehicle rapider so that the repair companies can realize higher working efficiency and economic benefits.
Precautions for repairs of plastic parts

1. Apply protective cream to exposed skin to guard against skin irritation.
2. Wear rubber gloves.
3. While using the compressed air or a sander, ensure to wear the protective goggles.
BW 4. Immediately remove any mixture in contact with your skin, as the mixture solidifies at a
fast speed.
5. During the grinding or sanding, wear the protective mask and protective goggles.
6. Clean your skin with cool water, in order to mitigate the minor skin irritation due to resin
dusts.
7. Guard your cloths against contamination of repair materials.
8. Use the repair materials in a well-ventilated environment, as the smoke, particles, and
contaminants generated by the repair materials are toxic.
9. After use, seal the containers of all repair materials. The repair materials are vulnerable to
the contamination by dusts or moisture to deteriorate the repair results.
Repair of plastic parts

1. Correction of thermoplastic parts (Slight elastic deformation)
a. The bumper is commonly deformed at the elastic locations, which is commonly manifested by
indentation and bending. Most deformations in the elastic locations can be repaired by heating
with a heat gun. Use a heat gun to uniformly heat the deformed area to approximately 200ºC. If
possible, heat simultaneously from both inner and outer sides.
b. In addition, assist the correction by mechanical tools such as wooden hammer and plastic wedge.
2. Welding of thermoplastic parts
Caution
The plastic welding is the most effective method for repair of thermoplastic, such as section with
sharp edge, square section, and narrow round section in reinforcement area.
a. Cut the cracking to V-shaped section to prepare the welding.
• Use a scraper to cut to V-shaped weld, with the weld opening angle at 60~70º.
• At the end of cracking, drill holes by a 3mm drill bit to prevent the expansion of cracking. In
event of rough weld edge, repair the start area of cracking by a clamp and then drill holes
at the ends of cracking before the start of welding.
b. Set up the welding temperature (200~700ºC) as per the manufacturer’s specification. The welding
temperature depends on the plastic material and welding rod thickness.
• Warm up the welding equipment for 3~4min, till the preset welding temperature is reached.
• Bevel the front end of welding rod, in order to fill gradually from the start position of the BW
weld for the cracking.
c. Weld.
• Push the welding rod with beveled front end into the warm-up chamber of heated rapid
welding nozzle, till the tip of the welding rod is protruded from the bottom. Start the welding
when the welding rod and the area to be welded are under plastic state. During the plastic
welding, maintain a stable welding speed and a steady operating pressure. Apply the
pressure only to the welding rod during welding.
• The lower end of the rapid welding nozzle must move in paralleling manner with the
repaired surface. The paralleling movement in larger length direction is realized by
appropriately tilting the welding equipment.
• During the movement of plastic welder, keep the welding rod perpendicular to the weld.
d. Check the welded joint.
• If only the small or smooth protrusions are formed along the weld edges during welding, it
indicates an ideal welding result. This is really critical for the welding of grooved welds.
Check the welds from the back for presence of following defects and when necessary
re-weld.
e. Re-machine the welds.
• After cooling, the weld protrusions can be ground by an angular grinder. Type of abrasive
paper: P80 coarse abrasive paper. Then grind the surface by a rail grinder. Type of
abrasive paper: P120~P220 fine abrasive paper.
• Clean the repaired surface by a plastic cleaning brush.
• Apply plastic primer to the repaired surface.
3. Plastic bonding
Caution
It’s applicable for thermoplastic and thermosetting plastic parts. A polyurethane-contained
adhesive must be used for all thermoplastic parts. The reinforcement bands can be used for the
welds and broken cracks to ensure the original elongation.
a. Clean the area to be repaired.

• Before the repair, clean two sides of the plastic part by high pressure water cleaner and
then dry.
• Clean the surface to be repaired by a plastic cleaner.
b. Pre-treat the scratches:
• Thoroughly grind the scratch or cracking to smoothness by a rail grinder and P80~P120
abrasive paper.
• Grind fine by a rail grinder and P120 abrasive paper.
• Thoroughly clean the repair surface by a plastic cleaner or paper towel.
• Apply plastic primer uniformly to the repair surface.
c. Pre-treat the cracking:
• Grind the front side of cracking by an angular grinder or belt grinder. The width of the
grinding surface is 40~60mm.
• Re-grind by a rail sander (Type of abrasive paper: P120).
BW • At the end of cracking, drill holes by a 3mm drill bit to prevent the expansion of cracking.
• Grind along the inner side of the cracking.
• Clean the location to be repaired by a plastic cleaner or paper towel.
• Apply plastic primer to the location to be repaired.
d. Bond the scratches:
• After the cleaning and the application of primer, fill the scratch by an adhesive.
• Spread and smoothen the adhesive by a flexible plastic feeler gauge.
• Dry by an infrared heater or dryer.
e. Bond and repair the cracking:
In event of large area cracking or breakage, reinforcing the location to be repaired can improve
the torsional strength. Therefore, the approximate reinforcement materials (Such as metal band
and reinforcement fiber) can be added on the back of the parts.
• Cover the front side of the cracking by PE sheet or tape.
• Fill the weld by a plastic adhesive from the inner side.
• Meanwhile fill a wide reinforcement fiber into the weld along with the adhesive.
• Reinforce the end of the cracking by the metal band embedded additionally on the plastic
parts.
• Trim the top surface of the reinforcement material to the same height of the entire surface
to be repaired.
• The PE sheet is used to prevent the overflow of adhesive from the front side of the
cracking.
• Take out the PE sheet after the drying of the adhesive.
• Apply adhesive to the front side of the location to be repaired.
• Cool down the adhesive to the room temperature to prevent the falloff of adhesive and
overheating of abrasive paper during grinding.

f. Grind.
• Grind away the protrusions of adhesive by a rail grinder (Type of abrasive paper:
P120~P220 coarse abrasive paper).
• Manually trim the sunk and bent areas.
• Rub the paint surface by a grinding pad.
• Thoroughly clean the plastic parts.
• Thoroughly dry and then apply plastic primer.
BW
BW-12 Vehicle Body - Windshield, window glass, rearview mirror
Windshield, window glass, rearview mirror
Glass and rearview mirror

Overview
The vehicle glass is one kind of indispensable accessories of vehicle body and mainly used for
protection. At present, the vehicle glass mainly uses the tempered laminated glass and regional
tempered laminated glass, and can bear the strong impact force. The laminated glass has a transparent
adhesive plastic film affixed between two-layer or three-layer glass; it combines the toughness of plastic
with the harness of glass, increasing the cracking resistance of glass. The tempered glass forms certain
internal stress inside the ordinary glass through quenching so as to increase the strength of glass; when
the glass is broken due to impact, the glass will be broken to the small pieces with dull edge so the
passengers are not hurt. The regional tempered glass is a new kind of tempered glass; through special
treatment, the glass cracks can keep certain definition to ensure that the driver's vision field is not
affected when the glass is broken due to impact.
Precautions
1. While disassembling a damaged glass, wear protection appliances to prevent scratches.
2. While installing glasses, take cautions to prevent falloff and keep them against mutual
collision.
BW
Vehicle Body - Windshield, window glass, rearview mirror BW-13
Preparations
Recommended tools
Glass sucker For installation of windscreen
Rubber hammer For installation of windscreen
BW
Electric lifter
Part diagram
BW
Front left door electrical window lifter

1 3 Window glass mounting clamp
assembly
Front right door electrical window lifter

2
assembly
Replacement
Caution
The replacement method is same for the left and right front door window glasses and lifters.
1. Disassemble the door inner guard panel. (Refer to Chapter BW Body - Interior and
Exterior Trim Parts - Door Inner Guard Panel, Replacement.)
2. Disassemble the window glass. (Refer to Section BW: Vehicle body - Windscreen glass,
window glass and rearview mirror- Door glass, Replacement.)
3. Disassemble the door window lifter.
a. Disassemble the fastening bolts and nuts of window
lifter, adjust the window lifter assembly to
appropriate angle, and take it out from the inside of
door frame.
Caution
• Take cautions to prevent the window lifter from
folding or crushing fingers.
• Avoid the collision of the window lifter with the
door frame as much as possible.
4. Check and repair the door window lifter.
a. Check the lifting teeth of the window lifter for presence of damage. BW
b. Before installation, apply an appropriate amount of lubricating grease uniformly to the sliding and
rotating positions of window lifter assembly.
5. Install the door glass and window lifter.
a. Install the window lifter to installation position and
install and tighten the fastening bolts and nuts.
6. Install the window glass. (Refer to Section BW: Vehicle body - Windscreen glass, window
glass and rearview mirror- Door glass, Replacement.)
7. Install the door inner guard panel (Refer to Chapter BW Body - Interior and Exterior Trim
Parts - Door Inner Guard Panel, Replacement.).
Front windscreen
Replacement
1. Disassemble the wiper arm assembly. (Refer to Chapter EL Electric Devices - Wiper and
Washer - Wiper, Replacement.)
2. Disassemble the front windscreen.
a. Tear the sealing strip of front windscreen.
Caution
Add the fit markings on the windscreen and the body.
It’s unnecessary to add the fit markings if the
windscreen is not to be reused.
b. Use a knife to cut the sealant of front windscreen for

a distance.
Caution
Cut for a distance enough to insert a steel wire. It’s
unnecessary to cut for a long distance.
BW
c. Insert a steel wire between body and front

windscreen from the inside.
Caution
Affix a wooden block or similar object to two ends of
steel wire to ease the subsequent operations.
d. Cover the defroster air vents.
Caution
If the glass fragments fall into the defroster vents, the
defroster will probably blow the glass fragments into
the passenger compartment to injure the passengers
during working. Therefore, cover the defroster vents
to prevent the ingress of glass fragments.
e. Pull the steel wire to cut the sealant of front windscreen.
Caution
• It’s difficult to complete this operation by single operator.
Complete this operation jointly with an assistant.
• Before pulling the steel wire, affix the protective
tape to the external body surfaces around the front
windscreen and at the same time place safety pad
on the dashboard to prevent scratching the
external body surfaces and dashboard.
f. Take out the front windscreen by glass suckers.

Caution
It’s difficult to complete this operation by single
operator. Complete this operation jointly with an
assistant.
3. Install the front windscreen.

a. Use a knife to remove the sealant from the contact
surface between body and front windscreen and
clean the contact surface between body and front
windscreen by a rag dipped with detergent.
b. Use the glass suckers to place the front windscreen

to installation position and ensure the smooth
contact surface around the front windscreen. BW
c. Take out the front windscreen and apply primer to

the exposed area of body and edges of front
windscreen by a brush.
Caution
If the primer is painted to other areas due to
carelessness, immediately wipe it clean, in order to
prevent the difficult cleaning of solidified paint.
d. Apply sealant to the mounting contact surface of
front windscreen.
e. Install the front windscreen to the installation
position.
Caution
Install the front windscreen to the installation position
as per the markings.
f. Lightly press along the edges of front windscreen to
ensure the intact installation of front windscreen
without gap.
4. Install the front windscreen wiper. (Refer to Chapter EL Electric System - Electric
Devices - Wiper and Washer - Wiper, Replacement.)
5. Rainfall test
a. After the installation of front windscreen, 20min rainfall test shall be conducted in the rainfall test
workshop to check the windscreen for presence of water leakage. In event of water leakage, find
out and solve the cause. When necessary, reinstall the front windscreen.
b. If no rainfall test workshop is available, park the vehicle on a level ground and use a rubber hose
to simulate the rainfall, with the water pressure no more than 155kPa. Check the windscreen for
presence of water leakage. In event of water leakage, find out and solve the cause. When
necessary, reinstall the front windscreen.
BW
Rear windscreen
Replacement
1. Disassemble the rear windscreen
a. Place two glass suckers onto the rear windscreen
and pull down the sucker switches to securely fix
the windscreen by suckers.
Caution
While disassembling a damaged windscreen, wear the
protection appliances and notice the safety.
b. As shown in the figure, squeeze outward the

sealing strip from the inside of cab, pry out the
Body
entire sealing strip slowly along the circumference,
Sealing and push out the windscreen assembly with sealing
strip
strip.
Caution
Glass Ensure to hold the glass suckers securely by one or
operators outside of the cab to prevent the falloff of BW
windscreen.
c. Check the windscreen sealing strip for aging and

damage and replace damaged windscreen sealing
strip.
2. Install the rear windscreen

a. Install the rear windscreen sealing strip to the rear
windscreen.
b. Wind a rope in diameter of 5~6mm into the

mounting groove of the windscreen sealing strip for
the whole circumference and coincide two ends at
the lower center of windscreen for a distance.
c. As shown in the figure, wind the rope into the

mounting groove of windscreen sealing strip.
Seal strip
Rope
Glass
d. Place two glass suckers onto the rear windscreen

and pull down the sucker switches to securely fix
BW the windscreen by suckers.
e. Install the rear windscreen to the body windscreen

frame and adjust it to the center of the windscreen
frame.
Caution
Place the ends of rope for installation of windscreen
sealing strip in the cab.
f. Compress the windscreen from outside of cab and

then pull the rope slowly along the edge of
Body
windscreen in the cab to install the rear windscreen
sealing strip to the body flange.
Rope
Seal strip Caution
After installation, check the windscreen sealing strip
Glass and ensure there is no squeezed edge or distorted
sealing strip. Otherwise the manual repair is required.
g. Lightly hammer the edges of windscreen by a rubber hammer to ensure the sufficient contact
between body flange and sealing strip.
3. Rainfall test
a. After the installation of rear windscreen, 20min rainfall test shall be conducted in the rainfall test
workshop to check the windscreen for presence of water leakage. In event of water leakage, find
out and solve the cause. When necessary, reinstall the rear windscreen.
b. If no rainfall test workshop is available, park the vehicle on a level ground and use a rubber hose
to simulate the rainfall, with the water pressure no more than 155kPa. Check the windscreen for
presence of water leakage. In event of water leakage, find out and solve the cause. When
necessary, reinstall the front windscreen.
BW
Exterior rearview mirror

Adjustment
1. Adjust the observation angle of the exterior
rearview mirror.
a. Adjust the observation angle of exterior rearview
mirror by adjusting the position of mirror body of the
exterior rearview mirror.
BW
Replacement
1. Disassemble the exterior rearview mirror.
a. Lightly pry open the trim caps for fastening bolts of
exterior rearview mirror by an interior trim crow
plate.
b. Disassemble the fastening bolts of exterior rearview

mirror assembly and take out the exterior rearview
mirror and mounting gasket.
2. Install the exterior rearview mirror. BW

a. Install the exterior rearview mirror and mounting
gasket and install and tighten the fastening bolts.
b. Install trim caps for the fastening bolts of exterior

rearview mirror and push down by hand to ensure
the proper installation.
Interior rearview mirror

Adjustment
1. Adjust the observation angle of the interior
rearview mirror assembly.
a. Adjust the observation angle of interior rearview
mirror by adjusting the position of mirror body of the
interior rearview mirror.
BW
Replacement
1. Disassemble the interior rearview mirror.
a. Disassemble the fixing screws of interior rearview
mirror and take out the interior rearview mirror.
2. Install the interior rearview mirror.

a. Place the interior rearview mirror to the installation
position and install and tighten the fixing screws.
BW
Door windows
Replacement
Caution
The replacement method is same for the left and right front door window glasses and lifters.
2. Disassemble the left front door window lifter.
a. Disassemble the fastening screws of door
loudspeaker.
b. Disconnect the door loudspeaker connector and

take out the door loudspeaker.
BW
c. Uncover the door rainproof membrane.

Caution
Avoid damaging the door waterproof membrane
whenever possible, in order to help the reuse.
d. Install the door window lifter switch to the harness

and lift the window glass to the highest position.
e. Disassemble the fixing screws of window glass
guiderail.
f. Take out the glass guiderail.
g. Lower the window glass to an appropriate position

and disassemble the front fastening nuts of window
glass.
h. Lower the window glass to an appropriate position

and disassemble the rear fastening nuts of window
glass. BW
Caution
Notice to prevent the falloff of glass after the fastening
nuts of window glass are disassembled.
i. Rotate the door window glass for 90º and take out
the window glass in upward direction.
Caution
Pay attention to prevent colliding the window glass
with door frame and prevent the edge of door frame
from cutting your arm during this operation. Handle
the glass with care to prevent damage.
3. Install the door glass.

a. Vertically install the door window glass and align the
door window glass with the mounting holes on the
window lifter.
Caution
Ensure to install the glass into the glass runners,
otherwise the glass will probably be damaged during
the lifting.
b. Install the rear fastening nuts of window glass.

Caution
Take cautions to prevent the falloff of glass.
c. Install the front fastening nuts of window glass.
d. Install the door window lifter switch to the harness

and lift the window glass to the highest position.
BW e. Install the glass guiderails.
f. Install and tighten the fastening bolts of glass

guiderails.
g. Install door waterproof membrane

h. Connect the door loudspeaker connector.
i. Install and tighten the fastening screws of door

loudspeaker.
4. Install the door inner guard panel (Refer to Chapter BW Body - Interior and Exterior Trim
Parts - Door Inner Guard Panel, Replacement.).
BW
BW-30 Vehicle Body - Interior/exterior trims
Interior/exterior trims
Interior/exterior trims
Overview
1. Interior trims
The interior trims refer to the parts functioned to protect the human bodies or play the decoration
role and the vehicle body accessories of independent functions within the vehicle body.
2. Exterior trims
The exterior trims refer to the parts functioned to play the protection or decoration role for the
vehicle body and the vehicle body accessories of independent functions outside of the vehicle.
Precautions
1. To work inside the vehicle, the seat, steering wheel and other components shall be
covered and protected from oil stain.
2. There are special dismantling tools for inner trims; if there is no special dismantling tool,
the screwdriver or equivalent tool can be used instead, but the tool shall be wrapped.
3. When sharp tool is used to disassemble parts, adhesive tape shall be used to wrap the tool,
or it may scratch the parts.
4. In case the parts can’t be disassembled, don’t force to take down, check if there is
forgotten fixed screw.
BW 5. The buckle is a wearing part. Check if the disassembled buckle is damaged; if yes, renew
the buckle.
6. To install the parts, check if the buckles of parts are missing.
Preparations
Recommended tools
For disassembling and installation of

Screwdriver
screws
For disassembling and installation of

Interior trim crow plate
interior trim panels
Speed wrench Disassemble and install bolt

Vehicle Body - Interior/exterior trims BW-31
Inner guard panel of door

Replacement
1. Disassemble the door inner guard panel.
a. Lightly pry open the trim caps for fastening bolts of
exterior rearview mirror by an interior trim crow
plate.
b. Disassemble the fastening screws of door handle

trim part and take out the door handle trim part.
BW
c. Disassemble the fastening screws of window lifter

switch.
d. Pry out the window lifter switch by an interior trim

crow plate, disconnect the window lifter switch
harness connector, and take out the window lifter
switch.
e. Insert the interior trim crow plate between the door

and the door inner guard panel assembly, pry open
the inner guard panel assembly, observe the
distribution of door guard panel snap joints, try best
to insert the interior trim crow plate to position of
every snap joint, and pry out the snap joints one by
one.
f. The distribution of door inner guard panel snap

joints is shown in the figure.
g. Take out the door inner guard panel and observe the snap joints for damage. Replace any
damaged snap joint.
BW • While replacing a damaged snap joint, push the damaged snap joint along the horizontal
direction of inner guard panel to the large bore and take it out.
• Push new or intact snap joints into the snap joint mounting holes of inner guard panel and
push them into the fastening holes of snap joints in reverse direction of disassembling
procedure.
2. Install the door inner guard panel
a. Lift up the door inner guard panel, pull up the door
lock inner handle, and insert it into the inner guard
panel hole.
b. Align every snap joint with door mounting hole and
flap the snap joint position lightly by your palm. After
the installation, the inner guard panel shall fit
closely with the door.
c. Install the door handle trim part and fix it by screws.

d. Connect the harness connector of window lifter

switch and place the window lifter switch to
e. Install the fastening screw of window lifter switch.
f. Install trim caps for the fastening bolts of exterior

rearview mirror and push down by hand to ensure
the proper installation. BW
Sun visor
Replacement
1. Disassemble the sun visor.
a. Disassemble the fastening screws of sun visor.
b. Take out the sun visor from the sun visor holder.
c. Disassemble the fastening screws of sun visor
holder and take out the sun visor holder.
BW
2. Install the sun visor

a. Install the sun visor holder to the installation
position and install and tighten the fastening
screws.
b. Install the sun visor to the holder and install and

tighten the fastening screws of sun visor.
Floor trim
Part diagram
BW
1 Front carpet assembly 6 Carpet clamp
2 Left footplate 7 Plastic nut seat
3 Right footplate 8 Insulation pad clamp
Engine compartment front insulation

4 9 Foot footplate
pad
Intermediate connection plate

5
insulation pad
Replacement
1. Disassemble the footboard.
a. Disassemble the fastening screws of left and right
footplates and take out the left and right footplates.
2. Disassemble the carpet.

a. Disassemble the driver seat. (Refer to Section BW: Vehicle body- Seat - Driver seat,
Replacement.)
b. Disassemble the front passenger seat. (Refer to Section BW: Vehicle body- Seat - Front
Passenger Seat, Replacement.)
c. Disassemble the dashboard. (Refer to Section BW: Vehicle body- Dashboard/ Combination
instrument/Ash tray - Dashboard, Replacement.)
d. Disassemble the fastening bolts on the lower end of
steering drive shaft to disconnect the steering drive
BW shaft from steering gear.
e. Disassemble the fastening bolts on the rear end of

intermediate connecting plate.
f. Disassemble the fastening bolts on the front end of

intermediate connecting plate.
g. Disassemble the insulation pad snap joints and take

out the insulation pad.
h. Disassemble the lower fastening bolts of seat belt.
i. Disassemble the middle carpet.
BW
j. Disassemble the seat lock catches and take out the front carpet assembly.
3. Install the carpet in reverse sequence of the disassembling procedure.
Front bumper
Replacement
1. Disassemble the front dumper
a. Disassemble the lower fastening screws on two
sides of front bumper.
b. Open doors and disassemble the fastening screws

on two sides of the front bumper.
BW
c. Disassemble the middle fastening bolts of the front

bumper.
Caution
The middle fastening bolts of the front bumper are
located behind the front license plate. Before
disassembling these bolts, disassemble the front
license plate.
d. Slowly move away the front bumper for a little and

disconnect the connectors of front fog lamps on two
sides.
e. Take out the front bumper assembly.
f. If necessary, disassemble the front fog lamp assembly. (Refer to Chapter EL Electric System -
Electric Devices - Lighting System - Front Fog Lamp, Replacement.)
2. Install front bumper

a. Connect the front fog lamp connector and install the
front bumper.
b. Install the front bumper to installation position and

install and tighten the intermediate fastening bolts.
c. Install and tighten the fastening screws on two sides

of front bumper.
BW
d. Install and tighten the lower fastening screws on

two sides of front bumper.
Vehicle trim parts

Replacement
1. Dismantle the front wheel mudguard sheet.
a. Disassemble the fastening bolts of front wheel
mudguard sheet and take out the front wheel
mudguard sheet.
2. Install the front wheel mudguard sheet.

a. Install the front wheel mudguard sheet and install
and tighten the fastening bolts.
BW
3. Dismantle the rear wheel mudguard sheet.

a. Disassemble the fastening bolts of rear wheel
mudguard sheet and take out the rear wheel
mudguard sheet.
4. Install the rear wheel mudguard sheet.

a. Install the rear wheel mudguard sheet and install
5. Disassemble the front mudguard of rear wheel.

a. Disassemble the fastening bolts of front mudguard
of rear wheel and take out the front mudguard of
rear wheel.
6. Install the front mudguard of rear wheel.

a. Install the front mudguard of rear wheel and install
7. Disassemble the rear mudguard of rear wheel.

a. Disassemble the fastening nuts of rear mudguard of
rear wheel and take out the rear mudguard of rear BW
wheel.
8. Install the rear mudguard of rear wheel.

a. Install the rear mudguard of rear wheel and install
and tighten the fastening nuts.
Roof panel
Replacement
1. Disassemble the roof panel.
a. Disassemble the sun visors on two sides. (Refer to Section BW: Vehicle body- Inner and outer
trims- Sun visor, Replacement.)
b. Disassemble the interior rearview mirror. (Refer to Section BW: Vehicle body - Windscreen glass,
window glass and rearview mirror- Interior rearview mirror, Replacement.)
c. Disassemble the interior lamp. (Refer to Section EL: Electrical system- Electrical elements-
Lighting system- Interior lamp, Replacement.)
d. Disassemble the safety handrail. (Refer to Chapter BW Body - Interior and Exterior Trim Parts -
Safety Handrail, Replacement.)
e. Disassemble the fastening snap joints of roof panel
and take out the roof panel.
BW
2. Install the roof panel.

a. Install the roof panel to the installation position and
install the roof panel fastening snap joints.
b. Install the safety handrail. (Refer to Chapter BW Body - Interior and Exterior Trim Parts - Safety
Handrail, Replacement.)
c. Install the interior lamp. (Refer to Section EL: Electrical system- Electrical elements- Lighting
system- Interior lamp, Replacement.)
d. Install the interior rearview mirror. (Refer to Section BW: Vehicle body - Windscreen glass,
window glass and rearview mirror- Interior rearview mirror, Replacement.)
e. Install the sun visors on two sides. (Refer to Section BW: Vehicle body- Inner and outer trims-
Sun visor, Replacement.)
Footplates
Replacement
1. Disassemble the footplates.
a. Disassemble the fastening screws of left and right
footplates and take out the left and right footplates.
2. Install the footplates.

a. Place the left and right footplates to installation
position and install and tighten the fastening
screws.
BW
Body logo
Replacement
1. Disassemble the front bumper. (Refer to Chapter BW Body - Interior and Exterior Trim
Parts - Front Bumper, Replacement.)
2. Disassemble the front logo.
a. Push the clamping bolt outward from the inside of
front bumper and disassemble the front log.
3. Install the front logo.

a. Place the front logo to the installation position, align
with the clamping bolt, and push down to ensure
proper installation.
BW
Safety handrail
Replacement
1. Disassemble the side safety handrail.
a. Disassemble the fastening screws of side safety
handrail and take out the side safety handrail.
2. Install the side safety handrail.

a. Install the side safety handrail and install and
BW
Gearshift lever shield

Replacement
1. Disassemble the gearshift lever shield.
a. Pry out the lower end of gearshift lever shield from
the auxiliary dashboard.
b. Rotate the gearshift lever and take out the gearshift

lever shield.
BW
2. Install the gearshift lever shield.

a. Place the gearshift lever shield to installation
position and rotate it to tighten.
b. Push down the gearshift lever shield to ensure

proper installation.
Boarding handrail
Replacement
1. Disassemble the boarding handrail.
a. Pry out the trim caps for fastening screws of
boarding handrail.
b. Disassemble the fixing screws of boarding handrail

and take out the boarding handrail.
BW
2. Install the boarding handrail.

a. Install the boarding handrail and install and tighten
the fastening screws of boarding handrail.
b. Install the trim caps for fastening screws of boarding

handrail.
BW-48 Vehicle Body - Dashboard / combination instrument /ashtray
Dashboard / combination instrument /ashtray

Overview
The vehicle dashboard mainly includes the instrument panel and central console composed of many
parts and is mainly functioned to adjust the interior space and provide driver with convenient operations.
The diversified types of indicator lamps and warning lamps are provided on the instrument panel of
modern vehicles, including high/low beam indicator lamp, engine malfunction indicator lamp, and turn
signal indicator lamp.
Precautions
5. The buckle is a wearing part. Check if the disassembled buckle is damaged; if yes, renew
BW the buckle.
7. In the course of dismantling the instrument panel, the saved setting of audio system may
be lost if the electric connector of audio system is unplugged. After the instrument panel is
installed, the audio system shall be reset.
8. Before any electrical device is disassembled or installed, and when the tool or equipment
contacts the naked electrical terminal, the battery negative cable shall be disconnected in
order to protect the repair personnel or vehicle.
Preparations
Recommended tools
Screwdriver For disassembling and installation of screws

Vehicle Body - Dashboard / combination instrument /ashtray BW-49
Dashboard
Part diagram
BW
1 Instrument panel body assembly 8 Instrument panel right blank cover
Instrument panel middle left blank

2 Instrument cover assembly 9
cover
Instrument panel middle right blank

3 Heater controller panel assembly 10
cover
Side washing fluid reservoir cover

4 Glovebox assembly 11
plate
5 Central control panel assembly 12 Philips large cup head screw
6 Ashtray assembly 13 Clamp for instrument panel
Instrument panel left blank cover

7
assembly
Replacement
1. Disassemble the dashboard.
a. Disassemble the steering wheel. (Refer to Chapter ST Steering System - Steering Mechanism -
Steering Wheel, Replacement.)
b. Disassemble the combination switch. (Refer to Section ST: Steering system - Steering
mechanism - Combination switch, Replacement.)
c. Disassemble the combination instrument. (Refer to Section BW: Vehicle body- Dashboard/
Combination instrument/ Ash tray- Combination instrument, Replacement.)
d. Disassemble the brake fluid reservoir cover plate.
e. Disassemble the fastening screws of brake fluid

reservoir.
BW Caution
• Before disassembling, drain the brake fluid from
the brake fluid reservoir.
• If the brake fluid is not drained, ensure not to tilt
the brake fluid reservoir after disassembling,
otherwise the brake fluid will flow out.
f. Pry out the middle air vents of A/C, disconnect the

connector of hazard warning lamp switch, and take
out the middle air vents of A/C.
g. Pry out the fog lamp and headlamp adjustment

switch, disconnect the connector, and take out the
fog lamp and headlamp adjustment switch.
h. Take out the glovebox in tilted direction.
i. Disassemble the radio/audio player. (Refer to Chapter EL Electric System - Electric Devices -
Audio System - Radio/Audio Player, Replacement.)
j. Pry out the trim panel of heater controller.
k. Disassemble the fastening screws of heater

controller.
BW
l. Disconnect the heater controller control cable from

the HVAC assembly.
m. Disconnect the cigarette lighter and 12V power

harness connector from the inside of instrument
panel.
n. Disassemble the lower fastening screws of

dashboard.
o. Pry out the trim caps for upper fastening screws of

dashboard and disassemble the upper fastening
screws of dashboard.
p. Disassemble the fastening screws on two sides of

dashboard and take out the dashboard assembly.
BW
2. Install the dashboard.

a. Install the dashboard to installation position and
install the fastening screws on two sides of
dashboard.
Caution
• While installing the screws, do not tighten the
screws immediately, in order to ease the
installation of other fastening screws. Tighten
only after all bolts of the dashboard are
installed.
• While installing the dashboard, install the A/C
control panel in place.
• Notice the positions of various harness
connectors to prevent squeezing and twining.
b. Install the upper fastening screws of dashboard and

install the trim caps for the screws.
Caution
While installing the screws, do not tighten the screws
immediately, in order to ease the installation of other
fastening screws. Tighten only after all bolts of the
dashboard are installed.
c. Install the lower fixing screws of dashboard.
d. Install the fastening screws of heater controller.
BW
e. Connect the control cable of heater controller.
f. Install the trim panel of heater controller.

g. Install the radio/audio player. (Refer to Chapter EL Electric System - Electric Devices - Audio
System - Radio/Audio Player, Replacement.)
h. Install the glovebox in tilted direction.
i. Connect the fog lamp and headlamp adjustment

switch connector and install the fog lamp and
headlamp adjustment switch.
j. Connect the warning lamp switch connector and

BW install the middle air vents.
k. Install the fastening screws of brake fluid reservoir.

l. Install the brake fluid reservoir cover plate and

m. Install the combination instrument. (Refer to Section BW: Vehicle body- Dashboard/ Combination
instrument/ Ash tray- Combination instrument, Replacement.)
n. Install the combination switch. (Refer to Section ST: Steering system - Steering mechanism -
Combination switch, Replacement.)
o. Install the steering wheel. (Refer to Chapter ST Steering System - Steering Mechanism -
Steering Wheel, Replacement.)
BW
Auxiliary dashboard
Replacement
1. Disassemble auxiliary dashboard
a. Pry out the lower end of gearshift lever shield from
the auxiliary dashboard.
b. Rotate the gearshift lever and take out the gearshift

lever shield.
BW
c. Pry out the trim caps for rear fastening screws of

auxiliary dashboard and disassemble the fastening
screws.
d. Pry out the trim caps for front fastening screws of

auxiliary dashboard and disassemble the fastening
screws.
e. Disassemble the fastening screws on two sides of

dashboard and take out the auxiliary dashboard.
2. Install the auxiliary dashboard.

a. Adjust the position of parking brake handle and
install the auxiliary dashboard.
b. Install the fastening screws on two sides of
dashboard.
c. Install the trim caps for rear fastening screws of

auxiliary dashboard.
BW
d. Install the front fastening screws of auxiliary

dashboard.
e. Rotate to install the gearshift lever shield.

