After-Technical Training Handbook-MAXUS V80

PREFACE
PREFACE
This Handbook is provided by SMCV After Sales to technical directors/service technicians of
dealers, including a range of contents such as new technical features, engine mechanical, engine
management, transaxle, chassis, and body electrics of V80.
Parts of information are taken from Driver‘s Handbook, Service Handbook and other relevant
technical documents. Update of Driver‘s Handbook, Service Handbook and other relevant technical
documents may cause discrepancy(s) with this Handbook. If there is any discrepancy, the latest
SMCV Service Handbook and technical notice or technical handbook updated shall prevail.
Some contents in this Handbook are written by trainers in the training center with reference to
relevant technical documents. If any mistakes are found, contact our training center immediately.
We will make corrections as soon as possible.
Training Center, SMCV After Sales
Training for new model of V80

CONTENTS
CHAPTER 1 NEW TECHNICAL FEATURES ............................................................................................................. 1
1.1 OVERVIEW ................................................................................................................................................................. 3
1.1.1 Origin and advantages ...................................................................................................................................... 3
1.1.2 Vehicle Identification ......................................................................................................................................... 7
1.1.3 Vehicle dimension .............................................................................................................................................. 8
1.1.4 Vehicle features .................................................................................................................................................. 9
1.2 MAINTENANCE ........................................................................................................................................................ 10
1.3 EXERCISES ............................................................................................................................................................... 11
CHAPTER 2 ENGINE ................................................................................................................................................... 13
2.1 OVERVIEW ............................................................................................................................................................... 15
2.2 ENGINE MECHANICAL ............................................................................................................................................. 16
2.2.1 Technical specifications ................................................................................................................................... 16
2.2.2 Cylinder block ................................................................................................................................................. 17
2.2.3 Crank link mechanism ..................................................................................................................................... 18
2.2.4 Cylinder head .................................................................................................................................................. 21
2.2.4 Valve actuating mechanism ............................................................................................................................. 22
2.2.5 Inspection and installation of main components ............................................................................................. 24
2.3 LUBRICATION SYSTEM ............................................................................................................................................. 31
2.3.1 Technical data.................................................................................................................................................. 31
2.3.2 Lubrication system oil flow illustration ........................................................................................................... 31
2.3.3 Introduction of main elements ......................................................................................................................... 32
2.4 COOLING SYSTEM.................................................................................................................................................... 34
2.4.1 Overview.......................................................................................................................................................... 34
2.4.2 Technical date of cooling system ..................................................................................................................... 34
2.4.3 Cooling system circulation .............................................................................................................................. 34
2.4.4 Renew coolant ................................................................................................................................................. 34
2.4.5 Fault diagnosis: ............................................................................................................................................... 35
2.5 FUEL SUPPLY SYSTEM .............................................................................................................................................. 36
2.5.1 Technical data.................................................................................................................................................. 36
2.5.2 Operation principle of fuel system ................................................................................................................... 36
2.5.3 Introduction of system elements....................................................................................................................... 37
2.6 AIR INTAKE & EXHAUST SYSTEM ............................................................................................................................. 41
2.6.1 Overview.......................................................................................................................................................... 41
2.6.2 Inlet manifold .................................................................................................................................................. 41
2.6.3 Exhaust manifold ............................................................................................................................................. 41
2.6.4 Silencer ............................................................................................................................................................ 41
2.6.5 Turbocharging system ...................................................................................................................................... 42
2.6.6 Emission purifying system ............................................................................................................................... 42
2.7 VACUUM SYSTEM .................................................................................................................................................... 44
2.7.1 Overview.......................................................................................................................................................... 44
2.7.2 Technical data.................................................................................................................................................. 44
2.7.3 Layout of vacuum system ................................................................................................................................. 44
2.7.4 Introduction of elements .................................................................................................................................. 44
2.8 STARTING & CHARGING SYSTEM ............................................................................................................................. 46
2.8.1 Overview.......................................................................................................................................................... 46
2.8.2 Introduction of elements .................................................................................................................................. 46
2.8.3 Analysis of starting & charging system circuit diagrams ................................................................................ 47
2.8.4 Fault diagnosis ................................................................................................................................................ 47
2.9 ENGINE MANAGEMENT SYSTEM .............................................................................................................................. 48
2.9.1 Overview.......................................................................................................................................................... 48
2.9.2 Sensors ............................................................................................................................................................ 48
2.9.3 Electronic Control Unit (ECU) ........................................................................................................................ 53
2.9.4 Actuator ........................................................................................................................................................... 53
2.9.5 Control strategy of EMS .................................................................................................................................. 56
2.9.6 Immobilizer...................................................................................................................................................... 57
2.9.7 Fault diagnosis ................................................................................................................................................ 58
Training for new model of V80 -1-

CONTENTS
2.9.8 Exercises .......................................................................................................................................................... 59
CHAPTER 3 TRANSAXLE .......................................................................................................................................... 65
3.1 OVERVIEW ............................................................................................................................................................... 67
3.2 TECHNICAL DATA .................................................................................................................................................... 67
3.3 STRUCTURE, PRINCIPLE & FITTING/REMOVAL OF TRANSAXLE ................................................................................ 68
3.3.1 Structure of transaxle ...................................................................................................................................... 68
3.3.2 Power Flow ..................................................................................................................................................... 72
3.3.3 Differential ...................................................................................................................................................... 73
3.3.4 Keys for fitting/removal ................................................................................................................................... 74
3.4 CLUTCH ................................................................................................................................................................... 80
3.5 AXLE SHAFT ............................................................................................................................................................ 80
3.6 FAULT DIAGNOSIS .................................................................................................................................................... 81
3.7 EXERCISES ............................................................................................................................................................... 82
CHAPTER 4 CHASSIS .................................................................................................................................................. 83
4.1 SUSPENSION ............................................................................................................................................................ 85
4.1.1 Overview.......................................................................................................................................................... 85
4.1.2 Technical Data................................................................................................................................................. 85
4.1.3 Front Suspension ............................................................................................................................................. 85
4.1.4 Rear Suspension .............................................................................................................................................. 86
4.1.5 Wheel ............................................................................................................................................................... 86
4.1.6 Hubs ................................................................................................................................................................ 87
4.1.7 Wheel Alignment .............................................................................................................................................. 87
4.2 BRAKE SYSTEM ....................................................................................................................................................... 91
4.2.1 Overview.......................................................................................................................................................... 91
4.2.2 Technical data of brake system ........................................................................................................................ 91
4.2.3 Regular brake system ...................................................................................................................................... 91
4.2.4 Handbrake System ........................................................................................................................................... 93
4.2.5 ABS System ...................................................................................................................................................... 93
4.2.6 Fault diagnosis ................................................................................................................................................ 95
4.3 STEERING SYSTEM................................................................................................................................................... 96
4.3.1 Overview.......................................................................................................................................................... 96
4.3.2 Elements Instruction ........................................................................................................................................ 96
4.3.3. Fault diagnosis ............................................................................................................................................... 97
4.4 EXERCISES ............................................................................................................................................................... 98
CHAPTER 5 AIR-CONDITIONING SYSTEM .......................................................................................................... 99
5.1 OVERVIEW ............................................................................................................................................................. 101
5.2 TECHNICAL PARAMETERS ...................................................................................................................................... 101
5.3 HEATER ................................................................................................................................................................. 101
5.4 COOLER SYSTEM.................................................................................................................................................... 103
5.5AIR CONDITIONING AND DISTRIBUTION SYSTEM ..................................................................................................... 107
5.6 AIR CON CONTROL ................................................................................................................................................. 107
5.7 COMMON TROUBLESHOOTING ............................................................................................................................... 108
CHAPTER 6 BODY ELECTRICS ............................................................................................................................. 109
6.1 CIRCUIT DIAGRAM DESCRIPTION.............................................................................................................................111
6.2 POWER AND PUT UP IRON DISTRIBUTION ................................................................................................................ 115
6.3 BODY CONTROL MODULE ....................................................................................................................................... 116
6.4 CENTERAL DOOR LOCKING AND VEHICLE IMMOBILISER SYSTEM ........................................................................... 119
6.5 WINDOW SYSTEM .................................................................................................................................................. 121
6.6 ELECTRIC MIRROR AND HEATED REAR WINDOW..................................................................................................... 122
6.7 SEATS .................................................................................................................................................................... 123
6.8 INTERIOR ILLUMINATION SYSTEM ......................................................................................................................... 124
6.9 EXTERIOR ILLUMINATION SYSTEM ........................................................................................................................ 125
6.10 WIPER SYSTEM .................................................................................................................................................... 126
6.11 INSTRUMENT CLUSTER ........................................................................................................................................ 127

CONTENTS
6.12 TPMS .................................................................................................................................................................. 132
6.13 AUDIO & ENTERTAINMENT SYSTEM ..................................................................................................................... 133
6.14 PDC .................................................................................................................................................................... 134
6.15 SUPPLERMENTAL RESTRAINT SYSTEM ................................................................................................................. 135
6.16 VEHICLE INVERTER ............................................................................................................................................. 137
6.17 EXERCISES ........................................................................................................................................................... 138
CHAPTER 7 APPENDIX ............................................................................................................................................ 145
SPECIAL TOOLS ............................................................................................................................................................ 147
CIRCUIT DIAGRAMS ..................................................................................................................................................... 150

CONTENTS

New Technical Features
Chapter 1 New Technical Features


1.1 Overview
1.1.1 Origin and advantages
Maxus is the new generation of Light Commercial Vehicle platform provided by Britain LDV with 4 years of
dedicated research and development. It has been regarded as the star model immediately after the launch on 2005,
with a harvest of honors during 2005 to 2007.Based on market demands and technology development trends,
SAIC improves and optimizes the origin in terms of ten aspects and nearly a hundred items, as well as left and
right steering wheel to satisfy the global market.
Engine
V80 commercial vehicle is equipped with 2.5 liter common rail diesel engine with turbocharger and intercooler.
The engine is mounted transversely on the frame and provides the front wheel drive. The engine employs a
common rail fuel injection system for improved combustion efficiency, as well as a low fuel consumption and low
emission - Chinese Emission Standard IV; hence an economical and environmental innovation.
Transaxle
The manual operated 5 Gear Transmission can significantly improve the acceleration performance; and the
reliable operation control can ensure a stable and smooth driving.

Suspension
A Macphersan front suspension and a steel leaf spring rear suspension are applied on V80 commercial vehicle,
ensuring the suspension rigidity and comfortability.
Brake System
V80 commercial vehicle is equipped with four-wheel disc brakes. Both on the front and rear wheels are installed
with ventilated disc brakes which have excellent heat dissipation and brake performance. In addition, with the
improved rigidness of the brake pedal, brake friction disk with high COF and advanced tyres with strong adhesivity,
outstanding brake performance can be ensured. To prevent wheel locking when an emergency braking is applied,
V80 commercial vehicle is installed with Four-wheel Anti-lock Brake System (ABS). In this case, driving safety is
guaranteed.

Supplermental Restraint System

V80 commercial vehicle is equipped with Dual Air Bags (SRS) to sense, analyze and initiate relevant program
based on the crash condition. The initiator can, according to the crash severity, launch a short interval explosion
on the purpose of controlling the initiation of the air bags. In addition, seat belt pre-tensioner is equipped for a
better safety.
Air Conditioning
V80 commercial vehicle is installed with Front & Rear Electronic Air conditioning. Dedicated AC air outlet is
equipped in each row of seats. For the rear AC, hidden design is applied which locates the cool air outlet on the
top of the body. Both the temperature and air flow of rear AC can be adjusted by the control panel in the top of the
passenger compartment.
Steering system
V80 commercial vehicle is equipped with hydraulic power steering system which facilitates the steering control.
Body Electrics
Central door locking, power heated mirrors and rear windows heated improve the driving comfort and safety a lot.

PDC could help spare driver‘s worries.
Sophisticated vehicle security with ignition key response system reassure customers.
Under the driver‘s seat located a vehicle inverter, providing more convenience for electric equipments.

1.1.2 Vehicle Identification
Body code
Body code is the identification code of vehicle which will be illustrated as follows:
Vehicle Identification Number (VIN ):

Example:
LSK G 4 G C 1 9 A A 200000
1 234 56 7 8 9 10
1: Identification code of the manufacturer
2: Vehicle Brand
G: Datong
3: Vehicle Length (4: L<5.3 ;5:5.3 < L < 6.0)
4: Engine Type (G: 60 ~ 149KW diesel)
5: PV Types and Steering Wheel Layouts
C: Small PV (LEFT)
L: Small PV (RIGHT)
6: Engine Layout (1:Front-engine)
7: Check digit
8: Model Year (A:2010, etc).
9: Assembly Plant (A = Manufacturer)
10: Production Serial Number
VIN Plate

1.1.3 Vehicle dimension
SWB (Short Wheelbase):
LWB (Long Wheelbase):

1.1.4 Vehicle features
Main Technical Data
Model SH6501, SH5040 SH6571, SH5041
Low Roof Middle Roof Middle Roof High Roof
Drive Type 4 × 2, Front-wheel Steering, Front-engine Front-drive (FF)

External Length 4950 5700
Dimension
(mm) Width 1998
Height 2132 2345 2345 2552
Internal Length 2586 3355

Dimension
(mm) Width 1770
Height 1505 1710 1925
GTW (kg) 2160 ～ 2240 2230 ～ 2380
GVW (kg) 3200 3500
Fuel Tank Capacity (L) 80
Top Speed (km/h) 150
Number of Seats 5 ～ 13 5 ～ 16
Wheelbase (mm) 3100 3850
Front Track (mm) 1734

Rear Track (mm)
1728
Front Suspension (mm) 865
Rear Suspension (mm) 985
Approach Angle (°) 26
Departure Angle (°) 17 (without rear step), 14 (with rear step)
Minimum Ground 200 (Oil pan)

Clearance (mm)
Minimum Turning Radius (m) 12.4 14.8
Fuel Tank Capacity (L) 80
Top Speed (km/h) 150

Fuel consumption on comprehensive 9.1~9.3
operation modes per 100km
(L/100km)
Fuel consumption on six operation <6
modes per 100km (L/100km)
0-100km/h acceleration time (s) 23.3 ～ 28

Table of feature codes
Feature code Feature description

ALL All models
CBW Rear Air Conditioning
CBW&HBW Rear Heating & Rear Air Conditioning
CRUS Cruise Control
DEF Heated Rear Window
FFOG Front Fog Light
HBW Rear Heating
INV Vehicle Inverter
LSLD Left Side Load Door
MP5 MP5
OSM Heated Exterior Mirror
PAB Front Passenger Airbag
PDC Parking Distance Control
SPKS Rear Speaker
TPMS Tire Pressures Monitoring System
1.2 Maintenance
Lifting
CAUTION: Since there is no independent chassis, the lift should be operated at the pivot point specified below to
ensure no damage to the vehicle.
Front lifting point Rear lifting point
Maintenance & Service

Service contents (requirements)
Renew oil/Clean air filter 7500km or every 750 liter consumption

Renew oil filter 7500km or every 750 liter consumption
Renew air filter element Every 10000km or 1 year
Renew fuel filter Every 10000km
Renew timing belt Every 60000 km or every 5 years
Renew engine coolant Every 2 years or 60000km (Pay attention to coolant
compositions)
Renew transmission oil At the first 10000km, then every 30000km
Renew brake fluid/power steering fluid Every 2 years (or every 40000km)
Renew AC air filter element Every 1 year
Replace drive shaft support shaft grease and hub Every 40000km
bearing grease

1.3 Exercises
Cognitive exercises (1h)

Objectives: Enable trainees to recognize the vehicle with an understanding of vehicle overview.
Vehicle and tools required: A featured vehicle and a diagnostic instrument.
Contents
1、 Please find out following components and record their locations.
Component Location
Hood handle
VIN
VIN Plate
Tyre pressure identification plate
Tyre type
Diesel filler
Lifting points
Transmission oil filler
Engine compartment fuse box 1
Engine compartment fuse box 2
Interior fuse box
Engine control module
Body control module
ABS control module
PDC module
SRS control module
AC control module
Instrument cluster (observing information area) Record pressures and temperatures of four tyres
Vehicle Inverter
Tool kit
Spare type location
Rear fan heater
Rear AC air distributor assembly
Expansion valve
Receiver drier
AC pressure switch
AC filter element
Rear screen heated button
Fuel filter
Manual pump
Central lock switch
Rear vanity light switch
Rear view mirror adjusting switch
Headlamp height adjuster switch
Front/Rear fog light switch
Cruise switch
Front/Rear speaker
Vacuum reservoir
Driver‘s seat adjuster button (operation)
Requirements: Carefully follow the instructor‘s commands and pay attention to safety.
Summary:


Engine
Chapter 2 Engine

Engine

Engine
2.1 Overview
SC25R Engine is a high efficient small and medium power diesel engine equipped with overhead camshaft,
16 valve direct injection, turbocharger & intercooler and electronically controlled high pressure common rail.
It boasts an international advanced level of energy-saving and high efficient performance with a Chinese
Emission Standard IV achieved by EGR.
Technical Data
Engine displacement (ml) 2499

Engine type 16 valve direct injection using common rail fuel system, with
turbocharger and intercooler.
Engine Layout Transversely mounted
Fuel type 0# diesel
Emission Level Chinese Emission Standard IV
Drive Type 4×2; Front-wheel Steering; Front-engine Front-drive
Injection order 1-3-4-2
Power and Torque 120 PS @ 3800 rpm 300 Nm @ 1800 rpm
136 PS @ 3800 rpm 330 Nm @ 1800 rpm
Compression Ratio 17.5:1
Idle speed (r/min) 850±20
Maximum speed 4500 rpm
Fuel tank capacity 80L
Engine oil CH-4;10W/40;7.5L
Anti-freeze 11L
Engine steel seal
Location: on the cylinder block behind the fuel pump assembly, adjacent to intake manifold and oil dipstick
seat hole.