Combination instrument
Replacement
1. Disassemble the combination instrument.
a. Disassemble the fastening screws of steering
column shields and take out the steering column
shields.
b. Disassemble two fastening screws of combination

instrument shield and pry out the combination
instrument shield by an interior trim crow plate.
BW
c. Disassemble the fixing screws of combination

instrument.
d. Overturn the combination instrument, disconnect

the combination instrument connector.
e. Take out the combination instrument.
2. Install the combination instrument.

a. Install the combination instrument connector.
b. Install the fixing screws of combination instrument.
c. Install two fastening screws of combination

instrument shield.
BW
d. Install the upper and lower shields of steering

column, completely align their side gaps, and install
and tighten the fastening screws.
Dashboard framework
Replacement
1. Disassemble the steering column. (Refer to Chapter ST Steering system - Steering
mechanism - Steering Wheel, Inspection and Repair.)
2. Disassemble the wiper motor assembly. (Refer to Chapter EL Electric System - Wiper
and Washer - Wiper Motor, Replacement.)
3. Dashboard framework
a. Disconnect the wiper intermittent relay connector.
b. Disassemble 2 fastening bolts on the front side of

framework.
BW
c. Disassemble the fastening bolts between

framework and HVAC.
d. Disassemble the fastening bolts on two sides.

e. Take out the harness from the framework and then
take out the dashboard framework.
4. Install the dashboard framework.

a. Place the dashboard framework to the installation
position, properly arrange the harnesses, and install
and tighten fastening bolts on two sides.
b. Install the fastening bolts between framework and

HVAC.
c. Install 2 fastening bolts on the front side of

framework.
BW
d. Connect the wiper intermittent relay connector.
5. Install the wiper motor assembly. (Refer to Chapter EL Electric System - Wiper and
Washer - Wiper motor, Replacement.)
6. Install the steering column. (Refer to Chapter ST Steering system - Steering mechanism -
Steering wheel, Inspection and repair.)
BW-62 Vehicle Body - Vehicle door and engine hood
Vehicle door and engine hood
Vehicle door and engine hood

Overview
The vehicle body is installed on the vehicle body housing through hinge, and has the complex structure;
it is an important component ensuring the use performance of vehicle. The vehicle door is the passage
for driver and passengers to get on or off the vehicle, and can separates the driver and passengers from
exterior interference, reduce the lateral impact to some extend and protect the passengers. The beauty
of vehicle is also related with the shape of vehicle door. The quality of vehicle door is mainly represented
by its anti-collision performance, tightness, opening and closing convenience as well as indicators of
other use functions. The anti-collision performance is most important because the buffer distance is
short and it is easy to hurt people inside the vehicle in case of lateral collision.
Precautions
BW 4. In case the parts can’t be disassembled, don’t force to take down, check if there is
the buckle.
Preparations
Recommended tools

Vehicle Body - Vehicle door and engine hood BW-63
Front door
Replacement
1. Disassemble the door loudspeaker. (Refer to Chapter EL Electric System - Electric
Devices - Audio System - Loudspeaker, Replacement.)
2. Disassemble the front door.
a. Disassemble the split pin of door limiter and unplug
the pin.
b. Disassemble the fastening bolts of door lower

hinge.
Caution
The door assembly is heavy. Assist by an assistant
while disassembling the fastening bolts of hinge.
BW
c. Unplug the door harness.

d. Disassemble the fastening bolts of door upper hinge
and take out the door.
3. Install the front door.

a. Align the door mounting holes with door hinges and
install and pre-tighten the fastening bolts of door
upper hinge.
b. Install the door harness into the door.
Caution
The door assembly is heavy. Assist by an assistant
while installing the fastening bolts of hinge.
c. Install the fastening bolts of door lower hinge.

d. Adjust the door position to ensure uniform
circumferential gap and then tighten the fastening
bolts of door upper and lower hinges.
e. Install the door limiter pin and install the split pin.
4. Install the door loudspeaker. (Refer to Section EL: Electrical System- Electrical Devices -
Audio System- Loudspeaker, Replacement.)
BW
Door outer handle

Replacement
2. Disassemble the rainproof membrane.
a. Disassemble the fastening screws of door
loudspeaker.

BW
c. Uncover the door rainproof membrane.

Caution
3. Disassemble the door outer handle.

a. Disconnect the push rod connection of door outer
handle.
b. Disassemble the fastening screws of the door outer

handle.
c. Take out the door outer handle from the outer side.
4. Install the door outer handle.

a. Install the door outer handle to the installation
BW position.
b. Install and tighten the fixing screws of door outer

handle.
c. Connect the push rod of door outer handle.

d. Affix the door rainproof membrane to the original

position.
e. Install the door loudspeaker and connect the door

loudspeaker connector.
f. Install and tighten the fastening screws of door

loudspeaker.
g. Install the door inner guard panel (Refer to Chapter BW
BW Body - Interior and Exterior Trim Parts - Door
Inner Guard Panel, Replacement.).
BW-68 Vehicle Body - Door lock
Door lock
Door lock
Overview
In the car parts system, the vehicle door lock system is a special component integrating process,
decoration and safety. The trend of modern car lock market requires the lock with higher safety and
reliability and more functions and beautifully coordinated with the whole shape of vehicle. The door lock
is the important safety element. The door lock is composed of two parts: one fastened on the door and
the other fastened on the vehicle body; the buckle can prevent the door from opening outward through
the latch and disengage its two components through the simple lever motion or the button. The door lock
must operate reliably and not be opened under the certain impact force.
Precautions
BW forgotten fixed screw.
the buckle.
Vehicle Body - Door lock BW-69
Preparations
Recommended tools
Rubber hammer For adjustment of door lock catch.
BW
Front door lock

Replacement
1. Disassemble the front door lock.
a. Disassemble the door inner guard panel. (Refer to
Chapter BW Body - Interior and Exterior Trim
Parts - Door Inner Guard Panel, Replacement.)
b. Disassemble the fastening screws of door
loudspeaker.
c. Disconnect the door loudspeaker connector and

BW
d. Uncover the door rainproof membrane.

Caution
e. Disassemble the fixing screws of window glass

guiderail.
f. Take out the glass guiderail.
g. Disconnect the front door lock harness connector.
h. Disconnect the connection between door outer

handle push rod and outer handle.
BW
i. Disconnect the connection between lock cylinder

assembly and inner lock pull rod.
j. Disassemble 3 fastening bolts of lock body.

k. Take out the lock body assembly.
2. Install the front door lock.

a. Install the front door lock body and install and
tighten 3 fastening bolts.
Caution
Before installation, notice to properly arrange various
pull rods to ease the installation.
b. Connect the lock cylinder assembly with inner lock

pull rod.
c. Connect door outer handle push rod with outer

handle.
BW
d. Install the glass guiderails.
e. Install and tighten the fastening bolts of glass

guiderails.
f. Install door waterproof membrane
g. Install the door loudspeaker and connect the

loudspeaker connector.
h. Install and tighten the fastening screws of door

loudspeaker.
l. Install the door inner guard panel (Refer to Chapter
BW Body - Interior and Exterior Trim Parts - Door BW
Inner Guard Panel, Replacement.).
3. Disassemble the front door lock cylinder.

a. Uncover the door rainproof membrane.
b. Disconnect the connection between lock cylinder
assembly and inner lock pull rod.
c. Pull out the fixing clamp of lock cylinder assembly

by long nose pliers.
d. Push out the lock cylinder towards the outer side of

door.
4. Install the front door lock cylinder.

a. Install the front door lock cylinder from the outer
side of door.
b. Install the fixing clamp of lock cylinder.
BW
c. Connect the lock cylinder assembly with inner lock

pull rod.
d. Install door waterproof membrane
5. Disassemble the door latch

a. Disassemble the fastening bolts of door lock catch.
b. Take out the door lock catch and adjustment shim.
6. Install the door latch

a. Select appropriate door lock catch adjustment shim
and install the door lock catch.
Caution
The adjustment of door lock is mainly the selection
process of lock catch adjustment shim. Select the
shim of appropriate thickness.
b. Install and tighten the fastening bolts of door lock

catch.
BW
BW-76 Vehicle Body - Seat
Seat
Seat assembly
Overview
The modern vehicle seat must meet two requirements: convenient adjusting and comfort. Namely the
driver can adjust the seat to the optimal position in order to ensure the best visual field and the
convenient operation of steering wheel, pedal and shift lever, and achieve the most comfortable and
accustoming seat angle.
Precautions
1. Never adjust the seat when the vehicle is running.
2. After the back-forth position of seat is adjusted, loosen the regulator lever, slide the seat
back and forth, and make sure that the seat is locked completely.
3. After the backrest angle of seat is adjusted, the operator shall tilt backward to make his
body lean against the seat backrest, and make sure that the backrest is locked completely.
BW Preparations
Recommended tools

Vehicle Body - Seat BW-77
Part diagram
BW
1 Single-row driver seat assembly 2 Seat buckle

Driver seat
Replacement
1. Disassemble the driver seat.
a. Pull up the driver seat buckle.
b. Fold the driver seat and disassemble the fastening

bolts of driver seat.
BW
c. Disconnect the seat belt buckle connector.

d. Take out the driver seat.
Caution
While taking out the seat, notice not to collide with
vehicle body or door, in order to prevent damaging the
vehicle body or interior trims.
2. Install the driver seat

a. Install the driver seat in place and install and tighten
the fastening bolts.
Caution
While installing the seat, notice not to collide with
vehicle body or door, in order to prevent damaging the
vehicle body or interior trims.
Vehicle Body - Seat BW-79
b. Connect the seat belt buckle connector.
c. Lock the driver seat buckle.
BW
Front passenger seat

Replacement
Caution
The disassembling method for front passenger seat is same with that for driver seat. (Refer to
Section BW: Vehicle body- Seat- Driver seat, Replacement.)
BW
Vehicle Body - Seat belt BW-81
Seat belt
Seat belt
Overview
The seat belt is the most important safety protector of driver and passenger, and can minimize the
impact onto the passengers in the passenger compartment in case of front collision, rear collision, side
collision and turnover. The seat belt has the self locking function which can be activated when the belt is
pulled out from the retractor and prevent the belt from exceeding the stipulated limit position.
Precautions
1. Do replace all the defective parts of seat belt system (including the fabric, retractor, buckle,
tongue, bolt and nut)
2. The seat belt shall be checked carefully even if the belt is not used when the collision
occurs. The belt that is broken, damaged or operates abnormally must be renewed.
Preparations
Recommended tools BW

BW-82 Vehicle Body - Seat belt
Part diagram
BW
Front row seat belt assembly (With

1 3 Plastic nut seat
alarm)
2 Front row seat belt assembly

Driver/front passenger seat belt

Inspection
1. Checking of seat belts
a. When being pulled out at uniform speed by a
constant force, the seat belt shall be pulled out
easily.
b. When being pulled rapidly, the seat belt shall be
locked immediately.
• Replace the seat belt if the above-mentioned
requirements can’t be met.
2. Checking of belt buckle

a. Insert the seat belt into the buckle.
• If the seat belt can’t be easily inserted into
the buckle, replace the buckle and re-check.
BW
b. When being pulled by a force, the seat belt shall be

kept locked.
• If the seat belt detaches from the buckle, the
seat belt buckle must be replaced.
c. When the buckle button is pressed, the seat belt

shall be easily released.
• If the seat belt buckle can’t be easily
released, the immediate replacement is
recommended, in order to eliminate the
potential danger.
Replacement
1. Disassemble the seat belt.
a. Uncover the dust cover for upper fastening bolts of
seat belt.
b. Disassemble the upper fastening bolts of seat belt.
BW c. Fold the seat and disassemble the outer dust shield

of seat belt retractor.
d. Disassemble the upper fastening screws of seat

belt retractor assembly.
e. Disassemble the lower fastening bolts of seat belt
retractor assembly.
f. Disassemble the lower fastening bolts of seat belt.

g. Take out the seat belt assembly.
2. Install the safety belt

a. Install the lower fastening bolts of seat belt.
b. Install the lower fastening bolts of seat belt retractor

assembly.
c. Install the upper fastening screws of seat belt BW
retractor assembly.
d. Install the outer dust shield of seat belt retractor and

e. Install the upper fastening bolts of seat belt.

f. Close the dust cover for upper fastening bolts of

seat belt.
3. Disassemble the seat belt buckle.

a. Disassemble the fastening bolts of seat belt buckle
and take out the seat belt buckle.
4. Install the seat belt buckle

a. Install the seat belt buckle and install and tighten
BW the fastening bolts.
Vehicle Body - Cargo body BW-87
Cargo body
Cargo body assembly

Overview
The cargo body is the compartment for loading of cargos on a truck. All parts of cargo body shall be
correctly assembled and properly adjusted. The railings shall be opened and closed and effectively
locked easily without using any tool. The railings of the openable cargo body shall be free noise and
stagnation during opening and closing.
Precautions
1. Take cautions not to damage the paint of vehicle body during the removal and assembling
of cargo body.
2. The cargo body assembly is really heavy. Ensure to notice the personal safety during the
hoisting.
3. Before hoisting, check the areas around the cargo body to ensure that all harnesses are
disconnected and there is no interference part.
4. The cargo body shall be fixed securely and kept balanced during hoisting.
Preparations
Recommended tools
BW

BW-88 Vehicle Body - Cargo body
Part diagram
BW
1 Single row cargo body assembly 4 Buffer block
2 Cargo body rubber pad 5 License fixing board
3 Buffer cushion for packing case

Cargo body
Replacement
1. Disassemble the cargo body.
a. Disconnect the reversing sensor harness
connector.
b. Disconnect the rear combination lamp wiring

harness connector.
BW
c. Disconnect the license plate lamp harness

connector and disassemble the harness from the
cargo body.
d. Fix the cargo body by a hoist.

BW-90 Vehicle Body - Cargo body
e. Disassemble 8 fastening nuts on two sides of cargo

body and disassemble the cargo body by a hoist.
2. Install the cargo body

a. Place the cargo body onto the frame by a hoist and
align with the installation positions of studs.
b. Install and tighten 8 fastening nuts on two sides of

cargo body.
BW
c. Connect the license plate lamp harness connector.
d. Reconnect the rear combination lamp wiring

harness connector.
e. Connect the license plate lamp harness connector.
BW
EL Electric system
Electrical elements .............................................................. 1
Battery ............................................................................ 1
Lighting system .............................................................. 9
Wiper and Washer ....................................................... 39
Audio System ............................................................... 57
Information System ...................................................... 68
Heating and Air Conditioning System .......................... 77
Vehicle Control System .............................................. 103
Electric circuit ................................................................... 110
Circuit guide ................................................................ 110
System circuit diagram............................................... 134
Harness connector information .................................. 216

EL
Location diagram of harness and electronic unit
connectors.................................................................. 265
Electric system - Electrical elements EL-1
Electrical elements
Battery
Battery assembly
General
Battery is indispensable part of automobile that transfers chemical energy into electric energy to power
on the engine. There are common lead-acid battery and maintenance-free battery. When it is ready to
start the vehicle, the battery powers on the starter to drive the flywheel and crankshaft to start the engine.
The battery supplies power to audio system and lighting system when the engine is powerless or is not
working. When the engine starts to supply power to the systems, the battery collects and stores electric
energy for future use.
Preparations
Recommended tools
Speed wrench
bolts and nuts
High rate discharge gauge Check battery.
EL
EL-2 Electric system- Electrical elements
Part diagram
EL
1 Battery pressure plate 3 Battery stand

2 Battery
Use and maintenance

1. Charging equipment:
Caution
Charge battery with DC power supply; however, the power station supplies AC power supply,
which shall be converted to DC before charging the battery.
a. Rectifier.
b. SCR voltage-regulated charger.
2. Charging notes:
a. Charging shall be carried out in a dry room with good ventilation and the indoor temperature shall
be 5-40℃ .
b. Batteries shall not be overlapped or directly put on the ground, but placed on a wooden support,
and cannot be placed together with alkaline batteries or other chemicals.
c. The charging location shall be prohibited from fire sources and kept away from heat sources.
d. The temperature of electrolyte shall not exceed 45℃, or else cooling measures (reduce the
charging current or stop charging or cool it in a water tank) shall be taken.
3. Charging connection:
a. The positive pole of the charger is connected with the positive pole of the battery, and the
negative pole is connected with the negative pole of the battery. Do not make reverse polarity
connection.
b. The charging of most batteries can be determined by charger power size, and charger connection
must be firm. EL
4. Charging method:
Generally there three ways to charge the battery: constant-current charging, constant-voltage
charging and quick charging.
5. Measure with instruments after charging, and determine whether the battery capacity
recovers to the standard valve by voltage method or volumetric method
a. Voltage method
Voltage Judgment Handle
Above 12.5V Acceptable Continue to use
11.5~12.5V Undercharge Charge the battery again
Below 11.5V Over-discharge or internal fault Check after charging

b. Indicator display status
Capacity display Judgment Handle
White area Sufficient Continue to use
Green area Acceptable Continue to use
Yellow area Undercharge Charge the battery again
Red area Over-discharge Check after charging

6. Operation and maintenance of battery in winter:

a. The battery shall always be fully charged to prevent the reduction of electrolyte specific gravity to
cause freezing to further lead to rupture of containers, bending of plates, falling of active
substances, etc.
b. Because the battery capacity will drop in winter, preheating is needed during the cold start of the
engine, and the time of connecting the engine shall not be over 15s each time, with an interval of
2-3min between two starts. When the vehicle cannot be started for three times, look for the engine
fault, and start the engine again after the fault is solved.
7. Notes for using battery:
a. Explosive gas may escape from the battery. To try to avoid personal injury as much as possible,
before maintaining battery, keep the engine cabin in good ventilation. To avoid the electrical arcs,
firstly remove the negative (-) battery cable and connect the negative (-) battery cable at last.
b. Battery electrolyte is extremely dangerous, and it can damage machine and lead to serious burn.
When maintaining the battery, prepare a bucket of high-concentration soda water as neutralizer.
Wear the goggles and protection clothes to avoid personal injury.
c. The short-circuits of the two battery terminals are absolutely not allowed to happen. Otherwise,
batteries will get hot very quickly and are likely to burst. Besides, the air released from batteries is
flammable by sparks. Therefore, open fire is not allowed besides batteries.
d. To remove the battery, remove the negative wire followed by the positive wire, then remove the
battery fixing support, and take out the battery from the bracket. The sequence of installing the
batteries is opposite to this.
e. It is forbidden to run the engine with disconnected battery, or else, the electric system (electronic
EL components) will be damaged.
f. The alternator is connected to the ground via the negative pole, so the ground polarity of the
battery must be the same as this, otherwise the battery will discharge through the silicon diode,
and the diode will be burnt out.
Danger
The electrolyte in battery is lean sulfuric acid. This kind of liquid is harmful for anyone, therefore
care shall be taken to avoid burning skin or clothes, and special attention shall be paid to prevent
it from splashing to eyes. If the battery electrolyte is splashed to eyes, it is imperative to
immediately wash eyes with abundant clean water, then go to hospital.
Basic inspections
1. Appearance check:
a. Firstly observe whether the battery appearance is in good condition and whether the fixing pull
rod and the wire are connected firmly.
b. Observe whether the battery shell and central separator have cracks, knock the shell and the
central separator separately with a wooden stick, and listen whether there is a breakage sound.
Cracks are easy to occur especially at interfaces between the central separator and four sides of
the shell, so that these areas need careful inspection.
c. If there is a sight glass, green indicates sufficient power, red and white indicate insufficient power
and no power. It is required to examine the capacity, specific gravity, voltage as below.
2. Capacity detection:
a. High-frequency discharge gauge is also called as discharge tongs, and is composed of a DC
voltmeter and a load resistor.
b. Different brands of high-frequency discharge gauges shall be based on the specified values of
original manufacturers’ instructions. In general, the unit voltage of the battery with good technical
condition shall be more than 1.5V, and maintains stable within 5s. If the voltage quickly decreases
within 5s or the voltage of certain battery unit is more than 0.1V lower than that of other battery
units, it means the battery fails.
c. The following table is a comparison obtained by using a high-frequency discharge gauge to
detect.
Capacity display Judgment Handle
EL
White area Sufficient Continue to use
Green area Normal Continue to use
Charge the battery again (refer to “Chapter EL Electric

Yellow area Undercharged
System-Electric Parts-Battery, Use and Maintenance”).
Charge the battery and inspect (refer to “Chapter EL Electric
Red area Over-discharge
System-Electric Parts-Battery, Use and Maintenance”).
3. Voltage detection:
Voltage Judgment Handle
Above 12.5V Normal Continue to use
Auxiliary charge (refer to “Chapter EL Electric System-Electric

11.5~12.5V Undercharged
Parts-Battery, Use and Maintenance”).
Over-discharge Auxiliary charge (refer to “Chapter EL Electric System-Electric
Below 11.5V
or internal fault Parts-Battery, Use and Maintenance”).
Common malfunctions, cause analysis, and troubleshooting of battery

1. A fully charged battery does not lose electric quantity after long time placement.
• Reason:
The electric quantity of the full y charged battery will be lost gradually after long time
placement, which is called "self discharging". The main cause of self-discharge is material
impurity. If there is impurity in the polar plate materials or electrolyte, the impurities and
polar plate, impurity and impurity will generate potential difference and form closed “local
current” to make battery discharge.
• Solutions:
The accumulator self discharged severely can be discharged completely or discharged
excessively to let the impurities on the pole plates come into the electrolyte, and then drain
the electrolyte and use the distilled water to wash the accumulator cleanly, and fill in the
fresh electrolyte again and charge it again.
2. Battery explosion
• Reason:
The causes for battery explosion are mostly because the water in electrolyte decomposed
into hydrogen or oxygen and produces a large amount of air bubbles when battery is
overcharged; short-circuit and vulcanization fault in the battery; the temperature of
electrolyte rises rapidly when charging and makes a large amount of water evaporate; at
this time, if the vent holes in the liquid adding cover is blocked or the gas is too much to
emit in time, and when the internal pressure of the battery reaches a certain limit (or meet
EL fire) will cause the battery explosion.
• Solutions:
a. The battery vent hole should be smooth.
b. The wire on the terminal must be firm to avoid sparks caused by looseness.
c. Control the charging volume, do not charge excessively to decrease the gas precipitation volume.
Charge indoor. No open flame. Keep ventilation.
3. The level drops rapidly during use of battery
• Reason:
a. Charge current is too large, resulting in the evaporation of water.
b. Battery cell is broken.
• Solutions
a. Inspect the engine and its control circuit.
b. Replace the battery.
Caution
The maintenance-free battery is adopted here. In case of fault in battery, please replace it. To
avoid personal injury, it is prohibited to decompose battery. Only professional personnel can
detect and find fault cause and provide information.
Battery
Replacement
1. Turn off every electrical device
2. Ignition key: LOCK
3. Remove the battery assembly.
a. Loosen the bolt of negative wiring post and
disconnect the negative wiring post of battery.
Caution
Replace battery after disconnecting from battery

negative terminal.
b. Uplift the rubber sleeve of positive wiring post,
loosen the bolt of positive wiring post, and
disconnect the wiring post wire of battery.
c. Disassemble the fastening bolts and nuts of battery
pressure plate and take out the battery pressure
plate.
d. Take out the battery assembly.
Caution
Handle the battery with cares.

EL
4. Remove the battery stand.
a. Disassemble the fastening bolts of battery bracket
and take out the battery bracket.
5. Check the battery for any following phenomenon, and replace it if any.
a. Battery septum is broken.
b. Battery case is cracked.
c. Battery shell bulging and deformation.
d. Active substances of the battery plates fall off.
e. The corrosion for the battery post.
f. The battery does not store power.
6. Installing Battery Stand

a. Install the battery bracket to the installation position
and install and tighten the fastening bolts of battery
bracket.
7. Install the battery assembly.

a. Install the battery assembly to battery bracket.
b. Install the battery pressure plate to the installation
position and install and tighten the fastening bolts
and nuts of battery pressure plate.
c. Connect the positive wiring post wire of battery,
tighten the wiring post bolt, and cover the wiring
post rubber sleeve.
d. Connect the negative wiring post wire of battery
and tighten the negative wiring post bolt.
EL
Lighting system
Lighting system
General
To ensure the driving safety under the condition with insufficient illumination and promote the driving
speed, the vehicle is equipped with various lighting devices. These lighting devices, circuits, and their
switches and control devices constitute the lighting system. These lighting devices can fulfill the different
functions independently or through combinations.Based on the installation locations and the applications,
these lighting devices can be divided into front combination lamp, rear combination lamp, turn signal
lamp, clearance lamp, and interior lamp. Depending on specific functions, these lighting devices are
installed in the different portions of the vehicle to fulfill the designated functions and guarantee the
driving safety under the condition with insufficient illumination. The lighting system has been one vital
part of the vehicle.
Lighting devices:
1. Front combination lamp
The front combination lamp is installed on both left and right front sides of the vehicle, which is not
only used to illuminate the road ahead, but also is used to alert other vehicles and pedestrians of
the vehicle width and the driving direction. The front combination lamp is composed of high beam,
turn signal lamp, low beam, and position lamp.
2. Rear Combination Lamp
The rear combination lamp is generally composed of the turn signal lamp, brake lamp, position
lamp, and reversing lamp (Installed on both sides of the vehicle tail). EL
3. Fog lamp
The fog lamp includes front fog lamp and rear fog lamp. The fog lamp is intended to improve the
road illumination conditions and alert the drivers behind under the foggy, snowy, stormy, or dusty
conditions.
4. Left turn signal lamp
The turn signal lamp is intended to issue the one-sided alternated flashing signal at the cornering
of the vehicle, in order to indicate the left turn or right turn of the vehicle. The turn signal lamp
includes front turn signal lamp, rear turn signal lamp, and side turn signal lamp (The front turn
signal lamp is integrated in the front combination lamp, the rear turn signal lamp is integrated in
the rear combination lamp, and the side turn signal lamp is installed on two sides of the cab).
5. Brake light
The brake lamp shares one same bulb with the marker lamp, with two tungsten wires. When the
marker lamp is turned on, the brake lamp will turn on one tungsten wire. When the brake pedal is
depressed, two tungsten wires of the brake lamp will turn on at the same time to issue a relatively
strong red light, in order to alert the drivers behind of the stop or slow-down of your vehicle (The
brake lamp is combined with the rear combination lamp and is installed on both sides of the
vehicle tail).
6. Reversing lamp
The reversing lamp is intended to illuminate the back of the vehicle and alert the vehicles and
pedestrians behind, indicating your vehicle is reversing (The reversing lamp is combined with the
rear combination lamp and installed on both sides of the vehicle tail).
7. License plate lamp
The license plate lamp is functioned to illuminate the license plate of the vehicle (The license
plate lamp is installed at the middle position of the vehicle tail, above the license plate of vehicle).
8. Interior Lamp
Also referred to as the roof lamp, the interior lamp is functioned for internal illumination (Installed
on the top of the vehicle compartment or the cab).
EL
Precautions
1. During the installation, cautions shall be taken to avoid colliding with the lamps, especially
the reflectors and housings within the lamps, in order to avoid scratching the lamps and
impairing the illumination intensity of the lamps.
2. During the installation, notice not to forcibly pull the bulb harness, in order to avoid the
poor contact between the lamps and the power wires from causing abnormal functioning
of the lamps and other malfunctions.
3. The lamps must be securely installed in the due locations, in order to avoid the fall-off of
the lamps during the driving.
4. During the installation, guard the heads of the bulbs against oil dirt, which will impair the
illumination intensity of the lamps. Especially for the bulbs of high beam and low beam in
front combination lamp, the oil dirt will easily burn out the lamps.
5. The bulb of rear brake lamp shall never be mixed with other bulbs during installation.
6. Safety precautions
a. Park the vehicle on the vehicle trough or the vehicle service bench.
b. Shift the parking brake handle to parking position.
c. Block the wheels by triangular woods or wedges. The triangular woods or the wedges shall be
placed closely before and after the wheels, preferably the rear wheels.
d. Before operations beneath the vehicle, ensure to stop the engine and turn off the ignition lock
switch (The ignition switch shall be at OFF position).
e. Before the operations beneath or behind the vehicle, place a warning sign of “NO START” on the
steering wheel or on the driver seat. EL
Preparation
Recommended tools
Speed wrench Bolt disassembly
Screwdriver for disassembling of For disassembling and installation

bolts of screws
Measurement of voltage/current/
Digital multimeter
resistance
Disassemble the hazard warning

EL lamp switch.

order of possibility of malfunction reasons. Check each part as per this order and replace as the case
may be.
1. Fuse on failed side

Replace the friction plate.
(Damaged)
Only one side of low 2. Bulb (damaged) Replace the friction plate.
beam is out
3. Wire harness (broken
Repair the damaged
circuit or short to
circuit
ground)
1. Fuse (Damaged) Replace the fuse.
2. Low beam relay Replace the low beam

(damaged) relay
Low beam lamp
3. Combination switch Replace combination
Low beams on both sides
(damaged) switch
are out
4. Bulb (damaged) Replace the friction plate.
5. Wire harness (short

Repair the damaged
circuit or short to
circuit
ground)
1. Combination switch Replace combination EL
Low beams on both sides (short circuit) switch
are normally on 2. Wire harness (short Repair the damaged
circuit) circuit
Only one side of high 2. Bulb (damaged) Replace the bulb

beam is out
Repair the damaged
circuit or short to
circuit
ground)
1. High beam relay Replace the high beam
(damaged) relay
High beam

High beams on both sides
(damaged) switch
are out

Repair the damaged
circuit or short to
circuit
ground)
High beams on both sides (short circuit) switch
High beam
are normally on 2. Wire harness (short Repair the damaged
circuit) circuit
Front fog lamp Only one side of front fog 1. Bulb (damaged) Replace the bulb

lamp is out 2. Wire harness (broken
Repair the damaged
circuit or short to
circuit
ground)
1. Fuse (Damaged) Replace the friction plate.