Engine
2.2 Engine Mechanical
2.2.1 Technical specifications
Cylinder head
Cylinder head height 94.95 - 95.05 mm
Maximum permissible unevenness on cylinder head 0.1 mm
undersurface
Cylinder head gasket thickness 0 hole 1.32 mm
1 hole 1.42 mm
2 holes 1.52 mm
Valve sinkage on cylinder head Inlet -0.15 - +0.15 mm
Exhaust -0.15 - +0.15 mm
Hydraulic tappet outside diameter 11.988 - 12.00 mm
Valves
Valve cone angle Inlet and exhaust 45° 25‘ - 45° 35‘
Valve head diameter Inlet 32.30 - 32.50 mm
Exhaust 30.80 - 31.00 mm
Valve stem diameter Inlet 5.952 - 5.97 mm
Exhaust 5.942 - 5.96 mm
Clearance between valve stem and guide Inlet 0.442 - 0.56 mm
Exhaust 0.452 - 0.57 mm
Valve guide inside diameter 6.00 - 6.012 mm
Valve guide fitted height Inlet 14.5 - 15.0 mm
Exhaust 16.5 - 17 mm
Valve spring Free height 45.26 mm
Fitted height 38.0 mm
Camshaft
Inlet Before top dead center 15°
OPEN 15°BTDC
After bottom dead center 64°
CLOSE 64°ABDC
Exhaust Before bottom dead center
66°OPEN 66°BBDC
After top dead center 32°
CLOSE 32°ATDC
End-float 0.10-0.55 mm
Journal diameter 39.25-39.27 mm
Bearing clearance 0.03-0.08 mm
Connection rod
Connection rod bush inside diameter 32.035 32.050 mm
Connection rod big end inside diameter 53.994 54.014 mm
Piston
Piston diameter (measured at 10 mm above bottom of skirt) 91.912 - 91.928 mm
Piston clearance 0.069 - 0.103 mm
Piston crown to cylinder head 0.66 - 0.91 mm
0.46 - 0.609 mm;
fitting of 1.32 mm head gasket (0 hole)
0.61 - 0.709 mm;
fitting of 1.42 mm head gasket (1 hole)
Piston protrusion 0.71 - 0.81 mm;
fitting of 1.52 mm head gasket (2 holes)
First compression ring 0.12 - 0.154 mm

Piston ring groove clearance
Second compression ring 0.055 - 0.1 mm
Oil ring 0.035 - 0.08 mm

Engine
First compression ring 0.25 - 0.40 mm
Split after fitting of piston ring Second compression ring 0.30 - 0.50 mm
Oil ring 0.25 - 0.50 mm
Piston pin diameter 31.992 - 31.996 mm
Clearance 0.007 - 0.018 mm
Crankshaft
Crankshaft end-float 0.13 - 0.33 mm
End-float thrust washer thickness 2.31 - 2.36 mm
Front end journal diameter 62.985 - 63.005 mm
Front end journal to bearing clearance 0.04 - 0.089 mm
Center journal diameter 63.005 - 63.02 mm
Center journal to bearing clearance 0.048 - 0.091 mm
Rear end journal diameter 89.98 - 90.00 mm
Rear end journal to bearing clearance 0.045 - 0.08 mm
Main bearing dimension out-of-tolerance allowance 0.25 mm
Connection rod journal 53.994 - 53.955 mm
Connection rod journal to bearing clearance 0.012 - 0.066 mm
Cylinder block
Cylinder liner protrusion 0.01 - 0.05 mm
Cylinder liner protrusion adjustment shims 0.15, 0.17, 0.20, 0.23, 0.25 mm
Cylinder liner inside diameter 92.006±0.009 mm
Cylinder block flatness 0.1mm
2.2.2 Cylinder block
The cylinder block consists of a block and a liner. Combination of cast iron block and tunnel-type crankshaft
can ensure sufficient rigidity; cylinder liner is a wet type.
Three are three seals in total on the cylinder liner, two of which are black and one is green. The liner is equipped
with adjusting shims to adjust the cylinder liner protrusion.

Engine
2.2.3 Crank link mechanism
1. Crankshaft pulley (damper)

2. Crankshaft timing pulley
3. Oil pump drive gear
4. Main bearing bush
5. Connection rod bearing bush
6. Connection rod bush
7. Piston ring
8. Hole spring retaining ring
9. Piston pin
10. Piston
11. Connection rod
12. Rear bearing seat
13. Flywheel dust shield
14. Crankshaft speed signal panel
15. Connection rod bearing cap
16. Oil baffle plate
17. Main bearing seat
18. Crankshaft
Piston linkage
Aluminum alloy piston and ω type combustion chamber with forward mark; full-floating piston pin; Cast steel
connection rod with reverse mark; Connection rod big end applies the process of instant broken when expansion,
maintaining the original fractures. When assembling, no dirt must be ensured at fracture. Connection rods are
supplied in groups with color marks. Connection rods of same color marks must be used for the same engine.
Piston ring
Piston ring consists of two compression rings and one combined oil ring. The first compression ring is in light color,
while the second in dark. When fitting, put the face with letters upward. The second compression ring opening is
located at the inlet side of vertical piston pin; the first compression ring opening is located at the rearward of the exhaust
side, forming an angle of 120°with the second one. Oil ring forms an angle of 120°with the first ring at the exhaust
side. The waveform ring opening in the oil ring forms an angle of 180 with the oil ring opening.

Engine
Crankshaft
The crankshaft is supported by five main bearing seats. Thrust washers are on the 5th main bearing bush.
Crankshaft end-float can not be measured until flywheel is fitted. Crankshaft speed signal panel is equipped on the
crankshaft.
Main bearing seat

Since the crankshaft is a tunnel type, main bearing seat and crankcase are separated.
Main bearing seat is a top to bottom structure with corresponding marks. Main bearing seat is connected with
bolts and is secured with main bearing seat setting pins when fitted to crankcase. Oil channel can be machined to
communicate with cylinder block oil channel. Put the face with protruded letters rearward.
The 5th main bearing seat is equipped with thrust washer. Apply a ring of sealant around inside seals when
assembly.

Engine
Crankshaft rear oil seal

Crankshaft rear oil seal can only be supplied with rear oil seal metal seat and can not be supplied separately.
Flywheel
Steel flywheel is machined with timing pin locating hole.
Precautions: When fitting flywheel setting pin at the crankshaft rear end, do not fit it too deep to leave an
insufficient length to locate the flywheel.

Engine
2.2.4 Cylinder head
Aluminum alloy cylinder head consists of upper and lower parts with 16 valves, center located fuel injector and
glow plug.
Cylinder upper head
Cylinder upper head is machined with inlet manifold, fuel injector installation hole seat, camshaft bearing seat,
PCV valve seat and timing pin hole.
Cylinder head
Cylinder head is machined with hydraulic tappet seat, inlet manifold and glow plug threaded hole.
Precautions: The oil channel and water channel on the cylinder head are near to the machining hole seat, so
check channels for any damage and upper and lower gaskets for correct positioning when fitting.
Cylinder gasket
Multiple layers of steel sheets with marks for gasket thickness. Three thicknesses are available to adjust the
clearance between the piston crown and cylinder head; measure piston protrusion first when fitting.

Engine
2.2.4 Valve actuating mechanism
Illustration of valve actuating mechanism
Valve gear
The equipped hydraulic tappet is driven with rocker by the camshaft fitted in the cylinder upper head. Camshaft
position sensor is fitted on the side of cylinder upper head exhaust camshaft.
Precautions:
1. Mark and record sequences when removing valve components. Ensure that hydraulic tappet is correspondent
to the original tappet seat.
2. The valve protrudes from the cylinder head surface. Pad woods in when fitting or removing to avoid damage
to the valve.

Engine
Camshaft
Overhead camshaft is made of cast iron and is fitted from the rear of the cylinder upper head. The front end of
the camshaft is axial positioned with snap spring. On the camshaft timing pin locating hole can be machined.
Precautions:
The timing pin locating holes of inlet camshaft and exhaust camshaft are different.
The front end of camshaft is machined with positioning keyway. Protect the keyway with tape when fitting oil
seals and the remove the tape.
Timing mechanism
Note:
1. Timing mechanism is belt driven for also driving
fuel pump and water pump.
2. No setting pin is located between the camshaft
timing gear and shaft.
3. In the figure * indicate left hand bolts.
4. See "Inspection and installation of main
components" for fitting/removal of timing.

Engine
2.2.5 Inspection and installation of main components
Inspection of accessories and drive belts

Check belts for any crack or damage. Check tension pulley for any wear or roughness in the surface. Check for
free rotation or any noise.
Inspection of timing belt
Timing belt is renewed in travel mileages (Every 60000KM), and idler pulley and tension pulley should be also
replaced. Check idler pulley and tension pulley for any wear, free rotation, any noise, and excessive end-float.
Inspection of oil pump
a. Clean oil pump components and check for any damage.
b. Check outer rotor end-float c. Check rotor to rotor clearance
d. Check outer rotor to body clearance e. Check inner rotor end-float
Inspection of cylinder head

Check the cylinder head for any deformation and clean cylinder head face of all deposits etc. using a non-steel
scraper. Use straight edge and feeler gauge to check for distortion in a number of planes as illustrated. Maximum
permissible unevenness: 0.1 mm.
Precautions: Cylinder head can not be machined.

Engine
Measurement of valve sinkage

Measure valve sinkage, inlet: 1.08 - 1.34 mm, exhaust: 0.99 - 1.25 mm. If sinkage exceeds the specification,
install a new valve and measure again. Re-machine the valve seat ring as necessary.
Identification of cylinder head gaskets

If cylinder liner or piston is not replaced, use a cylinder head gasket as thick as used before (according to the
number of holes).If not, choose among the following after obtaining piston protrusion.
Piston protrusion Thickness Holes
0.460-0.609 1.32 N/A
0.610-0.709 1.42 1
0.710-0.810 1.52 2
Measurement of piston protrusion

1. Position tool C00017009 fitted with suitable dial indicator
vertically over line of gudgeon pin and approximately 5mm
from edge of No.1 piston.
2. Turn crankshaft until precise TDC position is found. Set
the dial indicator to zero.
3. Maintain the position, allow the probe to touch surface of the
block (not the cylinder liner), and the reading is the piston
protrusion.
4. Repeat steps above to obtain protrusions of the other three
pistons.
5. Calculate the average protrusion and select appropriate gasket.
Cylinder head bolt tightening sequence

New cylinder head bolts must be used and pre-lubricated. Tighten bolts in steps as below:
Keys:
1.Tighten all bolts to 30 Nm in following sequence:
1 to 18.
2.Tighten a further 75°in following sequence:
4 - 5 - 6 - 7 - 8 - 9 - 10 - 1 - 2 – 3.
3.Tighten a further 50°in following sequence:
11 to 18.
4.Torque all bolts for a further 75°in following
sequence: 4 - 5 - 6 - 7 - 8 - 9 - 10 - 1 - 2 - 3 - 11 - 12 -
13 - 14 - 15 - 16 - 17 - 18.

Engine
Cylinder upper head bolt tightening sequence

Keys:
1. Fit guide pins at No. 11 and 16 on
the cylinder.
2. Fit the cylinder upper head with
guide pins
3. Fit bolts at No. 7 and 12 and
finger-tight bolts.
4. Remove guide pins, fit and
finger-tight all bolts.
5. Progressively tighten upper head
bolts 11 and 16 to 7 Nm.
6. Progressively tighten all bolts in
sequence illustrated to 25 Nm.
Selection of desired thickness of cylinder liner spacer

Put the cylinder liner into the block (without spacer or
O ring). Apply pressure downwards and turn the
cylinder liner clockwise and anti-clockwise by 45°for
several times. Select thickness of liner spacer according
to following measurements.
1. Measure cylinder liner sinkage as illustrated on the

left
2. Choose the spacer (5 choices), and adjust the cylinder
liner protrusion to the specified value range.
Caution: Only one spacer can be used.
Cylinder liner protrusion: 0.01 to 0.05 mm.
3. Fit the selected clean spacer on the cylinder liner and
fit new O rings as follows:
Black O rings are fitted in the two grooves on the top of
the cylinder liner (coolant rings).
Green O ring is fitted in the groove on the bottom of the
cylinder liner (lubricant ring)
4. Lubricate the lower part for assembling cylinder liner
in the block (O rings should not be lubricated).
5. Carefully fit the cylinder liner, ensuring the spacer is
installed correctly. Use retainer LDV 197 to retain the
cylinder liner.
6. After 10 minutes measure cylinder liner protrusion as
before. The protrusion should be 0.01 to 0.05 mm.
Caution: The engine can only be started 6 hours after
the cylinder liner has been installed. If the engine is not
refitted after the cylinder has been fitted, the cylinder
liner shall be compressed for at least 12 hours.

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Inspection of camshaft end-float

Measure the camshaft end-float which should be:
0.10 - 0.55 mm.
Caution: Measurement can be performed only after the
camshaft retaining ring has been installed.
Inspection of piston ring split

Caution: Measure the split at 15mm away from the top of
cylinder liner.
Connection rod bolt tightening sequence

Connection rod bolts are pre-lubricated. Fit and progressively
tighten new bolts in following 3 stages:
Stage 1 - 10 Nm; Stage 2 - 30 Nm; Stage 3 - 40°
Caution: After stage 3, check all bolts for tightness using
torque wrench set to 88 Nm.
Fitting/removal of crankshaft front main bearing
Tool number: C00017021

Special tools must be used
Corresponding bearing bushes are equipped with block grouping marks. When block is marked with ―H‖,
―BROWN‖ bearing bush is selected.
Caution: When fitting bearing, oil hole in bearing bush must be aligned with the oil hole in the block.

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Fitting of crankshaft
1) Attention should be paid to relevant marks and correct positioning of bearing seat
2) Tighten bolts to 44 Nm
3) Push crankshaft into place with alignment of bearing pin hole and then fit setting pins
Caution:
1.Do not damage 1st main bearing
2.Crankshaft rotation torque should be checked (after flywheel fitted)
Fitting of rear main bearing seat

1) Rear main bearing seat requires sealant to be applied at
points illustrated.
2) Locate and secure the bearing seat with two setting bolts
3) Fit dust shield and tighten bolts to 25Nm
Fitting of crankshaft rear oil seal

Fit shims
1) Fit setting pins with a enough length left outside
2) Fit guide pins
3) Fit thick shims to the crankshaft

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Fit rear oil seal components after aligning setting pins
Press oil seal into position with special tool C00016995

and two old flywheel bolts
Fit flywheel
Fitting of flywheel
1. Fit the clean flywheel to the crankshaft with alignment
with setting pin
2. Tighten all new bolts to 50Nm in following sequence
3. Progressively tighten all new bolts in following stages
1) Loosen the first bolt
2) Re-torque to 25Nm
3) Tighten for a further 60 degree
4. Check crankshaft rotation torque and end-float
Caution: Only with flywheel bolts fitted can crankshaft
end-float be checked.

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Fitting/removal of timing
Note: 1. Timing mechanism is belt driven for also driving fuel pump and water pump.
2. No setting pin is located between the camshaft timing gear and shaft.
3. The indicated bolts are LH bolts.
Fitting/calibration of timing belts:
1. Before removing the timing belt, rotate crankshaft 90°ATDC and fit crankshaft and camshaft timing pins. When
belt is removed, it is forbidden to rotate the crankshaft to avoid damage to valves.
2. When fitting belt, ensure timing pins are correctly positioned.
3. Finger-tighten camshaft timing gear fastening screws and then release for 1/16 to rotate the gear.
4. Fit timing belts to gears and idler pulleys progressively from right to left, stating from the crankshaft.
5. Adjust tension pulley to specified position (slightly over standard position), then tighten tension pulley securing
screw.
6. Tighten camshaft screws with special tool.
7. Mark on the timing belt and timing cover. Remove timing pins and rotate belt one turn. Fit timing pin to check
timing for correctness.
Precautions:
1. Belt should not contain stains such as oil or water.
2. Do not lever belt onto pulley; use finger pressure only.
3. Remember to remove timing pins.
4. Camshaft timing gear bolts require to be replaced.
5. Crankshaft pulley fitting bolt must be of specified length. Otherwise timing structure may be damaged.

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2.3 Lubrication System
2.3.1 Technical data
Engine oil CH-4 & 10W/40;7.5L

Minimum oil pressure (warm up) 3.5 bar @ 3000 rpm
Oil pump Rotary
Oil pressure regulating valve open pressure 7 bar
Oil pressure regulating valve spring free height 46.8 mm
2.3.2 Lubrication system oil flow illustration
1. Camshaft bearings
2. Cylinder head
3. Piston cooling nozzle
4. Connection rod journal
5. Crankshaft main bearing
6. Crankshaft
7. Oil pan
8. Vacuum pump
9. Oil strainer
10. Oil pump
11. Oil pressure regulating
valve
12. Modularized oil cooler
13. Engine oil filter
14. Main oil gallery
15. Turbocharger

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2.3.3 Introduction of main elements
Oil pump
Location: in the crankshaft gear casing cover and driven by crankshaft gears.
Function: sucks the oil from oil pan and delivers pressurized oil to lubricant channel to lubricate engine,
vacuum pump and turbocharging system
Oil pressure regulating valve

Location: on the block and front of the contact surface with the oil pan. Function: opens when oil pressure
reaches 7bar to release pressure.
Oil coarse filter

Function: Coarsely filters the oil to oil pump.

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Oil pressure switch
Location: on the right main oil channel of engine block and next to starter.
Function: powers on when oil pressure decreases, illuminating oil pressure indicator on the instrument panel to
alert the driver for prevention of excessive engine damage.
Oil radiator
Location: on the right side of engine and at the oil filter seat.
Function: communicates with the cooling system to cool down oil, ensuring lubricating properties. When fitting,
avoid the rotation of oil radiator. Otherwise location of water pipe may be incorrect.

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2.4 Cooling System
2.4.1 Overview
Cooling system consists of water pump, thermostat, radiator, cooling fan and expansion tank. Besides cooling
engine body, this system is used to cool down oil and Exhaust Gas Re-circulation (EGR).
2.4.2 Technical date of cooling system
Thermostat opening 82°C ±2°C

Pressure cap pressure setting 1.1 bar
Solution mix 50% anti-freeze, 50% water
Capacity 11L
2.4.3 Cooling system circulation
2.4.4 Renew coolant
Test with coolant hydrometer and determine to renew or not based on the test results.

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2.4.5 Fault diagnosis:
Fault Possible cause Solution

Insufficient coolant Check for leakage; refill; expel air fully.
Dirty or plugged radiator Check radiator, clean if necessary.
(external surface)
Cooling fan air-guide hood Check air-guide hood, repair or replace if
broken or vane fallen necessary.
Cooling fan not running Check cooling fan system circuits
Radiator pressure cap fault Check radiator pressure cap functioning
Overheating engine Water temperature sensor Check the sensor
Thermometer broken (fake fault) Check the thermometer
Water pump fault Dismantle the pump for inspection
Communication between coolant Check exhaust gas
and combustion chamber
Thermostat fault Dismantle the thermostat for inspection
Engine overload continue for a Unload appropriately
long time
Temperature sensor Check/replace sensor
Engine coolant Cooling fan continuous rotation Check cooling fan system circuits
temperature too low Thermometer failure Check thermometer, replace if necessary
Thermostat broken Replace thermostat

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2.5 Fuel supply system
Injection system Direct injection, electronically

controlled common rail
High pressure pump Bosch CP1H
ECM Bosch EDC17C53
Fuel injector Bosch CR12
Common rail pressure Min. 135MP
2.5.2 Operation principle of fuel system
1. Fuel metering unit 2.Injectors 4.Common rail 5.Fuel rail pressure sensor
6. One-way valve 7. Fuel tank 8. Water in fuel sensor 9. Fuel filter
10. Primer pump 11. Fuel heater 12. High pressure fuel pump 13. Fuel pump

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2.5.3 Introduction of system elements
Fuel tank
at the middle of frame, capacity of80L, with floats.
Fuel filter and oil/water separator assembly

under the engine compartment front windshield and for
filtering fuel to ensure cleanness and separating water
from the fuel. Water in fuel alarm is located under the
fuel filter. Renew fuel filter every 30.000km.
Manual pump
On the fuel filter seat for manual bleed of fuel system.
Caution: Bleed screws are located inside of manual
pump (fire proof side)

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Fuel pump assembly
Fuel pump is located at the left middle of engine body and upper of the alternator, including fuel low pressure
pump, high pressure pump and flow regulating solenoid valve. Low pressure pump is a gear pump while high
pressure pump is a 3-plunger structure. Fuel pump is driven by timing belt. The low pressure pump sucks fuel
from the fuel tank and delivers it to the high pressure pump for pressurization and to high pressure oil rail where
mechanical pump and flow regulator work together to establish stable fuel pressure to supply continuous high
pressure fuel to injector nozzle.
Illustration of fuel pump
Operation principle of fuel pump

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Fuel pump - gear pump
Gear pump inlet pressure -70 to -30kpa; measuring position: between filter and gear pump; Gear pump outlet
pressure 4.5 to 6.0bar.
Fuel pump-secondary oil pump

Actually, the high pressure pump is a 3-cylinder radial piston pump which is driven by axle shaft with gear
pump.3 pump plungers with 120°between each other allow an even load on the pump driver to reduce the
pressure difference in the high pressure storage.
1 Axle shaft 2 Eccentric cam 3 Piston

4 Cavity 5 Bleed valve 6 Inlet
Fuel rails and high pressure fuel pipes

Fuel rails are located on the engine cylinder upper head which is connected with fuel injector and fuel pump
with high pressure fuel pipes. Fuel rails are equipped with rail pressure sensors whose pre-tension forces have
been set and which can not be removed. The internal oil pressure of fuel rails could be as high as 160MPa with a
buffering function for oil pressure fluctuation to ensure that sufficient and stable oil pressure can be supplied to
the fuel injector throughout the engine operation period.
Fuel return pipes

Fuel return pipes are used to pipe excess fuel back to the fuel tank to reduce fuel system temperature.

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Fuel injector
Fuel injector is located at the middle of cylinder upper head and controlled by ECM. Accurate oil can be
directly injected to relevant cylinder(s) at correct moments according to engine operations.
Structure principle:
Oil return pressure at the upper of needle valve is controlled by solenoid valve whose opening and closing can
alter the pressure on the upper of needle valve. The pressure difference between upper and lower of needle valve
can open the needle valve to supply oil to the cylinder.
Caution: Never plug or unplug casually to stop cylinder operation.
1.Tappet
2.Plunger
3.Injector
4.Coil
5.Guide valve
6. Ball seal valve
7. Control area
8. Pressure chamber
9. Controlled capacity
10. Oil return channel
11. Controlled oil channel
12. Pick-up channel
13. Electrical connection
14. High pressure fuel inlet
15. Spring

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2.6 Air intake & exhaust System
2.6.1 Overview
Air intake system introduces air and mixture gas into the engine cylinder while exhaust system discharges
exhaust gas out of the engine cylinder. Valve timing can be ensured by connection between engine crankshaft and
camshaft with timing belts.
2.6.2 Inlet manifold
Inlet manifold is integrated with cylinder upper head and there are 2 inlet channels for each cylinder.
2.6.3 Exhaust manifold
Exhaust manifold receives exhaust gas from every cylinder to turbocharger pump impeller and to exhaust pipe.
When over-pressurized, exhaust gas can be piped to exhaust pipe via bypasses. When fitting, pay attention to the
direction of manifold gasket.
2.6.4 Silencer
Function: two-stage type to reduce engine emission noise.

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2.6.5 Turbocharging system
Turbocharger
Location: on the right side of engine and connected with exhaust manifold. Turbocharger is lubricated and
cooled only by lubrication system.
Function: pressurizes the air flow for increased charging efficiency so as to improve engine power.
Structure principle: When engine operates, turbocharger pump impeller is driven by exhaust gas which will
rotate the coaxial turbo to compress the air flow for pressurization. As engine speed increases, boost pressure
increases continuously. When diaphragm pressure exceeds spring pressure, the by-pass valve will open to release
pressure.
Precautions: Oil pressure lubrication is not water-cooled, add lubricants after replacing.
Intercooler
Intercooler is used to cool down pressurized high-temperature air to avoid knocking as well as increased air
density for improved charging efficiency.
2.6.6 Emission purifying system
Oxidation catalytic converter

Oxidation catalytic converter is used to oxidize organic matters contained in the soot.

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Exhaust Gas Recirculation (EGR)

Location: on the throttle body assembly.
Function: The digital control EGR valve accurately controls the exhausted air entering into the air intake pipe to
control the cylinder temperature and NOX emissions. EGR valve actuating mechanism is driven by ECM via
vacuum solenoid valve.
Throttle
on the inlet manifold and behind the Air conditioning pump. Throttle valve is the valve controlling the air intake
of the engine. Throttle body opening is controlled by ECM via vacuum solenoid valve to reduce engine vibration
and noise at idle. The valve is closed and opened when engine is stopped for engine flameout control. When at
low load operations, an improved EGR efficiency can be achieved.
Crankcase ventilation system (PCV)

PCV valve is installed on the cylinder upper head and at the exhaust side. When the crankcase pressure is too high,
it causes the diaphragm in the PCV valve to open against the spring, and allows crankcase ventilation to take place
via the air vent hose. It also separates the oil from the crankcase air and returns it to the crankcase.
Caution: Check carefully and clean regularly.

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2.7 Vacuum System
2.7.1 Overview
Vacuum system is used to build up and store vacuum into the vacuum reservoir to provide vacuum supply to
brake servo for the purpose of controlling EGR open position and throttle opening.
Minimum vacuum at idle 700 mm/Hg
2.7.3 Layout of vacuum system
2.7.4 Introduction of elements
Vacuum pump
Location: in the crankshaft gear casing and driven by crankshaft gears. There are oil channels inside to
communicate with engine lubricant channel to lubricate rotary parts of pump.
Function: builds up vacuum
Structure principle: When rotation, the volume generated by inside walls of vanes and pump gradually
expands, building up vacuum to pick up air; meanwhile the volume of other side gradually sinks, discharging air
into crankcase.

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Vacuum reservoir
Between the fuel tank and sub-frame and used to store vacuum. When engine stops operation, it can also supply
certain amount of vacuum to the system.
Vacuum control valve
Location: in the engine compartment and on the left of water tank cross-beam.
Function: sends commands to solenoid valve by ECM according to operation conditions and control the vacuum
applied on EGR valve and throttle valve with duty cycle so as to control valve openings.

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2.8 Starting & Charging System
2.8.1 Overview
Start system consists of a 12V starter motor which is under the control of ECM.
The charging system is composed of 1 battery, 1 alternator and 1 charging indicator. The alternator will
supply power with the engine running and the charging indicator located on the instrument cluster will be
illuminated when there is low or no output electric energy on the alternator.
2.8.2 Introduction of elements
Starter
Starter is located on the right rear of engine with planetary gear reducer for starting engine.
Alternator
When engine is running, alternator supplies electric energy with single-line control; some models are equipped
with one-way clutch.
Battery
Battery is used to provide power, to stabilize power voltage and to store electric energy. In addition, battery
also provides electric energy to starter when engine is started and supplies other excitation sources to alternator.

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2.8.3 Analysis of starting & charging system circuit diagrams
Refer to ―Appendix - Circuit Diagrams‖
2.8.4 Fault diagnosis
Fault Possible cause Solution

Battery Check battery post and starter
voltage.
Immobilizer Check immobilizer
Start circuit slacken or corrosion Clean and secure circuit
Starter can not operate
connections
Starter circuit Check circuit
Starter Check starter
Ignition switch Check ignition switch
Battery connection slacken or corrosion Clean/tighten battery connection
Engine belt slippery Check/replace belt
Alternator under charge or no charge Fascia or indicators failure Check/replace fascia
Alternator wires loose or damaged Repair wires
Alternator failure Replace alternator

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2.9 Engine Management System
2.9.1 Overview
This system consists of Engine Control Module (ECM), sensors, actuators and wiring harness, etc. Based on
information provided by sensors, ECM controls rail pressure, injector timing, fuel injection, EGR, throttle opening,
etc. with calculated values in order to ensure optimum dynamics, economy and environmental protection.
Meanwhile, data communication is performed via ECM, ABS and Body Control Module (BCM) to achieve
electronic control throughout the vehicle. EMS is composed of:
Sensors: Air flow meter, inlet air pressure and temperature sensor, crankshaft position sensor, camshaft position
sensor, rail pressure sensor, coolant temperature sensor, accelerator pedal position sensor, clutch pedal switch,
brake switch, speed signal, oil temperature sensor, water-in-fuel sensor, cruise switch and air conditioning
pressure switch.
ECM: core of control unit, including software and hardware.
Actuators: Fuel injector, flow control valve, glow plug, fuel heater, EGR vacuum solenoid valve, throttle opening
control vacuum solenoid valve, cooling fan and air conditioning compressor.
2.9.2 Sensors
Air flow meter

Location: on the air intake pipe behind air filter.
Function: tests air flow quality and transfers
signals to ECM. Mainly used for emission
control.
Structure principle: HFM hot film air flow meter
Signal: 0~5V square wave
Testing:
Inlet air pressure/temperature sensor (MAP)

Structure principle: Inlet air pressure sensor is a piezoresistive effect sensor. When the inlet air pressure changes,
resistances of sensor elements will change correspondingly, causing pressure signals converted electric signals to
ECM; Inlet air temperature sensor is a thermistor sensor to convert temperature changes to resistor changes.
Testing: Measure to see whether output voltages under different pressures meet the specification. For
temperature sensor, test sensor resistors and output voltages under different temperatures.

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Crankshaft position sensor

Location: on the left rear block of engine and near to inlet pipe throttle body.
Function: ECM uses it to sense engine speed and determine piston location.
Structure principle: CKP is an electromagnetic inductive sensor which generates induced AC voltage as long as
there is periodic variation of coil magnetic flux due to signal panel teeth and gaps alternately passing through the
sensor. Voltage frequency is proportional to crankshaft speed.
Testing: 1.Check for any appearance damage 2. Check surface for any dirt 3.Check installation clearance 4. Test
coil resistor 5. Check signal generator (panel teeth) for correctness 6. Test oscilloscope waveforms.
Camshaft position sensor

Location: on the cylinder upper head and rear of exhaust camshaft.
Function: determines camshaft position (valve timing) and transfers signals to ECM.
Structure principle: CPS is a Hall sensor. When camshaft signals are passing through this sensor, internal magnetic
strength of sensor will be changed, causing Hall voltage which will convert camshaft position to electric signals to
ECM after processing on sensor circuit.
Testing: 1. Measure output voltage with a digital multimeter. 2. Check whether Hall sensor power source and
earthing are in good conditions. 3. Check sensor signal generator.

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Water temperature sensor

Location: cylinder head air intake side, #2 cylinder
Function: tests engine cooling water temperature and transfers such information to ECM to control operations
of other systems (including cooling fans, air conditioning and cold start control, etc.).
Structure principle: Water temperature sensor is a thermistor sensor.
Testing:1. Test sensor resistance value in different temperatures. 2. Test whether sensor signal line and
put-up-iron are in good conditions. 3. Test output voltage.
Resistance changes with temperatures as follows:

Temperature in °C Resistance in KΩ
nominal minimal maximal
-40 45.313 40.490 50.136
-30 26.114 23.580 28.647
-20 15.462 14.096 16.827
-10 9.397 8.642 10.152
0 5.896 5.466 6.326
10 3.792 3.542 4.043
20 2.500 2.351 2.649
25 2.057 1.941 2.173
30 1.707 1.615 1.798
40 1.175 1.118 1.231
50 0.834 0.798 0.870
60 0.596 0.573 0.618
70 0.435 0.421 0.451
80 0.323 0.313 0.332
90 0.243 0.237 0.250
100 0.186 0.182 0.191
110 0.144 0.140 0.148
120 0.113 0.109 0.116
130 0.089 0.086 0.093
140 0.071 0.068 0.074

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Accelerator pedal position sensor

Position: at the accelerator pedal side
Function: converts engine load to electric signals and transfers to ECM for calculation of basic fuel injection.
Structure principle: Accelerator pedal position sensor is a dual Hall sensor.
Testing: 1. Check whether Hall sensor power source and earthing are in good conditions. 2 Measure whether
output voltages meet the specification. 3. Test with a diagnostic instrument
Water in fuel sensor

Location: under the fuel filter
Function: sends signals to ECM to notify fascia
to illuminate water in fuel indicator
Structure principle: a potentiometer
Testing: measure the circuit (power source,
earthing and signals)
Fuel rail pressure sensor

Location: end face of fuel rail, integrated with
fuel rail, can not be removed.
Function: Fuel rail pressure sensor sends fuel
pressure information to ECM so that ECM can
monitor and regulate system oil pressure in a
continuous manner to satisfy system needs.
Structure principle: Fuel rail pressure sensor is
a piezoresistor sensor.
Testing:
1. Check whether sensor power source and
earthing are in good conditions.
2. Measure signal output voltage.
3. Test with a diagnostic instrument

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Brake switch
Location: brake pedal side
Function: releases cruise control to take priority of engine brake and
controls illumination of brake lamp to provide brake signals to ABS.
Structure principle: dual-brake switch - NO and NC for redundancy
check.
Testing: measure switch status when at normal and when brake pedal
pressed.
Clutch switch
Location: clutch pedal side
Function: reflects clutch status to help ECM finish cruise control and
comfort control.
Structure principle: a NO switch
Testing: measure circuit and switch status
Network signal
Data communication and information sharing are achieved through W line, R line and Body Control Module
(BCM). See ―Immobilizer‖ for more information.