Front fog lamps on both (damaged) switch
sides are out

Repair the damaged
circuit or short to
circuit
ground)
Front fog lamps on both (short circuit) switch
sides are normally on 2. Wire harness (short Repair the damaged
circuit) circuit

Rear fog lamp is out (damaged) switch
EL
Rear fog lamp
Repair the damaged
circuit or short to
circuit
ground)
(short circuit) switch
Rear fog lamp keeps on.
2. Wire harness (short Repair the damaged
circuit) circuit

Front position lamp at one
side does not work. Repair the damaged
circuit or short to
circuit
ground)

Front position lamp (damaged) switch
Failure of front position
lamps on both sides 3. Bulb (damaged) Replace the bulb

Repair the damaged
circuit or short to
circuit
ground)
Constant lighting of front
position lamps on both
sides
Rear position light Rear position lamp at one 1. Bulb (damaged) Replace the bulb

side is out. 2. Wire harness (broken
Repair the damaged
circuit or short to
circuit
ground)
1. Fuse (Damaged) Replace the friction plate.

(damaged) switch
Rear position lamps on
both sides are out. 3. Bulb (damaged) Replace the bulb

Repair the damaged
circuit or short to
circuit
ground)
Rear position lamps on
both sides are normally
on.
1. Fuse (damaged) Replace the fuse.
2. Reversing switch
Replace reversing switch.
(damaged)
Reversing lamp does not
work. 3. Bulb (damaged) Replace the bulb
Reverse lamp
Repair the damaged
circuit or short to
circuit
ground)
1. Reversing switch EL
Reversing lamp keeps on. Replace reversing switch.
(short circuit)
Part diagram (I)
EL
1 Side turn signal lamp assembly 7 Headlamp plug

2 Left front combination lamp assembly 8 Phillips large button head bolt
3 Right front combination lamp assembly 9 Left daytime running lamp assembly
4 Roof lamp 10 Right daytime running lamp assembly
5 Sealing gasket 11 Fog lamp assembly (FR, LH)
6 Rubber stopper for headlamp 12 Fog lamp assembly (FR, RH)
Part diagram (II)
EL
1 Left rear taillight assy 5 Right rear tail lamp assy

2 Bulb 6 Bulb
3 Bulb, brake light/position light 7 Bulb, brake light/position light
4 License lamp assembly
Front combination lamp

Testing and adjustment
1. Preparations before checking
a. Hang the special screen vertically.
Screen
Ground
EL
Caution
If the special screw is not available, draw the graph on the wall, as per the figure shown above.
Screen description:
• Draw three vertical lines and three horizontal lines on the screen. The middle vertical line
V-V is aligned with the longitudinal central plane of the vehicle being tested and the
vertical lines on two sides VL-VL and VR-VR are the vertical lines of left headlamp and
right headlamp of the vehicle being tested respectively, with the spacing at S.
• The line h-h among the three horizontal lines is at same height with the benchmark center
of the headlamp of vehicle being tested and is H in height from the ground.
• The middle horizontal line is at the same height with the beam center of high beam of the
vehicle being tested and is H1 in height from the ground (0.85～0.90H).
• The bottom horizontal line is at the same height with the beam center of the low beam of
the vehicle being tested and is H2 in height from the ground (0.60～0.80H).
b. Park the vehicle on a horizontally solid ground and
in right angle to the screen.
• Position the vehicle head in right angle to the
Screen
screen and keep the headlamp 10m reach
from the screen.
• Unload the vehicle and ensure that the tire
pressure is normal and the battery is fully
charged.
Caution
• The height of the cut-off line angle or the middle point of the low beam shall be (0.6~0.8)H
(H is the central height of the headlamp), of which the leftward or rightward offset in the
horizontal direction shall be equal to or less than 100mm.
• The high beam shall be adjusted in such manner that the beam center on the screen is at
(0.85~0.90)H in height from the ground. For the requirements on horizontal position, the
leftward offset shall not exceed 100mm and the rightward offset shall not exceed 170mm
for the left headlamp and the leftward and rightward offsets shall not exceed 170mm for
right headlamp.
• While adjusting the high beam and low beam of the front combination lamp, shield the
beam on one side by a light-proof cloth or glare shield and test the beam on other side.
2. Adjust the low beam.

a. Disassemble the front combination lamp.
b. Adjust the beam offset of low beam.
Method:
Adjust the vertical and longitudinal offsets of the low
beam by the adjustment screws behind the front
combination lamp.
EL
Replacement
Caution
The disassembling procedure is basically same for the left and right front combination lamp
assemblies. This manual takes the replacement method of right front combination lamp for
instance to describe the procedure.
1. Remove the front bumper. (Refer to “Chapter BW Body - Interior and Exterior Trim Parts -
Front Bumper, Replacement”)
2. Change of right front grouped lights
a. Disassemble 2 fastening screws on the outer side
of right front combination lamp.
b. Disassemble 2 fastening screws of the right front

combination lamp on the inner side of cab.
EL
c. Move the right front combination lamp for a

distance, disconnect the harness connector of right
front combination lamp, and take out the right front
combination lamp.
3. Install the right front combination lamp.

a. Reconnect the right front combination lamp wiring
harness connector.
b. Install the right front combination lamp to the

installation position and install 2 fastening screws of
right front combination lamp on the inner side of the
cab.
c. Install 2 fastening screws on the outer side of right

front combination lamp.
4. Install the front bumper. (Refer to “Chapter BW Body - Interior and Exterior Trim Parts -
5. Remove the low beam bulb.
a. Disassemble the bulb dust cover of low beam.
EL
b. Disconnect the bulb connector of low beam.

c. Loosen the bulb compression spring of low beam

and take out the bulb of low beam.
6. Install the low beam bulb.

a. Install the bulb of low beam and lock the bulb
compression spring of low beam.
b. Connect the bulb connector of low beam.
EL
c. Install the bulb dust cover of low beam.
7. Disassemble the bulb of high beam (Refer to Chapter EL Electric Devices - Lighting
System - Front Combination Lamp, Replacement.).
8. Remove the position lamp bulb

b. Disassemble the bulb dust cover of high beam.
c. Pull out the bulb of position lamp.
9. Install the position lamp bulb

a. Install the position lamp bulb
EL
b. Install the bulb dust cover of high beam.

c. Install the front combination lamp.
10. Remove the turn signal lamp bulb.

b. Rotate counter-clockwise to take out the turn signal
lamp holder.
c. Rotate to take out the bulb of turn signal lamp.
11. Install the turn signal lamp bulb.

a. Rotate to install the bulb of turn signal lamp.
b. Rotate clockwise to install the holder of turn signal

lamp.
d. Install the front combination lamp.
EL
Front fog lamp

Replacement
Caution
The disassembling procedure is basically same for the left and right front fog lamp assemblies.
This manual takes the replacement method of left front fog lamp for instance to describe the
procedure.
2. Disassemble the left front fog lamp assembly.
a. Remove the fixing nuts and remove the left front fog
lamp assembly.
3. Check the left front fog lamp assembly for presence of following symptoms. If yes, repair,
adjust, or replace left front fog lamp assembly.
EL
a. Cracking of left front fog lamp cover.
b. Looseness of left front fog lamp fastening bolts.
c. Water ingress of left front fog lamp.
d. Short-circuit of left front fog lamp circuit.
4. Install the left front fog lamp assembly.
a. Install the left front fog lamp assembly to the
b. Install and tighten the fastening screws of the left
front fog lamp assembly.
5. Remove the front left combination lamp bulb.

a. Rotate to take out the holder of left front fog lamp.
b. Loosen the bulb compression spring of left front fog

lamp and take out the bulb of left front fog lamp.
b. Disconnect the harness connector and take out the

bulb of left front fog lamp.
6. Install the bulb of left front fog lamp.

a. Install the bulb connector of left front fog lamp.
EL
b. Lock the bulb compression spring of left front fog

lamp.
7. Rotate to install the holder of left front fog lamp.

EL
Turn signal lamp

Replacement
Caution
The disassembling procedure is same for left and right turn signal lamp assemblies. This manual
takes the replacement method of right turn signal lamp assembly for instance to describe the
procedure.
1. Remove right turn signal lamp assembly.

a. Pry out the turn signal lamp assembly.
b. Disconnect the harness connector of right turn

signal lamp and take out the right turn signal lamp
assembly.
EL Caution
Do not directly apply the force onto the harness while

unplugging the connector.
c. Rotate the lamp holder and take out the bulb of turn
signal lamp.
2. Install the right turn signal lamp assembly.

a. Rotate the lamp holder to install the bulb of turn
signal lamp.
b. Reconnect the right side turn signal lamp wire

connector.
Caution
While connecting the connector, ensure that a light

“click” sound is heard and then pull back lightly once
to ensure the secure connection.
c. Install the right turn signal lamp assembly onto the

vehicle body.
EL
Interior lamp
Replacement
1. Disassemble the interior lamp assembly.
a. Disassemble the interior lamp cover.
Caution
Do not directly pull out the lamp cover, in order to

avoid damaging the snap joints of the lamp cover.
b. Disassemble the fastening screws of interior lamp.
c. Disconnect the interior lamp wiring harness

EL connector, and take down the interior lamp
assembly.
2. Install the interior lamp assembly.

a. Reconnect the interior lamp wiring harness
connector.
Caution
While connecting the connector, ensure that a light

“click” sound is heard and then pull back lightly once
to ensure the secure connection.
b. Install and tighten the fixing screws of interior lamp.
c. Install the interior lamp cover and ensure the secure

clamping of snap joints.
EL
Door lamp switch

Replacement
1. Remove the door lamp switch.
a. Disassemble the fastening screws of the door lamp
switch.
b. Disconnect the connector of door lamp switch and
take out the door lamp switch.
2. Install the license plate light assembly.

a. Install the license plate lamp assembly to the
fastening nuts of license plate lamp assembly.
EL
Rear combination lamp

Replacement
1. Disassemble the rear combination lamp
assembly.
a. Disconnect the rear combination lamp assembly
wire connector.
Caution
While disconnecting the connector, avoid pulling the

harness directly.
b. Disassemble the fastening nuts of rear combination

lamp assembly and take out the rear combination
lamp assembly.
2. Install the rear combination lamp assembly.

EL
a. Install the rear combination lamp assembly to the
fastening nuts of rear combination lamp assembly.
b. Reconnect the rear combination lamp assembly

wire connector.
3. Disassemble the rear combination lamp bulb.

a. Disassemble the fastening screws of rear cover of
rear combination lamp and take out the rear cover
of rear combination lamp.
b. Rotate to take out the bulb of turn signal lamp and

check the bulb. Upon detection of damage, replace.
c. Take out the bulbs in turn by same method and
check the bulbs. Upon detection of damage,
replace.
4. Install the rear combination lamp bulbs.

a. Install all disassembled bulbs and ensure the
secure installation.
EL
b. Install the rear cover of rear combination lamp to the

fastening screws of rear cover of rear combination
lamp.
License plate lamp

Replacement
1. Remove the license plate light assembly
a. Disconnect the license plate lamp assembly wire
connector.
b. Remove the fixing nuts of license plate lamp

assembly and take out the license plate lamp
assembly.

a. Install the license plate lamp assembly to the EL
fastening nuts of license plate lamp assembly.
b. Connect the harness connector of license plate

lamp assembly.
3. Check the rear license plate lamp assembly for presence of following symptoms. If yes,
repair, adjust, or replace rear license plate lamp assembly.
a. Cracking of rear license plate lamp cover.
b. Water ingress of rear license plate lamp.
4. Remove the license plate bulb.

a. Dismantle the fastening screws of license plate
lamp cover.
b. Move the license lamp cover for a distance and take

out the bulb of license plate lamp.

a. Install license plate light bulb.
EL
b. Install the license plate lamp cover to installation

position and install and tighten the fastening screws
of license plate lamp cover.
Hazard warning lamp switch

Replacement
1. Disassemble the hazard warning lamp switch.
a. Pry open the A/C middle air vent by an interior trim
crow plate.
b. Disconnect the connector of hazard warning lamp

switch and take out the A/C middle air vent.
c. Push out the hazard warning lamp switch from the

rear side of the A/C middle air vent. EL
2. Install the hazard warning lamp switch.

a. Install the hazard warning lamp switch to the A/C
middle air vent.
b. Connect the connector of hazard warning lamp

switch.
c. Install the A/C middle air vent to the installation

position.
EL
Wiper and Washer

Wiper and Washer
General
1. Purpose of the wiper
a. The wiper is an indispensable part of the automobile, used to clear the rain water, snow or dust on
the windshield glass, thus to ensure the good vision of the driver for safe driving, being very
crucial for the safety of the driver and others and the property.
b. In this vehicle, the electric control device is used, featuring outstanding performance, and is
equipped with an automatic resetting device which can automatically stop the wiper at the lower
position of the windshield when the wiper circuit is cut off at any position. The wiper is provided
with three levels to realize the changeover between high and low speeds, thus to enable the
driver to operate the wiper as needed.
c. The wiper mechanism is powered by the DC motor at different voltages to realize the moving
speeds at different levels. Generally, a cycle regulator is provided for the first speed level,
intended to regulate the wiper operation by a certain time interval. The said regulator will
automatically interrupt the wiper motor for 1-2 cycles as per the fixed cycle, with the interval within
20-30s.
d. If the windshield washer switch is turned on, the nozzle will spray water onto the windshield glass;
after a delay, the wiper motor will be restarted. If the switch is turned off, the wetting will be
stopped, but the wiper will still work for 5-6s to wipe clean the glass till the wiper is reset.
2. Purpose of the washer EL
The windshield glass washer is used to spray the clean water or washing liquid onto the
windshield glass to clear the dust or pollutant on the glass, thus maintaining a good vision for the
driver.
Precautions
1. If the movement of the wiper is accidentally obstructed during the functioning, timely cut
off the power supply in order to prevent burning out the motor. In such case, turning the
wiper switch to position OFF is not enough. Instead, immediately disconnect the negative
cable of battery and unplug the plug of wiper motor from the socket of the combination
switch. In such case, the power supply of the wiper motor is fully cut off.
2. The wiper shall maintain the close contact with the windscreen during the use. The
presence of any gap will result in the cleaning failure of wiper. During the use, the dry
wiping is prohibited in order to prevent damaging the wiper. If the wiper switch is
accidentally turned on, turn off the wiper switch timely. Notice to fulfill the cleaning and
maintenance for the windscreen and the wiper, in order to avoid the accumulation of dusts.
3. After the wiper is used for 1,000 hours, the wiper motor shall be disassembled for
maintenance. When cleaning the commutator, grind the grinding traces of electric brush
on the surface of the commutator by 00# abrasive paper and replace the electric brush.
4. The washer shall not run continuously for a long time and the working time shall not
exceed 5s each time. The interval between any two continuous operations shall not be less
than 10s. If no washing fluid is available, do not turn on the washer.
5. Secure the spray hose and avoid unplugging the spray hose at will. During the vehicle
washing, pay attention not to spray towards the connector of spray hose for a long time, in
order to prevent the corrosion and aging.
Preparation
Recommended tool
Speed wrench For disassembling of bolts and nuts
Measure the voltage/ current/

Digital multi-meter
resistance
Interior trim crow plate Disassemble the nozzles.
EL

Refer to the following table to find out the cause of fault. Serial number indicates the order of possibility
of a failure cause. Check each part according to orders, replace as required.
1. Wiper motor/washer motor fuse Replace it with a fuse of the same

(damaged) specification
2. Related harness (open circuit or
Repair or replace relevant harness
short circuit)
Turn off the switch, the wiper does 3. Relay(damaged) Replace the relay
not work
4. Wiper combination switch Repair or replace the wiper
(damaged) combination switch
5. Wiper motor (damaged) Replace the wiper motor
6. BCM (damage) Replace the BCM
Charging or replacement of the

1. Battery (voltage too low)
battery.
2. Related harness (poor contact) Repair or replace relevant harness

The wiper action is slow
3. Motor bearing and reducer gear
Fill lubricating oil
(poor lubrication)
4. Wiper motor (damaged) Replace the wiper motor

EL
2. Washer motor relay (damaged) Replace the washing motor relay

The washer motor does not work
3. Washer motor (damaged) Repair or replace the washer motor
4. Related harness (open circuit or

Repair or replace relevant harness
short circuit)
1. Washing agent (insufficient) Fill washer fluid
2. Washer hose (damaged) Replace the washer hose
Washer fluid fails to eject 3. Washer nozzle (blocked) Replace washer nozzle

5. Washer motor (damaged) Replace the washing motor
1. Wiper worm rust or lack of Remove rust on wiper worm and

lubricating oil apply lubricating oil
2. Wiper arm deformed or frayed Replace the wiper arm
Abnormal noise is loud when the 3. The replaced wiper linkage Replace the wiper linkage
wiper works mechanism does not match mechanism
4. Rubber aging or cracking of
Replace the wiper blade
wiper blade
5. Wiper linkage mechanism is not Tighten the wiper linkage
fixed in place mechanism
1. Windscreen (with oil stains or

Clean the windscreen
car wax)
2. Washer fluid (poor quality) Replace the washer fluid
3. Wiper blade (the model is

incorrect)
The wiper does not work well
(wiper inefficiency or shaking) 4. Wiper blade (rubber aging or
cracking) Replace wiper blade or wiper
5. Wiper arm (deformed or assembly
damaged)
6. Wiper arm (the spring force
declined)
EL
Part diagram
EL
Wiper motor (FR)and connecting rod

1 6 Snap joint
mechanism assembly
2 Washer 7 Left front wiper arm blade assembly
3 Washer reservoir assembly 8 Right front wiper arm blade assembly
4 Washing fluid reservoir pipe assembly 9 Water pipe grommet
Washing fluid reservoir left bracket
5 10 Two-way joint
assembly
Inspection and adjustment

1. Check the wiper.
Caution
Mainly check the movement status of wiper blades when the wiper handle is at high speed and
low speed positions. In addition, check whether the wiper arm can stop at the designated
position.
a. Shift the wiper handle to high speed position. When the wiper blades run at high speed,
determine the movement of the wiper blades. In such case, the wiper blades shall run normally
without jitter.
b. Shift the wiper handle to low speed position. When the wiper blades run at low speed, determine
the movement of the wiper blades. In such case, the wiper blades shall run normally without jitter.
c. Shift the wiper handle to intermittent position. When the wiper blades run intermittently, determine
the movement status of the wiper blades, with the wiping time at 2~4s and the interval at 4~6s. In
such case, the wiper blades shall run normally, without any vibration (During the functioning of the
wiper blades, the motor and the drive mechanism shall be free of abnormal noise).
d. Check the reset function of the wiper. Turn off the wiper switch and determine whether the wiper
blades can run to the designated position and stop.
e. Check the wiper arms for appropriate pressure, check for good contact between wiper blades and
front windscreen, check wiper blades for aging, and check all connections for secureness.
EL Caution
At completion of checking, apply the lubricating oil to various moving portions of the wiper and
turn on the switch to run the wiper, in order to enable the permeation of lubricating oil into
various working surfaces.
2. Check the washer.
a. Check the connections of all water pipes. Any loose or fallen-off connection shall be re-installed
and any aged, broken, or rupture rubber blade shall be replaced.
b. Check the working status of nozzles and clean the nozzles by a brush. Turn on the washer switch
and check the spray angle of nozzles. If the spray angle is appropriate, adjust.
c. Check the working status of the washer. When the washer switch is turned on, the nozzles shall
spray the washing fluid onto the front windscreen. Meanwhile, the wiper arms of the wiper shall
continuously wipe for 2~3 times. If not, check and solve the malfunction.
Wiper
Replacement
1. Remove the wiper assembly.
a. Uplift the nut caps of wiper assembly.
b. Disassemble the fastening nuts of the wiper

assembly.
c. Disconnect the washer hoses and shake to take out
the wiper assembly.
2. Check the wiper assembly for presence of following symptoms. If yes, repair or replace
wiper assembly. EL
a. Breakage of wiper connecting shaft.
b. Deformation of wiper.
c. Rusting of wiper.
d. Check the wiper springs for damage.
Caution
Observe the wiper arms for damage or aging. Any

wiper arm in need of replacement shall be replaced
timely. While installing the new wiper arm, notice to
check for the matching of model number and check for
intact integral connection, especially the connection
of spring.
3. Install the wiper assembly.
a. Clean the spline hole of the wiper assembly with a
round file or similar tool.
b. Use a wire brush to clean the rotating shaft spline of
the wiper link mechanism assembly.
4. Install the wiper assembly.

a. Install the wiper assembly to installation position,
connect the washer hoses, and install and tighten
the fastening nuts of wiper assembly.
Caution
• The wiper assembly shall be located on the

lower edge of windscreen assembly.
• Uplift the wiper assembly and place it to correct
position.
b. Properly restore the fastening nut caps of wiper
assembly.
Caution
• Turn down the wiper assembly after installation.

• Ensure that the wiper blade is located on the
lower edge of windscreen.
5. Check the auto return of the wiper assembly.

a. Operate the switch of wiper assembly to position INT/LO/HI to swing the wiper assembly.
EL Caution
Do not turn on the wiper switch while the windscreen is still dry, in order to prevent scratc hing
the windscreen.
b. Turn off the wiper switch to automatically return the wiper assembly.
c. Check whether the wiper assembly is located on the lower edge of the windscreen assembly.
Wiper motor
Replacement
1. Remove the instrument panel . (Refer to "Section BW: Vehicle body- Dashboard/
Combination instrument/ Ash tray- Dashboard, Replacement".)
2. Remove the wiper motor.
a. Disconnect the wiper motor wiring harness
connector.
b. Disconnect the ball joint connection between wiper

linkage and wiper motor
EL
c. Disassemble the fastening bolts of wiper motor and
take out the wiper motor.
3. Check the wiper motor for presence of following symptoms. If yes, repair or replace wiper
motor.
a. Internal short-circuit noise of wiper motor.
b. Poor contact of wiper motor internal contact.
c. Internal noise of wiper motor.
4. Install the wiper motor

a. Install the wiper motor to the installation position
and install and tighten the fixing bolts of the wiper
motor.
b. Connect the ball joint between wiper motor and

wiper linkage.
Caution
Before installing the wiper linkage, turn on the power

supply to return the wiper motor.
c. Reconnect the wiper motor wiring harness

connector.
EL
5. Install the instrument panel.(Refer to "Section BW: Vehicle body- Dashboard/ Combination
6. Check the automatic return of the wiper arm blade assembly
Wiper liquid reservoir

Replacement
1. Remove the instrument panel . (Refer to "Section BW: Vehicle body- Dashboard/
Combination instrument/ Ash tray- Dashboard, Replacement".)
2. Remove the washing fluid reservoir
a. Disconnect the washer motor connector.
b. Remove the fixing bolts of washing fluid reservoir.
c. Disconnect the washer hoses and take out the

wiper washing fluid reservoir assembly.
Caution
Check the wiper washing fluid reservoir for cracking

and damage, check all connections for secure
connection, check for presence of washing fluid
leakage, check for dirt in wiper washing fluid reservoir,
EL
clean the wiper washing fluid reservoir, and tighten its
connections or replace wiper washing fluid reservoir.
3. Install the washing fluid reservoir
a. Connect the washer hoses.
Caution
Before connections, heat the washer hose connectors

to ease the installation.
b. Install the fixing bolts of washing fluid reservoir.

c. Reconnect the washer motor connector.
4. Install the instrument panel.(Refer to "Section BW: Vehicle body- Dashboard/ Combination
5. Selection of windscreen washing fluid
It's preferable to select the mixture of water and DPI antifreeze as the windscreen washing fluid, of which
the mixture ratio is shown in the table below.
Outside Temperature -35℃ -20℃ -10℃ 0 Summer
DPI (Mixture ratio) 1 1 1 1 1
Water (Mixture ratio) - 1 2 6 10

6. Add the cleaning solution.
EL
Wiper arm and linkage

Replacement
2. Remove the wiper assembly. (Refer to "Chapter EL Electric System - Electric Devices -
Wiper and Washer - Wiper”)
3. Disassemble the wiper linkage.
a. Take out the rubber caps.
b. Disassemble the lock nuts of wiper linkage.
EL
c. Disconnect the ball joint connection between wiper

linkage and wiper motor
d. Disassemble the fastening bolts of right support of

wiper linkage.
e. Disassemble the fastening bolts of left support of

wiper linkage and take out the wiper linkage.
4. Check the wiper linkage for presence of following symptoms. If yes, replace the wiper
linkage.
a. Deformation of wiper linkage.
b. Serious rusting of wiper linkage.
5. Install the wiper linkage.
a. Install the wiper linkage to installation position.
b. Connect the ball joint between wiper motor and
wiper linkage.
Caution
Before installation, apply lubricating grease to the

motion pair portion of wiper linkage.
EL e. Install the fastening bolts of left support of wiper

linkage.
d. Install the fastening bolts of right support of wiper

linkage.
c. Install and tighten the lock nuts of wiper linkage.
d. Install the rubber caps.
6. Install the wiper assembly. (Refer to "Chapter EL Electric System - Electric Devices - Wiper
and Washer - Wiper”)
7. Install the dashboard.(Refer to "Section BW: Vehicle body- Dashboard/ Combination
EL
Wiper blade
Replacement
Caution
The disassembling method is same for left and right wiper blades.
1. Remove the wiper blade.

a. Overturn the wiper arms.
b. Push the wiper blade snap joints and take out the
wiper blades.
2. Check the wiper blades for presence of cracking, falloff, and aging. If yes, replace the
wiper blade.
3. Install the wiper blade.
a. Install the wiper blade to the wiper arm.
Caution
EL
If a click sound is heard, it indicates that the wiper
blade is installed in correct position.
b. Turn down the wiper arm.
Washer
Replacement
1. Remove the washing fluid reservoir (Refer to “Chapter EL Electric Parts - Wiper and
Washer - Washing Fluid Reservoir, Replacement”).
2. Remove the washer.
a. Pour the washing fluid and unplug the washer from
the washer washing fluid reservoir.
3. Check the washer motor for presence of following symptoms. If yes, repair or replace
washer motor.
a. Internal short-circuit noise of washer motor.
b. Poor contact of washer motor internal contact.
c. Internal noise of washer motor.
4. Install the washer.
a. Install the washer to the washer washing fluid
reservoir.
EL
5. Install the washing fluid reservoir (Refer to “Chapter EL Electric Parts - Wiper and Washer -
Washing Fluid Reservoir, Replacement”).
Nozzle
Replacement
1. Disassemble the nozzles.
a. Overturn the wiper arms.
b. Disconnect the washer hoses.
b. Pry out the nozzles from wiper arms.
2. Check two nozzle orifices. If blocked, dredge the nozzles and remove the dirt by a pin. If
EL ineffective, replace the nozzles.
3. Install the nozzles.
a. Connect the washer hoses and nozzles and install
the washer nozzles in place.
Caution
Before connections, heat the washer hose connectors

to ease the installation.
4. Turn on the washer switch and check the spray range of nozzles.
Audio System
Audio System
General
The radio/audio player receives signal via external antenna to receive AM/FM radio stations. In addition,
the radio/audio player integrates the MP3 function and can connect a mobile device via USB port to play
the audio files in the mobile device and enhance the vehicle entertainment.
Precautions
1. When the negative cable of battery is disconnected, the AM/FM radio station information
stored in the radio/audio player will be cleared.
Caution
If necessary, please record the radio station information before disconnecting the negative cable
of battery and set up again after the connection of battery negative cable.
2. Avoid touching the conical paper basin of loudspeakers.
3. While installing the antennae assembly, ensure the secure connection of ground.
Caution
If the antenna ground is insecurely connected, it will generate noise and weaken the received
signal during the receiving of broadcasting information. EL
Preparation
Recommended tools
Speed wrench For disassembling of bolts and nuts
Screwdriver Remove and install screw.
Disassemble the radio/audio player

cover.
EL

may be.
1. Fuse (Fuse burnout) Replace the same type of fuse.
2. Radio/audio player (No power Repair or replace corresponding

supply) harness
3. Radio/audio player (Internal
No sound Change of radio and player
damage)
4. Leads (Open-circuit) Repair or replace leads.
5. Loudspeakers (Damaged
Replace loudspeaker
loudspeakers)
Drive out from the interference
1. Vehicle (Interference)
area.
2. Antenna (Poor receiving of
-
signal)
Noise 3. Leads (Loose) Unplug and re-plug the connector.
4. Loudspeakers (Not properly

Reinstall the speaker
installed)
5. Radio/audio player (Internal EL
Change of radio and player
damage)
1. Leads (Loose) Unplug and re-plug the connector.

Poor sound quality Reinstall the speaker
installed)
damage)
Drive out from the interference
1. Vehicle (Interference)
area.
2. Antenna (Poor receiving of
-
signal)
Low volume 3. Leads (Loose connector) Unplug and re-plug the connector.

Reinstall the speaker
installed)
damage)
1. Lead at failed loudspeaker Repair or replace open-circuited
Only one speaker has sound (Open-circuit) harness.
output
2. Another speaker (Damaged) Replace damaged loudspeaker.
Part diagram
EL
1 Whip antenna 6 Threading jacket

2 Radio assembly 7 Plastic nut seat
3 Loudspeaker 8 Rubber plug
4 Reversing sensor controller 9 Block cover
5 Sensor assembly
Radio/audio player
Replacement
Caution
Before checking and repairing the radio/audio player, firstly check if the fuse of the radio/audio
player is burnt out.
1. Disassemble the A/C middle air vent.

a. Pry out the middle air vents of A/C, disconnect the
connector of hazard warning lamp switch, and take
out the middle air vents of A/C.
2. Remove the radio/audio player.

a. Remove the fixing screws of radio/audio player.
EL
b. Move the radio/audio player for a distance.
Caution
Do not pull forcibly or pull out too long, in order to

prevent damaging the lead connector.
c. Unplug the antenna connector.
Caution
Apply the force onto the connector, instead of onto the

lead.
d. Disconnect the radio/audio player connector and

take out the radio/audio player.
Caution

lead.
3. Check the radio/audio player for presence of following symptoms. If yes, repair or replace
the radio/audio player.
a. Breakage of radio/audio player knob.
b. Cracking of radio/audio player casing
c. Serious wear of radio/audio player antenna interface.
d. Burning of radio/audio player internal fuse
4. Installing radio/audio player
a. Connect the connector of radio/audio player.
EL
b. Connect the antenna lead connector.
c. Push the radio/audio player into installation position

and install and tighten the fastening screws of
radio/audio player.
Caution
If the fastening screws can’t be tightened, replace with

larger self-tapping screws.
5. Install the A/C middle air vent.

a. Connect the warning lamp switch connector and
install the middle air vents.
Caution
Apply the force by hand onto the portions with snap

joints and do not knock with other hard tools.
6. Test the radio/audio player for normal functioning.
EL
Loudspeaker
Replacement
1. Remove the door inner guard panel. (Refer to “Chapter BW Body - Interior and Exterior
Trim Parts - Door Inner Guard Panel, Replacement”)
2. Remove the loudspeaker.
a. Remove the fixing screws of loudspeaker.

EL
3. Check the loudspeaker for clear damage.
• Check the connector for looseness.
• Check the loudspeaker harness terminals for
fall-off.
• Check the loudspeaker body for clear
cracking.
4. Install the loudspeaker.

a. Connect the loudspeaker connector.
b. Install the loudspeaker to installation position and

install and tighten the fastening screws of
loudspeaker.
5. Install the door inner guard panel (Refer to “Chapter BW Body - Interior and Exterior Trim
Parts - Door Inner Guard Panel, Replacement”).
6. Test the loudspeaker for normal functioning.
EL
Antenna
Replacement
1. Disassemble the radio/audio player. (Refer to Chapter EL Electric System - Electric
Devices - Audio System, Radio/Audio Player, Replacement.)
2. Disassembling of antenna
a. Unplug the antenna feeder connector.
Caution

lead.
b. Cut off all cable ties and fixing clamps of antenna
feeder.
c. Disassemble the fastening screws of antenna and

take out the antenna feeder assembly.
Caution
In event of difficult pull-out or over-high resistance

while pulling out the lead, please move away the
antenna feeder pressure plate beneath the dashboard.
EL
3. Installation of antenna
a. Install the antenna connector through the antenna
mounting hole.
Caution
• Do not miss the antenna support rubber sleeve.