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2.9.3 Electronic Control Unit (ECU)
Location: behind the battery and fixed to main fusebox holder with a carrier.
Function: As a core control unit of common rail system, ECU is mainly used for analyzing information
collected by sensors and sending control demands to actuators. Additionally, it has fault diagnosis and failure
protection functions. With a diagnostic instrument, ECM can be accessed to read and clear fault diagnosis code
and to perform active testing and other functions.
Structure: An electronic control center with SCM as the core, including hardware, software, housing and wiring
harness, etc.
Precautions: Since no data available on a new engine module, programming (writing data) is required when
module is replaced. See “Immobilizer” for more information.
2.9.4 Actuator
Fuel injector
ECM controls opening time of fuel injector with pulse
signals to control injection amount and injection timing
accurately. See ―Fuel System‖ for its structure
Inspect: resistance measurement; circuit check; injector
testing
Caution: New fuel injector requires matching
(calibration)
Precautions on pressure release when fitting/removal
Flow control valve

Location: on the fuel pump assembly.
Function: The ECM-controlled valve is used to regulate
fuel entering into high pressure pump so as to control
fuel system pressure.
Structure principle: Solenoid valve is located at the oil
inlet of high pressure oil pump. When powered off, oil
inlet gives maximum opening to provide maximum
flow of fuel (NO). ECM controls solenoid valve with
duty cycle to alter cross section of oil inlet and oil flow
so as to control fuel rail pressure.
Testing: 1. Measure solenoid valve resistance.
2. Measure whether solenoid valve power source and
circuit are in good conditions.

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Structure of flow control valve

A--From fuel supply pump B-- To HP fuel pump
1. Socket
2. Solenoid valve housing
3. Bearing
4. Pivot with tappet
5. Coil with housing
6. Casing
7. Remaining air gap pad
8. Magnetic core
9. ‗O‘ ring
10. Plunger
11. Spring (internal)
12. Safety elements
Operation principle of flow control valve
Fuel heater
over the fuel filter. When ambient temperature is below
6℃, ECM controls fuel heater relay to heat the fuel
system via fuel heater.
Testing: Check circuit and heater

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Glow plug
Location: left of each engine cylinder head.
Function: Before engine starting, it can control heating time of glow plug based on ambient temperature to
increase temperature of compressed air in the cylinder for a better engine start and improved emission
performance.
Structure principle: LP armoured type with heating wires for a more rapid heating as well as better heat
preservation.
Testing: 1. Measure the power source 2. Test with a diagnostic instrument
Cooling fan
Location: behind water tank, dual electronic fan.
Function: Based on coolant temperature and AC status,
ECM starts cooling fan for radiation for heat dissipation.
Control mode:Series/parallel connection control
Testing: 1. Drive with a diagnostic instrument
2. Circuit check.
Vacuum control valve (EGR and throttle)

Location: in the engine compartment and on the left of
water tank cross-beam.
Function: sends commands to solenoid valve by ECM
according to operation conditions and control the
vacuum applied on EGR valve and throttle valve with
duty cycle so as to control valve openings and reduce
NOx emission.
Diagnosis interface
Front passenger side and below the middle of instrument
desk, used with diagnostic instrument to access the vehicle.
Pins:
4#: Chassis put-up-iron
5#: Signal GND
7#: K LINE—BCM (0-12V square wave)
8#: K LINE—ABS/SRS
16#: Constant power supply

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2.9.5 Control strategy of EMS
Control chart of EMS
Control strategy
System properties of common rail injection
- Electronically controlled fuel metering unit for reduced emission.
- Flexible injection pressure control range: 250Bar ~ 160MPa, optimized fuel spray and improved combustion
efficiency.
- Injection pressure control independent from engine speed and load.
- Pilot injection control.
Control of injection amount
Injection amount can be basically calculated with engine speed and accelerator pedal position sensor and
modified with other operational parameters (water temperature sensor, inlet air temperature sensor and
acceleration/deceleration, etc.), ensuring an optimum operation condition in every operation mode.
Control of idle speed
Injection amount can be regulated with water temperature sensor, load signal (AC switch and vehicle inverter),
alternator voltage and other information to achieve engine target speed, preventing increase of engine noise and
vibration, even flameout due to idler speed too low. Inconsistent idle speed due to sudden change of load can also
be regulated.
Control of starting
ECM controls powering time of glow plug with various parameters, such as water temperature and speed
sensor to facilitate engine start.
Control of immobilizer
Whenever immobilizer receives no correct signal from ignition switch, ECM will sends out commands to
disable operation of starter and fuel injector.
Control of air conditioning
When engine water temperature reaches 102 degree, ECM will stop operation of air conditioning to prevent
engine overheat. When there is a high speed or overload, ECM will also stop operation of air conditioning to
provide a stronger power.
Control of even injection between cylinders
ECM is able to monitor change of engine speed due to cylinder operation to determine torque difference
between cylinders. Same operating torque can be achieved by regulating cylinder injection amount so as to ensure
a more stable engine operation.
Control of throttle
When at low load operations, ECM can control pulses of throttle vacuum solenoid valve with duty cycle so as
to regulate throttle openings and control air input for a higher EGR efficiency. ECM can also help reduce noise
and vibration when at idle speed. When engine is stopped, it can turn down air input to reduce vibration.

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Control of EGR
Based on engine load and speed, water temperature, air input and other parameters, ECM controls pulses of
EGR vacuum solenoid valve to allow EGR valve a proper opening so as to regulate exhaust gas into the cylinder
and reduce NOX emission.
Control of cooling fan
Based on water temperature and air conditioning signals, ECM controls high and low speed of cooling fan to
provide engine an optimum operation temperature and cooling effect.
Control of cruise control
When cruise control is set, ECM regulates injection amount to keep a consistent vehicle speed. When brake
pedal or clutch pedal is pressed, cruise control is released.
Self-diagnosis function
ECM is equipped with self-diagnosis function to request instrument panel to illuminate engine fault indicator or
emission indicator whenever there is a fault or engine emission is affected. Serviceman can read fault code and
data stream with a diagnostic instrument to carry out active testing function.
Warning:
Do not work on any part of the fuel system when the engine is running. Diesel fuel is delivered under extreme
pressure in the fuel pipes from the injection pump to the injectors. This may be as high as 1600 Mpa. Use extreme
caution when inspecting for leaks as fuel under that pressure can penetrate skin causing injury or death therefore
any contact with fuel spray must be avoided. Inspect for fuel leaks using thick card. Wear safety goggles and
adequate protective clothing when serving the fuel system. Do not smoke or allow open flame of any type when
working on or near any fuel related components. Fuel vapor can ignite and cause damage and/or personal injury.
2.9.6 Immobilizer
Logic diagram of immobilizer
NOTE: Only 1 plip and 8 auxiliary keys can be set

Matching of immobilizer

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Difficult or impossible to start engine
Inconsistent engine operation
Insufficient engine power
Blue smoke emission from exhaust pipe
Black smoke emission from exhaust pipe
White smoke emission from exhaust pipe

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2.9.8 Exercises
Exercise 1
Fitting/removal exercises for engine mechanical (hours)
Objectives: To know engine structures well and be familiar with fitting/removal procedures and precautions as
well as component dimensions and measurement of matching clearance.
Correct use of special tools.
Vehicle and tools required: Engine assembly, general tools and special tools.
Contents:
1. Understand water circulation flow with reference to engine water circulation illustration.
2. Disassemble the engine and familiarize yourself with its structure, paying attention to keys on disassembly and
use of special tools.
3. Understand oil flow with reference to engine oil flow illustration.
4. Measure piston protrusion and select cylinder gasket
Piston protrusion Value:
5. Selection and fitting of cylinder liner shim
6. Fitting of crankshaft
7. Fitting of crankshaft rear oil seal
8. Fitting of cylinder head and upper head
9. Calibration of engine timing
Requirements:
1. Safety first, especially for fitting and removal of high pressure system or heavy components.
2. Fitting/removal procedures must be strictly adhered to, paying attention to fitting/removal of wearing parts.
3. Keep clean with 5S.
Summary:

Engine
Exercise 2
(1) Completion
1 Engine crankcase is a ( ) type.
2 Besides camshaft, timing belt can also drive ( ) and ( ).
3 The minimum oil pressure is ( ).
4 Vacuum pump is driven by ( ) and lubricated by ( ) and discharges the pumped air to ( ).
5 EGR is short for ( ), the function of which is to ( ).
6 Camshaft sensor is a ( ) type, the function of which is to ( ).
7 Flow control valve is located ( ), the function of which is to ( ).
8 When engine operates, the rail pressure can reach as high as ( ) and can be checked by ( ).
9 The initial temperature of thermostat is ( ).
10 Engine idle speed is ( ).
11 Electronic control system is mainly composed of ( ), ECU and ( ).
12 Oil specification for this model is ( ).
(2) Judgment
1 When fitting timing belt, first secure camshaft screws and then adjust belt tension force. ( )
2 Crankshaft end-float can not be measured until flywheel is installed. ( )
3 When timing belt is removed, crankshaft can be rotated to align with timing pin hole. ( )
4 Connection rod connections can be hit to remove rod bush. ( )
5 Engine is equipped with wet cylinder liner. ( )
6 Fuel injector injects oil by powered solenoid valve picking up needle valve. ( )
7 Turbocharger is a by-pass type. ( )
8 As long as cylinder head is removed, crankshaft can be removed. ( )
9 Fuel temperature sensor is located in fuel tank. ( )
10 As long as engine is switched off, fuel injector can be removed. ( )

Engine
Exercise 3
Cognitive exercises for EMS elements (0.5h)
Objectives: To understand compositions and locations of EDC system elements.
Contents:
1. Please find out following components on EDC and record their locations.
Component Location
Sensors
Air flow meter
Inlet air pressure/temperature sensor
Coolant temperature sensor
Accelerator pedal position sensor
Clutch pedal switch
Brake switch
Vehicle speed sensor
Oil temperature sensor
Water in fuel sensor
Cruise switch
AC pressure switch
Engine control module
Actuators
Fuel injector
Flow control valve
Glow plug
Fuel heater
EGR vacuum solenoid valve
Throttle opening control vacuum solenoid valve
Cooling fan
AC Compressor
Requirements: Carefully follow the instructor‘s instructions and pay attention to safety.
Summary:

Engine
Exercise 4
Operation exercise of ECS (0.5h)
Objectives: To be familiar with functions and test methods of sensors and actuators; as well as use of diagnostic
instrument.
Vehicle and tools required: A featured vehicle and a diagnostic instrument. Digital multimeter (2), general tools
and test lamps.
Contents:
1. Remove following sensors and record failure protection symptoms.
Caution: Each time a sensor is removed record relevant symptom and clear fault code when installation finished
for subsequent operations.
Sensors Symptoms (starting performance, acceleration performance, operation performance

and emission performance)
Air flow meter
Accelerator pedal position

sensor
Flow control valve
2. Read data stream to understand its meaning.
3. Run active tests with a diagnostic instrument.
Requirements:
a. Safety first. Some tests require engine operation, so pay attention to rotary and high temperature parts.
b. When engine requires to be started, DO confirm in NEUTRAL position. Press the clutch and notify others to
start the engine.
c. Since sensors and actuators are precision parts, DO NOT damage when fitting or removal.
d. Keep clean with 5S.
Summary:

Engine
Exercise 5
Matching exercise of immobilizer (0.5h)
Objectives: To understand matching principle of immobilizer

Vehicle and tools required: A featured vehicle, 1 diagnostic instrument, 1 new ECM and 1 new BCM, and 1 new
key.
Contents:
1. Replacing the key
2. Replacing BCM
3. Replacing ECM
Requirements:
Safety first and instructions followed.
Keep clean with 5S.
Summary:

Engine

Transaxle
Chapter 3 Transaxle

Transaxle

Transaxle
3.1 Overview
The transaxle, equipped with aluminum alloy housing, is composed of twin-shaft 5MT with three fork shafts
and differential. The transmission is installed with reverse switch and vehicle speed sensor.
3.2 Technical Data
Transmission Data
Model HTX - PVH
Manufacturer WIA
Driving mode of Transversal arrangement and front wheel drive
gearbox
1st 3.769
2nd 2.105
3rd 1.300
Gear ratios 4th 0.941
5th 0.750
Reverse 3.167
Final drive 4.188
Oil capacity 2.30L
Clearances and tolerances
Description Value
Gear end-float 1st : 0.07 - 0.36 mm
2nd : 0.07 - 0.29 mm
3rd : 0.06 - 0.21 mm
4th : 0.135 - 0.335 mm
Reverse: 0.07 - 0.25 mm
Input shaft end-float 0.00 - 0.10 mm
Output shaft end-float 0.03 - 0.10 mm
1st/2nd: 0.56 - 1.83 mm
Synchromesh ring 3rd: 0.73 - 1.56 mm
clearance 4th: 0.72 - 1.55 mm
5th: 0.94 - 1.78 mm
Torque
Application Torque value (Nm)
Differential gear housing 130 ~ 140
and ring gear
Output shaft locknut 150 ~ 220

Transaxle
3.3 Structure, Principle & Fitting/Removal of Transaxle
3.3.1 Structure of transaxle
Transmission housing:
Transmission housing is mainly composed of clutch housing, transmission housing and rear end cover.
Transmission control gear-------3-fork shaft

Control gear mainly consists of selector lever, cables, selector shafts, forks and fork shafts, in which fork shafts
include 1st/2nd fork shaft, 3rd/4th fork shaft, 5th/reverse selector fork shaft. Self-locking gear is installed at the
end of fork shaft and interlocking gear is installed on the selector shaft. Locking gear is installed between 5th and
reverse selector to prevent shift from 5th to reverse selector.
Fork shaft; Selector fork; Synchromesh fork Reverse selector fork
Transmission driving mechanism

Transmission driving mechanism is a twin-shaft type:
Machined components on input shaft:
1st drive gear, reverse drive gear and 2nd drive gear.
Assembled components on input shaft:
3rd drive gear, 4th drive gear, 3rd/4th synchromesh
component, gear hub sleeve assembly (3rd/4th), 5th
drive gear, 5th/reverse synchromesh component and
gear hub sleeve assembly (5th/reverse).
Machined components on output shaft:
Differential drive gear
Assembled components on output shaft:
1st gear assembly, 2nd gear assembly, 1st/2nd
synchromesh component, 1st/2nd gear hub sleeve
assembly, 3rd/4th/5th output gears.
See ―Exploded diagram of gear transmission

mechanism‖ for more information.

Transaxle
Exploded diagram of gear transmission mechanism
1. Reverse idler gear 13. 3rd synchromesh ring 25. 5th gear shaft sleeve 37. 2nd gear
shaft assembly
2. Reverse idler gear 14. 3rd gear assembly 26. Twin cone 38. Gear hub sleeve
synchromesh ring assembly (1st/2nd)
3. Input shaft 15. Retaining ring 27. Needle roller bearing 39. Synchromesh
guide block
4. Ball bearing 16. Adjusting shim 28. 1st gear assembly 40. Retaining nut
5. Oil seal 17. Ball bearing 29. Bearing cap 41. Tapered roller
bearing
6. Needle roller bearing 18. Reverse cone shaft sleeve 30. Tapered roller bearing 42. Adjusting shim
7. 4th gear assembly 19. Clutch reverse cone stop pin 31. Output shaft 43. Spacer
8. Retaining ring 20. Reverse synchromesh ring 32. Sealing cap 44. 5th output gear
9. 4th synchromesh ring 21. Gear hub sleeve assembly 33. 4th output gear 45. Bolt
(5th/reverse)
10. Gear hub sleeve 22. 5th synchromesh ring 34. 3rd output gear 46. Screw
assembly (3rd/4th)
11. Synchromesh guide 23. Needle roller bearing 35. 2nd gear shaft sleeve
block
12. Needle roller bearing 24. 5th gear assembly 36. Needle roller bearing

Transaxle
Introduction of major components
Input shaft
Caution: Input shaft bearings are pre-packed sealed units and must not be washed out.
Output shaft
1st/2nd twin cone synchromesh ring

1st gear 2nd gear
Twin cone synchromesh ring helps to increase friction for synchronization of speed as soon as possible.
1st/2nd gear hub sleeve assembly
Synchromesh guide block is an integrated piece Assembly is machined with reverse output gear

Transaxle
3rd/4th gear hub sleeve assembly: 5th gear shaft sleeve
3rd/4th gear hub sleeve assembly 5th gear shaft sleeve
Carbon-coating within 3rd synchromesh ring. Shaft sleeve and input shaft are interference
Synchromesh snap rings rotate to the same direction. fitted for axial positioning. Align with oil
channel hole when assembled.