• Sort out the antenna lead while installing the
antenna. Do not excessively pull the antenna
lead.
b. Install the antenna to installation position and install
c. Install the antenna feeder connector.
Caution

lead.
d. Re-bind and fix the antenna feeder.
4. Install the radio/audio player. (Refer to Chapter EL Electric System - Electric Devices -
Audio System, Radio/Audio Player, Replacement.)
Cigarette lighter
Replacement
1. Remove the cigarette lighter.
a. Unplug the cigarette lighter core.
b. Disconnect the positive and negative connectors of
cigarette lighter.
c. Take out the cigarette lighter socket from the outer side of the instrument panel.
2. Install the cigarette lighter.
a. Install the cigarette lighter socket from the outer side of the instrument panel.
b. Connect the positive and negative connectors of
cigarette lighter.
c. Install the cigarette lighter core.
EL
Information System
Information System
General
The information system includes horn and reversing lamp switch.
Horn: The horn issues sound by means of the vibration of metal diaphragm.
Reversing lamp switch: When the reverse gear is shifted, the mechanical mechanism pushes down the
switch contact to close the circuit and turn on the reverse gear lamp. When the reverse gear is
disengaged, the switch contact pops up to open the circuit of reverse gear lamp.
Precautions
1. Ensure that the parking brake handle is at parking position.
2. Before conducting the operations under the vehicle, ensure to stop the engine and turn off
the ignition lock switch.
3. While washing the vehicle, guard the horn against being wetted. Upon detection of water
ingress, blow dry by a blower gun as soon as possible.
4. Press the horn as short as possible, otherwise it will lead to earlier ablation of the horn
contacts.
EL
Preparations
Recommended tools
Speed wrench Remove and install bolt and nut

Monkey spanner
of reversing switch
EL
Part diagram
EL
1 Electric horn assembly


may be.
1. Connector (Loose) Unplug and re-plug the connector.
Sound failure of horn 2. Horn switch (Elastic failure) Replace horn switch
3. Horn (Body damage) Replace horn
1. Horn harness (Ground) Repair or replace horn harness.
Constant sounding of horn 2. Horn switch (Elastic failure) Replace horn switch
3. Horn (Internal ground) Replace horn
1. Connector (Loose) Unplug and re-plug the connector.
2. Horn switch (Poor contact of

Poor tone of horn Replace horn switch
contact)
3. Horn (Body damage) Replace horn
EL
Horn
Replacement
1. Remove the horn.
a. Disconnect the horn connector.
b. Remove the fixing bolts of horn and take out the

horn.
2. Check the horn for presence of following symptoms. If yes, replace horn.
EL a. Cracking of horn body.
b. Internal short-circuit of horn.
c. Failure of horn body.
3. Install the horn.
a. Install the horn to the installation position and install
and tighten the fixing bolts of the horn.
b. Connect the horn connector.

c. Test horn for normal functioning.
Reversing switch
Replacement
1. Disassemble the reversing switch.
a. Disconnect the reversing switch harness
connector .
b. Rotate to disassemble the reversing switch.
2. Disassemble the reversing switch.

a. Install and tighten the reversing switch to the EL
transmission.
b. Connect the reversing switch harness connector.

Reversing Sensor
Replacement
1. Disassemble the reversing sensor.
a. Disconnect the reversing sensor harness
connector .
b. Rotate to disassemble the reversing sensor from

the cargo body.
2. Install the reversing sensor.

EL a. Install the reversing sensor onto the cargo body.
b. Connect the reversing sensor harness connector.

Reversing sensor controller

Replacement
1. Disassemble the reversing sensor controller
a. Disconnect the harness connector of reversing
sensor controller.
b. Disassemble the fastening bolts of reversing sensor

controller and take out the reversing sensor
controller.
2. Install the reversing sensor controller

a. Place the reversing sensor controller to the EL
fastening bolts.
b. Connect the harness connector of reversing sensor

controller.
Power socket
Replacement
1. Disassemble the power socket
a. Disconnect the wiring harness connector of power
socket.
c. Remove the power socket from the outer side of the instrument panel.
2. Install the power socket
a. Install the power socket from the outer side of the instrument panel.
b. Connect the wiring harness connector of power
socket.
EL
Heating and Air Conditioning System

Heating and Air Conditioning System
General
The heater system is mainly functioned to heat up the driver cab in the winter, in order to improve the
working conditions of the driver and promote the driving/riding comfort. The heater system utilizes the
temperature of the engine coolant. When the engine coolant passes through the heater radiator via the
pipeline, the fan motor on the bellow blows the heat of the engine coolant into the air duct and the heat
radiators into the driver cab via the air duct.
Precautions
1. Do not carry out the operation at kerbside or in crowded places, and park the vehicle on a
level ground wherever possible.
2. Ensure that the parking brake handle is at parking position.
3. Block the wheels by triangular woods or wedges. The triangular woods or the wedges
shall be placed closely before and after the wheels, preferably the rear wheels.
4. Before conducting the operations under the vehicle, ensure to stop the engine and turn off
the ignition lock switch.
5. While repairing the heating system, notice the temperature of engine coolant. When the
temperature of engine coolant is too high, it’s prohibited to disassemble the pipeline.
EL
Preparations
Recommended tools
Speed wrench Remove and install bolt and nut
EL

may be.
2. Fan relay (Poor contact) Replace fan relay

Heating failure (The fan has no air
output) 3. Fan connector (Loose
Reconnect connector or replace.
connector or open-circuit)
1. Fan circuit (Poor contact) Check and repair fan circuit

Insufficient hot air (Abnormal
airflow) 3. Relay (damaged) Replace relay.
4. Air passage (Blockage or

Unclog the air duct.
leakage)
1. Fan harness (Poor contact) Check and repair fan circuit.
Occasional failure of hot air output 2. Speed regulating resistor Change the speed regulation
(Occasionally no airflow) (damaged) resistance.
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3. Air duct (jammed) Unclog the air duct.
Part diagram (I)
EL
1 Evaporator assembly 12 Condenser bracket

2 Condenser - evaporator pipeline 2 13 Condenser bracket
3 Evaporator - compressor pipeline 1 14 Bracket
4 A/C pipeline 3 15 Pipe clip
Compressor-condenser pipeline (Front
5 16 Pipe clip
segment)
6 Compressor - condenser pipeline 2 17 Double-pipe clamp
7 Condenser - evaporator pipeline 1 18 Pipe clip
8 Condenser assembly 19 Pipe clip
9 Compressor belt 20 Bracket
Front evaporator weep pipe thru hole
10 Compressor 21
rubber grommet
11 Tensioning pulley 22 Compressor bracket
Part diagram (II)
EL
1 Chassis heater line 8 A/C double-pipe clamp

2 Heater water valve 9 Warm air controller
Internal/external recirculation
3 Heater water pipe 10
assembly
4 Heater box assembly 11 Air heater accessory
5 Heater pipe clip 12 Bracket
6 Fixing bracket , chassis harness 13 Floor hole plug
7 Retaining clip, harness
Heater water pipe

Replacement
2. Discharge the coolant. (Refer to “Chapter EG Engine part -Cooling system - Coolant,
Replacement”)
3. Disassemble the heater water inlet and outlet
pipes.
a. Loosen the clamps of water inlet and outlet pipes of
heater pipeline connected to the heater water tank,
shake the pipes back and forth to loosen, and then
pull out the water inlet and outlet pipes.
Caution
While pulling out the heater pipeline assembly, as the

pipeline probably still contains some coolant, cautions
shall be taken to prevent splashing onto your body.
b. Loosen the connecting clamps between heater
pipeline and heater pipe, shake back and forth to
take out the hose, and disassemble the fastening
bolts between heater pipe and frame.
EL
c. Loosen the connecting clamp of heater hose on the

other end of heater pipe.
d. Disassemble the fastening bolts between heater
pipe and frame and take out the heater pipe.
e. Disassemble the connecting clamp between heater

water outlet hose and engine and take out the
heater water outlet hose.
f. Overturn the driver seat and front passenger seat

and fix.
g. Disassemble the connecting clamp between heater
water inlet hose and engine and take out the heater
water inlet hose.
4. Install the heater water inlet and outlet pipes.

a. Install the heater water inlet hose to the engine.
b. Install and tighten the clamp of heater water inlet
hose.
c. Install the heater water outlet pipe to the engine and

install and tighten the clamp.
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d. Install and tighten the fastening bolts between

heater pipe and frame.
e. Install the connecting clamp between heater pipe
and heater hose.
f. Install and tighten the fastening bolts between

heater pipe and frame and install the connecting
clamp of heater hose on the other end of heater
pipe.
g. Install and tighten the clamps of water inlet and

outlet pipes between heater pipeline and heater
water tank.
h. Fix the hoses by cable ties.
i. Restore the driver seat and front passenger seat.
6. Fill the coolant. (Refer to “Chapter EG Engine part -Cooling system - Coolant,
Replacement”)
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Refrigerant
Replacement
1. Recover the refrigerant
a. Place the ignition switch to “LOCK” position.
b. Turn on the power supply of A/C refrigerant filling
machine.
c. Connect the high and low pressure pipelines of
refrigerant circuit.
d. Turn on the low pressure valve switch ① and high
pressure valve switch ② of A/C refrigerant filling
machine.
e. Select the “Recover refrigerant” function of the A/C
refrigerant filling machine to start the machine for
recovery.
f. Observe the pressure reading of low pressure
gauge of A/C refrigerant filling machine. When the
reading of pressure gauge reaches -34kPa vacuum
pressure, turn off the machine to stop the recovery.
2. Add the refrigerant
a. Connect the high and low pressure pipes of refrigerant circuit.
b. Select the “Refill refrigerant” function of the A/C refrigerant filling machine to adjust the filling
volume. EL
c. Open the low pressure valve switch and start the A/C refrigerant filling machine to start filling.
d. Observe the display screen of the A/C refrigerant filling machine. When the set filling volume is
reached, the display screen will display the completion of filling.
e. Close the valve.
Caution
If the A/C refrigerant filling machine indicates under-low filling speed, please refer to the
following filling methods:
• Disconnect the high pressure connector of refrigerant circuit and only connect the low
pressure connector.
• Close the high and low pressure valves of A/C refrigerant filling machine.
• Shift to parking gear, start the engine, turn on the A/C, and set the A/C mode.
• Open the low pressure valve of A/C refrigerant filling machine to fill the refrigerant from
low pressure end into the refrigerant pipeline.
• When the pressure gauge indicates that the standard low pressure value is reached,
disconnect the low pressure connector.
• The filling of refrigerant is completed.
Refrigerant oil
Replacement
1. Drain the refrigerant oil.
a. Connect the high and low pressure pipelines of
refrigerant circuit.
b. Turn on the low pressure valve switch ① and high
pressure valve switch ② of A/C refrigerant filling
machine.
c. On the control panel of A/C refrigerant filling
machine, open the oil drainage valve, start the
machine, and observe whether the A/C compressor
oil is drained into the collection bottle.
d. After the A/C compressor oil is fully drained, stop
the oil drainage and close the oil drainage valve.
e. Check the collection bottle and record the oil
volume.
Caution
• Drain the A/C compressor oil only after the

recovery of refrigerant is completed.
• Recover and dispose the used oil and
EL
refrigerant as per relevant regulations.
• Empty the oil collection bottle of the filling
machine.
2. Fill the refrigerant oil.

a. Connect the high and low pressure pipelines of refrigerant circuit, open the high pressure valve of
A/C refrigerant filling machine, and turn on the compressor oil filling switch.
b. Start the A/C refrigerant filling machine and observe the oil level in the filling bottle, till the required
oil volume is reached.
c. Close the high pressure valve.
Caution
Fill the compressor oil only after the vacuumizing is completed.

A/C Pipe
Replacement
2. Recover the refrigerant. (Refer to “Chapter EL Electric System - Electric Devices - Heating
and Air Conditioning System - Refrigerant, Replacement”)
3. Disassemble the refrigerant pipeline.
a. Disassemble the fastening bolts of compressor high
and low pressure pipes and move away the high
and low pressure pipelines.
Caution
After the high and low pressure pipelines are

unplugged, block the pipelines by plugs to prevent the
b. Disassemble the fastening bolts of high and low
pressure pipelines from the condenser and move
away the high and low pressure pipelines.
EL
c. Disassemble the fastening bolts of pipe clamps

between refrigerant pipeline and frame.
d. Take out the refrigerant pipeline from the vehicle.
4. Install the refrigerant pipe.

a. Place the refrigerant pipeline to the installation
position, install the connecting pipe clamps to the
frame, and fix by bolts.
b. Install the high and low pressure pipelines to the

condenser and fix by bolts.
c. Disassemble the fastening bolts of compressor high

and low pressure pipes and move away the high
and low pressure pipelines.
5. Add the refrigerant. (Refer to “Chapter EL Electric System - Electric Devices - Heating and
Air Conditioning System - Refrigerant, Replacement”)
6. Start the engine, run the engine to normal working temperature, turn on the A/C, and check
the compressor for normal functioning and for refrigerant leakage.
EL
A/C compressor
Replacement
2. Recover the refrigerant. (Refer to “Chapter EL Electric System - Electric Devices - Heating
and Air Conditioning System - Refrigerant, Replacement”)
3. Disassemble the compressor
a. Disassemble the fastening bolts of compressor high
and low pressure pipes.
b. Loosen the bolts of compressor belt tensioner and

take out the belt.
EL
c. Disassemble 2 fastening bolts of compressor and

take out the compressor assembly.
4. Check the compressor for presence of following symptoms. If yes, replace the
compressor.
a. Cracking of A/C compressor assembly rear cover.
b. Refrigerant leakage of A/C compressor assembly.
c. Noise of A/C compressor assembly.
5. Install the compressor

a. Install the compressor assembly and tighten 2
fastening bolts of compressor.
b. Install the compressor belt, rotate the tension bolts

of compressor belt to tension the compressor belt,
and tighten the fastening bolts of compressor.
c. Install the fastening bolts of compressor high and

low pressure pipes.
EL
6. Add the refrigerant. (Refer to “Chapter EL Electric System - Electric Devices - Heating and
Air Conditioning System - Refrigerant, Replacement”)
7. Start the engine, run the engine to normal working temperature, turn on the A/C, and check
the compressor for normal functioning and for refrigerant leakage.
Blower
Replacement
1. Disassemble the fan
a. Disconnect the fan wiring harness connector.
b. Disassemble the fastening screws of fan and take

out the fan.
2. Install the fan

a. Place the fan to the installation position and install EL
b. Connect the fan wiring harness connector.

Condenser
Replacement
1. Discharge the coolant. (Refer to “Chapter EL Electric Devices - Heating and Air
Conditioning System - Refrigerant, Replacement”)
2. Remove the condenser
a. Disassemble the fastening bolts of high and low
pressure pipelines from the condenser and move
away the high and low pressure pipelines.
Caution
After the high and low pressure pipelines are

unplugged, block the pipelines by plugs to prevent the
b. Disconnect the harness connectors between
electric fan and high and low pressure switches.
EL
c. Disassemble 4 fastening bolts of condenser and

electric fan assembly and take out the condenser
and electric fan assembly.
d. Disassemble the fastening bolts between
condenser and electric fan and separate the
condenser from electric fan.
3. Install the condenser

a. Assemble the condenser and electric fan and fix by
bolts.
b. Place the condenser and electric fan assembly to
the installation position and install and tighten the
bolts.
c. Connect the harness connectors between electric

fan and high and low pressure switches.
d. Install the high and low pressure pipelines of A/C

and fix by bolts.
4. Add the coolant. (Refer to “Chapter EL Electric Devices - Heating and Air Conditioning
System - Refrigerant, Replacement”)
EL
A/C control switch

Replacement
1. Remove the A/C control switch.
a. Pry out the A/C control switch trim panel.
b. Disconnect the control cable of A/C control switches

from HVAC assembly.
c. Disassemble the fastening screws of A/C control

EL switches, disconnect the harness connector, and
take out the A/C control switches.
2. Install the A/C control switch

a. Connect the wiring harness connector of A/C
control switch.
b. Place the A/C control switches to the installation
position and install and tighten the screws.
c. Connect the control cable of A/C control switches.
d. Install the A/C control switch trim panel.
EL
Speed regulation resistor

Replacement
1. Disassemble the speed regulation resistor.
a. Turn off the ignition switch and disconnect the
harness connector of speed regulation resistor.
b. Disassemble the fastening screws of speed

regulation resistor and take out the speed regulation
resistor.
2. Install the speed regulation resistor.

EL a. Install the speed regulation resistor and install and
tighten the fastening screws of speed regulation
resistor.
b. Connect the harness connector of speed regulation

resistor.
Instrument Panel Air Passage

Replacement
1. Remove the dashboard. (Refer to "Section BL: Vehicle body- Dashboard/ Combination
2. Disassemble the A/C air passage.
a. Disassemble all fastening screws of A/C air
passage and take out the A/C air passage.
3. Install the A/C air passage.

a. Install the A/C air passage to the installation
position and install and tighten all fastening screws
of A/C air passage.
EL
4. Install the dashboard.(Refer to "Section BL: Vehicle body- Dashboard/ Combination
Heater mechanism
Replacement
2. Discharge the coolant. (Refer to “Chapter EG Engine part -Cooling system - Coolant,
Replacement”)
4. Remove the dashboard framework(Refer to Chapter BW Body - Dashboard, Combination
Instrument, and Ashtray - Dashboard Framework, Replacement”)
5. Disassemble the heater mechanism assembly.
a. Loosen the clamps of water inlet and outlet pipes of
heater pipeline connected to the heater water tank,
shake the pipes back and forth to loosen, and then
pull out the water inlet and outlet pipes.
Caution
While pulling out the heater pipeline assembly, as the

pipeline probably still contains some coolant, cautions
shall be taken to prevent splashing onto your body.
b. Disconnect the connectors of speed regulation
EL
resistor and fan.
c. Disassemble the right fastening bolts of heater

mechanism.
d. Disassemble the left fastening nuts of heater

mechanism and take out the heater mechanism.
6. Install the heater mechanism assembly.

a. Install the heater mechanism assembly to the
installation position and install and tighten the left
fastening nuts of heater mechanism.
b. Install and tighten the right fastening bolts of heater

mechanism.
EL
c. Connect the connectors of speed regulation resistor

and fan.
d. Install and tighten the clamps of water inlet and

outlet pipes between heater pipeline and heater
water tank.
7. Install the dashboard framework.(Refer to "Section BW: Vehicle body- Dashboard/

Combination instrument/ Cigar lighter/ Ash tray- dashboard framework, Replacement".)
10. Fill the coolant. (Refer to “Chapter EG Engine part -Cooling system - Coolant,
Replacement”)
EL
A/C Filter Element/Filter Screen

Replacement
1. Disassemble the A/C filter screen.
a. Take out the glovebox in tilted direction.
b. Take out the A/C filter screen from the HVAC.
2. Install the A/C filter screen.

a. Install the A/C filter screen to the air inlet port of EL
HAVC.
b. Install the glovebox in tilted direction.

A/C Electric Fan

Replacement
1. Remove the A/C electronic fan
a. Disconnect the wiring harness connector of
electronic fan .
b. Disassemble the fastening bolts between electric

fan and condenser.
c. Take out the A/C electric fan from the bottom of
vehicle.
2. Install the A/C electronic fan

EL a. Place the A/C electric fan to the installation position.
electric fan and condenser.
c. Connect the wiring harness connector of electronic

fan .
Vehicle Control System

Vehicle Control System
General
1. Function:
a. Turn on the power supply.
b. Start and stop the engine.
2. Description on Positions of Ignition Switch
Rotation position Function
LOCK Stop gear, turn on the electric equipment when car stops, such as radio, etc.
ACC Stop gear, turn on the electric equipment when car stops, such as radio, etc.
Travel gear, turn on the electric equipment when car travels, such as
ON
instrument, preheat and wiper, etc.
Start position is used to start the engine. The ignition switch will automatically
START
return to “ON” position after the engine is started.
Precautions
1. Before turning on the ignition switch, ensure that the gearshift lever is at neutral gear and
the handbrake is applied.
2. Block the wheels by triangular woods or wedges. The triangular woods or the wedges
shall be placed closely before and after the wheels, preferably the rear wheels. EL
3. When testing the gears on the vehicle, ensure to depress and hold the clutch pedal and
ensure that the gearshift lever is in neutral gear and the handbrake is applied.
4. After the ignition key is pulled out, do not rotate the steering wheel forcibly.
Preparation
Recommended tools

Hexagon square spanner
of ignition switch bolts

may be.
EL
1. Wires of ignition switch (Power Check ignition switch wires and
failure) power on.
Poor ignition
2. Ignition switch body (Damaged) Replace ignition switch body.
Return failure of ignition switch 1. Ignition switch body (Damaged) Replace ignition switch body.
1. Ignition switch body (Damaged

Locking failure of steering wheel Replace ignition switch body.
lock part)
Ignition switch
Checking
1. Check the ignition switch assembly
a. When rotating the ignition key in turn by the
specified torque, the rotation shall be clear, without
any blockage. In event of difficult rotation, replace
the ignitions witch.
b. Rotate the ignition key and check if the steering lock

mechanism can telescope freely. In event of the
blockage or telescoping seizure, replace the ignition
switch.
EL
Replacement
1. Remove the ignition lock
a. Disassemble 2 fastening screws of the combination
switch.
b. Take out the combination switch shield.
c. Disconnect the connector of ignition switch.
d. Disassemble the fastening bolts of ignition switch

and take out the ignition switch.
EL
2. Install the ignition lock assembly

a. Install the horn to the installation position and install
and tighten the fixing bolts of the horn.
b. Connect the ignition lock connector.
c. Install combination switch shield to installation

position and install and tighten the fastening screws
of combination switch shield.
EL
Body controller
Replacement
2. Disassemble the body control module
a. Disconnect the body controller harness connector.
b. Disassemble the fastening bolts of body controller

and take out the body controller.
EL
3. Install the body control module
a. Install the body controller to the installation position
and install and tighten the fastening bolts of body
controller.
b. Connect the body controller connector.

Remote control key

Replacement
1. Disassemble the battery of remote control key
a. Separate the emitter upper housing of the key by an
appropriate tool.
b. Take out the battery of remote control key.
2. Install the battery of remote control key

a. Install new battery of remote control key.
b. Place the battery of remote control key to the
emitter housing and buckle tightly the emitter upper
housing.
EL
EL-110 Electric system- Electric circuit
Electric circuit
Circuit guide
Circuit guide
General
The manual provides circuit data for relevant vehicles and different system circuits are provided based
on functions. Each system circuit actually describes the relationship between the power supply, fuse,
relay, controls, electrical equipment, and ground points (the ignition switch is in OFF state in all circuit
diagrams).
In case of any failure phenomenon in system circuit, please understand the operating principle of circuit
(refer to system circuit). Besides, understand the power supply (refer to power supply) as well as circuit
operating process (refer to system overview). Understand the operating state of the whole system circuit
and analyze and solve problems based on failure phenomenon (such as used relay, controller, electrical
equipment and connector among harnesses, sensor, actuator, switch and circuit earth point, electric
connector position and harness layout drawing).
EL
Electric system - Electric circuit EL-111
Example of system circuit diagram

Fog lamp system
Battery
Front fog
Frame fuse lamp relay Body fuse case
box
Rear fog Front fog

EL

fog lamp lamp
Left rear fog

lamp
EL
Detailed description for circuit diagram example

No. Meaning General
1 System name Identify different systems and functions according to names for inquiring.
Identify wires with different functions based on color for inquiring and
maintenance. Single color or double colors are used for wire.
2 Wire color
For example: Br-brown; B-black; O-orange; W-white; R-red; P-pink;
Sb=sky blue; V-violet; L-blue; Gr-grey; Y-yellow; G-green; Lg=light green
Define name according to the function of electrical components in order to
Electrical
3 be convenient for query. One electric component corresponds to one
component name
name
The number of electric part connector is defined by its harness to ease the
inquiry.
For instance: The left front fog lamp is one 2-pin connector. This connector
belongs to the front bumper harness and the front bumper harness is
Electrical
4 defined as harness T. Therefore, the left front fog lamp number is defined
component number
as T005.
B = Frame harness, C = Body main harness, E = Engine harness, F =
Ceiling harness, J = Left front door harness, H = Right front door harness,
L = Rear lamp harness, T = Front bumper harness, and etc.
A connector number defined between the harness and harness,
convenient for searching the definition of its terminal.
EL
Electrical
5 component
connector pin Example of harness connector:
Connecting point of the return wire of the electric element and the vehicle
metal body. Define different numbers according different grounding points.
6 Grounding point
If “G307” indicates that it belongs to the frame harness; meanwhile, it has
“body harness connector layout” to determine its position.
The instructions of Indicate the correlation between the wire and other systems or indicate
7 related system or the components and parts connected with the wire, for details, refer to the
elements related systems indicated.
The connector No. of connectors between harnesses. One group of
8 Connector number connectors includes two connectors, a male connector and a female
connector.
Female connector Female plug
Male connector Male symbol Female plug Female symbol
9 Connector
It refers to the welding point in an electrical appliance or switch.

10 Branch It refers to the match line on the harness, and current divides from this
point.
No. Meaning General
Distinguish different systems and functions according to names for

11 System name
inquiring.
Describe the value or working status of the electrical elements, and bing
12 Maintenance guide
used as reference during troubleshooting.
Indicate the harness page to be referred to (positions of electrical
13 Parts position components and parts on the vehicle and the orientation of their
harnesses).
Indicates the reference harness page of two interconnection - connector
Connectors
14 subordinate harness (harness with female connector is before harness
between harnesses
with male connector).
Indicates the reference area of connecting point of the return wire of the
15 Ground
electric element and the vehicle metal body in the vehicle position.
EL
Example of a power supply circuit diagram

The power supply circuit diagram describes the current transmission trend of all system (fuse protector,
fuse and relay). In the power supply circuit diagram, the power supply conditions for each system are
described, because all the system circuit diagram are start from the power, so a full understanding about
the power system is very necessary, there is only an example system here which is different from the
actual system circuit .
Frame fuse box
Main relay
Engine ECU
Ignition coil 1
Ignition coil 2
Front oxygen
sensor
Rear oxygen
sensor
Fuel injector 1 E005-2

High-speed fan relay Fuel injector 4 E002-2
E020-1
Radiator fan
Engine ECU
EL
Low-speed fan relay
Radiator fan
Engine ECU
Compressor relay
Compressor B009-1
Engine ECU
Fusible wire Condenser relay
Condenser
fan
Oil pump relay
Engine ECU
Fuel
pump
Example of connector information

F Ceiling harness
F001 to front ceiling lamp
Terminal No. Wire diameter/ color Function
Front ceiling lamp door control

1 0.75L/R
switch signal
2 0.75Br/L Front ceiling lamp power supply
3 0.75B Ground
EL
No. Name Description
Describes the profile of the connector and the order of its internal
1 Connector shape
pins.
A number is defined based on the harness containing the electrical
Electrical component
2 component connector. One connector corresponds to one number,
number
used for searching.
Electrical component
3 A name is defined based on the function of the component.
name
4 Connector information Defines the color and function of the terminal wire.
Electrical part symbol

Figure Description
Battery
The stored chemical energy is converted into electric
energy required by vehicle electrical equipment.
Ground (bonding)
The cathode line of electric equipment is on the frame
and other metal parts. Use vehicle metal engine body
as the public passage and this way of connecting
cathode line and body is called grounding (bonding).
EL
Fuse protector (fuse)

Fuse In a high power circuit (or an electric equipment
circuit), if the passing current exceeds the rated load,
Fuseyer self-burning will occur to achieve the purpose of
cutoff, thus protecting the safe operation of the circuit.
Electromagnetic induction coil

When the magnetic filed has fluctuation (or is cut), the
coil loop will produce the sensing electromotive force.
Figure Description
Solenoid valve
When the current passes through the solenoid coil,
an electromagnetic field will be formed, and the
component working is controlled by the
electromagnetic field.
Single filament
illuminating lamp
Lighting lamp
It is a lighting equipment to make lamp filament
Double filament
illuminating lamp temperature rise and light when the current flows
through the lamp filament.
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Single speed motor
Motor
It turns electric energy into mechanical energy
Speed regulation motor according to electromagnetic induction principle.
Connector
It is the interconnecting plug-in between harnesses.
Figure Description
Crystal diode
It is a semi-conductor and the function is to only allow
the current to flow in the fixed direction.
LED
It is a crystal diode and the function is to translate the
electric energy into luminous energy.
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Horn
It is an electroacoustic component and the function is
to translate the electrical signal into warning sound.
Speaker
It is an electroacoustic component and the function is
to translate the electrical signal into sound wave.
Resistance
Resistance It is an electroacoustic component and the function is
to take partial pressure and current limiting.
Speed-regulating resistance
Speed-regulating resistance
N resistors are in series to change the resistance and
current in the circuit. Thus, the speed can be
controlled. (High-power status)
Slide rheostat Slide rheostat
Change the resistance of access circuit through
changing the length of resistance wire in the access
circuit so as to control the circuit. (Low-power status)
Figure Description
Temperature sensor (liquid level sensor)

It is a resistance changing with the change of
temperature (liquid level) and the function is to
translate the temperature (liquid level) into electrical
signal.
Cigar lighter
It is a resistance wire and the function is to power on
the resistance wire to generate large quantities of
thermal energy and light the cigar.
EL
Contact switch
It is a switch and the function is to connect and
disconnect the circuit through contact of two points in
the same plane.
Rotation-type switch
It is a switch and the function is to change the gear
through rotation of axes so as to connect and
disconnect the circuit.
Figure Description
Heating wire
It is a pure resistance load and the function is to
power on and heat the surrounding temperature.
Clock spring
It is used for the rotary type connector, the role of
which is to transfer current between two relatively
rotating parts.
Large relay
EL
Relay Relay
It is an automatic switch using small current to control
large current and the function is automatic
adjustment, safety protection and switching circuit.
Small relay
Fuse and relay

Cab fuse case
EL
Fuse
No. Name Rated current No. Name Rated current
IF03 Left high beam fuse 10A IF14 Brake lamp fuse 7.5A
Instrument and audio

IF04 Right high beam fuse 10A IF15 5A
system fuses
IF05 Front fog lamp fuse 15A IF16 Lighting switch fuse 5A
IF06 Wiper fuse 10A IF17 Instrument IG fuse 7.5A
Turn signal lamp and

IF07 10A IF18 ECU fuse 7.5A
reversing lamp fuses
Daytime running lamp

IF08 5A IF21 Cigarette lighter fuse 15A
fuse
Heater control and audio
IF09 Ceiling lamp fuse 5A IF22 7.5A
system fuses
IF10 Left low beam fuse 10A IF23 Power socket fuse 15A
IF11 Right low beam fuse 10A IF24 Horn fuse 7.5A
IF12 Marker lamp fuse 7.5A IF29 Fan fuse 25A
Hazard warning lamp

IF13 15A IF30 Fan signal fuse 5A
switch fuse
Major fuses
EL
IF33 EPS fuse 40A IF35 Ignition switch fuse 30A
IF34 BCM fuse 25A
Small relay
S/N Name No. Name
IR02 Front fog lamp relay IR13 Small lamp relay
IR11 Horn relay

Large relay
S/N Name No. Name
IR04 Flasher relay IR07 Low-beam relay
IR06 High-beam relay IR08 Heater relay
EL
Frame fuse box
EL
Fuse
S/N Name Rated current No. Name Rated current
EF06 Ignition coil fuse 15A EF14 ECU power fuse 5A
EF07 Oxygen sensor fuse 15A EF15 Main relay power fuse 30A
EF08 Nozzle and valve fuses 15A EF18 Reserved 10A
EF10 Compressor fuse 7.5A EF19 Reserved 10A
EF11 Condenser fuse 30A EF20 Reserved 15A
EF12 Fuel pump fuse 10A EF21 Reserved 30A
EF13 Cargo body lamp fuse 15A

Major fuses
EF02 Ignition switch fuse 40A EF04 Lighting fuse 40A
EF03 BCM&EPS fuse 60A EF05 Fan fuse 40A
Small relay
EL
S/N Name No. Name

ER01 Compressor relay ER05 Fuel pump relay
ER04 Condenser relay
Large relay
S/N Name No. Name
EF02 High-speed fan relay ER06 ECU relay
ER03 Low-speed fan relay

Plate fuse
EF01 Charging fuse 100A
EL
Troubleshooting
1. Precautions
a. The harness shall be fixed by the snap spring or cable clamp to avoid loosening and wear.
b. The harness shall not be connected too tightly, especially at the turning point. The rubber or
insulation pipe shall be used for protection where the harness turns around an acute angle or
metal hole; otherwise, the harness is easily worn to generate short circuit or grounding, and
possibly cause fire.
c. When connected to the electrical appliances, the harness shall be connected respectively
according to the specifications of connectors and the color of wires or insulation pipes at the joint.
When the head and tail of the wire are difficult to identify, they can be generally distinguished by a
test lamp instead of fire test, because the use of sparkling test method, because in the power
supply system, the sparkling test is easy to burn out the wire.
2. Replacement of connector
a. Press down the connector latch.
EL b. Draw the connector towards both sides, and do not

draw the wire too hard directly.
c. Pick out the protective sleeve in the connector by a

small screwdriver. If there is no protective sleeve,
go to the next step directly.
d. Pry out by a small screwdriver the protective

sleeve from the inside of the connector. If no
protective sleeve is present, proceed to next step
directly.
Caution
When pulling out the terminal, record the jack

corresponding to the each terminal, which can raise
the installation speed and avoid reviewing the
terminal.
e. Use a new connector, adjust the wire terminal to a

proper angle and insert into the connector.
Caution
It is necessary to tide the terminal leads, and the

crossed leads are not allowed.
EL
f. Install the protective sleeve in the connector, and

compact it.
g. Connect the connectors at both ends. The

connection is not completed until the “pop” sound
is heard.
Caution
After the connection, gently pull the two ends

outwards; In case of separation, it indicates that the
connector is damaged, and it is necessary to replace
it.
3. Replacement of terminal
a. Take down the old terminal.
b. Peel off a section of insulation layer at the tail end
of the wire.
c. Select the insulation pipe and wire terminal of a

proper size, and put them on the end of the wire.
EL
d. Use pliers to clamp the wire connecting handle part

with the insulation layer and the wire core
respectively.
4. Repair of the broken wire

a. The wire in the harness is usually broken due to wear, vibration or accidental load. Usually, it can
be repaired by broken-point welding method, sleeve-pressing method or additional connector
method.
b. Broken-point welding method.