Transaxle
3.3.2 Power Flow
1st gear 2nd gear
Route: Input shaft (1st drive gear) —1st gear Route: Input shaft (2nd drive gear) —2nd gear
assembly—gear hub sleeve assembly (1st/2nd)—output assembly—gear hub sleeve assembly (1st/2nd)—output
shaft (differential drive gear) shaft (differential drive gear)
3rd gear 4th gear
Route: Input shaft—gear hub sleeve assembly Route: Input shaft—gear hub sleeve assembly
3rd/4th)—3rd gear assembly—3rd output gear—output 3rd/4th)—4th gear assembly—4th output gear—output
shaft (differential drive gear) shaft (differential drive gear)
5th gear Reverse
Route: Input shaft—gear hub sleeve assembly Route: Input shaft (reverse drive gear)—reverse idler
5th/reverse)—5th gear assembly—5th output gear—gear hub sleeve assembly (1st/2nd)—output shaft
gear—output shaft (differential drive gear) (differential drive gear)

Transaxle
3.3.3 Differential
Overview
Caution: Differential bearing pre-tension

force requires adjustment with shims.
Exploded diagram of differential
1. Differential assembly
2. Oil seal
3. Adjusting shim
4. Tapered roller bearing
5. Final drive driven gear
6. Differential drive sealing
bolt
7. Mileage drive gear
8. Differential gear housing
9. Thrust washer
10. Side gear
11. Differential planet gear
12. Differential spider

Transaxle
3.3.4 Keys for fitting/removal
Keys for fitting/removal of transaxle assembly
 Separate clutch slave cylinder. Make

hard pipe upward to prevent brake fluid
leakage when removing.
 Use special tool - LDV 210 to support

engine
Caution: If refitting the original transmission, oil seal of drive shaft shall be replaced.
Keys for fitting/removal of transaxle left hand mounting

When fitting transaxle left hand mounting it must be positioned correctly as follows:
–Use tool LDV 209 to check for equal 5mm clearance on both sides of mounting (as illustrated)
– If incorrect, slacken mounting nuts and re-position. Tighten nuts and re-check.
Notes: After drive shafts have been fitted, fill with 2.30 liters of specified oil through speed sensor
aperture. Refit speed sensor. Remove oil level plug and allow excess oil to run out. Then refit oil level plug.

Chassis
Keys for disassembly of manual transmission

a. Secure input shaft with LDV 205 b. Remove output shaft locknut.
c. Remove setting screw ①, locking spring ②, steel d. Remove transmission housing with LDV208.
ball ③ and reverse light switch ④.
e. Remove magnet ①, output shaft adjusting shim ②, f. Check gear clearance and compare obtained
output shaft spacer ③ and input shaft adjusting shim ④ clearance with the information provided in
―Technical Data‖. If outside tolerance, adjust again.

Chassis
g. Remove input shaft bearing and 5th gear assembly h. Remove output shaft 4th/5th gear with gear puller
② simultaneously with gear puller.
Caution: Note the original positions of all
components to ensure reassembly in their original
locations if not being renewed. Temporarily mark if
necessary.
i. Fit input shaft 5th gear shaft sleeve. (apply heat if j. Remove 4th gear, 4th gear bearing and 4th
necessary and pull off using tool 16-056) synchromesh ring with gear puller.
k. Remove output shaft

Caution: Refit and tighten output shaft locknut with stop shim, and then pry output shaft assembly out with
proper tools as shown in the figure.

Chassis
Adjustment of differential pre-tension force

Select and fit differential bearing shim
1. After fitting differential assembly, measure distance 2. Measure distance (B) between sealing surface of
(A) between sealing surface of clutch housing and outer transmission housing and mounting surface of outer
ring of differential. ring of transmission housing bearing with height
indicator.
Standard value B: 16.3 mm
3.Selection of shim
Shim thickness: B-A- Differential end clearance. Standard differential end clearance: -0.1 ~ -0.2 mm
Part No. Shim thickness (mm)
C00013929 0.10
C00013930 0.20
C00013931 0.30
C00013932 0.15
C00013933 0.25
C00013934 0.35
Adjustment of input/output shaft end-float

Fit magnet ①, output shaft spacer ③, output shaft adjusting shim ② and input shaft adjusting shim ④.

Chassis
Selection of input shaft shim
a. Measure C dimension (C = C' - C");Standard value C:243.87 mm ~ 244.0 mm.
Use height indicator to measure C' dimension of Measure C" dimension with a micrometer.
transmission housing.
b. Measure distance (D) between sealing surface of clutch housing and input shaft ball bearing with
height indicator.
c. Selection of shim
Shim thickness:(D-C) - (end clearance of input shaft) Standard end clearance of input shaft:0 ~ 0.10 mm
Input shaft shims
C00013855 0.20
C00013856 0.15
C00013857 0.30
C00013858 0.10
C00013859 0.25

Chassis
Selection of output shaft shim

a. Temporarily fit original shim and transmission housing b. Temporarily fit output shaft taper roller bearing
and tighten output shaft locknut and fit dial gauge.
c. Place two screwdrivers under nut to measure end-float of output shaft and record the reading. Standard end
clearance of output shaft: 0.03 ~ 0.1 mm. If measured end-float is incorrect, thickness of shim pack must be
adjusted after removing housing.
Output shaft shims
C00013885 0.10
C00013886 0.15
C00013887 0.20
C00013888 0.30
C00013889 0.50
C00013890 0.25

Chassis
3.4 Clutch
Technical Data
Model Hydraulic power-assisted clutch
Thickness of driven plate 7.2±0.3mm
Limit wearing capacity of driven plate Single face 1mm
Layout of clutch system
1. Clutch disc 2. Driven plate 3. Release bearing
3.5 Axle shaft
Torque
Application Torque value (Nm)
Hub locknut ① 100±10, ②300±30, ③450±16
Layout of axle shaft
1. Axle shaft (L/H)
2. Axle shaft (R/H)
3. Constant velocity
joints
4. Tripod universal joint
(L/H)
(R/H)
6. CV joint gaiter
gaiter
8. Spring retaining ring
9. Hub washer
10. Retaining nut
11. Bearing plate
12. Bolt
13. Bearing seat carrier
14. Transmission

Chassis
3.6 Fault diagnosis
Clutch slipping
Shaking on engine start
Difficulty in engaging gears
Abnormal sound on gearbox
Body vibration

Chassis
3.7 Exercises
Exercise 1
Fitting/removal and measurement of transaxle (3h)
Objectives: To understand internal structure of transaxle and be familiar with procedures and keys for
fitting/removal.
Vehicle, equipments and tools required: 1 transaxle assembly, 1 set of general tools, special tools and measuring
devices.
Contents:
1. Disassemble components on each gear
2. Adjust differential bearing pre-tension force.
3. How to measure input/output shaft end-float and how to select adjusting shims.
4. Assemble transaxle
Requirements: Safety first and proper use of tools. Correct procedures for disassembly, measurement and
assembly must be followed and 5S must be observed.
Summary:

Chassis
Chapter 4 Chassis

Chassis

Chassis
4.1 Suspension
4.1.1 Overview
Macphersan independent suspension is used for front suspension of V80, while transversal leaf spring dependent
suspension is used for rear suspension.
Front Suspension Rear Suspension
4.1.2 Technical Data
Positioning data
Front wheel Rear wheel
Wheel Camber 0°30 Wheel Camber 0°
Kingpin Castor 1°30 Wheel Toe 0°
Wheel Toe -0°3′ — -0°6′ Rear-wheel Thrust Angle 0°
Kingpin Inclination 13º
Included Angle 12º20´
4.1.3 Front Suspension
Macphersan independent suspension is used for front suspension of V80. It consists of spring and shock
absorber with bearing on top, and the lower of strut is fitted on knuckle. The ball joint is connected with the lower
control arm on the large rubber bush, able to rotating upward and downward on the sub-frame. Anti roll bar is
connected with lower control arm by connection rod.

Chassis
4.1.4 Rear Suspension
V80 uses transversal leaf spring dependant suspension. Steel leaf spring is made by 2 steel leaves, with a span
of leaf spring of 1450mm. The center of leaf spring is secured on the axle with 2 U bolts. The leaf spring and front
bracket are connected by the front spring eye using bolts; while the leaf spring and rear bracket are connected by
the rear spring eye using lifting eyes.
1. Rear steel leaf spring assembly

2. Rear shock absorber assembly
3. Rear steel leaf spring bump stop
4. Rear suspension bump stop bolt
5. Rear steel leaf spring U bolt
6. Rear spring upper cover
7. Rear axle assembly
8. Rear shock absorber to rear axle bolt
9. Rear steel leaf spring U bolt to rear axle nut
4.1.5 Wheel
There are two kinds of wheel rim structures, which are shown below: Tyre Pressure Monitor System can be
used to monitor tyre pressure and temperature, see ―Body Electrics - Tyre Pressure Monitor System‖ for details.
Aluminum alloy wheel rim Steel wheel rim
Tyre model Tyre pressure (kPa)

205/75R16C Front wheel:400 Rear wheel:475
215/75R16C Front wheel:400 Rear wheel:475

Chassis
4.1.6 Hubs
Front hub Rear hub
1. Knuckle assembly 4. Bush There is a taper bearing inside the rear hub, and its
2. Hub bearing seal 5. Front hub pre-tension force should be adjusted before service.
3. Front hub bearing 6. Knuckle ball pin
Service: Service:
End-float should not be adjusted. Bearing pre-tension force should be adjusted, and then
Bearing and basket are provided in pairs, which should be adjusted again after fitting wheel.
replaced together. Adjustment procedure:
Fitting the flange fasten nut 1) Tighten the nut to11Nm
1) Tighten to a torque of 300Nm 2) Carefully move the nut back to reveal pin hole, and
2) Rotate the flange to fit bearing into place. then fit the new split pin.
3) Tighten the nut to 450Nm 3) Check to ensure that the end-float is zero
4.1.7 Wheel Alignment
Geometrical axis of vehicle

Thrust line:
It is the angle bisector of rear wheel toe
and determined by rear axle toe. It is not
only the thrust line of driving vehicle, but
also the measuring basis of front wheel toe.
Central symmetry plane of vehicle
Geometrical central plane of vehicle,
which is perpendicular to the driving
plane and passes through the track
central points of front and rear axles; It
is the measuring basis of rear wheel toe.
1. Centre line of wheel 2. Contact point of wheel 3. Thrust line

4. Central symmetry plane of vehicle
Wheel Alignment Data
There are various of wheel alignment data, such as wheel toe, wheel camber, kingpin castor, kingpin inclination,
included angle, scrub radius, etc. Anyway, wheel toe, wheel camber and kingpin inclination are major alignment data.

Chassis
Front wheel toe

Toe is the crucial angle of tyre wearing.
When the vehicle is driven straight-ahead, toe can ensure
wheels rolling in straight. In vehicle turning, toe can
improve steering response and is very important in
curves driving.
Excessive toe in can cause insufficient steering; Indent
wearing and outside shoulder wearing on tyre.
Excessive toe out can cause excessive steering; Indent
wearing and inside shoulder wearing on tyre.
Incorrect rear wheel toe adjustment can cause thrust
direction offset, tail swing on slippery road and tyre slant
wearing
Wheel Camber
The wheel camber is an angle which not only affects tire
wearing, but also acts as a direction controlling angle.
It provides a proper load point to maximize the contact
area between the tire and the road during vehicle loading
and operation, hence creating even wearing on the tire as
well as reducing load on the outer bearing of the hub.
The normal wheel camber is positive, will ideally be
nearly zero under load.
An incorrect wheel camber will speed up the tire wearing.
If the values at both sides are unequal, the vehicle will be
off tracking in driving.
In actual cases, however, the left angle is often slightly
larger than the right one, so as to compensate any effects
caused by unbalanced load and road crown.
Kingpin Inclination
When the wheel turns direction, kingpin inclination will
create a torque which takes the wheel and the steering
back to their straight positions.
The wheel camber, together with the kingpin inclination,
determines the position of contact point between tire and
the ground.
The kingpin inclination provides automatic returning
force to maintain stable direction, acting as a direction
controlling angle.

Chassis
Included Angle
The included angle is calculated with the sum of KPI
and front wheel camber.
It acts as a direction controlling angle. If the included
angles at both sides are unequal, the vehicle will be off
tracking in travelling.
Kingpin Castor
Kingpin castor is not an angle affecting tyre wearing,
but only a direction controlling angle.
It is helpful to keep wheels rolling in straight (direction
stability) and ensure steering wheel back to its straight
position after turning. The positive kingpin castor is
larger, this kind of capability will be stronger, while
steering force needed in turning will be increased.
If all of the other factors are same but left and right
kingpin castor are different, the vehicle will be off
tracking to the side of less positive kingpin castor.
Scrub radius
(1)Kingpin inclination
(2)Wheel camber
(3)Scrub radius

Chassis
Thrust angle
Thrust line; The actual thrust line of vehicle is the angle bisector of
rear axle toe.
Thrust angle: The included angle of thrust line and vehicle
geometrical centre line
The direction of thrust line will be changed when rear axle is
deformed or rear axle toe is changed.
If there is excessive deformation on vehicle body, wheel alignment
may not be enough. In this case, crossbar correction should be done
prior to wheel alignment.
Thrust angle is formed by rear axle toe, transverse run out and
axle offset. In wheel alignment, rear axle should be adjusted
before front axle.
The front axle toe is adjusted based on thrust line formed by rear
axle toe.
Steering toe out

Steering toe out refers to the angular difference of inner wheel and
outer wheel.
Measurement: It is measured when inner wheel is turned by 20
degree, and out wheel is turned by about 18 degree.
Adjustment sequence of wheel alignment:

a. Examine prior to alignment
b. Replace any worn parts
c. Fit the vehicle onto alignment shelf
e. Shake the front and rear of vehicle
f. Adjust the rear axle first, then the front axle
g. For a single axle, adjust the kingpin castor and camber first, then the toe angle. The reason is that adjusting
kingpin castor will cause change of toe angle. Adjusting toe will not affect kingpin angle and camber.

Chassis
4.2 Brake system
4.2.1 Overview
V80 is equipped with front and rear floating calipers disc brake system and X pipe, with ABS and EBD
equipped as standard. Rear disc brake method is used for parking, controlled by handbrake cable mechanism.
Layout of brake hydraulic system is shown below:
4.2.2 Technical data of brake system
Diameter of brake disc Front:294 mm

Rear:304 mm
Minimum thickness of front New (nominal size ):24mm
brake disc Repair limit:22mm
Minimum thickness of rear New (nominal size ):16mm
brake disc Repair limit:14mm
Front brake pad (with self-adhesive shim fitted): 9 mm
(only 2mm remained for friction piece)
Minimum thickness of brake Rear brake pad (with self-adhesive shim fitted): 7.6 mm
liner material (only 2mm remained for friction piece)
Rear brake shoe (with self-adhesive shim fitted): 4 mm
(only 2mm remained for friction piece)
Anti-lock Braking System Equipped with ABS as standard
Type of brake pipe X pipe layout
Brake master cylinder Tandem double chamber independent master cylinder
Vacuum servo With double diaphragm vacuum servo
4.2.3 Regular brake system
Brake system consists of brake and brake actuating mechanism. The brakes generates the brake effect, the
brake actuating mechanism controls the brakes operation. Brakes consist of front and rear disc brakes, while brake
actuating mechanism mainly consists of brake pedal, push rod, vacuum servo, fluid reservoir, brake master
cylinder and pipes.

Chassis
Introduction of major elements

Vacuum servo
Located in engine compartment and fitted together with brake master cylinder, this servo can amplify the brake
force applied on brake pedal and then pass it to brake master cylinder. Vacuum servo consists of front/rear
chambers and control valve. Brake assistance is generated by controlling pressure difference of front and rear
chambers.
Test method:
Brake master cylinder

Brake master cylinder is fitted together with the servo. It passes the brake force from vacuum servo to brakes
hydraulically, and then distributes brake force. Illustration of its operation principle is shown below:
Apply the brake pedal Release the brake pedal
Brakes
Both front and rear brakes are floating calipers disc brakes, and handbrake is fitted in the rear disc brake.
Front brake/brake disc Rear brake/brake disc

Chassis
4.2.4 Handbrake System
Handbrake system is the hand-operated brake system, which is located in the hub of rear brake disc. Drivers
can operate it with the handbrake grip.
4.2.5 ABS System
Operation principle of ABS

ABS system is used to control the slip rate in a range of 10-30% when the brake pedal is applied, to offer
optimum brake performance for vehicle (shortened brake distance, improved direction stability and enhanced
steering control).
Longitudinal adhesion coefficient of wheel under braking is related with wheel slip rate, as shown below:
A: Longitudinal adhesion
coefficient of wheel
B: Braking lip rate
C: Stable area
D: Unstable area
E: Critical area
F: Wheel locking
In the stable area, vehicle driving direction is well controlled but brake force is insufficient. In the unstable
area, driving direction is unstable and brake force is insufficient. The optimum brake force control can be obtained
in the critical area, in which the brake force is maximized and driving direction is well controlled. The objective of
ABS operation is ensuring that the brake adhesion coefficient is within the critical area under braking. In the
operation of ABS, there are 3 stages named pressure boost, pressure maintaining and pressure reduction.
Illustration of hydraulic control is shown below:
System elements
ABS system of V80 is mainly composed of wheel speed sensor, brake pressure adjuster, electronic controls
and ABS warning lights.

Chassis
Elements instruction
Wheel speed sensor
Detects speed of each wheel, and transfers this data to ABS
module; Leverages electromagnetic speed sensor, 2 lines system,
Resistance: 75 Ω.
Brake switch
Located above the brake pedal, it will transfer brake signal to ABS
module and engine module when brake pedal is applied.
Meanwhile, the brake light will be on. This switch is double switch
type, one is consistently on while the other is consistently off.
ABS hydraulic control unit assembly

Located in the engine compartment, it is next to the air filter and
above the front left frame. This assembly is used to receive signals
from wheel speed sensor and brake switch, determine if wheels are
tend to be locked and slip rate is within unstable area, and then
issue command to initiate hydraulic controlled solenoid valve to put
brake system into pressure boost, pressure maintaining and pressure
reduction statuses, to adjust wheel brake force, keep wheel slip rate
in the stable area and ensure safe driving. Control module can
identify and store faults, which can be accessed via diagnostic
apparatus.

Chassis
Status of ABS warning light in fault diagnosis

When fault diagnosis begins, ABS controller will be set into test mode and instruct ABS warning light on fascia to
be on (not flash). At this time, ABS controller will not be functional any more.
ABS configuration
No. Controller configuration Configuration options description
Filling failed/Filling completed successfully/Filling completed but
1 Fill status
unsuccessfully
2 Variant data Long wheelbase models/Short wheelbase models
Fault symptom
1. Vacuum servo failed
2. Brake pedal is too soft
3. Off track when braking
4 .Steering wheel shaking when braking
5. ABS Fault diagnosis

Chassis
4.3 Steering System
4.3.1 Overview
Generally, steering system is mechanical steering system or power assisted steering system. There are two
kind of power assisted steering systems, which are hydraulic power assisted and electric power assisted. In V80,
hydraulic power assisted pinion and rack steering system is used.
4.3.2 Elements Instruction
Components of V80 steering system are shown below:

1. Steering wheel
2. Steering column assembly
3. Steering intermediate shaft
4. Steering unit assembly
5. Steering oil pipe assembly
6. Steering fluid reservoir assembly
7. Power-assisted steering oil pipe
assembly
8. Fluid reservoir to steering pump oil
pickup hose
9. Steering oil pump
Power steering pump

Located at the right above engine and driven by
crankshaft pulley, it is used to create oil pressure for
hydraulic power system and control oil outlet.
Steering unit
Fitted at the rear of sub-frame, it is used to amplify the steering torque applied on steering wheel and make
wheels to turn.
Operation principle:
It connects the hydraulic oil high pressure side and low pressure side with both sides of steering unit power
chamber piston via steering control valve, pushes the piston hydraulically and provides power assisted steering.
Illustration of power assisted steering oil is shown below:

Chassis
Intermediate status Left turn
Right turn
Precautions of exchanging power assisted steering oil
4.3.3. Fault diagnosis
1. Steering assistance is heavy
2. Noise in power steering pump

Chassis
4.4 Exercises
(1) Judgment
1. Power steering pump is driven by crankshaft via timing belt. ( )
2. Steering wheel is allowed to stay in steering limit positions when engine is run, because flow regulating valve
in the power steering pump can be controlled. ( )
3. Steering control valve is used to adjust oil pressure into power chamber. ( )
4. Only ABS does not work, but there is still brake force for vehicle. ( )
5. Vehicle of Front-engine Front-drive is more likely to be excessive steering. ( )
(2) Completion
1. There are two kinds of power steering system, which are ( ) and ( ).
2. Steering system of V80 is mainly composed of ( ), ( ), steering column, ( ), ( ), ( ) and pipes.
3. Power steering pump of V80 uses ( ) structure, and the model of its power assisted oil is ( ).
(3) Short Answer

1. Operation principle of ABS
2. Slip rate
3. Types of brake switch and their purposes
(4) Operation exercise - ABS configuration

Air-conditioning system
Chapter 5 Air-conditioning system


5.1 Overview
The MAXUS air-conditioning system offers effective performance for driving comfort even in extreme
weathers. With engine control optimization, economy is achieved while power performance is not damaged.
The MAXUS heater transmits engine heat through coolant cycling to the air warming water-tank in passenger
compartment.
The MAXUS cooler is equipped with H expansion valve and R134a refrigerant that is environmental-friendly.
Cooling efficiency is greatly enhanced by increased thermo-exchange area and air-flow provided by fixed
displacement swash plate compressor, optimized condenser, and evaporator.
The ventilation and air distribution system uses dampers to control air-intake, temperature, wind-blowing mode
and defrost mode. The air-filter within the air inlet ensures the cleanness air taken in from outside of the vehicle.
The MAXUS air-con electronic controller allows air in/out, defrost, and blower RPM settings through knobs
and buttons. The high/low and medium pressure switch provides responses to cooling system abnormal operation.
5.2 Technical parameters
Compressor model 10B20 10B17 7G13

Rated voltage 12V
Power consumed 45W
Refrigerant R134a
LWB with rear AC 1750 ±30 g
Refrigerant charge
SWB with rear AC 1450 ±30 g
amount
No rear AC 600 ±30 g
5.3 Heater
Overview
Heating is to take advantage of the heat of engine cooling water and transfers the heat to the vehicle by heater
core to keep comfortable temperature. Interior temperature is controlled by the electrical water valve and blend
doors which adjusts warm water flow.
Layout of front heating

Layout of rear heating
1. Rear heating inlet pipe 2. Rear heating outlet pipe 3. Rear fan heater 4. Rear heating air duct assembly
5. Rear heating control
Exploded diagram of rear fan heater
1. Rear heating assembly

2. Rear heating core component
3. Rear heating speed regulation resistor
4. Rear heating wiring harness
5. Rear heating air duct assembly
6. Plug

5.4 Cooler system
Overview
The R134a refrigerant cycles around the cooler to transmit heat from vehicle interior to exterior. The refrigerant
cycling circuit illustration:
1. Compressor
2. High temperature and
pressure gas
3. Condenser
4. High temperature and
pressure liquid
5. Expansion valve
6. Low temperature and
pressure liquid
7. Evaporator
8. Low temperature and
pressure gas
Compression
The compressor spends mechanical work to draw in low temperature and pressure gaseous refrigerant, pressurize
to increase its temperature and pressure without changing its physical state so as to create superheated gas.
Condensation
The gaseous refrigerant leaves the compressor to enter the condenser where it will be liquidized without
pressure and temperature alternation.
Throttled expansion
The liquidized refrigerant flows through expansion valve where it is rapidly depressurized and cooled to
become low temperature and pressure liquid, then into the evaporator. Both the pressure and temperature of the
refrigerant drops, its flow adjusted, and the refrigeration output controlled through this process.
Evaporation
In the evaporator, the low temperature and pressure liquid refrigerant absorbs the vehicle interior environment
heat, then be drawn into the compressor to complete the cycle. Throughout this process, the liquid refrigerant will
be evaporated with its pressure maintained.
Expansion valve cooling system

The MAXUS uses ‗H‘ expansion valve cooling system which is characterized by using expansion valve as the
throttle and depressurization component and utilizing evaporated refrigerant temperature to adjust the throttling
section which controls its flow. Such a system mainly includes compressor, condenser, expansion valve, receiver
drier, and pipelines.

Layout of MAXUS air conditioning refrigerating system
Layout of front air conditioning refrigerating system

1. Air distributor
assembly
2. Expansion valve
3. High pressure
pipe
4. Low pressure
pipe
5. Receiver drier
6. Compressor
7. CONDENSER
8. Tri-phase
pressure switch
Layout of rear air conditioning refrigerating system

5/6 Air-con
pipeline (high/low
pressure)
7 Expansion valve
8 Evaporation box
assembly
Introduction of elements
AC Compressor
Compressed refrigerant gas; Clutch solenoid resistant
at 3.9 ohm
Condenser
Refrigerant gas is condensed into high temperature and
pressure liquid

Receiver drier
Refrigerant dehydration and filter. Storing refrigerant and
oil from condenser.
Pressure switch
The high/low pressure switch is used for compressor
control
The medium pressure switch is for cooling fan control
Expansion valve
The expansion valve is installed before the
evaporator inlet, which throttles pressurized
refrigerant into steam for the evaporator.
Closed expansion valve Opened expansion valve
1. From Dryer bottle 2. to Evaporation box 3. Evaporation box 4. Compressor 5. Orifice 6. Flow control ball 7.
Spring 8. Pilot rod 9. Refrigerant 10. Compensation pressure 11. Metal film 12. Temperature sensor
A closed expansion valve while cooler is not An opened expansion valve while cooler is under normal
running is illustrated. operation is illustrated.
According to formula F1=F2+F3, since the In case of cooler load adjustment such as blower RPM
temperature of refrigerant within the temperature rises, air flow into the evaporator will increase. This is
sensitive pack and at the outlet are identical, their providing more heat to refrigerant within the evaporator in
pressures satisfies: F1=F2. The pilot rod will press the effect. Therefore facilitating refrigerant boiling.
flow control ball unto the valve seat to close off the
orifice under the effect of force F3 from the spring

Evaporator and surface temperature sensor

This is where refrigerant absorbs heat, evaporates, and
enters the compressor.
The temperature sensor controls the compressor to
prevent frost.
Air con panel

The passenger request signal will be processed and sent
to the ECU or request for operation
Refrigerant and lubricant

The refrigerant used in MAXUS is R134a which is non-toxic, inflammable, clear, no-color, and liquidized
gas. R134a system accepts only one type of lubricant: polyalkylene glycol (PAG). Any lubricant unable to resolve
into the R134a could cause problem in the compressor or components.

5.5Air conditioning and distribution system
Air conditioning and distribution system illustration

1. Mode actuator
2. Blend door motor
3. Blower relay
4. Blower assembly
5. In/exterior circulation motor
6. Speed regulation resistor
7. Warm water valve component
8. Pollen filter
9. Heater core
5.6 Air con control
Compressor control
The MAXUS vehicle air con compressor is controlled by ECM which decides the air-con relay application
based on the signals below:
 Air-con request ECM signal
 Engine temperature
 Air-con high/low, medium pressure switch
 Evaporator surface temperature sensor
 Engine operation

5.7 Common troubleshooting
Condition: Poor cooling
1. Run performance test to identify the cause.

2. Basic inspection
1) Air flow check
2) Condenser check
3) Air distribution system check
3. Pressure test
Pressure deviation types Possible cause Elimination

Body Electrics
Chapter 6 Body Electrics

Body Electrics

Body Electrics
6.1 Circuit diagram description
Cable color codes
Color code Color (English) Color (Chinese)

BARE Bare 屏蔽裸线
BLK Black 黑色
BRN Brown 棕色
DRAIN WIRE Drain Wire 屏蔽线
GRA Gray 灰色
GRN Green 绿色
GRN DK Green Dark 深绿色

GRN DK/BLK Green Dark Black 深绿黑
GRN LT Green Little 浅绿色
GRN LT/BLK Green Little Black 浅绿黑
ORN Orange 橙色
PNK Pink 粉红色
PPL Purple 紫色
RED Red 红色
TAN Tan 褐色
WHT White 白色
YEL Yellow 黄色
YEL/BLK Yellow/Black 黄黑
Wiring harness codes

Wiring harness Wiring designations Wiring
code (English) designations
(Chinese)
RA REAR ABS 后 ABS 线束
BT BATTERY 蓄电池线束
DD DRV DOOR 驾驶员侧门线束
PD PASS DOOR 乘客侧门线束

FB FRONT 前线束
IP IP 仪表板线束
XL LH ROOF 左顶棚线束
XR RH ROOF 右顶棚线束
RB RR BUMPER 倒车雷达线束
BW RR H/BLOWER 后暖风线束
AB SRS 安全气囊线束

Body Electrics
Wiring harness layout

Body Electrics
Power distribution diagram

Power distribution diagram is designed to show connections between battery and engine compartment and
cabin fuse box. It also shows internal connections in the fuse box.
Wire property
Description of wire property is over the wire in the circuit diagram.
―121‖ represents wire code;
―GRA‖ represents wire color. Refer to ―Cable color codes‖ for more information;
―2.5‖ represents the diameter of wire, in mm;
―ALL‖ represents features on the vehicle, herein applicable to all models.
Connectors
The numbered suffix of the connector designation is used to indentify pin number of the wire. For example:
RA03-1 represents connector RA03, pin number 1.
― ‖represents female connector;
― ‖ represents male connector.
Parts
The description of part name is shown below and usually represented with a black box.

Body Electrics
Earth points
Earth point is usually represented with a double ring symbol and an overhead earth point number (e.g. G204-1)
Twisted Pairs
The twisted pair in the circuit diagram is shown below.
Shielded wire
The shielded wire in the circuit diagram is shown below.
Page-crossed wire
The figure below indicates this wire is connected to the wire No. "CLUSTER_EBD" on Page 24.
Feature codes table

Feature code Feature description
ALL All models
CBW Rear Air Conditioning
CBW&HBW Rear Heating & Rear Air Conditioning
CRUS Cruise Control
DEF Heated Rear Window
FFOG Front Fog Light
HBW Rear Heating
INV Vehicle Inverter
LSLD Left Side Load Door
MP5 MP5
OSM Heated Exterior Mirror
PAB Front Passenger Airbag
PDC Parking Distance Control
SPKS Rear Speaker
TPMS Tire Pressures Monitoring System

Body Electrics
6.2 Power and put up iron distribution
Power distribution
Engine compartment (pre) fuse box

There are three terminals on the battery positive
and the middle one is connected to the starter
and the other two are fitted with 175A fuses
separately.
Engine compartment (auxiliary) fuse box Cabin (main) fuse box
Put up iron distribution

Body Electrics
6.3 Body control module
Overview
Body control module is in charge of a series of vehicle functions and communicates with other control modules
through K bus. Body control module can control the following vehicle functions directly or indirectly: Central
door locking; vehicle immobilization; wiper and washer; vehicle interior illumination; vehicle exterior
illumination; heated rear window; key in switch alarm; engine immobilization; faults record and diagnosis;
software online refresh.
Body control module (BCM) is located behind the glove box of front passenger side. BCM is secured on
cross-beam of instrument panel framework with two bolts and accessible after removing the glove box.
Operation principle
BCM receives and calculates switch signal before sending control command to each actuator
BCM features
No. Controller features Feature option description
Feature options of body side load Left side load door / right side load door / left
1
door and right side load doors
Manual exterior mirror / standard electric heated
2 Feature options of exterior mirror
exterior mirror
3 Feature options of front fog light With front fog light /without front fog light
Foldable plip/ordinary key without remote
4 Feature options of plip
control
5 Feature options of tyre 205/75R16C / 215/75R16C
Undefined mode /manufacturing mode /
6 Feature options of BCM status
transportation mode / normal mode
7 PIN PIN
LOCK: 1 Locked 0 Unlocked
Features of engine IMMO coil
8 SK: 1 Written 0 Unwritten
status
PIN: 1 Written 0 Unwritten
KEY slot status (key is inserted
9 Status: 1 Key available 0 No key
into the ignition switch or not)
RFID (Radio frequency
10
identification)
VIN (Vehicle identification
11
number)
12 IMMO operator C3 C3

Body Electrics
Fault code list and diagnosis help

1. Fault code list
All faults information of BCM body controller and the respective faults code, fault description and possible
reasons are listed below.
No. Fault code Fault code description
U1562 Power input above max. limited voltage
1
U1562 Power input below min. limited voltage
2 U1601 EEPROM CRC error detection
3 U1602 EEPROM error communication
B104A Left direction indicator open circuit
4 B104A Left direction indicator short circuit to ground
B104A One-side light of left direction indicator fails
B104B Right direction indicator open circuit
5 B104B Right direction indicator short circuit to ground
B104B One-side light of right direction indicator fails
6 B104C Alarm indicator switch conglutination
B104D Rear fog light open circuit
7
B104D Rear fog light short circuit to ground
B104E Front fog light open circuit
8
B104E Front fog light short circuit to power
B104F Main beam open circuit
9
B104F Main beam short circuit to power
B1050 Exterior side light open circuit
10
B1050 Exterior side light short circuit to power
B1051 Front roof light or foot light open circuit
11
B1051 Front roof light or foot light short circuit to ground
12 B1060 Rain regulating switch intermittent delay beyond limits
13 B1061 Rain regulating switch open circuit
B1062 Front wiper open circuit
14
B1062 Front wiper short circuit to ground
B1070 Rear window heater open circuit
15
B1070 Rear window heater short circuit to ground
B1071 Alarm open circuit
16
B1071 Alarm short circuit to power
17 B1090 IMMO coil failure
18 B1091 No key found
19 B1092 Unmatched key
20 B1093 No SK generated
21 B1094 No written PIN
22 B1095 No key‘s ID stored in immobilizer
23 B1096 VirginECM (no PIN and SK)
24 B1097 Unmatched ECM
25 B1098 No ECM response