• Respectively peel off a section of insulation lay at
both ends of the broken point.
• Wind the two wire cores together by pliers.
• Use an electric soldering iron to heat the wire

cores.
EL
• After heating the wire cores, weld the wire cores by

using rosin and solder to be in contact with the
heated wire cores so as to repair the broken wire.
c. Sleeve-pressing method.
• Insert the two wire cores in a special copper joint

sleeve.
• Use pliers to press the wire cores and the copper

joint sleeve into a whole.
• Perform insulation-binding treatment.
EL
d. Connector method.
• Respectively arrange the two wire cores on the

plug-in chips of connectors.
• Connect connectors.
EL
Electric circuit
System circuit diagram

Circuit diagram of power source
System Power Distribution 1
Frame fuse box
Main relay
Engine ECU
Ignition coil 1
Ignition coil 2
Front oxygen
sensor
Rear oxygen
sensor

High-speed fan relay Fuel injector 4 E002-2
E020-1
Radiator fan
Engine ECU
Low-speed fan relay
EL
Radiator fan
Engine ECU
Compressor relay
Compressor B009-1
Engine ECU
Fusible wire Condenser relay
Condenser
fan
Oil pump relay

Battery
Engine ECU
Fuel
pump
Frame fuse box
Generator B+B007-1
Dashboard fuse
box
Dashboard fuse
box
Dashboard fuse box
EL
Cargo
compartment
lamp
Engine ECU
Fusible wire
Battery
Starter
Body fuse case
High-beam relay
Lighting
combination
switch
Left front combination lamp
C005-2
C019-8
Right front
combination
lamp
Low-beam relay
Lighting
combination
switch

C005-3,4
Combination instrument B
C020-28
Right front
combination
lamp
EL
Front fog lamp relay
Rear fog lamp switch C011-5

Front fog lamp switch C010-2
C019-11
Right front fog lamp T002-2
Left front fog lamp T005-2
Small lamp relay
Small light switch C017-3
Front fog lamp
switch
Rear fog lamp switch
Headlamp adjustment switch
A/C control panel
Radio/audio player
Hazard warning lamp switch
Right front combination lamp
Left rear combination lamp
Right rear combination lamp
Body fuse case
Front
roof
lamp
Hazard warning
lamp switch
Diagnostic
interface
Brake
switch
Combination
instrument A
Radio/audio
player
Small lamp
switch
Lighting
combination switch
Electric-assisting
power supply
EL
Horn relay
Horn
switch
Electric
horn
Ignition
switch
Heater relay
A/C control
panel
Blower
A/C control panel 1
Ignition
switch
Ignition switch
Body fuse case
Cigarette
lighter
Starter coil
Power
socket
Wiper combination
switch
Wiper intermittence relay
Wiper motor
Hazard warning
lamp switch
Generator
EL Reversing lamp
switch
Frame
fuse box Combination instrument A
Combination
instrument B
Engine ECU
Fusible
wire
Daytime running
lamp switch
Right daytime
running
Left daytime
running
Battery
System description:
• The system power supply is that the battery provides power supply to the whole vehicle via GF\L1
from eleven fuses EF01, EF02, EF03, EF04, EF05, EF10, EF11, EF12, EF13, EF14, and EF15 in
the frame fuse case to power on the frame fuse case, body fuse case, and electric devices.
• The power supply is supplied to the charging system via fuse EF01.
• The power supply is supplied to the horn, cigarette lighter, wiper and washer, combination
instrument, turn signal lamp and hazard warning lamp, and A/C system via fuse EF02 from the
ignition switch and the relevant fuses and relays in body fuse case.
• The power supply is supplied to the electronic power steering (EPS) system and body control
system via fuse EF03 from relevant fuses in body fuse case.
• The power supply is supplied to the interior lamp, turn signal lamp and hazard warning lamp,
diagnostic interface, brake lamp, combination instrument, audio system, front fog lamp, headlamp,
daytime running lamp, and A/C system via fuse EF04 from relevant fuses and relays in the body
fuse case.
• The power supply is supplied to the A/C system and engine electronic control system via fuse
EF05 from relevant relays in frame fuse case.
• The power supply is supplied to the engine electronic control system via fuse EF12 from relevant
relays in frame fuse case. EL
• The power supply is supplied to the cargo body lighting system via fuse EF13.
• The power supply is supplied to the engine electronic control system via fuse EF14.
• The power supply is supplied to the engine electronic control system via fuse EF15 from relevant
relays and fuses in frame fuse case.
：Connector between harnesses
Reference harness (Location of

S/N S/N
connector)
Frame harness and body main
B001 C032 harness (On right body electric box
of instrument panel)
: Ground
Location of grounding Location of grounding

S/N S/N
point point
Battery negative frame Ground connection point
G001 G205
ground 1 of left body
Ground
Grounding point 1
Battery negative pole
Front fog lamp

switch
Rear fog lamp

switch
Daytime running
lamp switch
Headlamp
adjustment switch
Hazard warning
lamp switch
Brake fluid level

warning switch
Left front
combination lamp
EL Driver door electric

window switch
Driver door electric

window switch
Left door lock
Left side turn

signal lamp
Right front
combination lamp
EPS controller
Grounding point 2
Diagnostic
interface
Wiper intermittent
relay
Washer
motor
A/C control panel

2
A/C control panel

1
Front fog lamp

relay
Flasher relay
High-beam
relay
Low-beam
relay
EL
Small lamp
relay
Cigarette
lighter
Power
socket
Wiper
motor
Front roof
lamp
Front passenger door

electric window switch
Grounding point 3
Left front
combination lamp
Right front
combination lamp
Left side turn

signal lamp
Engine ECU
Engine ECU
Engine ECU
Engine ECU
Knock sensor
EL Odometer sensor
Crankshaft position
sensor
Seat belt switch
Engine ECU
Radiator fan
Grounding point 4
Electric
horn
Condenser fan
Left fog
lamp
Fog lamp
(RH)
Left day
running lamp
Right daytime
running lamp
Fuel pump
Radio/audio
player
EL
Combined
instrument A
Combined
instrument B
Left rear
combination lamp
Cargo
compartment lamp
License
light
Reversing sensor
controller
Right rear
combination lamp
: Connector between harnesses
No. S/N Reference harness (Location of connector)
Frame harness and body main harness (On right body electric box of
B002 C040
instrument panel)
Frame harness and body main harness (On right body electric box of
B004 C042
instrument panel)
Frame harness and front bumper harness (Beneath right front
B006 T001
combination lamp and near electric horn)
Frame harness and rear lamp harness (Fixed on left rear crossbeam
B020 L001
of frame)
Body main harness and left front door harness (On inner side of left
C001 J001
A-pillar trim panel of instrument panel)
Body main harness and left front door harness (On inner side of left
C002 J002
A-pillar trim panel of instrument panel)
Body main harness and ceiling harness (Inner side of right A-pillar
C036 F002
trim panel)
Body main harness and right front door harness (On inner side of
C043 H001
right A-pillar trim panel of instrument panel)
Body main harness and right front door harness (On inner side of
C044 H002
right A-pillar trim panel of instrument panel)
E006 R001 Engine harness and rear wall harness (Beneath driver seat)
EL
Engine electronic control system

Engine electronic control system 1

box case
Main relay Oil pump

relay
Fuel pump
EL
Battery power Main relay Fuel pump relay Main relay Main relay Main relay IG1 power
supply control control output power output power output power
supply 1 supply 2 supply 3
Engine
Crankshaft
Sensor + position signal Actuator A+ Actuator B- Actuator B+ Actuator A- Ground Ground Ground Ground Ground
Crankshaft position sensor Stepping motor

Battery
Frame fuse box
Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4 Canister solenoid valve
Compressor
relay
Compres
sor
EL
Compressor relay Fuel injector 1 control Fuel injector 2 control Fuel injector 3 control Fuel injector 4 control Canister solenoid valve
control control
Engine
Throttle Camshaft position Intake temperature Intake pressure A/C request Assisted idling
Sensor+ position signal Sensor- signal signal signal signal up signal
Crankshaft position sensor Sensor for camshaft position sensor Intake pressure & temperature sensor To pressure switch To EPS sensor
Frame fuse
box
1st cylinder 4th cylinder 2nd cylinder 3rd cylinder

spark plug spark plug spark plug spark plug Self grounded
Front oxygen Rear oxygen

sensor sensor
Ignition Ignition
coil 1 coil 2
EL
Upstream Upstream Upstream Downstream Downstream 1st/4th cylinder 2nd/3rd cylinder

oxygen sensor oxygen oxygen sensor - oxygen sensor oxygen ignition control ignition control
heating control sensor heating control sensor signal
signal
Engine
Coolant temperature Knock sensor - Evaporator

sensor Sensor- Signal temperature signal
K line
Coolant temperature sensor Knock sensor Evaporator temperature sensor Diagnostic interface
To lighting To combined To EPS control To combined To combined To combined To combined To EPS control
unit instrument B instrument B instrument A instrument A unit To BCM-1
combination switch instrument A
EL Headlamp load
signal
RPM output Engine failure
indication
SVS indicator lamp Water temperature Vehicle speed signal
output input
Engine
System description:
The diesel engine management system is mainly composed of sensor signal input, electronic control
module, and actuator.
Signal input
The various sensors acquire the related signals, convert to electric signals, and transmit to the engine
ECU while monitoring the running status of the engine.
It measures the coolant temperature and converts this signal to an electric signal to control the water
tank fan, correct the fuel injection volume, and influence the idling control. The signal is transmitted from
the pin 1 of water temperature sensor E012 to the pin 39 of engine ECU E001.
It judges the engine crankshaft position. The crankshaft position signal is transmitted from pin 2 of
crankshaft position sensor E015 to pin 34 of engine ECU E001.
Intake pressure/temperature sensor
It judges the intake pressure and temperature and calculates the intake volume. The intake temperature
signal is transmitted from the pin 3 of intake pressure/temperature sensor E019 to pin 42 of engine ECU
E001 and the intake pressure signal is transmitted from pin 1 of intake pressure/temperature sensor
E019 to pin 37 of engine ECU E001.
It measures the throttle position to control the fuel injection volume and check the running status of
engine. The throttle position signal is transmitted from pin 3 of throttle position sensor E022 to pin 38 of
engine ECU E001.
Knock sensor
It monitors the engine for presence of knock and corrects the ignition advance angle. The knock signal is
transmitted from pin 2 of knock sensor E018 to pin 19 of engine ECU E001.
Oxygen sensor
It monitors the concentration of oxygen contained in the exhaust gas and transmits feedback signal to
the engine to thus control the fuel injection volume and air injection volume.
Electronic control module
The electronic control module refers to the engine ECU, which is functioned to continuously monitor and
control the running status of the engine and is the core control unit. The ECU acquires the current
working information of engine via various sensors, performs analysis and calculation, and controls the
fuel injection volume, air injection volume, fuel injection timing, and ignition timing of the engine as per
the pre-calibrated optimal working parameters for corresponding condition, in order to adjust the working
status of engine and realize the fuel-saving, high efficiency, and low emission.
Execution of Controls
Fuel pump
The running of electric fuel pump is realized by controlling the actuation of fuel pump relay ER05 via pin
70 of ECU E001.
EL
Compressor
Based on the signal of water temperature sensor, the ECU controls via pin 69 the compressor relay
ER01 to control the running of compressor.
Fuel injection nozzle
A control solenoid valve is installed on the top of fuel injector. The engine ECU controls the power-on
and power-off of control solenoid valve to control the fuel injection timing and volume for the fuel
injectors of all cylinders.
Ignition coil
The ECU issues commands to the ignition coils to control the ignition timing and the high voltage
generated by the ignition coils is transmitted to the spark plugs to generate sparks.
Based on the signals provided by various engine sensors, the engine ECU controls the energization time
of the carbon canister solenoid valve and thus indirectly controls the cleaning airflow rate.
Stepping motor
The rotor is a permanent magnet with a nut in the center. All stator coils are constantly energized. The
ECU changes the running direction of the motor by changing the current direction of one coil to realize
the adjustment of idling speed.
： Locations of part
S/N Reference harness S/N Reference harness
E001 Engine harness E018 Engine harness
E007 Engine harness B009 Frame harnesses
E012 Engine harness C003 Body main harness
E017 Engine harness
EL : Connector between harnesses

S/N S/N
connector)
Frame harness and engine
B012 E009
harness (Beneath driver seat)
B013 E008
: Ground

S/N S/N
point point
Battery negative earthing
G301 Engine ground point 1 G305
point
G302 Engine ground point 2

Starter system
Circuit diagram
Frame fuse box Body fuse case
Ignition switch
Fusible wire
EL
Battery
Starter
System description:
The battery current is supplied via fusible wire, fuse EF02 in frame fuse case, and fuse IF35 in body fuse
case to the pin 4 of ignition switch C015 and is outputted from pin 5 of C015 to the pin 1 of starter motor
E021 and to the starter electromagnetic switch so that the electromagnetic switch is energized to
generate a magnetic field and close the contact switch of starter motor. The battery current is supplied
via contact of starter motor to the starter motor so that the starter motor drives the rotation of engine
flywheel via gears.
： Locations of part
B014 Frame harnesses C045 Body main harness
C015 Body main harness E021 Engine harness

S/N S/N Reference harness (Location of connector)
Frame harness and body main harness (On right body electric
B001 C032
box of instrument panel)
Frame harness and body main harness (On right body electric
B003 C041
B012 E009 Frame harness and engine harness (Beneath driver seat)
: Ground
Location of grounding
S/N
point
G001
point
EL
Charging system
Circuit diagram

box case
Ignition switch
Fusible wire
To combined
instrument
EL
Battery
Generator
System description:
When the ignition switch is at ON position, the current is supplied via pin 2 of ignition switch C015 to pin
3(L) of alternator B008 and to the alternator so that the current is supplied to the alternator excitation
winding via its internal voltage regulator and the excitation winding is energized to generate a magnetic
field.
While the alternator is rotating, the stator coil cuts the magnetic lines of force to generate three-phase
induced electromotive force, which is converted by rectifier composed of diodes to DC and then is
outputted from pin B of alternator via fuse EF01 in frame fuse case and fusible wire to charge the battery
and power on other electric devices.
Service tips:
• Generator
IG - Ground: When the alternator rated speed is 6,000r/min, the outputted rated voltage of
alternator is 12V.
: Locations of part
B04 Frame harnesses

S/N S/N
connector)
: Ground
EL Location of grounding
S/N
point
G001
point
Ignition switch system

Circuit diagram

box case
Ignition switch
Fusible wire
EL
Battery
To EPS ECU Engine ECU To wiper combination switch To hazard warning lamp switch To power socket To cigarette lighter
Combined instrument A
Combined instrument B Wiper intermittence relay Generator
Reversing lamp switch
Wiper motor
System description:
The battery power supply is supplied via fusible wire and fuse EF02 in the frame fuse case to the
instrument panel fuse case and is outputted via fuse IF35 in body fuse case to pin 4 of ignition switch
C015 as the power supply of ignition switch.
ACC power supply
When the ignition switch is at ACC position, the pin 4 and pin 1 of the ignition switch C015 are connected
so that the pin 4 outputs ACC power supply to the cigarette lighter and power socket system.
ON power supply
When the ignition switch is at ON position, the pin 4 of ignition switch C015 is connected with pins 1, 2,
and 6 and the current is outputted to the combination instrument, wiper and washer, reversing lamp,
cigarette lighter, T-BOX, and steering and hazard warning systems as the triggering power supply.
ST power supply
When the clutch pedal is depressed, the transmission is shifted to neutral gear, and the ignition switch is
rotated to ST position, the pins 4 and 5 of ignition switch C015 are connected, the ST signal is outputted
via pin 5 to pin 1 of starter motor E021, and the starter motor is self-grounded to start the engine. After
the start of engine, the starter motor stops and the ignition switch automatically rotates from ST position
to ON position. The pins 4 and 6 of ignition switch C015 are connected and the IG signal is outputted
from pin 6 to combination instrument, T-BOX, engine electronic control, and electronic power steering
system as the triggering power supply.
: Locations of part
C015 Body main harness

S/N S/N
connector)
: Ground
S/N
point
EL G001
point
Central control lock system

Circuit diagram

box case
Battery power
supply
Battery power
supply
IG1 power EL


door (LH)
System description:
The battery power supply is supplied from fuse EF03 in frame fuse case via fuse IF34 in body fuse case
to pins 1 and 2 of central control lock controller C035. When the ignition switch is at IG1 position,
the battery power supply is supplied via fuse IF17 in body fuse case to the pin 1 of central control lock
controller C034 as the IG1 power supply.
When a front door is opened, the switch on the front door lock sends a signal to pin 16 of central control
lock controller C035 and the central control lock controller controls the front door lock motor to fulfill the
unlocking function.
When a front door is closed, the switch on the front door lock sends a signal to pin 17 of central control
lock controller C035 and the central control lock controller controls the front door lock motor to fulfill the
locking function.
: Locations of part
C034 Body main harness J008 Left front door harness
C035 Body main harness H007 Right front door harness

EL S/N S/N
connector)
B001 C032 harness (On right body electric
Body main harness and left front
door harness (On inner side of
C001 J001
left A-pillar trim panel of
instrument panel)
C002 J002
left A-pillar trim panel of
instrument panel)
Body main harness and right front
C044 H002
right A-pillar trim panel of
instrument panel)
: Ground

S/N S/N
point point
Ground connection point Ground connection point
G201 G206
1 of left body 2 of left body
Cigarette lighter system

Circuit diagram
Ignition switch ACC
Body fuse
case
Cigarette
lighter
EL
System description:
The battery power supply is supplied via fuse IF21 in body fuse case to the pin 1 of cigarette lighter C028
and is grounded at pin 2 via resistive heater of cigarette lighter.
: Locations of part
C028 Body main harness C045 Body main harness
: Ground
S/N
point
Ground connection point
G206
2 of left body
Turn signal lamp and hazard warning lamp system

Circuit diagram
Frame fuse Flasher Body fuse

box case
To small lamp relay
Hazard
Closed warning switch Lighting combination
switch
Open Left turn
EL Right
steering
Left
front Left side Right rear
turn turn Left rear Right front Right side turn
signal signal turn signal turn signal turn signal signal
lamp lamp lamp lamp lamp lamp
To combined To BCM-2 To BCM-2 To combined

instrument B instrument A
System description:
to pin 5 of hazard warning lamp switch C025 to power on the hazard warning lamp. When the ignition
switch is at IG2 position, the current is outputted from ignition switch via fuse IF07 in body fuse case to
pin 6 of hazard warning switch C025 so that the pins 6 and 4 of hazard warning switch C025 are
internally connected and the current is outputted from pin 4 of hazard warning switch C025 to pin B of
flasher IR04 in body fuse case and is outputted via pin L of flasher IR04 to pin 2 of lighting combination
switch C018 to power on the turn signal lamp.
Left turn lamp
When the lighting combination switch is placed at left turn position, the pins 1 and 2 of lighting
combination switch are connected so that the pin 1 of lighting combination switch C018 outputs left turn
signal information, which is divided into 5 circuits:
a. The output is grounded via pin 7 of left front turn signal lamp C005, lamp filament, and pin 1 so
that the left front turn signal lamp works.
b. The output is grounded via pin 1 of left turn signal lamp J003, lamp filament, and pin 2 so that the
left turn signal lamp works.
c. The output is grounded via pin 1 of left rear combination lamp L002, lamp filament, and pin 6 so
that the left rear turn signal lamp works.
d. The output is grounded via pin 25 of combination instrument B C020 and the inside of
combination instrument so that the left turn signal lamp indicator lamp works.
e. It’s supplied to pin 9 of BCM C035 to provide the left turn signal for BCM.
Right turn lamp
When the lighting combination switch is placed at right turn position, the pins 2 and 3 of lighting
EL
combination switch are connected so that the pin 3 of lighting combination switch C018 outputs right turn
signal information, which is divided into 5 circuits:
a. The output is grounded via pin 7 of right front turn signal lamp C038, lamp filament, and pin 1 so
that the right front turn signal lamp works.
b. The output is grounded via pin 1 of right door turn signal lamp H003, lamp filament, and pin 2 so
that the right door turn signal lamp works.
c. The output is grounded via pin 1 of right rear combination lamp L010, lamp filament, and pin 6 so
that the right rear turn signal lamp works.
d. The output is grounded via pin 24 of combination instrument A C019 and the inside of
combination instrument so that the right turn signal lamp indicator lamp works.
e. It’s supplied to pin 10 of BCM C035 to provide the right turn signal for BCM.
Hazard warning lamp
When the hazard warning lamp switch is pressed, the pins 5 and 3 of hazard warning lamp switch C025
are connected so that the current is outputted from pin 4 of hazard warning lamp switch C25 to pin B of
flasher IR04 in body fuse case and is outputted from pin L of flasher to pin 2 of hazard warning lamp
switch C025 to provide the hazard warning lamp switch turn-on signal, which is outputted from pin 1 of
C025 and is divided into 5 circuits:
a. The output is grounded via pin 7 of left front turn signal lamp C005, lamp filament, and pin 1 so
that the left front turn signal lamp works.
b. The output is grounded via pin 1 of left turn signal lamp J003, lamp filament, and pin 2 so that the
left turn signal lamp works.
c. The output is grounded via pin 1 of left rear combination lamp L002, lamp filament, and pin 6 so
that the left rear turn signal lamp works.

d. The output is grounded via pin 25 of combination instrument B C020 and the inside of
combination instrument so that the left turn signal lamp indicator lamp works.
e. It’s supplied to pin 9 of BCM C035 to provide the left turn signal for BCM.
The signal is outputted from pin 3 of C025 and is divided into 5 circuits:
a. The output is grounded via pin 7 of right front turn signal lamp C038, lamp filament, and pin 1 so
that the right front turn signal lamp works.
b. The output is grounded via pin 1 of right door turn signal lamp H003, lamp filament, and pin 2 so
that the right door turn signal lamp works.
c. The output is grounded via pin 1 of right rear combination lamp L010, lamp filament, and pin 6 so
that the right rear turn signal lamp works.
d. The output is grounded via pin 24 of combination instrument A C019 and the inside of
combination instrument so that the right turn signal lamp indicator lamp works.
e. It’s supplied to pin 10 of BCM C035 to provide the right turn signal for BCM.
: Locations of part

EL
C025 Body main harness L002 Harness, taillight

S/N S/N
connector)
Frame harness and rear lamp
B020 L001 harness (Fixed on left rear
crossbeam of frame)
door harness (On inner side of left
C001 J001
A-pillar trim panel of instrument
panel)
door harness (On inner side of right
C043 H001
panel)
: Ground

S/N S/N
point point
G201 G207
Ground connection point Rear lamp grounding
G202 G307
2 of left body point
G205
1 of left body
EL
Brake lamp system

Circuit diagram
Battery

box case
Brake switch
EL

light brake light
System description:
to pin 1 of brake switch C007 to power on the brake lamp. When the brake pedal is depressed, the brake
lamp switch closes and the pin 2 of brake lamp switch connector C007 outputs a signal to pin 4 of left
rear and right rear brake lamps respectively. This signal is grounded via the brake lamp filament by pin 6
of corresponding brake lamp so that the brake lamp works.
Service tips:
· C007 Brake lamp switch
1-2: The pins are connected when the brake pedal is depressed.
: Locations of part
B014 Frame harnesses L002 Harness, taillight

S/N S/N
connector)
B001 C032 harness (On right body electric box EL
crossbeam of frame)
: Ground
S/N
point
Rear lamp grounding
G307
point
Reversing lamp system

Circuit diagram
Ignition switch IG2
Body fuse
case
Reversing
lamp switch
Right rear
reversing lamp
EL
System description:
When the ignition switch is placed at IG2 position, the current is supplied from pin 2 of ignition switch via
fuse IF07 in body fuse case to pin 1 of reversing lamp switch E016 to power on the reversing lamp.
When the transmission is shifted to reverse gear, the reversing lamp switch closes and the current is
outputted from pin 2 of reversing lamp switch to pin 2 of right rear combination lamp L010 and is
grounded by pin 6 of right rear combination lamp via reversing lamp filament so that the reversing lamp
works.
Service tips:
· E016 Rearview lamp switch
1-2: The pins are connected when the transmission gearshift lever is in reverse gear.
: Locations of part
E016 Engine harness

S/N S/N
connector)
B013 E008
crossbeam of frame)
: Ground
S/N
point
G307
Rear lamp grounding EL
point
Fog lamp system

Circuit diagram
Battery
Front fog
box case
EL Front fog
lamp switch
Rear fog
lamp switch

fog lamp lamp
Left rear fog

lamp
System description:
Front Fog Lamp
Working condition: The marker lamp must be turned on.
The battery power supply is supplied from fuse EF04 in frame fuse case to pin 3 of front fog lamp relay
IR02. When the front fog lamp switch is turned on, the coil of the front fog lamp relay IR02 is energized to
generate a magnetic field and close the contacts (3-5). The current is outputted from pin 5 of front fog
lamp relay IR02 via front fog lamp fuse IF05 to pin 2 of left front fog lamp T005 and pin 3 of right front fog
lamp T002 and the pin 2 of left front fog lamp T005 and pin 1 of right front fog lamp T002 are grounded
so that both left and right front fog lamps work. Meanwhile, the current is outputted from pin 5 of front fog
lamp relay IR02 via front fog lamp fuse IF05 to pin 11 of combination instrument A C019 and the pin 25 of
combination instrument A C019 is grounded so that the front fog lamp indicator lamp works.
Rear fog lamp
Working condition: The marker lamp and front fog lamp must be turned on.
When the rear fog lamp switch is turned on, the current is outputted from pin 5 of front fog lamp switch
C011 to pin 2 of rear fog lamp switch C010 so that the pins 2 and 5 of rear fog lamp switch C010 are
connected. The current is outputted from pin 5 of rear fog lamp switch C010 to the pin 3 of left rear fog
lamp L002 and the pin 6 of left rear fog lamp L002 is grounded so that the left rear fog lamp works.
Meanwhile, the current is outputted from pin 5 of rear fog lamp switch C010 to pin 1 of combination
instrument A C019 and the pin 25 of combination instrument AC019 is grounded so that the rear fog
lamp indicator lamp works.
Service tips:
· C011 Front fog lamp switch EL
2-5: The pins are connected when the front fog lamp switch is turned on.
· C010 Rear fog lamp switch
2-5: The pins are connected when the rear fog lamp switch is turned on.
: Locations of part
B014 Frame harnesses T002 Front bumper harness
C010 Body main harness T003 Front bumper harness

S/N S/N
connector)

S/N S/N
connector)
Frame harness and front bumper
harness (Beneath right front
B006 T001
combination lamp and near electric
horn)
crossbeam of frame)
: Ground

S/N S/N
point point
G201 G304 Frame ground point 2
1 of left body
G205 G307
EL
Headlamp system
Circuit diagram
Battery
Frame fuse
box
Low beam High beam

case
Small lamp
relay
EL
Headlamp
adjustment
switch
Lighting
Low combination
beam switch
High
beam
Overtakin
g lamp

Right front high
Left
Left front high
Right front
combination
low beam
combination
front lamp lamp
beam
beam
low
beam
Small
lamp
Headlamp
Small light switch
To engine ECU
System description:
The battery current is supplied from fuse EF04 in frame fuse case via fuse IF16 in body fuse case to pin
2 of marker lamp switch C017. When the marker lamp switch is rotated to headlamp position, the pins 2
and 1 of marker lamp switch C017 are connected so that the current is outputted from pin 1 of marker
lamp switch C017 to pin 6 of lighting combination switch C018 to provide control power supply for
headlamp.
Low beam control
When the lighting combination switch is placed at low beam position, the pins 6 and 5 of lighting
combination switch C018 are connected and the current is outputted from pin 5 of lighting combination
switch C018 to pin 86 of low beam relay IR07 in body fuse case and the pin 85 of low beam relay IR07 is
grounded so that the coil is energized to generate a magnetic field and close the contacts. The battery
current is outputted from fuse EF04 in frame fuse case to pin 30 of low beam relay IR07 in body fuse
case. After the contact of low beam relay IR07 closes, the current is outputted from pin 87 of low beam
relay IR07 via left low beam fuse IF10 to pin 3 of left front combination lamp C005 and is grounded by
the pin 1 via left low beam filament so that the left low beam works. Meanwhile, the current is outputted
from right low beam fuse IF11 to pin 3 of right front combination lamp C036 and is grounded by the pin 1
via right low beam filament so that the right low beam works.
High beam control
When the lighting combination switch is placed at high beam position, the pins 6 and 4 of lighting
combination switch C018 are connected and the current is outputted from pin 4 of lighting combination
switch C018 to pin 86 of high beam relay IR06 in body fuse case and the pin 85 of high beam relay IR06
is grounded so that the coil is energized to generate a magnetic field and close the contacts. The battery
EL current is outputted from fuse EF04 in frame fuse case to pin 30 of high beam relay IR06 in body fuse
case. After the contact of high beam relay IR06 closes, the current is outputted from pin 87 of high beam
relay IR06 via left high beam fuse IF03 to pin 2 of left front combination lamp C005 and is grounded by
the pin 1 via left high beam filament so that the left high beam works. Meanwhile, the current is outputted
from right high beam fuse IF04 to pin 2 of right front combination lamp C036 and is grounded by the pin 1
via right high beam filament so that the right high beam works.
Service tips:
· Lighting combination switch C018
Low beam position: Pins 6-5 are connected.
High beam position: Pins 6-4 are connected.
Overtaking position: Pins 6-5 and pins 7-4 are connected.
: Locations of part


S/N S/N
connector)
: Ground

S/N S/N
point point
G201 G205
G202 G207
EL
Horn system
Circuit diagram
Battery
Frame fuse
box
Body fuse
case
EL Horn relay
Electric horn
Horn switch
System description:
The battery power supply is supplied via fuse EF02 in frame fuse case to the pin 1 and pin 3 of the fuse
IF24 and horn relay IR11 respectively in the body fuse case. When the horn switch is pressed, the horn
switch is self-grounded and the coil of horn relay IR11 is energized to generate a magnetic field and
close the contact of horn relay IR11 so that the current is outputted via pin 5 of horn relay IR11 to the pin
1 of electric horn B005 and is grounded by the pin 2 of B005 via the coil in the horn to sound the horn.
Service tips:
• B005 electric horn
1－2: About 2Ω
: Locations of part

S/N S/N
connector)
EL
: Ground
S/N
point
G304 Frame ground point 2

Reversing sensor system

Circuit diagram
Ignition switch IG2
Body fuse
case
Radio/audio
Reversing Reversing sensor Reversing player
Reversing
lamp switch
EL Reversing sensor
controller power supply
Multimedia reversing Multimedia reversing
sensor signal sensor -
Reversing
sensor
controller
Left sensor Left sensor Left middle Left middle sensor Right middle Right middle sensor Right sensor Right sensor
probe - probe signal sensor probe - probe signal sensor probe - probe signal probe - probe signal Ground
signal signal
System description:
Ignition switch power supply
When the ignition switch is placed at IG2 position, the current is outputted from ignition switch via fuse
IF07 in body fuse case to pin 1 of reversing lamp switch E016. When the gearshift lever is shifted to
reverse gear, the reversing lamp switch closes and the current is outputted from pin 2 of reversing lamp
switch E016 to pin 9 of reversing sensor controller L009 to power on the reversing sensor controller for
normal functioning.
Probe, backup sensor
When the reversing sensor controller is powered on, the sensor probes are powered on for working.
After processing the received signals of sensor probes, the reversing sensor controller issues the
sounds of different frequencies based on the spacing to obstacles.
: Locations of part
E016 Engine harness L009 Harness, taillight
L003 Harness, taillight

EL

S/N S/N
connector)
B013 E008
crossbeam of frame)
: Ground
No.
point
Rear lamp grounding
G307
point
Instrument system
Instrument system 1

Ignition switch IG1
Small
box relay case
Buzzer
EL PS module
Position Combined
Back lamp
light

speed signal

control unit
Instrument system 2
To lighting

of right indicator lamp indicator lamp indicator
indicator lamp lamp indicator lamp
steering lamp lamp
Combined
instrument
EL
lamp
Driver
Brake
seat belt
fluid level
switch
warning
switch


Instrument system 3

alarm lamp lamp
Combined
instrument
Fuel sensor
EL
System description:
31 of combination instrument A C019 to provide battery power for the combination instrument.
When the ignition switch is at IG1 position, the current is supplied from fuse IF17 in body fuse case to pin
32 of combination instrument A C019 and pin 26 of combination instrument BC020 to provide the IG
power supply.
Low fuel level indicator lamp
The low fuel level warning signal is outputted from pin 3 of fuel sensor B017 to pin 26 of combination
instrument A C019. The pin 1 of fuel level sensor B017 is internally grounded via the pin 26 of
combination instrument A C019 to check the fuel level.
Charging malfunction indicator lamp
The current is outputted via pin 7 of combination instrument A C019 to pin 2 of alternator B008 to check
whether the alternator is working normally.
Parking brake warning lamp
The current is outputted from pin 29 of combination instrument B C020 to pin 1 of handbrake switch
R003 and the handbrake switch is self-grounded to check the working status of handbrake.
Brake fault alarm lamp

The current is outputted from pin 9 of combination instrument A C019 to the pin 1 of brake fluid level
warning switch C004 and is grounded via pin 2 of C004 to check whether the level in the brake fluid
reservoir is below the minimum level or the brake fluid is empty.
Front fog lamp indicator lamp
When the marker lamp switch is turned on and the front fog lamp switch is pressed, the coil of front fog
lamp relay IR02 is energized and the current is outputted from pin 5 of front fog lamp relay IR02 via front
fog lamp fuse IF05 to pin 11 of combination instrument AC019 and the pin 25 of combination instrument
AC019 is grounded to turn on the front fog lamp indicator lamp.
Rear fog lamp indicator lamp
When the marker lamp switch is turned on and the front and rear fog lamp switches are pressed, the
power supply is outputted from pin 5 of rear fog lamp switch C010 to pin1 of combination instrument
AC019 and the pin 25 of combination instrument AC019 is grounded to turn on the rear fog lamp
indicator lamp.
Indicator light of left steering lamp
When the lighting combination switch handle is placed at left turn signal lamp position, a left turn signal is
outputted from the pin 1 of lighting combination switch C018 to pin 25 of combination instrument B C020
and is grounded via combination instrument so that the left turn signal lamp indicator lamp turns on.
Indicator light of right steering lamp
When the lighting combination switch handle is placed at right turn signal lamp position, a right turn
signal is outputted from the pin 3 of lighting combination switch C018 to pin 24 of combination instrument
A C019 and is grounded via combination instrument so that the right turn signal lamp indicator lamp
turns on.
EL
: Locations of part
B014 Frame harnesses E014 Engine harness
B017 Frame harnesses R002 Rear wall harness
C004 Body main harness R003 Rear wall harness
C019 Body main harness S002 Door lamp harness
C020 Body main harness S003 Door lamp harness


No. No.
connector)
B012 E009
B013 E008
Engine harness and rear wall
E006 R001
Frame harness and door lamp
B015 S001
: Ground
EL S/N
S/N
point point
Ground connection point Battery negative earthing
G201 G305
Ground connection point Combination instrument
G205 G306
1 of left body grounding point
G301 Engine ground point 1

Marker lamp system

Circuit diagram
Battery
Body fuse
case
Frame fuse
Small lamp box
relay
Small
lamp
Small lamp switch
Left front Right front Left rear Right rear

Position lamp
Position lamp
Position lamp
Position lamp
combination
lamp
combination
lamp
combination
lamp
combination
lamp
Rear license
plate lamp
EL
System description:
Marker lamp
1 of marker lamp relay IR13 to power on the marker lamp. The battery power supply is supplied via fuse
EF04 in frame fuse case and fuse IF16 in body fuse case to pin 2 of marker lamp switch C017. When the
marker lamp switch is rotated to marker lamp position, the current is outputted from pin 3 of marker lamp
switch C017 to pin 3 of marker lamp relay IR13 and the pin 2 of marker lamp relay IR13 is grounded so
that the coil is energized to generate a magnetic field and close the contacts of marker lamp relay IR13
and the current is outputted from pin 4 of marker lamp relay IR13 and is divided into 5 circuits:
a. to left front light cluster C005 pin 6, connect to the ground via pin 8 and the left front position light
starts to work;
b. to right front light cluster C038 pin 6, connect to the ground via pin 8 and the right front position
light starts to work;
c. to left rear light cluster L002 pin 1, connect to the ground via pin 6 and the left rear position light
starts to work;
d. to right rear light cluster L010 pin 5, connect to the ground via pin 6 and the right rear position light
starts to work;
License plate lamp
marker lamp switch is turned on, the current is outputted from pin 3 of marker lamp switch C017 to pin 3
of marker lamp relay IR13 and the pin 2 of marker lamp relay IR13 is grounded so that the coil is
energized to generate a magnetic field and close the contacts of marker lamp relay IR13 and the current
is outputted from pin 4 of marker lamp relay IR13 to pin 1 of rear license plate lamp L006 and is
grounded by 2 via license plate lamp filament so that the rear license plate lamp works.
Control signals
When the marker lamp switch is rotated to marker lamp position, the coil of marker lamp relay is
energized to generate a magnetic field and close the contacts of marker lamp relay and the current is
outputted from pin 4 of marker lamp relay IR13 to provide the fog lamp switch control power supply and
backlight power supply.
: Locations of part
EL B014 Frame harnesses C045 Body main harness

S/N S/N
connector)
crossbeam of frame)
: Ground

No. No.
point point
G201 G207
Front wall right grounding Rear lamp grounding
G205 G307
point 1 point
EL
Backlight lamp system

Circuit diagram
Battery
Body fuse
Frame fuse
case
box
Small
lamp relay
Daytime
Front fog Rear fog running Headlamp
lamp switch lamp switch lamp dimmer
switch
Small
lamp
Small lamp switch
EL
Radio/audio
Combined
player Cargo
instrument
A/C control compartment lamp
Hazard warning
panel 1 switch
System description:
marker lamp switch is rotated to marker lamp position, the current is outputted from pin 3 of marker lamp
switch C017 to pin 3 of marker lamp relay IR13 and the pin 2 of marker lamp relay IR13 is grounded so
that the coil is energized to generate a magnetic field and close the contacts of marker lamp relay IR13
and the current is outputted from pin 4 of marker lamp relay IR13 to terminal of corresponding switch or
control module lamp and is grounded by the other terminal of switch or control module to turn on the
backlight.
: Locations of part
No. Reference harness No. Reference harness

S/N S/N
connector)
Frame harness and body main EL
crossbeam of frame)
: Ground

S/N S/N
point point
Ground connection point Combination instrument
G201 G306
1 of left body grounding point
G205 G307
Electric window system

Circuit diagram

Body fuse
case
Lower
Up
EL Battery power Battery power IG1 Power Lowering control of Lifting control of right
window glass glass
Driver door
electric
Driver door window
electric switch
window Lower (Right
Lower
switch control)
Up Up
System description:
The battery current is supplied from fuse EF03 in frame fuse case via fuse IF34 in body fuse case to pins
1 and 2 of BCM C035 to provide battery power supply to BCM for normal functioning.
When the ignition switch is placed at IG1 position, the current is outputted from ignition switch via fuse
IF17 in body fuse case to the pin 1 of BCM C034 to provide IG power supply to the BCM for normal
functioning.
Left front electric window
Lift:
When the lifting button on the left front door is pulled up, the pins 5 and 4 of the electric window switch
J006 on the driver door are connected and the pin 4 of electric window switch J006 on the driver door is
grounded. The left front window lifting signal is outputted from pin 5 of the electric window switch J006 on
the driver door to pin 8 of BCM C034 and then from pin 5 of BCM C035 to pin 2 of left front window lifter
motor J005 so that the left front window lifter motor J005 is internally connected and the signal is
outputted from pin 1 of left front window lifter motor J005 to pin 6 of BCM C035 and is grounded
internally by BCM so that the left front window lifter motor starts lifting.
Lower:
When the lowering button on the left front door is pushed down, the pins 3 and 4 of the electric window
switch J006 on the driver door are connected and the pin 4 of electric window switch J006 on the driver
door is grounded. The left front window lowering signal is outputted from pin 3 of the electric window
switch J006 on the driver door to pin 9 of BCM C034 and then from pin 6 of BCM C035 to pin 1 of left
front window lifter motor J005 so that the left front window lifter motor J005 is internally connected and
the signal is outputted from pin 2 of left front window lifter motor J005 to pin 5 of BCM C035 and is
grounded internally by BCM so that the left front window lifter motor starts lowering.
EL
Right front electric window
Lift:
When the lifting button on the right front door is pulled up, the pins 5 and 4 of the electric window switch
H006 on the front passenger door are connected and the pin 4 of electric window switch H006 on the
front passenger door is grounded. The right front window lifting signal is outputted from pin 5 of the
electric window switch H006 on the front passenger door to pin 12 of BCM C034 and then from pin 3 of
BCM C035 to pin 2 of right front window lifter motor H005 so that the right front window lifter motor J005
is internally connected and the signal is outputted from pin 1 of right front window lifter motor H005 to pin
4 of BCM C035 and is grounded internally by BCM so that the right front window lifter motor starts lifting.
Lower:
When the lowering button on the right front door is pulled up, the pins 3 and 4 of the electric window
switch H006 on the front passenger door are connected and the pin 4 of electric window switch H006 on
the front passenger door is grounded. The right front window lowering signal is outputted from pin 3 of
the electric window switch H006 on the front passenger door to pin 13 of BCM C034 and then from pin 4
of BCM C035 to pin 1 of right front window lifter motor H005 so that the right front window lifter motor
J005 is internally connected and the signal is outputted from pin 2 of right front window lifter motor H005
to pin 3 of BCM C035 and is grounded internally by BCM so that the right front window lifter motor starts
lowering.
: Locations of part
B014 Frame harnesses H006 Right front door harness
H005 Right front door harness

No. No.
connector)
C001 J001
panel)
EL door harness (On inner side of left
C002 J002
panel)
C044 H002
panel)
: Ground
S/N
point
G201
1 of left body
A/C system
A/C system 1

box case
Heater
relay
Speed regulation
resistor
Blower
EL
gear gear A/C
control
panel

A/C
pressure
switch

A/C system 2
Battery
Evaporator
box

relay
Compressor
EL
Engine
ECU
System description
A/C control
With normal evaporator temperature, turn on the fan and press the A/C switch on A/C panel to issue the
A/C request signal. The pin 1 of A/C controller connector B018 transmits via three-state pressure switch
the A/C request signal to engine ECU.
Upon receipt of A/C request signal, the engine ECU controls via pin 69 the closing of compressor relay.
The battery power supply is supplied via fuse EF10 to pin 3 of compressor relay ER01 to close the
compressor relay contacts. The current is outputted from pin 5 of compressor relay ER01 to compressor
and the compressor is self-grounded to start working.
Fan control
When the ignition switch is placed at ACC position and the fan switch is not at OFF position, the A/C
panel controls the closing of heater relay IR06 and the fan is energized. Controlled by the speed
regulation resistor, the fan runs at corresponding speed of control position.
When the internal/external recirculation switch on the A/C control panel is pressed, the A/C panel
controls the forward or reverse rotation of internal/external recirculation servo motor to adjust the
positions of internal/external air vents. The A/C temperature mode is controlled by manual cable
adjustment method. When the temperature knob on the A/C panel is manually adjusted, the temperature
vent is adjusted by cable linage to reach different positions and change the mixing ratio between hot air
and cool air so that the A/C system completes the gradual adjustment of refrigerating/heating.
: Locations of part

S/N S/N
connector)
B012 E009
B013 E008
: Ground
S/N
point
G205
1 of left body
Body control system

Body control system 1
Front passenger door electric

Frame fuse box Body fuse case
window switch
Down
Up
EL Battery power supply Battery power supply IG1 Power supply Lowering control of Lifting control of right
right front door front door window
window glass glass
left front door window front door window right front door front door window left front front window right front door front door
glass glass window glass glass window glass glass window glass window glass

window switch
window switch
(Right control)
Down Down
Up Up
Body control system 2
To combination To daytime To front fog lamp To marker lamp To handbrake To left front door To right front
instrument A To fuse of body running lamp switch switch switch lamp switch door lamp
fuse case IF08
Vehicle speed Daytime running Daytime running Front fog Marker lamp Parking brake Unclosed door
signal lamp power supply lamp signal lamp signal signal signal signal
EL
Unlocking Locking Locking Unlocking Left turn Right turn Ground Ground
control control signal signal signal signal
Lock
actuator, Lock Unlock Lock actuator,
door (RH) door (LH)
To lighting To lighting
combination switch combination switch
System description:
Battery power supply
The battery current is supplied via fuse EF03 in frame fuse case and fuse IF34 in body fuse case to pins
1 and 2 of BCM C035 to provide battery power supply to BCM for normal functioning.
When the ignition switch is placed at IG1 position, the current is outputted via fuse IF17 in body fuse
case to the pin 1 of BCM C034 to provide IG power supply to the BCM for normal functioning.
Service tips:
• C034、C035 BCM
C034(1)-Ground: When the ignition switch is at IG1 position, the voltage is approximately
12V.
C035(1)-Ground: Approximately 12V.
C034 (12)-Ground: Always connected.
C034 (13)-Ground: Always connected.
: Locations of part
B014 Frame harnesses J007 Left front door harness

EL
J005 Left front door harness H007 Right front door harness
J006 Left front door harness

S/N S/N
connector)
B012 E009
B015 S001 switch harness (Beneath driver
seat)

S/N S/N
connector)
C001 J001
panel)
C002 J002
panel)
C044 H002
panel)
Engine harness and rear wall
E006 R001
: Ground

S/N S/N
point point
G201 G206
EL
Interior lamp system

Circuit diagram
Battery

box case
Ceiling
lamp
EL
Courtesy switch (LH) Courtesy switch (RH)

System description:
Front roof lamp
2 of front roof lamp F001. When the front roof lamp switch is placed at ON position, the current is
grounded internally via front roof lamp and front roof lamp switch so that the front roof lamp works.
Door control roof lamp
The battery current is supplied form fuse EF04 in frame fuse case via fuse IF09 in body fuse case to pin
2 of interior roof lamp F001. When the front roof lamp switch is placed at DOOR position, if any door is
not closed, the door control switch is under ON status and the signal is outputted form pin 1 of door
control switch to provide door status to interior roof lamp and combination instrument. The power supply
is supplied from pin 1 of interior roof lamp via lamp filament to pin 1 of door control switch and the door
control switch is self-grounded so that the interior roof lamp works.
: Locations of part
B014 Frame harnesses S002 Door lamp switch harness
C045 Body main harness S003 oor lamp switch
F001 Ceiling harness

EL
S/N S/N
connector)
B015 S001 switch harness (Beneath driver
seat)
Body main harness and ceiling
C036 F002 harness (Inner side of right A-pillar
trim panel)
: Ground
No.
point
G206
2 of left body
Wiper and washer system

Circuit diagram
Ignition switch IG2
Wiper
intermittence
relay
Wiper
Motor stop
Ground Washing motor Wiper + Intermittent position Body fuse
case
EL Washer
Wiper
motor Turn
Stop motor
nt
switch
Low
speed
High
speed
Wash
System description:
When the ignition switch is at IG2 position, the battery current is supplied from fuse IF06 in frame fuse
case to pins 4 and 8 of wiper combination switch C014, pin 4 of wiper intermittent relay C006, and pin 5
of wiper motor C033 respectively to provide working power supply to washer motor and provide reset
power supply to wiper motor.
Wiper combination switch LO position
When the wiper combination switch is place at LO position, the pins 8 and 5 of wiper combination switch
C014 are connected and the pin 5 of wiper combination switch C014 outputs the wiper LO signal to pin 3
of wiper motor C013 so that the pin 4 of wiper motor is grounded and the wiper motor runs under LO
mode.
Wiper combination switch HI position
When the wiper combination switch is place at HI position, the pins 8 and 9 of wiper combination switch
C014 are connected and the pin 9 of wiper combination switch C014 outputs the wiper HI signal to pin 2
of wiper motor C013 so that the pin 4 of wiper motor is grounded and the wiper motor runs under HI
mode.
Wiper combination switch washer position
When the wiper combination switch is placed at washer position, the pins 8 and 3 of wiper combination
switch C014 are connected and the pin 3 of wiper combination switch C014 outputs the washer signal to
pin 1 of washer motor C037 so that the pin 2 of washer motor C037 is grounded and the washer motor
runs.
Intermittent position of wiper combination switch
When the wiper combination switch is placed at intermittent position, the pins 4 and 7 of wiper
combination switch C014 are connected and the pins 6 and 5 are connected so that the pin 7 of wiper
combination switch C014 outputs wiper intermittent signal to pin 1 of wiper intermittent relay C006. The
low speed control signal of wiper motor is outputted from pin 2 of wiper intermittent relay C006 via wiper
intermittent relay to pin 6 of wiper combination switch C014 and the current is outputted from pin 5 of
wiper combination switch C014 to pin 3 of wiper motor C033 and is grounded by pin 4 of wiper motor so
that the wiper motor runs intermittently under LO mode.
Wiper combination switch OFF
When the wiper combination switch is at OFF position, if the wiper motor is at OFF position, the wiper
motor will not run. If the wiper motor is not at OFF position, the pins 5 and 1 of wiper motor are internally
connected and the battery power supply is supplied from fuse IF06 in body fuse case via pins 5 and 1 of
wiper motor to pin 6 of wiper intermittent relay C006. Upon receipt of the wiper motor stop signal, the
wiper intermittent relay outputs from pin 2 of wiper intermittent relay C006 to pin 6 of wiper combination
switch C014 and the pins 6 and 5 of wiper combination switch C014 are connected so that the signal is
outputted from pin 5 of wiper combination switch C014 to pin 3 of wiper motor C033 and is grounded by
pin 4 of wiper motor so that the wiper motor runs under LO mode and stops at the OFF position.
EL
: Locations of part
: Ground

S/N S/N
point point
G204 G206
G205
1 of left body
Electric fan system

Circuit diagram
Battery
Frame fuse
box
Main relay Low-speed High-speed Condenser

fan relay fan relay relay
Radiator fan Condenser

fan
EL
Main relay control Low speed fan relay control High speed fan relay control Condenser relay control
Engine
System description:
The battery current is supplied via fuse EF15 in frame fuse case to pins 30 and 86 of master relay ER06
to power on the master relay ER06. The battery current is supplied via fuse EF05 in frame fuse case to
pin 30 of low speed fan relay ER03 and pin 30 of high speed fan relay ER02 to power on the radiator fan
relay and run the radiator fan normally. The battery current is supplied via fuse EF11 in frame fuse case
to pin 3 of condenser relay ER04 to power on the condenser fan for normal functioning.
Control signals
The ECU controls the energization of the master relay coil to generate a magnetic field and close the
contacts (30-87). The current is outputted from pin 86 of master relay ER06 to pin 86 of low speed fan
relay ER03, pin 86 of high speed fan relay ER02, and pin 2 of condenser relay ER04 respectively.
Running of radiator fan
When the engine is started, the engine ECU controls the energization of low speed fan relay coil to
generate a magnetic field and close the contacts (30-87). The current is outputted from pin 87 of low
speed fan relay ER03 to pin 3 of radiator fan B010 and is grounded by pin 1 of radiator fan B010 to run
the radiator fan at low speed. When the coolant temperature reaches a threshold value, the engine ECU
controls the energization of high speed fan relay coil to generate a magnetic field and close the contacts
(30-87). The current is outputted from pin 87 of high speed fan relay ER02 to pin 2 of radiator fan B010
and is grounded by pin 1 of radiator fan B010 to run the radiator fan at high speed.
Running of condenser fan
When the engine is started and the A/C is turned on, the engine ECU controls the energization of
condenser relay coil to generate a magnetic field and close the contacts (3-5). The current is outputted
from pin 5 of condenser relay ER04 to pin 2 of condenser fan B019 and is grounded by pin 1 of
condenser fan B019 to run the condenser fan.
: Locations of part
B010 Frame harnesses B19 Frame harnesses
B014 Frame harnesses E001 Engine harness

S/N S/N
connector)
Frame harness and engine EL
B012 E009
B013 E008
: Ground

S/N S/N
point point
G303 Frame ground point 1 G304 Frame ground point 2

OBD diagnostic system

Circuit diagram
Battery

box case
EL Battery power
supply
Diagnostic
interface
Power supply Signal ground

K line earth wire
K line
Engine ECU
System description:
The battery power supply is supplied form fuse EF04 in frame fuse case via fuse IF14 in body fuse case
to pin 16 of diagnostic interface C003 to provide the battery power supply and is grounded by pins 4 and
5 of C003. In the C003, the pin 6 is the CAN-H1 communication line, pin 14 is CAN-L1 communication
line, pin 11 is CAN-L communication line, pin 3 is CAN-H communication line, and pin 7 is K-line.
: Locations of part

S/N S/N
connector)
B013 E008
: Ground
S/N
point
G204
4 of left body
Audio system
Circuit diagram

To reversing lamp
antenna
EL
player
signal

signal sensor -
System description:
The battery power supply is supplied via fuse EF04 in frame fuse case and fuse IF15 in body fuse case
to pin 4 of radio/audio player C024 to power on the radio/audio player unit for normal working.
When the ignition switch is placed at ACC position, the current is supplied via fuse IF22 in body fuse
case to the pin 3 of radio/audio player to provide ACC power supply to the radio/audio player unit for
normal functioning.
Service tips:
• C024 radio/audio player
C024(3)-Ground: When the ignition switch is at ACC/ON position, the voltage is
approximately 12V.
C024(7)-Ground: Always connected.
• J004 Left front loudspeaker
1-2: Approximately 4Ω
• H002 Right front loudspeaker
1-2: Approximately 4Ω
: Locations of part

EL
B014 Frame harnesses J004 Left front door harness

S/N S/N
connector)
B013 E008
crossbeam of frame)

S/N S/N
connector)
C001 J001
panel)
C043 H001
panel)
: Ground
S/N
point
Combination instrument
G306
grounding point
EL
Daytime running lamp system

Circuit diagram

box case
Daytime running Battery power Battery

power supply
IG1 Power EL
lamp power supply supply supply
Daytime running
lamp signal Ground Ground
To small lamp relay
Right daytime Left day Daytime

running lamp running lamp
running lamp
Open
System description:
to pins 2 and 1 of BCM C035 to provide battery power supply. When the ignition switch is at IG1 position,
the battery power supply is outputted from ignition switch via fuse IF17 in body fuse case to pin 1 of BCM
C034 to provide the IG1 power supply.
When the daytime running lamp switch is turned on, the pin 4 of BCM C034 receives the daytime
running lamp signal and the daytime running lamp signal is outputted from pin 11 of BCM C035 via IF08
in body fuse case to pin 2 of right daytime running lamp T003 and pin 2 of left daytime running lamp
T004 to provide the power supply and is grounded by pin 1 of right daytime running lamp T003 and pin 1
of left daytime running lamp T004 so that the daytime running lamp works.
: Locations of part
EL :Connector between harnesses

No. No.
connector)
Frame harness and front bumper
harness (Beneath right front
B006 T001
combination lamp and near electric
horn)
: Ground

S/N S/N
point point
G201 G304 Frame ground point 2
1 of left body
G206
2 of left body
Electronic power steering system (EPS)

Circuit diagram
Frame fuse
box
Body fuse
case
EL
Battery power IG1 Power
supply supply
Controller
Electric-assisting Electric-assisted Electric-assisted Electric-assisted
indicator lamp idling up K line vehicle speed signal speed signal Ground
Electric-assisted K line Electric-assisted Electric-assisted

idling up vehicle speed signal speed signal
Engine ECU
To combined
instrument
System description:
ACC power supply:
The battery current is supplied via fuse EF03 in frame fuse case and fuse IF33 in body fuse case to pin 1
of EPS controller C008 to provide battery power supply to EPS controller for normal functioning.
When the ignition switch is at IG1 position, the current is supplied from ignition switch via fuse IF17 in
body fuse case to pin 4 of EPS controller C009 to provide IG1 power supply to EPS controller for normal
functioning.
Service tips:
• C008, C009 EPS controller
12V.
: Locations of part

EL

S/N S/N
connector)
B012 E009
B013 E008
: Ground
No.
point
G203
3 of left body
Power socket system

Circuit diagram
Ignition switch ACC
Body fuse
case
Power
socket
EL
System description:
When the ignition switch is at ACC position, the current is supplied from ignition switch via fuse IF23 in
body fuse case to pin 2 of power socket C027 and is grounded by pin 1 of power socket C027 so that the
power socket works.
: Locations of part
: Ground
No.
point
G206
2 of left body
T-BOX system
Circuit diagram
Battery Ignition switch IG1 Ignition switch ACC
Frame fuse
box Body fuse
case
EL Battery power IG1 Power ACC Power

supply supply supply
Power supply
earth wire
Diagnostic
interface
System description:
The battery power supply is supplied via fuse EF04 in frame fuse case and fuse IF15 in body fuse case
to pin 3 of T-BOX C023 to power on the T-BOX unit for normal working.
When the ignition switch is at ACC position, the current is supplied via fuse IF22 in body fuse case to pin
2 of T-BOX C023 to provide ACC power supply to T-BOX unit for normal functioning. When the ignition
switch is at IG1 position, the current is supplied via fuse IF17 in body fuse case to pin 1 of T-BOX C023
to provide IG power supply to T-BOX unit for normal functioning.
Service tips:
• C023 T-BOX
C023(2)-Ground: When the ignition switch is at ACC position, the voltage is approximately
12V.
12V.
: Locations of part
B014 Frame harnesses C023 Body main harness EL

S/N S/N
connector)
: Ground
S/N
point
G204
4 of left body
Harness connector information

Frame harnesses
Wire
Terminal
diameter/ Function
No.
color
Evaporator
4 0.50 Gr/B
temperature signal
Door lamp switch
5 0.75 L/R
signal
6 0.50 Br/W CAN-H
Evaporator
7 0.50 Gr/W
DJ7061Y-4.8/9.5–11/20–CZT(black) temperature sensor
B001 to body harness connector 1 8 0.50 L/R K wire
Wire 9 - -
Terminal
diameter/ Function
No.
color 10 0.50 W/R Headlamp signal
1 - -
11 - -
Ignition lock power
2 4.00R 12 - -
supply
3 4.00G Lighting power supply Reversing sensor

13 0.50 G/R
signal
EL
4 - -
14 - -
5 - - Electric-assisted
15 0.50 O
idling up
6 6.00R/B BCM power supply
16 0.50 B Reversing sensor -
17 0.50 W/G A/C request
18 0.50 B Ground
2137352-1-AMP(gray)
B002 to body harness connector 2
Wire
Terminal
diameter/ Function
No.
color
1 - -
2 0.50Y IG power
3 0.50 P CAN-L
2137352-3-AMP(blue) 2137352-4-AMP(purple)
B003 to body harness connector 3 B004 to body harness connector 4
Wire Wire
Terminal Terminal
diameter/ Function diameter/ Function
No. No.
color color
1 - - Vehicle speed power

1 0.50 Gr/G
supply
2 - -
2 - -
Left rear turn lamp 3 - -
3 0.50G/B
signal
ECU vehicle speed
4 - - 4 0.50 G/R
signal
5 0.75Y/W Electric horn + Seat belt warning
5 0.50 L
signal
Right rear turn signal EL
6 0.50G/W 6 - -
lamp signal
7 - - Speedometer/odomet
7 0.50 Br
er signal
8 1.50L/B Rear fog lamp + 8 0.35 Y/L Fuel indicator signal
Rearview lamp switch Combination
9 0.75G/L
+ 9 0.50 Br/L instrument SVS
indicator lamp
10 - -
Oil pressure indicator
Daytime running lamp 10 0.35 W/R
11 0.50Br lamp
+
Right rear reversing
11 0.75 G/Y
12 0.75L/Y Brake lamp: + lamp +
Water temperature
13 - - 12 0.50 P/L
indication lamp
14 - - 13 0.50 B Instrument ground
15 0.50R/G Left rear fog lamp + Handbrake warning