Body Electrics
2.Diagnosis help
Fault code: U1562 BCM controller power input above the max. limited voltage / below min. limited voltage
Diagnosis help:
Check the wiring connection and voltage between battery - fuse EF4 in engine compartment auxiliary fuse
box - fuseF7 and F9 in cabin main fuse box - BCM controller. Check the wiring connection and voltage between
battery - fuse EF10 in engine compartment auxiliary fuse box - fuse F3 and F4 in cabin main fuse box - BCM
controller. Check connector IP07‘s terminal 5# and 11# and IP08‘s terminal 1#, 4#, 5# and 11# on fascia harness
assembly for corrosion, terminal damage, poor contact, slackened, physical harness damage etc.; Check fuse F3,
F4, F7 and F9 in cabin main fuse box and fuse EF4 and EF10 in engine compartment auxiliary fuse box for open
circuit; Check wiring connection and voltage between BCM controller - GND G201_IP-1 for open GND circuit or
high resistance and check GND G201_IP-1;Check for battery supply voltage.
BCM exercises

Body Electrics
6.4 Central door locking and vehicle immobilizer system
Overview
Central door locking and vehicle immobilizer system are two independent and interdependent systems and
the central door locking switch can only control the functions of central door locking; Remote control signal not
only can be used individually to realize locking and unlocking, but also set and remove immobilization. Central
door locking and vehicle immobilizer system consist of plip, BCM, instrument cluster, direction indicators, door
switch, door lock motor and horn etc.
Keys
Operate mechanical door open, door locking and ignition switch
Remote control door open, door locking and load space open
Set and disarm alarm
Engine immobilization
Automatic locking: No operation during one minute after
unlocking with plip, the vehicle will be locked automatically.
(Refer to real vehicle)
Replacing remote control transmitter requires fault diagnosis
instrument to program the BCM and only one key can be configured.
The battery shall be replaced when the remote control is only
available in shorter distance.
Central door locking switch
Non-self-locking switch, located in the upper left of driver‘s knee
bolster
The signal of this switch and driver door lock switch are sent to
BCM respectively.
Only control door open and close
This switch becomes invalid after locking with remote control
Side door switch Rear door switch Key contact switch
Monitor side door status and control door Monitor rear door status and Monitor key inserted or not
courtesy lamp and vehicle immobilization control door courtesy lamp and
vehicle immobilization
Driver side door lock assembly Rear door lock motor Horn
Located on the front left door, containing door Located on respective doors Located on the vehicle beam,
switch, locking and unlocking signal and three Operate locking and unlocking behind the left headlamp
plugs of door lock motor. Controlled by the horn or
The door lifting button cannot be pressed BCM
down until close the door.

Body Electrics
System control block diagram
Control strategy
1. After locking with remote control, all doors shall be locked and direction indicators flash 3 times, coming into
vehicle immobilization mode; after unlocking, direction indicators flashes 1 time slowly.
2. In vehicle immobilization mode, only open with remote control is allowed, otherwise alarm status will be ready.
3. After immobilization enabled, alarm status will be ready if the door is opened without authorization.
4. When the key is turned from ON to OFF and removed, the door will be unlocked automatically.
5. Automatic locking in accordance with vehicle speed.
6. Central door locking switch becomes invalid after locking with remote control.
7. With any door open, the horn will emit one sound if locking with remote control fails.
8. Automatic locking for second immobilization.
9. Automatic unlocking after collision.
10. Ignition key in switch alarm.
11. Locking device protection.
Central door locking and vehicle immobilizer system exercises

Body Electrics
6.5 Window system
Overview
The driver and front passenger windows apply electric window regulating system and the driver window
features one-touch lowering.
System composition
The window system consists of control switch, window regulator and motor.
Left front door window combined regulator switch Right front door window combined regulator switch
Location: On the driver door Location: On the front passenger door

Function: Control the driver and front passenger Function: Control the window‘s regulation directly
window‘s regulation with one-touch lowering
Window regulator
Window regulator consists of motor, cable, guide rail and slider.

Body Electrics
6.6 Electric mirror and heated rear window
Overview
Mirrors include interior and exterior mirrors; interior mirrors are stuck in the seat on the front windowscreen
with spring strip and exterior mirrors are electrically regulated. In addition to heating function, the angle of
exterior mirror is regulated by selective control switch (left, right) and direction adjustment button.
System composition
The system consists of interior mirrors, left and right exterior mirror assembly (including two regulating
motors), electric heated glass, mirror selective switch and direction adjustment button.
Interior mirror Left /right exterior mirror assembly
View conditions right behind the vehicle View conditions at right and left sides
Note fitting/removal method and behind the vehicle and electric
heating for defogging and defrosting to
improve clarity.
Mirror selective switch and direction
Heating button
adjustment button assembly
Select mirror that requires adjustment to regulate Select mirror and rear windscreen
the mirror angle. heating
System control principle block diagram

Control principle of mirror electric regulation

Body Electrics
Control principle of mirror heating
System function description

Electric regulation
Mirror regulation can work only with ignition switch in ―ON‖ position.
Two exterior mirror selective switches are available for selecting left or right exterior mirror adjustment.
Press electric mirror‘s ―L‖ button to adjust left exterior mirror; In this case, direction keys below can be used to
adjust the up and down, left and right position of left exterior mirror glass.
Press electric mirror‘s ―R‖ button to adjust right exterior mirror; In this case, direction keys below can be used
to adjust the up and down, left and right position of right exterior mirror glass.
Time for glass and rear window heating: Heating control logic: 15 minutes
Points for fitting/removal

Fitting / removal of exterior mirror
1. Slide interior mirror out of the seat by softly shaking it from side to side along mirror seat direction with even
force.
2. Align interior mirror with mirror seat position and softly hit interior mirror to snap spring clip into mirror seat
and check for secure fitting.
6.7 Seats
The seats are to be adjusted manually and the driver‘s seat is 8 - direction adjustable.
Inside seats distribution

Body Electrics
6.8 Interior Illumination System
System composition
Interior illumination system consists of front vanity light, rear vanity light, courtesy lamp, ignition switch
core light and control switch.
System elements
Front vanity light
Rear vanity light (ON/OFF)
(ON/DOORSIDE/OFF)
Function: reading illumination Function: reading illumination

Courtesy lamp Ignition switch core light
Greeting and illumination Easy for key operation
Control strategy
1. Unlocking with remote control, front vanity light / courtesy lamp / ignition switch core light will be on for
time delay of 30 seconds and off when the KEY in ACC/ON; with front / side door open, light on again and delay
for 30 seconds after the door close.
2. Unlocking with remote control, front vanity light / courtesy lamp / ignition switch core light will be on for
time delay of 30 seconds and off immediately after locking with remote control
3. Opening the rear door mechanically, rear vanity light will be on for time delay of 30 seconds.
4. After receiving collision signal, front and rear vanity lights will be on for 15 minutes until KEY is in OFF or
warning light switch is pressed down again at least 5 seconds later.

Body Electrics
6.9 Exterior Illumination System
System composition
It consists of BCM, all control switches, headlamp combination, and rear combined light, front fog light,
number plate light and high brake lamps for the purpose of exterior illumination and warning.
Headlamp combined switch Front exterior lights
Including position lamp, headlamp (main beam and Headlamp assembly (main beam, dipped
dipped beam), front fog light and direction beam, direction indicators and regulation
indicators. motor), font fog light.
Rear exterior lights Reverse switch
Rear combined light (brake light, reverse light,

position lamp, direction indicators, fog light), high Control reverse light, PDC enabling signal.
brake lamp, number plate light.
Hazard warning light and rear fog light switch Headlamp leveling switch
Enable hazard warning light and rear fog light. Leveling of headlamp.

Body Electrics
6.10 Wiper System
System composition
It consists of wiper control switch, wiper motor, transmission mechanism, washer and washer pump, blade
and injector.
Introduction of system elements
Wiper switch Wiper motor
Change wiper position (circuit switching) Dual speed motor and worm mechanism, in which
there is a reset switch and the motor runs with high
speed when the high speed terminal powered or
runs with low speed when the low speed terminal
powered.
Washer and washer pump
Press the water jet button to start washer pump and
wiper motor
Wiper system exercises

Body Electrics
6.11 Instrument Cluster
Layout of fascia and centre console assembly
Major instrument cluster compositions

The vehicle instrument system is driven by electronic stepping motor and consists of speedometer,
tachometer, fuel gauge, thermometer, alarm icons, dot-array LCD clock, sub-total, grand total and tyre pressure
information.
Basic function description of instrument cluster system

LCD display
LCD interface displays clock, subtotal and grand total of mileage (hereinafter referred as main interface), tyre
pressure, temperature and tyre pressure alarm and LCD display mode is switched by buttons.
LCD display overview
Subtotal mileage: Subtotal mileage automatically returns to zero after reaching max. reading (1999.9km).
Grand total mileage: Grand total mileage remains unchanged after adding up to max. reading. (999999km).
Requirements of LCD work mode:
a. LCD lights on after battery reconnected and reignited.
b. LCD does not display after ignition off when battery keeping connected. Subtotal and grand total remain
unchanged and clock times.
c. Subtotal displays 0 and grand total remains unchanged after battery and ignition switch disconnected at the
same time and then reconnected. Clock displays 12:00. Time format is 24-hour.
User can switch display mode to TPMS normal display mode by button on instrument panel to display current tyre
pressure or temperature on LCD at real time (alternative display).

Body Electrics
Main interface Tyre pressure interface -Normal Tyre pressure interface -Normal
tyre pressure tyre temperature
When low / high tyre pressure alarm or high tyre temperature alarm
occurs, corresponding TPMS warning lights will be on.
Wait for learning interface
Learn the system when replacing tyres
Instrument cluster elements

Instrument
Name Type Range Input signal type or source
Tachometer Stepping motor 0～6000r/min ECU, engine speed sensor
Speedometer Stepping motor 0～180km/h Square wave, vehicle speed sensor
Fuel gauge Stepping motor E～F Fuel level sensor
300Ω～40Ω
Thermometer Stepping motor C～H ECU, 2%～96%, 50Hz
Illumination and alarm indicators
No. Function Icon Color Control mode
Lights on when
1 Left turn Green
connected with battery +
Lights on when
2 Right left Green connected with battery +
Lights on when
3 Main beam Blue
Lights on when
4 Front Fog Light Green
Lights on when
5 Rear fog light Yellow
Low fuel level warning
Low fuel level alarm
In the direction where resistance increases,
resistance of fuel sensor ≥ 265.6Ω, alarm
6 Yellow Instrument cluster
indicator on;
In the direction where resistance reduces,
resistance of fuel sensor ≤ 260.6Ω, alarm
indicator off.
High engine cooling water temperature
7 Red Instrument cluster
warning
8 Water in fuel warning Yellow Lights on by earthing
9 Low oil pressure warning Red Lights on by earthing

Body Electrics
10 Brake System Warning Red Lights on by earthing
11 Power system fault warning Yellow Lights on by earthing
12 OBD Yellow Lights on by earthing
Lights on when
connected with power
13 ABS fault warning Yellow supply + or untouched
and off when connected
with low level
14 Airbag fault warning Red Lights on by earthing
Lights on by earthing
15 Seat belt warning Red
16 Cruise control indicator Green Lights on by earthing
17 TPMS warning Red Instrument cluster
18 Glow plug indicator Yellow Lights on by earthing
19 Door open warning Red Lights on by earthing
Lights on by earthing
20 Alternator charging warning Red
Exciting current 300mA
21 IMMO locking warning Yellow Lights on by earthing
22 Transmission box fault warning Yellow Lights on by earthing
23 EPS fault warning Yellow Lights on by earthing
24 Trailer light fault warning Green Lights on by earthing
Lights on when
connected with power
25 EBD EBD Red supply + or untouched
and off when connected
with low level
Sensor
Fuel level sensor
Fuel level sensor is located in the fuel tank. It uses sliding rheostat to detect fuel level and fuel gauge
indicates the level in accordance with the input resistance. Indication angle is as the following:
Indication point Input resistance (Ω) Indication angle (°)

E 300 0°
Alarm 265.6 13°
1/4 246.5 26°
1/2 170 52°
3/4 93.5 78°
F 40 104°

Body Electrics
Vehicle speed sensor Oil pressure switch Handbrake switch
Provide vehicle speed signal to the With low pressure, the switch Apply handbrake and light on
instruments closes and warning light on. parking lamp.
Brake fluid level switch Seat belt buckle switch
With low brake fluid level, warning light on. Seat belt not fastened, warning light on and bleeper enabled.
蜂鸣器报警
Alarm type Sound condition Connection Sound mode
mode of port
Ignition key in Alarm signal BCM sent to Battery = ON Continuous alarm
switch alarm / instrument =ON (low level Signal port of (External BCM signal
headlamp on signal is valid) alarm sound = Headlamp on alarm: with ignition switch
alarm (Note: These two alarm signals ON (low level switching from ON to OFF position,
are controlled by BCM and signal is valid) BCM instructs bleeper to sound alarm
outputted by the same pin） when dipped beam switch turned on.
2) Key in switch alarm: 1. key turns to
OFF position with driver side door open.2
When key stays in any position of ignition
switch, bleeper sounds alarm with RKE
locking or driver‘s side key locking.
Bleeper sounds with the cycle of 3S
audible alarm and 1.5 S stop)
Seat belt alarm 1.When speed >0 and seat belt Battery =ON Continuous alarm (constant sound)
unfastened (seat belt signal Ignition =ON
=OFF), bleeper sounds Seat belt signal
2.During driving: When the state =OFF (lights
of seat belt switch changes, on by
above judgment condition is to earthling)
be initiated again
3.When speed =0 , seat belt
=ON or =OFF, bleeper turns off
Hazard Hazard warning signal (left and Battery =ON Continuous alarm
warning alarm right turn =ON) Ignition =OFF Bleeper frequency
Left turn =ON 1600HZ_6ms_800HZ_8ms
right turn =ON (325ms on, 325ms off (1.54HZ).This
value can not be changed through
diagnostic instrument.)
(Ignition is controlled by BCM)

Body Electrics
Left and right Left turn =ON Battery =ON Continuous alarm
turn alarm or right turn =ON Ignition =ON Bleeper frequency
Left turn =ON 1600HZ _6ms_800HZ_8ms (When
(or right turn direction indicator works, it flashes with
=ON) frequency of 75 flashes per minute
(1.25HZ), but it is default value and can
be changed by diagnostic instrument
(write data by LID). Frequency set by
diagnostic instruments will be observed
to flash after change.
TMPS bleeper Tyre fast air leakage alarm, low Battery =ON
critical alarm pressure alarm, high pressure Ignition =ON
alarm, high temperature alarm Tyre pressure
signal =ON
(normal input)
TMPS bleeper Tyre under inflation, low Battery =ON
warning alarm sensor battery, malfunction of Ignition =ON
TPMS system Tyre pressure
signal =ON
(normal input)
Priority order:
1) Hazard warning alarm
2) TPMS critical alarm
3) TPMS warning alarm
4) Driver‘s seat belt untied alarm
5) Left and right turn audible indication
6) Ignition key in switch alarm
Instrument cluster system exercises

Body Electrics
6.12 TPMS
System composition
TPMS mainly consists of tyre pressure monitoring and control module, tyre pressure / temperature sensor and
instrument cluster.
Tyre pressure monitoring module
Location: On the middle cross-beam of roof
Function: Receiver judges pressure and temperature values from sensor and low / high tyre pressure alarm or
high tyre temperature alarm occurs, corresponding TPMS warning lights on.
Tyre pressure / temperature sensor

TPMS pressure sensors are directly installed on the hub of each tyre and suitable for tyres without inner tube.
The sensor can detect tyre pressure and temperature and transmit the data to receiver through wireless radio
frequency.
System function description

Receiver judges pressure and temperature values from sensor and low / high tyre pressure alarm or high tyre
pressure alarm occurs, corresponding TPMS warning lights on.
User can switch display mode to TPMS normal display mode by button on instrument panel to display current
tyre pressure or temperature on LCD at real time (alternative display).
If the tyre is not learned, in information frame sent by TPMS to the instrument, high four-digit of tyre position
means whether corresponding tyre position has been learned, if not, high four-digit is 0000 and instrument panel
displays ―ns‖ for corresponding tyre position and follow-up information does not need to be handled; If high
four-digit is 1111, it means the tyre has been learned and the instrument panel needs to handle information of
corresponding tyre. If high four-digit is 0000 in one piece of tyre position information, corresponding position
displays ―NS‖ and ―wait for learning‖ beside.
System learning function:

Body Electrics
6.13 Audio & entertainment System
System overview
Two audio units are available in accordance with vehicle features:
Standard feature is radio cassette player + MP3 with FM and AM radio functions and USB MP3 playing
functions.
Luxurious feature is GPS navigation and MP5 player with GPS navigation function, FM and AM radio
functions as well as streaming media functions of playing RM, RMVB, MPEG 1-4, avi, wmv and ASF format
read by SD card and USB.
Layout of vehicle entertainment system
FM+MP3 player Instrument desk left / right side Rear left / right speaker
speaker
DVD+navigator GPS antenna AM/FM antenna
Audio unit is located on the central instrument panel. A 16 - pin connector located under the unit provides
various control signals required by audio input of power speaker. A separate aerial coaxial-cable socket located
under the unit provides AM/FM signal and luxurious feature has GPS antenna as well. A 10A fuse on the unit
protects against power overload.
Block diagram of vehicle entertainment system control
Entertainment system exercises

Body Electrics
6.14 PDC
System composition
PDC is the parking or reversing aids, consisting of ultrasonic sensor (nicknamed probe), and controller (internal
bleeper).
PDC module Ultrasonic sensor
Handle signal from ultrasonic sensor and Ultrasonic sensor sends ultrasonic wave to the behind
provide alarm sound of different level in of the vehicle and, if obstructed, reflected wave will
accordance with distance after come back to the emitter (ultrasonic sensor surface),
calculating the distance value. then the distance can be obtained through time delay
between transmitted wave and reflected wave
Fault diagnosis
No alarm while approaching the obstacles
1. Snow or mud on the sensor probe;
Snow or mud on the sensor probe will significantly reduce the detective performance of the sensor. In this case,
cloth or water (low pressure) can be used to remove the snow or mud on the sensor probe.
Note: never wash with high pressure water gun. High pressure water flow like water gun or great external force
may cause faults.
2. Ice on the sensor probe;
Ice will significantly reduce the detective performance as well. No alarm is also normal and possible. Remove the
ice softly.
Note: never try to melt the ice with fire or hit the ice heavily with metal objects; otherwise the probe will be
damaged.
3. Prolonged vehicle parking in hot or cold weather;
Probe may be malfunctioned under –20℃or 50℃above.
4. Approaching small objects such as iron wire, rope, cell wall; No alarm while approaching such objects is
normal and possible.
5. Approaching low obstacles. As there is limited range for sensor detection, no alarm for approaching low
obstacles is normal and possible.
6. Approaching objects that can easily absorb ultrasonic wave such as floppy snow, cotton and sponge;
As ultrasonic wave is absorbed, no alarm while approaching such objects is normal.
7. For objects that are unable to reflect ultrasonic wave, no alarm is normal in accordance with the shape of the
obstacle;
8. Except for phenomenon above, the PDC may fail, such as:
 Probe damaged and can not work
 Harness disconnected
 Plug slackened
 Communication fault
Body Electrics
6.15 Supplermental Restraint System
Overview
When the vehicle suffers front impact of adequate strength, supplementary restraint system (SRS) will be
activated to protect the driver and front passenger. Main circuit of SRS module senses the strength of impact force
and ignites gas generator in the airbag assembly for gas charging when necessary to deploy airbag. If battery
voltage is low or power supply is disconnected for collision, voltage regulator and spare supply circuit will keep
constant voltage. The system consists of control module, spiral cable, main airbag, balloonet, seat belt,
malfunction indicator light and harness.
SRS control module Spiral cable
Monitor the vehicle collision and judge the collision for Wiring connecting the main airbag and airbag
setting level and send command to deploy the airbag to control module, always keeping connection
protect the people in the vehicle. At the same time it has with the turning of steering wheel.
the self-diagnosis function.
Main airbag Balloonet
It is control module that ignites the igniter of main airbag Protect the front passenger
to trigger the gas generator and large amounts of gas
generated comes into the airbag, making the airbag
breaking through airbag trim panel to become a air cushion
between the driver and steering wheel for the purpose of
reducing injury to the driver and at the same time air is
expelled out from the overflow ports around the airbag.
Seat belt pre-tensioner of front seat Seat belt switch
Assist the work of airbag and pre-tighten the seat belt to Seat belt untied alarm / warning
limit the movement of seat occupant during operation.

Body Electrics
Maintenance tips
1. With ignition switch in "ON", SRS warning light will light on and off after self-check, indicating normal SRS
operation. The warning light will be constant on when the system fails.
2. Only trained and authorized maintenance station can maintain the SRS and incorrect overhaul procedures may
cause serious injury for accidental airbag explosion.
3. Even with the power cut off, capacitor inside the airbag computer can also supply reserve energy to SRS and
the battery negative terminal shall be disconnected at least 90 seconds before removing any airbag components.
Airbag and spiral coil shall be removed and stored properly before steering system maintenance.
4. As there is built-in short-circuiting bar in the joint connected with airbag module, aigbag malfunction indicator
light will illuminate in case of poor joint connection.
5. Always fit as arrowed on the airbag module.
6. Never break down, repair or re-use the fittings below:
airbag spiral wire, airbag module, seat belt pre-tensioner, harness etc.
7. Always check any airbag fittings before fitting and observe the principles below:
Only use new fittings; Never use airbag fittings from other vehicles; Never use fittings that once fell down or
knocked; only check it with diagnostic instrument
8. Do not measure the resistance of airbag with multimeter.
Fault diagnosis
1. System initialization diagnosis
Airbag controller operates initialization diagnosis after powered up, during which (about 4s without faults) MIL
will illuminate without ignition.
2. MIL status during diagnosis
While the customer diagnoses airbag controller, the MIL illuminates (no flicker) and the controller can not detect
collision or enable algorithm.
3. System features
No. Controller features Feature option description
Establish communication between diagnostic
1
instrument and airbag controller
Customer development mode / customer production mode /
2 Start to select diagnosis mode
customer after-sale mode
Byte #3 - #15: user part number - 13 bytes
3 Read airbag controller information
Byte #16 - #22: software number - 7 bytes
4 Read history information of airbag controller
5 Write in vehicle manufacturing date
6 Write in VIN VIN – 17 bytes
Secondary circuit: (with driver‘s airbag and seat belt
pre-tensioner)
Third circuit:(with driver and front passenger‘s airbag and
7 Write feature information of airbag controller
driver‘s seat belt pre-tensioner）
Fourth circuit:(with driver and front passenger‘s airbag and seat
belt pre-tensioner）
Changing airbag controller configurations in customer
production mode and validating new configurations after
changing airbag controller peripheral configurations ($3B $D0
8 Software reset
command).During after sale service, power up again can
validate new configurations.(This step shall be applied as well
when setting the hardware again.)
9 Wait 7 seconds
Establish communication between diagnostic
10
instrument and airbag controller
The diagnostic instrument removes the storage
11
fault of airbag controller
The diagnostic instrument reads the storage fault
12
and status of airbag controller
Before fitted into the vehicle, the airbag controller is in sample
presentation status. If the controller does not have ignition function,
Configure airbag controller with ignition MIL will flashes with the cycle of 1 second. After fitted into the
13
function vehicle, airbag controller is configured with ignition function and
MIL will not flash any more.(This step is conducted only when no
fault code read by diagnostic instrument in step 12)
Note:
1) Read airbag controller before writing its configurations and if the read configuration and written configuration is the
same, airbag controller configuration writing can be skipped.
2) After writing in VIN and manufacturing date, always check those of the airbag are the same with the configured
information.
3) After writing in airbag controller configuration and software reset, check the aigbag controller configuration is the
same with the written configuration.

Body Electrics
6.16 Vehicle Inverter
Overview
The vehicle inverter is located under the driver‘s seat, as shown in the figure below. It can transform the DC
12V into AC 220V and when the ignition switch is in ACC position, it will start to work after connected with load
and the green indicator will light on.
Fault diagnosis
Indicator no display
Step Operation Yes No
1 Good battery contact? To step 2 Ensure good connection
of the battery
2 Battery damaged? Replace the battery To step 3
3 Fuse blown? Replacing fuse To step 4
4 Connector connected with the inverter Reconnect the connector To step 5
loosened?
5 Vehicle inverter fault, replace the End
inverter.
Inverter abnormal, fuse blown

Step Operation Yes No
1 Reverse connection of the battery? Correctly connect the To step 2
positive and negative
terminals of the battery
and then replace the fuse.
2 Elements damaged in the device and End
replace the inverter.
Inverter stops, red indicator flashes

No. Possible cause Solution
1 Battery voltage Several seconds after battery voltage is reduced lower than ―overvoltage
exceeds ―overvoltage recovery point‖, flashing red indicator goes off and green indicator goes
point‖ on constantly, inverter output recovers automatically.
2 Load beyond the Reduce load and close engine, and then restart the engine to recover AC
scope of the inverter output.
capacity
3 Load short circuit Close engine after eliminating the short circuit, and then restart the
engine to recover AC output.
4 Temperature is too Overtemperature protection will disappear and the inverter will recover
high inside the output automatically after the temperature inside the inverter is reduced
inverter to the normal value.

Body Electrics
6.17 Exercises
Exercise 1
Body control module (1h)
Objectives: Train the trainees to view BCM data stream and the drive of actuator
Vehicle and tools required: A luxury featured vehicle and a diagnostic instrument.
Contents: View BCM data stream and the drive of actuator
1. Use diagnostic instrument to view and record data stream
Data stream:
2. Use diagnostic instrument to drive the actuator
3. BCM features
Requirements: Carefully operate and record, keep safety first and instructions followed.
Operation summary:

Body Electrics
Exercise 2
Measurement of central door locking fitting / removal (2h)
Objectives: Train the trainees to operate and measure practically
Vehicle and tools required: A featured vehicle and a set of general tool
Contents: Trainees in two groups to remove and measure the driver and front passenger door lock motors
separately
1. Remove drive and front passenger door lock motor assembly and understand the function of each lever.
2. Locate motor, central lock switch (mechanical) signal and door switch plug in the door lock motor assembly.
3. Measurement
Name Motor Central lock switch (mechanical) status Door status
Resistance between pin 1 and 2 Pin 1 and 2
(locking) (open)
Resistance
Resistance between pin 1 and 3 Pin 1 and 2
Resistance between pin
(unlocking) (close)
1 and 2
Resistance between pin 2 and 3
(normal status)
Requirements: Carefully remove/fit and recover the original vehicle status.

Summary:

Body Electrics
Exercise 3
Operation and fitting/removal of light system (1h)
Objectives: Let trainees better understand the control strategy and operation of light system.
Vehicle and tools required: A luxury featured vehicle and a set of general tool
Contents:
1. One trainee operates the exterior and interior lights in accordance with instructor‘s instruction and other trainees
make record.
2. Remove and fit headlamp to understand the height adjustment of headlamp.
Summary:

Body Electrics
Exercise 4
Operation demonstration and measurement of wiper system (1h)
Objectives: Let the trainees better understand all positions of wiper system
Vehicle and tools required: A featured vehicle and a set of general tool
Contents: The instructor requires the trainee to demonstrate the wiper system operation and measure reset switch.
1. Completely demonstrate the operation status of each position and get better understood against the circuit
diagram.
2. With wiper arm reset, turn off ignition switch and unplug motor plug to measure the status of motor reset
switch.
Summary:

Body Electrics
Exercise 5
Understanding instrument cluster (1h)
Objectives: Let the trainees better understand and use the circuit diagrams of instrument cluster
Vehicle and tools required: A luxury featured vehicle and a diagnostic instrument.
Contents:
1. List the input/output signal and path of instrument cluster against circuit diagrams
Input signal
Output signal
2. Operate and view which indicators of the instrument cluster have self-check
3. Can diagnostics instrument be used to get access to the instrument cluster and why?
Requirements: Carefully record and operate in practical
Summary:

Body Electrics
Exercise 6
Learn TPMS (1h)
Objectives: Let the trainee understand the self-learning of tyre pressure
Contents:
1. The instructor explains the self-learning process
2. The trainees operate the self-learning of tyre pressure

Summary:

Body Electrics
Exercise 7
Operation of audio & entertainment system (1h)
Objectives: Let the trainee understand the operation of audio & entertainment system
Vehicle and tools required: A luxury featured vehicle
Contents: Carefully operate the audio & entertainment system against Driver‘s Handbook.
Requirements: Carefully follow the instructor‘s commands and pay attention to safety. Never start the vehicle
freely.
Summary:
Exercise 8
Airbag features (1h)
Objectives: Let the trainees understand the operation of airbag system features
Vehicle and tools required: A luxury featured vehicle and a diagnostic instrument
Contents: Operate the airbag system features with diagnostics instrument against this handbook.
Requirements: Carefully follow the instructor‘s commands and pay attention to safety. Never start the vehicle
freely.
Summary:

Appendix
Chapter 7 Appendix

Appendix

Appendix
Special tools
Engine
Clutch aligner Rear oil seal installer Inlet camshaft timing pin Exhaust camshaft timing pin
C00016994 C00016995 C00016996 C00016997
Camshaft oil seal installer Crankshaft front oil Flywheel timing pin Cylinder liner retainer
seal installer
C00016999 C00017002 C00017003 C00017004
Fuel injector remover Fuel pump wheel remover Cylinder liner measuring Flange retainer
tool
C00017007 C00017008 C00017009 C00017010
Cylinder liner remover High pressure pump Camshaft support Flywheel mounting pins
impeller timing tool guide pin
C00017011 C00017012 C00017013 C00017014
Camshaft setting tool Camshaft gear locking Crankshaft bearing fix pin Oil pressure release valve
tool remover remover
C00017015 C00017016 C00017017 C00017018

Appendix
Piston cooling nozzle Oil pressure release valve Crankshaft front bearing Camshaft oil seal fitting cover
replacer fitting tool replacer
C00017019 C00017020 C00017021 C00017022
Crankshaft front oil seal Piston ring retaining tool Torque angel gauge Flywheel locking tool
fitting cover
C00017023 C00017024 C00017025 C00017026
Valve spring compression Straight throat pipe bundle caliper Valve oil seal replacer tool set
tool
C00017027 C00017028 C00017029
Tension pulley adjuster Oil filter remover Oil pan seal separator Oil seal puller
C00017030 C00017031 C00017032 C00017033
Transaxle
Universal puller Input shaft retainer Thrust journal Bearing installer

C00017040 C00017041 C00017042 C00017043

Appendix
Housing separator Universal drive handle Gear lever setting pin Half axle oil seal fitting tool
C00017044 C00017045 C00017046 C00017047
High-quality dual disc puller

C00017048
Chassis
Wrench spring shock absorber Ball joint separator Rear wheel bearing
replacer tool set fitting tool
C00017034 C00017035 C00017036 C00017037
Rubber bush replacer Ball joint remover

C00017038 C00017039
Vehicle
5PCS plastic steel pry Engine supporting carrier Power set fitting tool
bar set
C00017049 C00017050 C00017051

Appendix
Circuit diagrams

After-Technical Training Handbook-MAXUS V80

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PREFACE

Training Center, SMCV After Sales

Training for new model of V80

Training for new model of V80 -1-

Training for new model of V80 -2-

Training for new model of V80 -3-

Training for new model of V80 -4-

Chapter 1 New Technical Features

Training for new model of V80 -1-

Training for new model of V80 -2-

1.1.1 Origin and advantages

Training for new model of V80 -3-

Training for new model of V80 -4-

Supplermental Restraint System

Training for new model of V80 -5-

PDC could help spare driver‘s worries.

Training for new model of V80 -6-

1.1.2 Vehicle Identification

Vehicle Identification Number (VIN ):

Training for new model of V80 -7-

1.1.3 Vehicle dimension

SWB (Short Wheelbase):

LWB (Long Wheelbase):

Training for new model of V80 -8-

1.1.4 Vehicle features

Main Technical Data

Model SH6501, SH5040 SH6571, SH5041

Low Roof Middle Roof Middle Roof High Roof

Drive Type 4 × 2, Front-wheel Steering, Front-engine Front-drive (FF)

Height 2132 2345 2345 2552

Internal Length 2586 3355

Height 1505 1710 1925

GTW (kg) 2160 ～ 2240 2230 ～ 2380

GVW (kg) 3200 3500

Fuel Tank Capacity (L) 80

Top Speed (km/h) 150

Wheelbase (mm) 3100 3850

Front Track (mm) 1734

Front Suspension (mm) 865

Rear Suspension (mm) 985

Approach Angle (°) 26

Departure Angle (°) 17 (without rear step), 14 (with rear step)

Minimum Ground 200 (Oil pan)

Minimum Turning Radius (m) 12.4 14.8

Fuel Tank Capacity (L) 80

Top Speed (km/h) 150

Training for new model of V80 -9-

Table of feature codes

Feature code Feature description

Maintenance & Service

Renew oil/Clean air filter 7500km or every 750 liter consumption

Training for new model of V80 -10-

Cognitive exercises (1h)

Training for new model of V80 -11-

Training for new model of V80 -12-

Training for new model of V80 -13-

Training for new model of V80 -14-

Engine displacement (ml) 2499

Training for new model of V80 -15-

2.2 Engine Mechanical

2.2.1 Technical specifications

First compression ring 0.12 - 0.154 mm