14 0.35 W/Y
lamp
16 - -
15 0.50 W/B EPS speed signal
17 2.00R/B Starter motor 16 - -
18 0.75G Rear position light + Generator charging

17 0.50 Gr
indicator lamp
Combination
18 0.35 P/B instrument OBD
indicator lamp
282080-1-AMP(black) PP1108602-THB
B005 To electric horn B007 To alternator
Wire Wire
Terminal Terminal
No. No.
color color
1 0.75 Y/W Electric horn signal 1 10.00R Generator B+
2 0.75 B Ground
EL
6195-0030-SWS (gray)
B008 To alternator
PP1512302-THB (black)
B006 To front bumper harness Wire
Terminal
diameter/ Function
No.
Wire color
Terminal
diameter/ Function
No. 1 - -
color
1 - - Generator charging
2 0.50 Gr
indicator lamp
2 0.50Br 3 0.50 G/L IG power
+
3 1.00B Ground 4 - -
4 1.50L/B Front Fog Lamp +

PP0459701-THB(gray) DJ7013Y-2.2-21/20-CZT (black)

B009 To compressor B011 To oil pressure
Wire Wire
Terminal Terminal
No. No.
color color
1 1.00V Compressor control Engine oil pressure

1 0.35 W/R
switch signal
EL
PP0335502-THB (brown)
PP1518102-THB(BK)
B010 To radiator fan motor
B012 To engine harness
Wire
Terminal Wire
diameter/ Function Terminal
No. diameter/ Function
color No.
color
1 3.00 B Ground Oxygen sensor power
1 1.50Br/R
supply
Electric fan low speed
2 3.00 G
signal Water temperature
2 0.50P/L
gauge indicator lamp
Electric fan high
3 3.00 Gr/B
speed signal Combination
3 0.50Br/L instrument SVS
indicator lamp
Condenser relay
4 0.50Gr
control
Fuel pump relay
5 0.50Gr/L
control
Ignition coil power
6 1.50O
supply
Combination
7 0.35 P/B instrument OBD
indicator lamp
Wire Wire
Terminal Terminal
No. No.
color color
8 0.50 W/B EPS speed signal Evaporator

6 0.50Gr/B
temperature signal
High speed fan relay
9 0.50 Y/L 7 0.50V/W Main relay control
control
10 0.50 W/R Headlamp signal A/C pressure switch

8 0.50P/L
signal
11 1.50 W Camera power supply
9 - -
12 0.50 L Seat belt alarm
10 0.50Br/W CAN-H
Handbrake warning
13 0.35 W/Y Evaporator
lamp 11 0.50Gr/W
temperature sensor-
Electric-assisted
14 0.50 O Tachometer and
idling up 12 0.50Br
odometer
Low speed fan relay
15 0.50 Gr/R Vehicle speed power
control 13 0.50Gr/G
supply
16 - - ECU vehicle speed
14 0.50G/R
signal
17 0.75 R ECU normally-live
15 - -
18 - -
16 - -
19 - -
EL 17 - -
Starter motor control
20 2.00 R/B
signal Reversing indicator
18 0.75G/Y
lamp signal
Rearview lamp switch
19 0.75G/L
+
20 - -
PP1518101-THB(GY)
B013 To engine harness
Wire
Terminal
diameter/ Function
No.
color
DJ7011Y-2.2-11/28-CZT (gray)
1 - - B015 to door lamp harness
2 - - Wire
Terminal
diameter/ Function
No.
3 0.50Y IG power color
Door lamp switch
4 0.50L/R K wire 1 0.75L/R
signal
5 0.50P CAN-L
PP0511501-THB (black) PP1530901-THB (gray)

B016 to battery fusible wire B018 To pressure switch
Wire Wire
Terminal Terminal
diameter/ Function
diameter/ Function No.
No. color
color
1 10.00W Power fuse
A/C pressure switch
2 0.50 P/L
signal
EL
282088-1-AMP(black)
B017 To fuel pump PP1520101-THB (gray)
Wire B019 to condenser motor

Terminal
diameter/ Function
No. Wire
color Terminal
diameter/ Function
No.
Fuel gauge indicator color
1 0.35 Y/L
lamp signal
1 2.00B Condenser motor -
2 0.50 B Ground
2 2.00V Condenser motor +
3 0.75 R/B Fuel pump +
4 0.75 B Fuel pump -

PP0487001-THB
B020 To taillight harness
Wire
Terminal
diameter/ Function
No.
color
1 1.00 G/R Compartment lamp +
2 0.50 R/G Left rear fog lamp +
Left rear turn signal

3 0.50 G/B
lamp +
4 1.50 B Ground
Right rear turn signal

5 0.50 G/W
lamp +
EL
Reversing sensor
6 0.50 G/R
signal
7 0.50 B Reversing sensor -
8 0.75 L/Y Brake lamp: +
9 0.75 G Rear position light +
10 0.75 G/Y Rear reversing lamp +

Body main harness
1376352-1-AMP(white) PP1515301-THB (white)

C001 to left front door harness A C002 To left front door harness B
Wire Wire
Terminal Terminal
No. No.
color color
1 0.50Y Left loudspeaker + Left front door control

1 0.50 Y/B switch - Right
2 0.50Y/B Left loudspeaker - lowering
Left front door control
3 0.50G/B Left turn lamp + 2 0.50 Y/W
switch - Right lifting
4 0.50B Left steering lamp- Locking of left front
3 0.50 W
door
Left front door control EL
5 0.50L/B 4 0.50 B Ground
switch - Left lowering
Left front door control Left front door central
6 0.50L/R 5 0.75 G
switch - Left lifting control locking
Unlocking of left front Left front door central
7 0.50L 6 0.75 B
door control unlocking
8 - - Left front door control
7 1.00 G/B
8 1.00 G/R
switch - Left lifting
PP0440501-THB(BK) PP0300401-THB(WH)
C003 To diagnostic interface C004 To brake fluid level warning switch
Wire Wire
Terminal Terminal
No. No.
color color
1 - - Brake fluid level

1 0.35 W/L
warning switch +
2 - - Brake fluid level
2 0.35 B
warning switch -
3 0.50Br/W CAN-H
4 0.50B Ground
5 0.50B Ground
EL 6 0.50Br CAN-H1
7 0.50L/R K wire
8 - -
9 - -
10 - - C005 To left front combination lamp
11 0.50P CAN-L Wire

Terminal
diameter/ Function
No.
12 - - color
1 1.00B Ground
13 - -
2 1.00Y Left high beam +
14 0.50Gr CAN-L1
3 0.75L/G Left low beam +
15 - -
Left low beam
4 0.50L/G
adjustment motor +
16 0.75Br/L Battery power supply
Left low beam
5 0.50L/W
adjustment control
6 0.50G Marker lamp +
7 0.75G/B Left turn lamp +
8 0.50B Ground
PP0301001-THB(WH) 7123-4123-30-YAZAKI(BK)
C006 to wiper intermittent relay C008 to EPS power supply
Wire Wire
Terminal Terminal
No. No.
color color
Wiper motor 1 4.00R EPS power supply +
1 0.75 G/B
intermittent mode
Wiper motor low 2 4.00B EPS power -
2 0.75 B/G
speed mode
3 1.50 B Ground
4 1.00 V/Y Power supply
5 0.75 L/Y Wiper washer mode

EL
Wiper motor return
6 0.75 L/W
mode
1379659-1-AMP(black)
C009 to EPS signal
Wire
Terminal
diameter/ Function
No.
color
1 0.50G/Br Vehicle speed signal
Electric-assisted
PP0300404-THB(WH) 2 0.50W/B
speed signal
C007 To brake switch
3 - -
Wire
Terminal 4 0.50W EPS IG power supply
diameter/ Function
No.
color
5 0.50L/R K wire
1 0.75Br/L Brake switch +
6 0.50O Idle speed boost
2 0.75L/Y Brake switch -
Electric-assisting
7 0.50Y/G
indicator lamp
8 - -
Wire
Terminal
diameter/ Function
No.
color
5 0.50 Gr/R Front fog lamp control
Front fog lamp switch

6 0.50 B
-
C010 To rear fog lamp switch
Wire
Terminal
diameter/ Function
No.
color
1 0.50 G Back light +
Rear fog lamp switch PP0404103-THB (yellow)

2 0.50 Gr/R
control C012 to daytime running lamp switch
3 0.50 B Back light - Wire

Terminal
diameter/ Function
No.
4 - - color
5 0.50 R/G Rear fog lamp + 1 0.50G Back light +

EL Rear fog lamp switch Daytime running lamp
6 0.50 B 2 0.50B
- -
3 0.50B working indicator
lamp -
4 0.50 Gr working indicator
lamp +
5 0.50 W
signal
6 0.50 B Back light -
PP0404107-THB (gray)
C011 To front fog lamp switch
Wire
Terminal
diameter/ Function
No.
color
1 0.50 G Back light +
Front fog lamp switch

2 0.50 G
+
4 - -
Wire
Terminal
diameter/ Function
No.
color
5 0.75R/W Wiper low speed gear
6 0.75B/G Wiper return
Wiper intermittent
7 0.75G/B
mode
Power supply of wiper
8 0.75V/Y
switch
PP0404105-THB (blue)
Wiper high speed
C013 to headlamp dimmer switch 9 0.75V/B
gear
Wire
Terminal
diameter/ Function
No.
color
Headlamp dimmer
1 0.50 B
switch -
Headlamp dimmer
2 0.50 L/G
switch +
Right low beam

4 0.50 L/Y
adjustment control PP0301001-THB(WH)
Left low beam C015 To ignition switch
5 0.50 L/W
adjustment control EL
Wire
6 0.50 G Back light + Terminal
diameter/ Function
No.
color
1 2.00 W/R Ignition switch ACC
2 2.00 R/G Ignition switch IG2
3 - -
Ignition switch power

4 3.00 R
supply
5 2.00 R/B Ignition switch ST
PP0403101-THB(Natural color) 6 2.00 Gr Ignition switch IG1

C014 To wiper combination switch
Wire
Terminal
diameter/ Function
No.
color
1 - -
2 - -
3 0.75L/Y Washer mode
Washer mode power

4 0.50V/Y
supply
DJ7012Y-2.2-11/2-CZT(WH) PP0402901-THB(Natural color)

C016 to horn C018 To lighting combination switch
Terminal Wire diameter/ Wire

Function Terminal
No. color diameter/ Function
No.
color
1 0.50Br Horn +
1 0.75G/B Left turn signal
2 0.75Y Flasher output
3 0.75G/W Right turn signal
4 0.51L/B High beam control
5 0.50Y/L Low beam control
EL 6 0.50W/R Lighting signal
Lighting switch power

7 0.50L
PP0303805-THB(Natural color) supply
C017 to marker lamp switch
Wire
Terminal
diameter/ Function
No.
color
1 0.50W/R Lighting signal
2 0.50L Small light switch +
Marker lamp switch

3 0.50G/Y
control
1719057-1-AMP(GN)
C019 To combination instrument A
Wire
Terminal
diameter/ Function
No.
color
Rear fog lamp
1 0.35 R/G
indicator lamp
2 - -
3 - -
Right turn indicator

4 0.35 G/W
lamp
Wire Wire
Terminal Terminal
No. No.
color color
5 - - Combination
31 0.50 B/G instrument normally
6 0.50 G/Br Speedometer energized
Generator charging 32 0.50 W IG power

7 0.35 Gr
indicator lamp
Left high beam
8 0.50 Y
indicator lamp
Brake fluid level alarm
9 0.35 W/L
lamp
Electric-assisting
10 0.50 Y/G
indicator lamp
Front fog lamp
11 0.50 L/B
indicator lamp
12 - -
1719057-2-AMP(BU)
13 0.50 G Fog lamp + C020 To combination instrument B
14 - - Wire
Terminal
diameter/ Function
No.
Reversing Indicator color
15 0.50 G/R
Lamp
1 - -
16 - - EL
2 0.50B Ground
Oil pressure indicator
17 0.35 W/R
lamp 3 - -
18 - - 4 - -
19 - - 5 - -
20 - - 6 0.50 B Ground
21 - - 7 0.50 B Ground
22 - - 8 - -
23 0.50 G Position lamp 9 - -
24 0.50 B Signal ground 10 - -
25 0.50 B Ground 11 - -
26 0.35 Y/L Fuel gauge 12 - -
Water temperature
27 0.35 P/B 13 - -
gauge
Tachometer and 14 - -
28 0.50 Br
odometer
15 - -
16 - -
Vehicle speed power
30 0.50 Gr/G
supply
Wire
Terminal
diameter/ Function
No.
color
17 - -
Alarm lamp of
18 0.50 L/W
unclosed door
Seat belt reminder
19 0.50 L
warning lamp
20 - -
PP0302903-THB(WH)
21 - -
C021 to fan
22 - - Wire
Terminal
diameter/ Function
23 - - No.
color
24 - - 1 2.00 Y/R Fan +
25 0.35 G/B Left turn lamp 2 2.00 R/G Fan -
26 0.50 W IG power
Combination
27 0.35 Br/L instrument SVS
warning lamp
28 0.50 L/G Left low beam

EL
29 0.50 W/Y Parking brake signal
Combination
30 0.35 Br/W instrument OBD
warning lamp
PP0303503-THB(WH)
31 - - C022 To speed regulation resistor
32 - - Wire
Terminal
diameter/ Function
No.
color
Second highest
1 2.00 Y
speed mode
2 2.00 R/G High speed mode
3 2.00 Y/B Medium speed mode
4 2.00 Y/G Low speed mode

Wire
Terminal
diameter/ Function
No.
color
4 0.50B/G Battery power supply
Right front
5 0.50L/B
loudspeaker -
Left front loudspeaker
6 0.50Y/B
-
7 0.50B Ground
1376352-1-AMP(white)
8 - -
C023 to T-BOX
Multimedia reversing
Wire 9 0.50G/R
Terminal signal
diameter/ Function
No.
color 10 0.50G Back light +
1 0.50W IG1 power
2 0.50R/L ACC power supply
3 0.50B/G Battery power supply
4 0.50 B Ground
5 0.50 Gr CAN-L1
6 0.50 Br CAN-H1 EL
7 - - PP0404201-THB(Natural color)
8 - - C025 To hazard warning lamp switch
Wire
Terminal
diameter/ Function
No.
color
1 0.75G/B Left turn signal
2 0.75G/W Flasher output
3 1.00Y Right turn signal
4 1.00Y/L Flasher positive input
5 1.00Br/O Battery power supply

PP0404301-THB
C024 to radio/audio player 6 0.75G/L IG2 power supply
Wire 7 0.50B Back light -

Terminal
diameter/ Function
No.
color 8 0.50G Back light +
Right front
1 0.50L
loudspeaker +
2 0.50Y
+
3 0.75R/L ACC power supply

PP0401801-THB(WH) MG630685-5-KET (black)

C026 to reversing sensor C028 to cigarette lighter
Wire Wire
Terminal Terminal
No. No.
color color
1 0.50G/R Reversing sensor + 1 1.00 P/G Cigar lighter +
2 0.50B Reversing sensor - 2 1.00 B Cigarette lighter-
3 - -
EL
PP1531001-THB (white)
C029 To A/C control panel assembly 1
PP0318701-THB(Natural color)
C027 to power socket Wire
Terminal
diameter/ Function
No.
Wire color
Terminal
diameter/ Function
No. 1 0.50 G Back light power
color
1 1.00B Power socket + 2 0.50 G/Y Internal recirculation
2 1.00L/G Power socket - 3 0.50 Gr External recirculation
3 - - 4 0.50 B Ground
6 0.50 R/L ACC power supply
7 - -
8 - -
9 - -
10 - -
Wire
Terminal
diameter/ Function
No.
color
11 - -
Heater relay output

12 0.50 Gr
power supply
PP0302903–THB(WH)
C031 to evaporator temperature sensor
Wire
Terminal
diameter/ Function
No.
color
Evaporator
1 0.50Gr/B
PP0304801-THB(Natural color) temperature signal
C030 To A/C control panel 2 Evaporator

2 0.50Gr/W
temperature sensor-
Wire
Terminal
diameter/ Function
No.
color
1 2.00 B Heater motor ground
2 0.50 Y/V Heater relay control EL

Second highest
3 2.00 Y
speed mode
4 2.00 Y/G Low speed mode
5 2.00 Y/B Medium speed mode DJ7061Y-4.8/9.5-21/20-CZT (black)

C032 To frame wire harness 1
6 2.00 R/G High speed mode
Wire
Terminal
diameter/ Function
No.
color
1 - -
2 - -
3 4.00R Battery power supply
4 - -
5 4.00R/G Battery power supply
6 6.00R/B Battery power supply

Wire
Terminal
diameter/ Function
No.
color
6 - -
7 0.50 G/Br Vehicle speed signal

8 0.50 L/R
9 0.50 L/B
C033 to wiper motor 10 0.50 Y/W
switch - Right lifting
Wire Left front door control
Terminal
diameter/ Function 11 0.50 Y/B switch - Right
No.
color lowering
Wiper motor return Right front door
1 0.75L/W
mode 12 0.50 Y/R control switch - Right
lifting
Wiper motor high
2 0.75V/B
speed mode Right front door
13 0.50 Y/Br control switch - Right
Wiper motor low
3 0.75R/W lowering
speed mode
Door open warning
4 0.75B Ground 14 0.50 L/W
signal
EL 5 0.75V/Y Wiper motor power 15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
DJ7201-1.2-21-ZJZ (black)
C034 to BCM-1
Wire
Terminal
diameter/ Function
No.
color
1 0.50W IG power

2 0.50W
signal
3 0.50Gr/R Front fog lamp signal
4 0.50W/R Lighting signal
5 0.50W/Y Hand brake signal

Wire
Terminal
diameter/ Function
No.
color
Locking of left front
17 0.50W
door switch
18 - -
DJ7181-1.8-21-ZJZ (white)
C035 to BCM-2
Wire
Terminal
diameter/ Function
No.
color
1 1.00 R/Gr Battery power supply

2 1.00 R/Gr Battery power supply
C036 To roof harness
Right front door
3 1.00 W/R control switch - Right Wire
Terminal
lifting diameter/ Function
No.
color
Right front door
4 1.00 W/B control switch - Right Interior roof lamp
1 0.75L/W
lowering signal
EL
Left front door control 2 0.75B Ground
5 1.00 G/R
3 - -
6 1.00 G/B
switch - Left lowering Interior roof lamp
4 0.75P
power supply
Unlocking of right
7 0.75 B front door central
control lock
Locking of right front
8 0.75 G door central control
lock
9 0.75 G/B Left turn signal
10 0.75 G/W Right turn signal

11 0.50 Br
signal
PP0302903-THB(WH)
12 1.00 B Ground
C037 to washer pump
13 1.00 B Ground Wire
Terminal
diameter/ Function
14 - - No.
color
15 - - 1 0.50L/Y Washer pump +
Unlocking of left front 2 0.50B Washer pump -
16 0.50L
door switch
Wire
Terminal
diameter/ Function
No.
color
3 - -
4 - -
5 0.50 Gr External recirculation
6 - -
PP0447804-THB (black) 7 0.50 G/Y Internal recirculation

C038 To right front combination lamp
Wire
Terminal
diameter/ Function
No.
color
1 1.00B Ground
Right front high

2 1.00G
beam +
Right front low beam
3 0.75W/B
+
Right low beam 2137358-1-AMP (gray)
4 0.75W/B adjustment power C040 To frame harness 2
supply
EL Wire
Right low beam Terminal
5 0.50L/Y diameter/ Function
adjustment control No.
color
6 0.50G Marker lamp 1 - -
7 0.75G/W Right turn lamp 2 0.50Y IG power
8 0.50B Ground 3 0.50P CAN-L
Evaporator
4 0.50 Gr/B
temperature signal
5 0.50 L/W Door lamp ON signal
6 0.50 Br/W CAN-H
Evaporator
7 0.50 Gr/W
temperature sensor -
8 0.50 L/R K wire

PP04O2901-THB(Natural color)
C039 To internal/external recirculation motor 9 - -
Wire 10 0.50 W/R Lighting signal

Terminal
diameter/ Function
No. 11 - -
color
1 - - 12 - -
2 - - Reversing sensor
13 0.50 G/R
signal
Wire Wire
Terminal Terminal
No. No.
color color
14 - - 14 - -
15 0.50 O Idle speed boost 15 0.50 R/G Rear fog lamp +
16 0.50 B Reversing sensor - 16 - -
17 0.50 W/G A/C request 17 2.00 R/B Ignition switch ST
18 0.50 B Ground 18 0.75 G Marker lamp +
2137358-3-AMP(blue) 2137358-4-AMP(purple)
C041 To frame harness 3 C042 To frame harness 4
Wire Wire EL
Terminal Terminal
No. No.
color color
1 - - Vehicle speed power

1 0.50 Gr/G
supply
2 - -
2 - -
Left rear turn signal
3 0.50 G/B 3 - -
lamp +
4 - - 4 0.50 G/Br Vehicle speed signal
5 0.75 Y/W Electric horn + Seat belt reminder

5 0.50 L
warning signal
6 0.50 G/W 6 - -
lamp +
7 - - Tachometer and
7 0.50 Br
odometer
8 1.50 L/B Front Fog Lamp +
8 0.35 Y/L Fuel sensor +
9 0.50 G/L Reversing lamp + Combination
9 0.35 Br/L instrument SVS
10 - - warning lamp
Daytime running lamp Oil pressure indicator
11 0.50 Gr 10 0.35 W/R
+ lamp
12 0.75 L/Y Brake lamp: + Reversing Indicator
11 0.50 G/R
Lamp
13 - -
Water temperature
12 0.35 P/B
indication lamp
Wire
Terminal
diameter/ Function
No.
color
13 0.50 B Ground
14 0.50 W/Y Parking brake signal
16 - -
Generator charging PP1515301-THB (white)

17 0.35 Gr
indicator lamp
C044 To right front door harness B
Combination
18 0.35 Br/W instrument OBD Wire
warning lamp Terminal
diameter/ Function
No.
color
Right front door
1 0.50Y/Br control switch - Right
lowering
Right front door
2 0.50Y/R control switch - Right
lifting
3 - -
4 0.50B Ground
EL
1376352-1-AMP(white) Locking of right front
C043 To right front door harness A 5 0.75G door central control
lock
Wire
Terminal Unlocking of right
diameter/ Function
No. 6 0.75B front door central
color
control lock
1 0.50L Right loudspeaker + Right front door
7 1.00W/B control switch - Right
2 0.50L/B Right loudspeaker - lowering
3 0.50G/W Right turn lamp + Right front door

8 1.00W/R control switch - Right
4 0.50B Ground lifting
5 - -
6 - -
7 - -
8 - -
Engine harness
1813712-8-AMP(BK)
E001 to engine ECU
Wire Wire
Terminal Terminal
No. No.
color color
Upstream oxygen Front oxygen sensor
18 0.50 G/Y
1 1.50Br sensor heating signal
control
19 0.50 R Knock sensor - Signal
2nd/3rd cylinder
2 1.50W/L
ignition control 20 - -
3 2.00B Ground
21 - -
Downstream oxygen EL
Evaporator
4 1.50P sensor heating 22 0.50 Gr/B
temperature signal
control
1st/4th cylinder 23 - -
5 1.50V/B
ignition control
24 - -
6 0.75G/Y Fuel injector 2 control
25 - -
7 0.50B/R Fuel injector 3 control
26 - -
8 0.50Br/R RPM output
27 0.75 G/W Fuel injector 1 control
9 - -
Engine failure
28 0.50 Br/W
10 - - indication
29 0.50 Br/L SVS indicator lamp

11 - -
30 - -
12 0.75R Battery power supply
Coolant temperature
13 0.75Y IG power 31 0.50 P/L
output
14 0.50V/B Main relay control Radiator fan high

32 0.50 Y/L
speed control
Crankshaft position
15 0.50R Crankshaft position
sensor + 33 0.50 Y/L
sensor +
16 - - Crankshaft position
34 0.50 G
sensor signal
17 0.50 Y/R Sensor-
35 0.50 B Sensor-
Wire Wire
Terminal Terminal
No. No.
color color
Upstream oxygen 62 0.50 Br/W CAN-H
36 0.50 W/L
sensor -
Main relay output
37 0.50 L/W Intake pressure signal 63 0.75 Br/R
power supply 3
Throttle position Stepping motor
38 0.50 R/L 64 0.50 O
sensor signal actuator B-
Coolant temperature Stepping motor
39 0.50 Gr 65 0.50 L
sensor signal actuator A+
40 - - Stepping motor
66 0.50 Gr/W
actuator A-
41 - - Stepping motor
67 0.50 B/R
actuator B+
Intake temperature
42 0.50 Y/V
signal 68 - -
43 - - Compressor relay
69 0.50 Gr/L
control
Main relay output
44 0.75 Br/R
power supply 1 Fuel pump relay
70 0.50 Gr
control
Main relay output
45 0.75 Br/R
power supply 2 71 0.50 L/R K wire
Canister solenoid
46 0.75 L 72 - -
valve control
EL
47 0.75 Y/B Fuel injector 4 control 73 - -
48 - - 74 - -
49 - - 75 0.50 G/W A/C request signal
Radiator fan low 76 0.50 W/R Headlamp load signal

50 0.50 Gr/R
speed control
Assisted idling up
51 0.75 B Ground 77 0.50 O
signal
52 - - 78 - -
53 0.75 B Ground Camshaft position

79 0.50 B/G
signal
54 - -
80 0.75 B Ground
Rear oxygen sensor
55 0.50 Lg/R 81 0.50 P CAN-L
signal
56 - -
57 - -
58 - -
Vehicle speed signal

59 0.50 G/Br
input
60 - -
61 0.75 B Ground
15419715-DELPHI 15419715-DELPHI
E002 to fuel injector 4 E004 to fuel injector 2
Wire Wire
Terminal Terminal
No. No.
color color
Fuel injector 4 power Fuel injector 2 power
1 0.75 W 1 0.75W
supply supply
2 0.75 Y/B Fuel injector 4 control 2 0.75G/Y Fuel injector 2 control
EL
15419715-DELPHI
15419715-DELPHI E005 to fuel injector 1
E003 to fuel injector 3
Wire
Terminal
Wire diameter/ Function
Terminal No.
diameter/ Function color
No.
color Fuel injector 1 power
1 0.75W
Fuel injector 3 power supply
1 0.75 W
supply
2 0.75G/W Fuel injector 1 control
2 0.75 B/R Fuel injector 3 control
PP0401801-THB(WH) PP1518001-THB (Grey)

E006 to rear wall harness E008 To frame harness 2
Wire Wire
Terminal Terminal
No. No.
color color
Handbrake indicator 1 - -
1 0.50W/G
signal
2 - -
2 0.50B Ground
3 0.75 Y IG1 power
Seat belt reminder
3 0.50Br 4 0.50 L/R K wire
signal
5 0.50 P CAN-L
Evaporator
6 0.50 G/R temperature sensor
EL signal
7 0.50 V/W Main relay control
8 0.50 G/W A/C request signal
9 - -
10 0.50 Br/W CAN-H

282189-1-AMP(BK) Evaporator
11 0.50 B
E007 to ignition coil 2 temperature sensor -
Odometer sensor
Wire 12 0.50 Br
Terminal signal
diameter/ Function
No.
color 13 0.50 Gr/G Odometer sensor +
2nd and 3rd cylinder Vehicle speed signal
1 1.50 O 14 0.50 L
ignition power supply input
2nd/3rd cylinder 15 - -
2 1.50 W/L
ignition control
16 - -
17 - -
18 0.50 Gr/R
-
19 0.50 G/L
+
20 - -
Wire
Terminal
diameter/ Function
No.
color
19 - -
20 2.00 R/B Starter motor control
E009 To frame harness 1
Wire
Terminal
diameter/ Function
No.
color
Main relay output
1 1.50R 1488991-5-AMP(BK)
power supply
Coolant temperature E010 to crankshaft position sensor
2 0.50P/L
output Wire
Terminal
3 0.50 Br/L SVS indicator lamp diameter/ Function
No.
color
Compressor relay Camshaft position
4 0.50 R/Y 1 0.50Y/R
control sensor -
Fuel pump relay Camshaft position
5 0.50 Gr 2 0.50B/G EL
control sensor signal
Camshaft position
Ignition coil power 3 0.50Y/L
6 1.50 O sensor +
supply
Engine failure
7 0.50 Br/W
indication
8 0.50 Br/R RPM output
Radiator fan high

9 0.50 Y/L
speed control
10 0.50 W/R Headlamp load signal
11 1.50 W Injector power
Seat belt reminder 282189-1-AMP(BK)

12 0.50 Br
signal
E011 to ignition coil 1
13 0.50 W/G Handbrake indicator
Wire
Terminal
Assisted idling up diameter/ Function
14 0.50 O No.
signal color
1st and 4th cylinder
Radiator fan low 1 1.50O
15 0.50 Gr/R ignition power supply
speed control
1st/4th cylinder
16 - - 2 1.50V/B
ignition control
17 0.75 R Battery power supply
18 - -
282189-1-AMP(BK) 85205-1-AMP(BK)
E012 to water temperature sensor E014 To odometer sensor
Wire Wire
Terminal Terminal
No. No.
color color
Coolant temperature 1 0.50Gr/G Odometer sensor +
1 0.50 Gr
sensor signal
Coolant temperature 2 0.50B Odometer sensor -
2 0.50 B
sensor -
Odometer sensor
3 0.50Br
signal
EL
174257-2-AMP(black)
E013 to downstream oxygen sensor 282191-1-AMP(BK)
E015 to crankshaft position sensor
Wire
Terminal
diameter/ Function
No. Wire
color Terminal
diameter/ Function
No.
Rear oxygen sensor color
1 0.50 Lg/R
signal
Crankshaft position
1 0.50R
Downstream oxygen sensor +
2 1.50 Br/R sensor heating power
Crankshaft position
supply 2 0.50G
sensor signal
3 0.50 W/L Rear oxygen sensor - Crankshaft position
3 0.50B
sensor -
Downstream oxygen
4 1.50 P
sensor heating control
PP0433603-THB(WH) 282191-1-AMP(BK)
E016 To rearview lamp switch E018 to knock sensor
Wire Wire
Terminal Terminal
No. No.
color color
Rearview lamp switch 1 0.50B Knock sensor -
1 0.50 G/L
+
Rearview lamp switch 2 0.50R Knock sensor - Signal
2 0.50 Gr/R
-
3 0.50B Ground
EL
174257-2-AMP(black)
12162833-DELPHI
E017 to upstream oxygen sensor
E019 To Intake pressure/temperature sensor
Wire
Terminal Wire
diameter/ Function Terminal
No. diameter/ Function
color No.
color
Front oxygen sensor
1 0.50 G/Y
signal 1 0.50L/W Intake pressure signal
Upstream oxygen Intake
2 1.50 Br/R sensor heating power 2 0.50Y/L pressure/temperature
supply sensor +
Upstream oxygen Intake temperature
3 0.50 W/L 3 0.50Y/V
sensor - signal
Upstream oxygen Intake
4 1.50 Br
sensor heating control 4 0.50Y/R pressure/temperature
sensor -
282189-1-AMP(BK) 282191-1-AMP(BK)
E020 to carbon canister solenoid valve E022 to throttle position sensor
Wire Wire
Terminal Terminal
No. No.
color color
Carbon canister Throttle position
1 0.50Y/L
1 0.75 W solenoid valve power sensor +
supply
Throttle position
2 0.50Y/R
Canister solenoid sensor -
2 0.75 L
valve control
Throttle position
3 0.50R/L
sensor signal
EL
DJ7011-6.3-21-CZT (white)
E021 to starter motor coil 12162190-DELPHI(BK)
Wire E023 to steeping motor
Terminal
diameter/ Function
No. Wire
color Terminal
diameter/ Function
No.
1 2.00 R/B Starter motor control color
Stepping motor
1 0.50 L
actuator A+
Stepping motor
2 0.50 O
actuator B-
Stepping motor
3 0.50 B/R
actuator B+
Stepping motor
4 0.50 Gr/W
actuator A-
Ceiling harness
HX39600-3Y
F001 to front ceiling lamp
Wire
Terminal
diameter/ Function
No.
color
Front ceiling lamp
1 0.75L/R door control switch
signal
Front ceiling lamp
2 0.75Br/L
power supply
3 0.75B Ground
EL
PP1512302(THB)
F002 To body main harness
Wire
Terminal
diameter/ Function
No.
color
Front ceiling lamp
1 0.75L/R door control switch
signal
2 0.75B Ground
3 - -
Front ceiling lamp

4 0.75Br/L
power supply
Right front door harness
1473793-1(AMP) PP1510801(THB)
H001 To body main harness A H002 To body main harness B
Wire Wire
Terminal Terminal
No. No.
color color
Right front Lowering control of
1 0.50L
loudspeaker + 1 0.50 Y/Br right front door
window glass
Right front
2 0.50L/B
loudspeaker - Lifting control of right
2 0.50 Y/R front door window
Right front turn signal
3 0.50G/W glass
lamp +
Right front turn signal 3 - -
EL 4 0.50B
lamp -
4 0.50 B Ground
5 - -
5 0.75 Gr/B Locking control
6 - -
6 0.75 Gr/W Unlocking control
7 - -
Lowering of right front
7 1.00 W/B
8 - - door window glass
Lifting of right front
8 1.00 W/R
door window glass
PP0439103(THB) PP0302903(THB)
H003 To right side turn signal lamp H005 To right front window lifter motor
Wire Wire
Terminal Terminal
No. No.
color color
Right side turn signal Lowering of right front
1 0.50G/W 1 1.00 W/B
lamp + door window glass
Right side turn signal Lifting of right front
2 0.50B 2 1.00 W/R
lamp - door window glass
EL
PP0401601(THB) PP0403602(THB)
H004 to right front door loudspeaker H006 to front passenger door electric window switch
Wire Wire
Terminal Terminal
No. No.
color color
Right front 1 - -
1 0.50L/B
loudspeaker -
Right front 2 - -
2 0.50L
loudspeaker +
Lowering control of
3 0.50 Y/Br right front door
window glass
4 0.50 B Ground
Lifting control of right

5 0.50 Y/R front door window
glass
DJ70216Y-2.2-20
H007 to right door locking mechanism
Wire
Terminal
diameter/ Function
No.
color
1 0.75Gr/B Locking control
2 0.75Gr/W Unlocking control
EL
Left front door harness
1473793-1 PP1510801(THB)
J001 to body main harness A J002 To body main harness B
Wire Wire
Terminal Terminal
No. No.
color color
Left front loudspeaker Lowering control of
1 0.50Y
+ 1 0.50 Y/B right front door
window glass
2 0.50Y/B
- Lifting control of right
2 0.50 Y/W front door window
Left front turn signal
3 0.50G/W glass
lamp +
3 0.50 W Locking signal
4 0.50B Ground EL
Lowering control of 4 0.50 B Ground
5 0.50L/B left front door window
glass 5 0.75 Gr/B Locking control
Lifting control of left 6 0.75 Gr/W Unlocking control

6 0.50L/W front door window
glass Lowering of left front
7 1.00 G/B
window glass
7 0.50L Unlocking signal
Lifting of left front
8 1.00 G/R
8 - - window glass
PP0439103(THB) PP0302903(THB)
J003 To left side turn signal lamp J005 to left front door window lifter motor
Wire Wire
Terminal Terminal
No. No.
color color
Left side turn signal Lowering of left front
1 0.50G/W 1 1.00 G/B
lamp + window glass
Right side turn signal Lifting of left front
2 0.50B 2 1.00 G/R
lamp - window glass
EL
PP0401601(THB) PP0403604(THB)
J004 To left front door loudspeaker J006 to driver door electric window switch
Wire Wire
Terminal Terminal
No. No.
color color
Left front door 1 - -
1 0.50Y/B
speaker -
Left front door 2 - -
2 0.50Y
speaker +
Lowering control of
3 0.50 L/B left front door window
glass
4 0.50 B Ground
Lifting control of left

5 0.50 L/W front door window
glass
PP0403602(THB) 3RSB05FGYM (Hu Lane)

J007 to driver door electric window switch (Right J008 to left door locking mechanism
control)
Wire
Terminal
Terminal No.
No.
color 1 0.50 B Ground
1 - -
2 0.50 W Locking signal
2 - -
3 0.75 Gr/W Unlocking control
Lowering control of
3 0.50Y/B right front door 4 0.75 Gr/B Locking control
window glass
5 0.50 L Unlocking signal
4 0.50B Ground
EL
Lifting control of right
5 0.50Y/W front door window
glass
Front bumper harness
PP1517301 PP0459501
T001 To frame harness T003 To right daytime running lamp
Wire Wire
Terminal Terminal
No. No.
color color
1 - - 1 0.50B Ground
Daytime running lamp Right daytime running

2 1.00Gr 2 1.00Gr
+ lamp +
3 1.00B Ground
4 1.50L/B Fog lamp +

EL
PP0459501
T004To left daytime running lamp
Wire
1421011 Terminal
diameter/ Function
No.
T002 to right front fog lamp color
Wire 1 0.50 B Ground

Terminal
diameter/ Function
No. Left daytime running
color 2 0.50 Gr
lamp +
1 1.00B Ground
2 1.50L/B Right front fog lamp +

PP0459501
T005To left front fog lamp
Wire
Terminal
diameter/ Function
No.
color
1 1.00B Ground
2 1.00L/B Left front fog lamp +
EL
Harness, taillight
PP0486901 PP1517501
L001 To frame harness L002 To left rear combination lamp
Wire Wire
Terminal Terminal
No. No.
color color
Right rear turn signal Left rear turn signal
1 0.50G/W 1 0.50 G/B
lamp + lamp +
2 1.50B Ground 2 - -
Left rear turn signal 3 0.50 R/G Left fog lamp +

3 0.50G/B
lamp +
4 0.75 L/Y Left brake lamp +
4 0.50R/G Left fog lamp +
EL
5 0.50 G Left rear small lamp
5 1.00G/R Compartment lamp +
6 0.75 B Ground
6 0.75G/R Reversing lamp +
8 0.75L/Y Brake lamp: +
9 0.50B Reversing sensor -
Reversing sensor
10 0.50G
signal
PP0459501
L003 to left sensor probe
Wire
Terminal
diameter/ Function
No.
color
Left side sensor
1 0.50B
probe -
Left sensor probe
2 0.50G
signal
PP0459501 PP0459501
L004 to left middle sensor probe L006 To license plate lamp
Wire Wire
Terminal Terminal
No. No.
color color
Left middle sensor 1 0.50 G License plate lamp +
1 0.50B
probe -
Left middle sensor 2 0.50 B License plate lamp -
2 0.50G
probe signal
EL
PP0459501
PP1517301 L007 to right middle sensor probe
L005 to cargo compartment lamp
Wire
Terminal
Terminal No.
No.
color
Right middle sensor
1 0.50 B
1 - - probe -
Right middle sensor
2 1.00G/R Compartment lamp + 2 0.50 G
probe signal
3 0.75B Ground

Wire
Terminal
diameter/ Function
No.
color
Reversing sensor
9 0.50 G/R controller power
supply
10 0.50 B Ground
Multimedia reversing
11 0.50 B
sensor -
PP0459501 Multimedia reversing

12 0.50 G/R
sensor signal
L008 to right side sensor probe
Wire
Terminal
diameter/ Function
No.
color
1 0.50B Right sensor probe +
2 0.50G Right sensor probe -
PP1517501
L010 To right rear combination lamp
EL Wire
Terminal
diameter/ Function
No.
color
1 0.50G/W
lamp +
DJ7125Y-2.2-21
L009 to reversing sensor controller 2 0.75G/R Right reversing lamp +
Wire 3 - -
Terminal
diameter/ Function
No. 4 0.75L/Y Right rear brake lamp +
color
Left sensor probe 5 0.75G Right rear small lamp
1 0.50 G
signal
Left middle sensor 6 1.50B Ground
2 0.50 G
probe signal
Right middle sensor
3 0.50 G
probe signal
Right sensor probe
4 0.50 G
signal
Left side sensor
5 0.50 B
probe -
Left middle sensor
6 0.50 B
probe -
Right middle sensor
7 0.50 B
probe -
8 0.50 B Right sensor probe -

Door lamp switch harness
DJ7011Y-2.2-21 PP0473205
S001 To frame harness S003 to right front door lamp switch
Wire Wire
Terminal Terminal
No. No.
color color
Door lamp switch Right door lamp
1 0.50L/R 1 0.50 L/R
signal wire switch signal
EL
PP0473205
S002 to left front door lamp switch
Wire
Terminal
diameter/ Function
No.
color
Left door lamp switch
1 0.50L/R
signal
Rear wall harness
PP0401701 PP0338102
R001 To engine harness R003 Handbrake switch
Wire Wire
Terminal Terminal
No. No.
color color
Handbrake switch Handbrake switch
1 0.50P 1 0.50 P
signal signal
2 0.50B Ground
3 0.50Br/Gr Seat belt switch +
EL
PP0435305
R002 to seat belt switch (Driver seat)
Wire
Terminal
diameter/ Function
No.
color
1 0.50Br/Gr Seat belt switch +
2 0.50B Ground
Power harness
L0362061602A0 (Zhongzhi)
Q001 To positive post of battery
Wire
Terminal
diameter/ Function
No.
color
To battery positive
1 16.00B/R
pole
EL
1102236200016
Q002 to starter motor
Wire
Terminal
diameter/ Function
No.
color
Starter motor power
1 16.00B/R
output wire
Engine earth harness
1102236200016
P001 To body ground
Wire
Terminal
diameter/ Function
No.
color
To vehicle body
1 16.00B
grounding point
EL
1029E-3724501
P002 to frame ground
Wire
Terminal
diameter/ Function
No.
color
1 16.00B To frame ground point

Negative pole harness
Q32008
M001 To battery negative terminal
Wire
Terminal
diameter/ Function
No.
color
To battery negative
1 16.00B
pole
EL
YA-090-B-125
M002 to frame ground
Wire
Terminal
diameter/ Function
No.
color

Grounding harness
DJ431-12A
N001 to transmission housing ground
Wire
Terminal
diameter/ Function
No.
color
To transmission
1 16.00B
housing ground
EL
DJ431-6A
N002 to frame ground
Wire
Terminal
diameter/ Function
No.
color

Location diagram of harness and electronic unit

connectors
Frame harnesses
Frame
fuse box
EL
E Frame harness - Electronic unit connectors
B005 Electric horn B011 Oil pressure

B007 Generator B016 Battery fusible wire
B008 Generator B017 Fuel pump
B009 Compressor B018 Pressure switch
B010 Radiator fan motor B019 Condenser motor
B frame harness - harness connectors
B001 To body main harness 1 B012 Connect to engine harness

B002 To body main harness 2 B013 Connect to engine harness
B003 To body main harness 3 B015 To door lamp harness
B004 To body main harness 4 B020 To taillight harness
B006 To front bumper harness
B frame harness - Grounding point
Combination instrument grounding

G303 Frame ground point 1 G306
point
G304 Frame ground point 2 G307 Rear lamp grounding point
G305 Battery negative earthing point
EL
Body main harness

Body main harness 1
EL
C body main harness - electric component connector
C003 Diagnostic interface C020 Combination instrument B

C004 Brake fluid level warning switch C022 Speed regulation resistor
C006 Wiper intermittence relay C025 Hazard warning switch
C007 Brake switch C027 Power socket
C008 Electric-assisting power supply C028 Cigarette lighter
C010 Front fog lamp switch C029 A/C control panel assembly 1
C011 Front fog lamp switch C030 A/C control panel 2
C012 Daytime running lamp C033 Wiper motor
C013 Headlamp dimmer switch C037 Washer pump
C017 Small light switch C038 Right front combination lamp
C018 Lighting combination switch C039 Internal/external recirculation motor
C019 Combination instrument A
B body main harness - harness connector
C001 To left front door harness A C041 To frame wire harness 3

C002 To left front door harness B C042 To frame wire harness 4
C036 To roof harness C043 To right front door harness A
C040 To frame wire harness 2 C044 To right front door harness B
EL
Body main harness 2
Cab fuse case
EL
C body main harness - electric component connector
C005 Combination headlight (LH) C023 T-BOX

C009 EPS signal C024 Radio/audio player
C014 Wiper combination switch C026 Reversing Sensor
C015 Ignition switch C031 Evaporator temperature sensor
C016 Horn switch C034 BCM-1
C021 Blower C035 BCM-2
C body main harness - harness connector
C032 To frame wire harness 1
C body main harness - grounding point
Body main harness right grounding

G201 Body main harness left grounding point 1 G205
point 1
point 2
point 3
G204 Body main harness left grounding point 4
Engine harness
EL
E Connectors between engine wiring harness and electric elements

E003 Fuel injector 3 E016 Switch, backup light
E007 Ignition coil 2 E019 Intake pressure/temperature sensor
E011 Ignition coil 1 E021 Starter coil
E012 Coolant temperature sensor E022 Throttle position sensor
E Connectors between engine wiring harness and wiring harness
E006 To rear wall wiring harness E009 To frame wire harness 1

E008 To frame wire harness 2
E Engine wiring harness -Earthing point
G301 Engine ground point 1 G302 Engine ground point 2

Ceiling harness
EL
F Roof harness - Electronic unit connectors
F001 Front roof lamp
F Roof harness - harness connectors
F002 To body main harness

Right front door harness
EL
H Right front door harness - electronic unit connectors
H003 Right turn light H006 Right electric window switch

H004 Right front door loudspeaker H007 Right front door lock
H005 Right front window lifter motor
H Right front door harness - harness connector
H001 To body main harness A H002 To body main harness B

Left front door harness
EL
J Left front door harness - electric component connector
J003 Left side turn signal lamp J006 Left power door glass and door switch
Left electric door window switch (Right
J004 Left front door speaker J007
control)
J005 Left front door electric window motor J008 Left front door lock
J Left front door harness - harness connector
J001 To body main harness A J001 To body main harness A

Front bumper harness
EL
T Front bumper harness - electric component connector
T002 Right front fog lamp T004 Left front daytime running lamp
T003 Right front daytime running lamp T005 Left front fog lamp
T Front bumper harness - harness connector
T001 To frame harness

Harness, taillight
EL
L Rear lamp harness - electric component connector
L002 Left rear combination lamp L002 Left rear combination lamp
L003 Left reversing sensor L003 Left reversing sensor
L004 Left middle reversing sensor L004 Left middle reversing sensor
L006 Rear license plate lamp L006 Rear license plate lamp
L Rear lamp harness - harness connector
L001 To frame harness

Door lamp switch harness
EL
S Door lamp switch harness - electric component connector
S002 Left front door lamp switch S003 Right front door lamp switch
S Door lamp switch harness - harness connector
S001 To frame harness

Rear wall harness
EL
R Rear wall harness - electric component connector
R002 Seat belt switch (Driver seat) R003 Handbrake switch
R Rear wall harness - harness connector
R001 Connect to engine harness

Power harness
EL
Q Power supply harness - electric component connector
Q001 To positive post of battery Q002 To starter

Engine earth harness
EL
P Engine earth harness - ground point
P001 To frame ground P002 To transmission housing ground

Negative pole harness
EL
M Negative harness - grounding point
M001 To negative post of battery M002 To frame ground

Grounding harness
EL
N Grounding harness - grounding point
N001 To frame ground N002 To fuel tank ground

Charging system ....................................... EL-153

Index Frame harnesses .........................EL-216, EL-265
A Body fault................................................... DI-415
Safety handrail .......................................... BW-45 Body logo ................................................... BW-44
Safety rules ..................................................IN-25 Door windows ............................................ BW-26
Seat belt .................................................... BW-81 Drive shaft..................................................... AX-9

Gear oil ....................................................... AX-39
B
Body............................................................. BW-1
Fuse and relay...........................................EL-122
CAN Communication Malfunction .............. DI-347
Transmission control mechanism ............... TR-63
Gearshift lever shield................................. BW-46 D
Backlight lamp system...............................EL-186 Fault of power door lock control system..... DI-134
Glass and rearview mirror ......................... BW-12 Electrical part symbol.................................EL-117
Transmission assembly .............................. TR-36 Reversing sensor controller ........................ EL-75
Knock sensor............................................ EG-239 Example of a power supply circuit diagramEL-115
Axle shaft assembly.................................... AX-35 Reversing sensor malfunction.................... DI-103
Sheet Metal Parts ........................................ BW-2 Reversing sensor system.......................... EL-176
Transmission is hard to engage a gear ......DI-390 Ignition switch system ............................... EL-155
Power window failure ................................. DI-117
C
Electric window system............................. EL-188
Vehicle axle, transmission shaft fault..........DI-394
Power socket system ................................ EL-213
Frame, suspension fault .............................DI-397
Reversing lamp system............................. EL-166
Wheel and tire assembly ............................ FR-36
Floor trim.................................................... BW-35
Wheel and tire fault.....................................DI-401
Ignition lighter fault..................................... DI-319
Vehicle door and engine hood ................... BW-62
Cigarette lighter system ............................ EL-159
Fault of the charging system ......................DI-331
Electric lifter ............................................... BW-14
Body control system ..................................EL-194
Electric fuel pump .....................................EG-108
Vehicle Control System ............... EL-103, EL-102
Electric fan system.................................... EL-202
Drive shaft assembly .................................... AX-1
Circuit diagram of power source ............... EL-134
Interior rearview mirror .............................. BW-24
A/C Electric Fan ........................................ EL-102
Exterior rearview mirror ............................. BW-22
Reversing switch......................................... EL-73
Body main harness...................... EL-223, EL-273
Reversing Sensor ....................................... EL-74
Remote control key....................................EL-109
Power steering ............................................ ST-19
Vehicle speed sensor ............................... EG-257
Over-high idling speed ................................. DI-81
Inner guard panel of door .......................... BW-31
Ignition system ..........................................EG-198
Door outer handle...................................... BW-65
Ignition coil................................................EG-209
Drive belt .................................................. EG-156
AX-2 Axle and drive shaft -
Power socket............................................... EL-76 Engine control module (ECU, ECM) .........EG-227

Power harness ............................ EL-261, EL-278
G
Circuit guide .............................................. EL-110
Wiper and washer fault .............................. DI-144
Boarding handrail .......................................BW-47
Troubleshooting .........................................EL-128
Roof panel ..................................................BW-42
High-voltage cable ....................................EG-207
Ceiling harness............................ EL-247, EL-271
Blower......................................................... EL-91
Cigarette lighter ........................................... EL-67
Unstable (Varying) idling...............................DI-75 H
Rear axle housing weldment assembly ...... AX-27
E
Rear oxygen sensor..................................EG-249
Output shaft assembly.................................TR-70
Rear wheels and tires ................................. FR-49
EPS fault ....................................................DI-353
Rear wheel brake........................................ BR-25
Electronic power steering system (EPS) ... EL-211
Rear windscreen........................................ BW-19
F Piston and connecting rod ..........................EG-68
Flameout of cold engine during idling...........DI-85 Rear wall harness ........................ EL-260, EL-277
Flameout of engine at startup of vehicle.......DI-88 Rear axle assembly .................................... AX-17
Engine electronic control system............... EL-145 Rear combination lamp ............................... EL-33
Engine electronic control malfunction diagnosis Cargo body assembly ................................ BW-87
.......................................................................DI-1
Rear wheel hub........................................... AX-32
Expansion tank......................................... EG-151
Sliding yoke ................................................ AX-16
Engine control system .............................. EG-212
Spark plug.................................................EG-204
Engine earth harness .................. EL-262, EL-279
Cargo body ................................................ BW-87
Engine mechanic part................................... EG-1
Front passenger seat .................................BW-80 I
Fault of auxiliary power supply ...................DI-325 How to troubleshoot the vehicle................... IN-37
Subframe assembly.....................................FR-20
J
Engine assembly ........................................ EG-21
Slow acceleration response and maladjustment
Engine Oil Level ....................................... EG-131 ..................................................................... DI-92
Engine harness ............. EG-265, EL-239, EL-270 Intake manifold pressure/temperature sensor
..................................................................EG-237
Engine accessories .................................... EG-30
Poor acceleration and poor performance..... DI-96
Generator assembly ................................. EG-196
Mechanical fault diagnosis overview.......... DI-366
Auxiliary dashboard....................................BW-56
Example of connector information .............EL-116
Negative pole harness................. EL-263, EL-280
Engine oil pressure sensor .......................EG-263
Fan malfunction............................................DI-56
Engine oil filter ..........................................EG-128
Steering wheel............................................... ST-7
Driver seat ................................................. BW-78
Engine control module (ECM) malfunction ...DI-17
Accelerator pedal......................................EG-229
Grounding harness ...................... EL-264, EL-281 Fault of the horn......................................... DI-340

Throttle unit .............................................. EG-235 Horn system.............................................. EL-174
Intake manifold ......................................... EG-166 Refrigerant oil ............................................. EL-86
Intake pipeline .......................................... EG-168 Condenser .................................................. EL-92
Intake system ........................................... EG-159 Coolant .....................................................EG-152
Engine oil pump........................................ EG-126 Horn ............................................................ EL-72
Footplates.................................................. BW-43
M
Thermostat ............................................... EG-145
Door lamp switch harness............EL-259, EL-276
Ground ......................................................EL-140
Door lamp switch ........................................ EL-32
Intake manifold pressure/temperature sensor
malfunction ...................................................DI-37 Door lock.................................................... BW-68
Driver/front passenger seat belt................. BW-83

N
K Heating and Air Conditioning System.......... EL-77
A/C control switch........................................EL-94 Heater mechanism...................................... EL-98
Fault of A/C system ....................................DI-170 Heater water pipe........................................ EL-82
Air filter ..................................................... EG-169 Interior/exterior trims .................................. BW-30
A/C compressor...........................................EL-89
O
A/C system ................................................EL-191
OBD diagnostic system............................. EL-204
A/C Filter Element/Filter Screen ................EL-101
OCV valve.................................................EG-267
L
P
Difficult start of cold engine and tremble of vehicle
.....................................................................DI-70 Exhaust pipe and muffler assembly ..........EG-182
Coolant Temperature Sensor Malfunction ....DI-33 Fuel injector circuit malfunction.................... DI-58
Clutch pressure disc and driven disc ...........TR-11 Exhaust manifold ......................................EG-178
Coolant temperature sensor ..................... EG-231 Exhaust system.........................................EG-172
Air bleeding of clutch system........................ TR-9 Fuel injector ................................................EG-99
Clutch oil pot............................................... TR-16 License plate lamp ...................................... EL-35
Clutch slave cylinder................................... TR-23 Pulley ........................................................EG-158
Clutch master cylinder ................................ TR-25 Nozzle......................................................... EL-56
Clutch fault .................................................DI-386 Q

Clutch system ............................................... TR-1 The starter motor rotates, but the engine can't
Clutch components..................................... TR-20 start.............................................................. DI-65
Clutch pedal ............................................... TR-28 Crankshaft position sensor malfunction ....... DI-41
Cooling pipeline ........................................ EG-154 Front independent suspension assembly...... FR-1
Cooling system ......................................... EG-133 Crankshaft position sensor........................EG-242
Cooling fan ............................................... EG-150 Cylinder block, flywheel housing .................EG-85

AX-4 Axle and drive shaft -
Front bumper harness ................. EL-254, EL-274 Radio/audio player...................................... EL-61

Shock absorber assembly (FR) ...................FR-12 Radiator ....................................................EG-147
Cylinder head and valves ........................... EG-60 Fuel delivery pipe...................................... EG-113
Front oxygen sensor................................. EG-246 Water pump ..............................................EG-143
Headlamp system...................................... EL-171
T
Front wheels and tires .................................FR-47
Camshaft position sensor malfunction ......... DI-53
Front wheel brake....................................... BR-22
Camshaft position sensor .........................EG-258
Front windscreen........................................BW-16
Camshaft, gear train ...................................EG-54
Starting and charging ............................... EG-185
Carbon canister solenoid valve malfunction DI-45
Crankshaft and flywheel ............................. EG-78
Front Thrust bar assembly .......................... FR-16
Gasoline filter ........................................... EG-114
Canister solenoid valve.............................EG-252
Starter assembly....................................... EG-190
Speed regulation resistor ............................ EL-96
Starter motor malfunction ...........................DI-101
Antenna ...................................................... EL-66
Front bumper..............................................BW-38
Painting........................................................ BW-6
Front combination lamp............................... EL-18
Canister .................................................... EG-116
Front door lock ...........................................BW-70
T-BOX system............................................EL-214
Cleaning specification ..................................IN-31
Starter system ........................................... EL-151 W
Front wheel hub...........................................FR-22 Hazard warning lamp switch ....................... EL-37
Front fog lamp ............................................. EL-25 General Rules for Maintenance and Service
Operation ..................................................... IN-17
Front door...................................................BW-63
Harness, taillight .......................... EL-256, EL-275
Positive crankcase ventilation valve (PCV)EG-272
Fog lamp system .......................................EL-168
R Universal joint ............................................. AX-11
How to use the manual...................................IN-1
X
Fuel system pipeline................................. EG-104
Example of system circuit diagram ............ EL-111
Lubricating system ................................... EG-118
Battery assembly .......................................... EL-1
Fuel system ................................................ EG-90
Information System..................................... EL-68
Fuel tank................................................... EG-107
Marker lamp system ..................................EL-183
S Lower swing arm......................................... FR-18
Three-element catalyzer........................... EG-274 Washer ....................................................... EL-55
Interior lamp system .................................. EL-198 Battery .......................................................... EL-7
Four-wheel alignment....................................FR-7 Service brake system (Hydraulic) .............. DI-408
Identification information ................................IN-5
Y
Plastic parts..................................................BW-8
Interior lamp ................................................ EL-30 ................................................................... BW-48
Rocker arm, rocker arm shaft, tappet ......... EG-47 Central control lock system....................... EL-157
Wiper arm and linkage.................................EL-51 Counter shaft components .......................... TR-76
Wiper and Washer .......................................EL-39 Brake lamp system ................................... EL-164
Wiper liquid reservoir...................................EL-49 Left front door harness .................EL-251, EL-273
Wiper and washer system .........................EL-200 Daytime running lamp system................... EL-209
Audio system fault ......................................DI-201 Steering drive shaft ..................................... ST-18
Dashboard framework ............................... BW-60 Steering gear reducer ................................. ST-25
Instrument Panel Air Passage .....................EL-97 Steering gear assembly .............................. ST-24
Right front door harness .............. EL-248, EL-280 Driving gear ................................................ AX-36
Wiper motor .................................................EL-47 Brake pedal.................................................BR-17
Input shaft module ...................................... TR-68 Seat assembly ........................................... BW-76
Instrument system .....................................EL-178 Lighting system ............................................. EL-9
Remote control key....................................EL-109 Combination instrument ............................. BW-58
Audio system.............................................EL-206 Combination switch..................................... ST-10
Audio System ..............................................EL-57 Steering column .......................................... ST-13
Dashboard................................................. BW-49 Steering system ............................................ FR-1
Loudspeaker................................................EL-64 Refrigerant .................................................. EL-85
Oil pan ...................................................... EG-124 A/C Pipe...................................................... EL-87
Oil dipstick ................................................ EG-130 Turn signal lamp ......................................... EL-28
Wiper ...........................................................EL-45 Steering knuckle.......................................... ST-16
Wiper blade .................................................EL-54 Sun visor.................................................... BW-34
Fuel rail..................................................... EG-101 Vacuum booster and brake master cylinder
(hydraulic) .....................................................BR-8
Z Brake Pipeline (Hydraulic) ..........................BR-30
Turn signal lamp and hazard warning lamp Communication failure between diagnostic unit
system .......................................................EL-160 and ECM...................................................... DI-62
Timing toothed pulley, toothed chain .......... EG-34
Steering motor controller .............................ST-27
Air bleeding of brake system ...................... BR-15
Brake system fault ......................................DI-408
Integrated vehicle fault ...............................DI-373
Lighting system failure................................DI-217
Combination instrument fault......................DI-290
Steering system fault ..................................DI-404
Parking brake handle.................................. BR-46
Parking brake cable.................................... BR-49
Parking brake system ................................. BR-39
Internal number:
Worriless
Whole-process
Total care in the whole journey
FOTON INTERNATIONAL TRADE CO., LTD, BEIJING

24-hour helpline: 4008199199
24-hour complaints hotline : (010)80722999
Welcome to visit: www.foton.com.cn

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Beijing FOTON TM1

Foton International Trade Co., Ltd,Beijing

Identification information ....................................... 5 IN

General Rules for Maintenance and Service

Safety rules ............................................................25

How to troubleshoot the vehicle...........................37

1 Left lower wing arm assembly 6 Pivot

Part name list

Operating step title Operating step description

Repair warning information

Operating step illustration

It is expressed in bold font, and providing additional instructions, helpful for

5. Unit -- International System of Units

BJ1030V4JV2-BH DAM15R China NS-V

Vehicle identification number (VIN)

Coding rules for vehicle identification number (VIN)

VIN: vehicle identification code

2. Composition and Meaning of WMI

WMI used by various vehicles of FOTON

N1-class (with a maximum design total mass ≤3500kg) truck (including

N2-class and N3-class (with a maximum design total mass>3500kg) truck

3 LVC M-class vehicle

4 LVD O-class trailer

3. Composition and Meaning of VDS (Category N)

Class II truck chassis V

Class III truck chassis Y

Low speed truck L

Integral body truck C

Chassisless truck (Excluding low speed truck) W

Meaning (Gross mass, kg) Code

Meaning (Body type) Code

Cab-over-engine single-row cab J

Cab-over-engine single-row cab with sleeper P

Cab-over-engine double-row cab A

Long-nose single-row cab K

Long-nose single-row cab with sleeper L

Long-nose single-row cab with sleeper M

No body (No cab or cargo body) O

Meaning (Vehicle wheelbase, mm) Code

f. The sixth digit of VDS denotes the check digit.

4. Composition and Meaning of VIS (Category N)

a. The first digit of VIS denotes the year.

Year Code Year Code

Vehicle assembling plant and assembling line Code

First assembling line (Auman export

Nanhai Auto Plant of Beiqi Foton Motor Co., Ltd. C

First assembling line S

First assembling line J

First assembling line N

First assembling line Z

Second assembling line W

Fourth assembling line Y

Zhucheng Ollin Auto Plant of Beiqi Foton Motor Co., Ltd. E

Huairou Heavy-Duty Machinery Plant of Beiqi Foton Motor Co., Ltd. V

Serial number (SN)

2. The rear axle serial number is stamped on the

Main technical parameters of complete vehicle

IN Vehicle number 1030V4JV2-BHD021 1030V4JV2-BHD030