Manual motor j 4

Service MANUAL
J4 (5MT) Model
EQUIPED WITH HFC4GB2.3D ENGINE
AND MF70B 5MT TRANSSIMISSION
JAC INTERNATIONAL
2014.02
General Information and
J4 Service Manual Maintenance
General Information and Maintenance

GI General Information
Precautions
Description:
Please read the following precautions to ensure personal safety and proper servicing.
Precautions for supplemental restraint system (SRS) “air bag” and (SB) “seat
belt pre-tensioner”:
The supplemental restraint system (SRS) “air bag” and (SB) “seat belt pre-tensioner”,
used along with a seat belt, help reduce the risk or severity of injury to the driver and
front passenger in the event of a vehicle collision. The information necessary to
service the system safely is included in the SRS section and SB section of this Service
Manual.
Warning:
 To avoid rendering the SRS inoperative, which could increase the risk of personal
injury or death in the event of a collision, all maintenance operations must be
performed by an authorized JAC dealer.
 Improper maintenance, including incorrect removal and installation of the SRS,
can lead to personal injury or death caused by unintentional activation of the
system.
 Do not use electrical test equipment on any circuit related to the SRS unless
instructed to in this manual. SRS wiring harnesses can be identified by yellow
and orange harnesses or harness connectors.
General precautions:
 Do not operate the engine for an GI001

extended period of time without proper
exhaust ventilation. Keep the work
environment well ventilated and away
from any inflammable materials. Special
care should be taken when handling any
inflammable or poisonous materials,
such as gasoline, refrigerant, natural gas,
etc. When working in a pit or other
enclosed room, ensure the working place
is ventilated well before handling any
hazardous materials. Do not smoke while
working on the vehicle.
GI-1
 Before jacking up the vehicle, put wheel GI002

chocks or other tire blocks under the
wheels to prevent the vehicle from
moving. After jacking up the vehicle,
support the vehicle weight with safety
stands at the points designated for proper
lifting before working on the vehicle.
This operation should be done on a level
ground.
 When removing a heavy component such GI003

as the engine or transmission, please do
not waggle it using excessive force in
order to disconnect it. Also, do not allow
them to strike adjacent parts, especially
the brake pipes and master cylinder. Battery
 Before starting repairs which do not GI004

require battery power: Turn off ignition
switch and disconnect the negative
battery terminal.
 If the terminal is disconnected, memory
in the control module will be cleared.
 To prevent scalds: Avoid contact with hot
metal parts. Do not remove the radiator
cap when the engine is hot.
 Dispose of drained oil or the solvent GI005
used for cleaning parts in an appropriate
manner.
 Clean all removed parts in the designated
liquid or solvent prior to inspection and
assembly.
 Replace oil seals, gaskets, packings,
O-rings, locking washers, cotter pins,
self-locking nuts, etc. with new ones.
 Replace inner and outer races of tapered roller bearings and needle bearings as a
set.
 Arrange the removed parts in accordance with their assembled locations and
sequence.
 Please do not touch the ports of electronic components which use
microcomputers (such as ECM). Static electricity may damage internal electronic
GI-2
components.
 After disconnecting vacuum or air tubes, attach a tag to indicate the proper
connection.
 Use only the oils and lubricants recommended in this manual.
 Use approved bonding agents, sealants or their equivalents when needed.
 Use hand tools, power tools (for disassembly only) and special tools correctly for
safe and efficient repairs.
 When the ongoing repairs relate to the fuel, oil, water, vacuum or exhaust system,
check all affected lines for leaks.
 Before repairing the vehicle:

Seat cover
① Protect fenders, upholstery and
carpeting with appropriate covers.
② Be careful not to allow things like keys
and buttons to scratch paintwork.
Fender pad
Warning:
To prevent ECM from storing the diagnostic trouble codes incorrectly, do not
carelessly disconnect the harness connectors which are related to the engine control
system. Operate only according to the work flow of trouble diagnoses in EC section.
Precautions for three way catalyst:
If a large amount of unburned fuel flows into the three way catalyst, the catalyst
temperature will rise sharply. To avoid this, follow the instructions below:
 Use unleaded gasoline only. Leaded gasoline will seriously damage the three way
catalyst.
 When performing spark plug tests or measuring cylinder pressure, do the jobs
quickly and only when necessary.
 Do not run engine when the fuel tank level is low, otherwise the engine may
misfire, causing damage to the three way catalyst.
 Please do not park the vehicle on inflammable materials. Keep inflammable
materials away from the exhaust pipe and the three way catalyst.
Precautions for fuel:
 The 4GB2.3D engine uses unleaded gasoline with an octane rating of number 93
or above
 Please do not use leaded gasoline. Using leaded gasoline will damage the three
way catalyst. Using a fuel other than that specified could adversely affect the
GI-3
emission control equipment and system, and could also affect the warranty
coverage validity.
Precautions for multiport fuel injection system or engine control system:
 Before connecting or disconnecting any harness connector for the multiport fuel
injection system or ECM:
① Turn ignition switch to “OFF” position.
② Disconnect negative battery terminal. Otherwise, there may be damage to ECM.
 Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to
release fuel pressure.
 Be careful not to shake components such as ECM and sensors.
Precautions for hoses: GI007 Do not scratch tube

1. Hose removal and installation
 To prevent damage to a rubber hose, do
not pry off it with pointed tool or
screwdriver.
 To fix the rubber hose securely, make GI008 Insert hose to here
sure that hose insertion length is
adequate and clamp position is correct.
(If metal tube is equipped with hose
stopper, insert hose into tube until it
butts up against hose stopper.)
Hose stopper
2. Hose clamp GI009 Trace of clamping

 If old rubber hose is reused, install hose
clamp in its original position (at the Bulge
indentation where the old clamp was). If
there is a trace of metal tube bulging left
on the old rubber hose, align rubber
Hose
hose at that position.
 Discard old clamps; be sure to replace Tube
with new ones.
GI-4
 After installing plate clamps, apply GI010 Depress for better fitting
force to them in the direction of the
arrow in the figure, clamping rubber
hose equally.
Plate clamp
Precautions for engine oil:
Prolonged and repeated contact with used engine oil may cause skin cancer.
Therefore, avoid direct skin contact with used oil. If skin contact is made, wash
thoroughly with soap or cleanser as soon as possible.
Health protection precautions:
 Avoid prolonged and repeated contact with engine oil, particularly used engine
oil.
 Wear protective clothing. Please use impervious gloves where practicable.
 Please do not put oily rags in pockets.
 Please do not contaminate clothes, particularly underwear, with oil.
 Heavily soiled clothing and oil impregnated footwear should not be worn.
Overalls should be cleaned regularly.
 First aid treatment should be obtained immediately for skin cuts and other body
wounds.
 Apply barrier cream to skin before starting each work in order to help the removal
of oil from the skin.
 Wash with soap and water to ensure all oil is removed (skin cleansers and nail
brushes will help). Use lanolin in replace of the natural skin oils which have been
removed.
 Please do not use gasoline, kerosene, diesel oil, gas oil, thinners or solvents for
cleaning skin.
 If skin disorders develop, take medical measures without delay.
 Where practical, degrease components prior to use.
 Where there is a risk of eye contact, goggles or face shields should be worn; in
addition, an eye wash facility should be provided.
Environmental protection precautions:
Dispose of waste oil and oil filters through officially approved waste disposal
contractors to licensed waste disposal sites, or to the waste oil reclamation enterprises.
If you have any question on disposal of waste substances, contact the local authority.
It is illegal to pour used oil on to the ground, down sewers or drain ditches, or into
GI-5
water sources; the laws and regulations concerning pollution vary between regions.
Precautions for air conditioning:
Use an approved refrigerant recovery unit any time the refrigerant in the A/C system
must be discharged. Refer to corresponding items in AC section for specific
instructions.
How to Use This Manual
Description:
This manual explains “Removal, Disassembly, Installation, Inspection and
Adjustment” and “Trouble Diagnoses”.
Terms:
 The captions WARNING and CAUTION warn staffs of steps that must be
followed to prevent personal injury or damage to some parts of the vehicle.
WARNING indicates the possibility of personal injury if instructions are not
followed.
CAUTION indicates the possibility of component damage if instructions are not
followed.
BOLD TYPED STATEMENTS besides WARNING and CAUTION also give you
helpful information.
Standard value: Tolerance at inspection and adjustment.
Limit value: The maximum or minimum limit value that should not be exceeded at
inspection and adjustment.
Units:
 The UNITS of measurement used in this manual are primarily expressed as the
SI UNIT (International System of Unit).
Example: Outer Socket Lock Nut: 59-78 N·m
Contents:
 THE CONTENTS are listed on the first page of each section.
 THE TITLE is indicated on the upper portion of each page and shows the parts
or systems involved in this page.
 THE PAGE NUMBER of each section consists of two or three letters which
designate the particular system and a number (e.g. “GI-6”).
 THE SMALL ILLUSTRATIONS show inspection, use of special tools, knacks
of work and hidden or tricky steps which are not shown in the previous large
illustrations.
Special tools:
 Tools marked with JAC special tool numbers are special tools provided by JAC.
Tools not marked or general-purpose tools are commercially available in the
GI-6
mark.
How to follow trouble diagnoses:

Description:
Trouble diagnoses indicate work procedures required to diagnose problems effectively.
Read the following instructions before diagnosing.
1. Before performing trouble diagnoses, read the “Preliminary Check”, the
“Symptom Chart” or the “Work Flow” first.
2. After repairs, recheck that the problem has been completely eliminated.
3. Refer to Component Parts and Harness Connector Location for the Systems
described in each section for identification/location of components and harness
connectors.
4. Refer to the Circuit Diagram Volume.
If you need to check circuit continuity between harness connectors in more detail,
such as when a sub-harness is used, refer to Wiring Diagram and Harness Layout in
each individual section for identification of harness connectors.
5. When checking circuit continuity, ignition switch should be set to OFF position.
6. Before checking voltage at electrical components, check battery voltage first.
7. After accomplishing the Diagnostic Procedures and Electrical Components
Inspection, make sure that all harness connectors are reconnected as they were.
Model Identification Information
Vehicle type:
Body number Engine model Manual transmission number
J4 HFC4GB2.3D MF70B10
Vehicle identification number (VIN):

1) Vehicle identification number (VIN) location: On name plate or at lower left
corner of windshield.
GI-7
2) Vehicle identification number description
Digit capacity
Geographic region Serial number
Country Vehicle feature code Assembly plant
Maker Check digit Year
A letter or number A number
① The first section: World Manufacturer Identifier (WMI) composed of 3 digits

according to GB16737. This code must be subject to application, approval and
filing. The code for JAC is LJ1 which applies to trucks, non-complete vehicles,
buses, passenger vehicles, tractors and special purpose vehicles manufactured by
our company. See the following table for the world manufacturer identifier
(WMI).
Table World Manufacturer Identifier (WMI)
Code Name of maker Applicable vehicle types
Trucks, non-complete vehicles, buses, passenger

LJ1 Anhui Jianghuai Automobile Co., Ltd.
vehicles, tractors, special purpose vehicles
② The second section: Vehicle Descriptive Section (VDS) code composed of 6

digits according to GB16737. It can reflect basic features of a vehicle type
adequately.
VDS composition:
GI-8
Digit capacity
Check digit
Engine type/rated power
Wheel base of truck/length of passenger

vehicle, bus and chassis
Maximum total mass
Body type
Vehicle type
① Vehicle type: 2 represents passenger vehicle.

F: 3-box 4-door
② Body type
G: 2-box 5-door
③ Maximum total mass: K: >1000~2000
④ Wheel base of truck/length of passenger vehicle, bus and chassis: R>2390~2600

1: Gasoline ≤70Kw
⑤ Engine type/rated power 2: Gasoline >70~90Kw
3: Gasoline >90~110Kw
3) The third section: Vehicle Indicator Section (VIS) composed of 8 digits.
Digit capacity
Production SN
Name of assembly
plant
Year
4: Passenger vehicle manufacturer/car plant/general assembly

shop/assembly plant
Assembly plant
7: Commercial vehicle manufacturer/general assembly shop of
commercial vehicles
B: 2011
GI-9
Year C: 2012
D: 2013
Engine model:
Location of HFC4GB2.3D engine model is shown in the figure:
Engine Type
Engine Sequence
Number
Manufacture Plant
Gasoline Engine
Manufacture Year
Manual transmission model:

Location of MF70B10 transmission model is
shown in the figure.
the Location Transmission

print Plate Number
GI-10
Vehicle parameters:
List of Vehicle Parameters
Overall body size
Overall length (mm) 4435
Overall width (mm) 1725
Overall height (mm) 1505
Front tread (mm) 1470
Rear tread (mm) 1460
Wheel base (mm) 2560
Front overhang (mm) 880
Rear overhang (mm) 995
Mass parameters
No. of seats (occupants) 5
Vehicle 1110
Kerb mass (kg)
Fore axle 680
GI-11
Back axle 430
Vehicle 1485
Gross mass (kg) Fore axle 775
Back axle 710
Wheels
Size 15×5 1/2J
Tires
Regular 185/65R15 88H
Lifting Points
Service tools:
Tool name Description
Board on attachment
Safety stand attachment
Caution:
 Make sure vehicle is empty when lifting.
 Since the vehicle’s center of gravity changes when removing main parts on the
nose (e.g. engine, transmission, suspension etc.), be sure to support a jack up
point on the rear side garage jack with a transmission jack or equivalent.
 Since the vehicle’s center of gravity changes when removing main parts on the
tail (e.g. rear axle, suspension, etc.), support a jack up point on the front side
garage jack with a transmission jack or equivalent.
GI-12
 Be careful not to smash any circuit or do anything that would affect the piping.
Garage jack and safety stand:
Warning:
 Park the vehicle on a level road before using the jack. In addition, make sure to
avoid damaging important parts such as pipes etc. under the vehicle.
 Never get under the vehicle while it is supported only by the jack. Use safety
stands to support the vehicle when you have to get under it.
 Place wheel chocks at both front and back of the wheels on the ground.
2-pole lift:
Warning:
 When lifting the vehicle, open the lift arms as wide as possible and ensure that the
front and rear of the vehicle are well balanced.
 When setting the lift arm, do not allow it to contact the brake lines, brake cable,
fuel lines and sill spoiler.
Board-on lift:
Caution:
 Make sure vehicle is empty when lifting.
 The board-on lift attachment set at front end of vehicle should be set on the front
of the sill under the front door opening.
 Position attachments at front and rear ends of board-on lift.
Tow Truck Towing
Caution:
 All applicable local laws regarding the

towing operation must be obeyed.
×
GI013
 Be sure to use proper towing equipment
to avoid possible damage to the vehicle
during towing operation. For more
details regarding towing, refer to related
instructions on the “Owner’s Manual”.
 Be sure to attach safety chains before
towing.
 When towing, make sure that the transmission, steering system and power train
are in good order. If any unit is damaged, dollies must be used. It is recommended
that the vehicle be towed with the driving (front) wheels off the ground as shown
in the above figure.
GI-13
Vehicle recovery (freeing a stuck vehicle):

 Pull the cable straight out from the front or rear of the vehicle. Never pull on the
hook at an angle.
 When towing a vehicle forward, remove front spoiler. Otherwise front spoiler
may be damaged by the towing equipment.
 Pulling devices such as ropes or canvas straps are not recommended for use in
vehicle towing or recovery.
 Use towing hook only and not other components of the vehicle. Otherwise, the
vehicle body will be damaged.
 Use towing hook to free a vehicle stuck in sand, snow, mud, etc. only. Please do
not perform long-distance towing using towing hook only.
 When used for freeing a stuck vehicle, the towing hook will be subjected to a
large force.
 Keep away from a stuck vehicle.
Tightening Torques of Standard Bolts

Tightening Torque Table
Tightening torque (without lubricant)

Bolt diameter Pitch
Grade Bolt size Hexagon head bolt Hexagon flange bolt
mm mm
N·m N·m
M6 6.0 1.0 5.5 7
1.25 13.5 17
M8 8.0
1.0 13.8 17
1.5 28 35
4T M10 10.0
1.25 28 35
1.75 45 55
M12 12.0
1.25 45 65
M14 14.0 1.5 80 100
M6 6.0 1.0 9 11
1.25 22 28
M8 8.0
7T 1.0 22 28
1.5 45 55
M10 10.0
1.25 45 55
GI-14
1.75 90 100
M12 12.0
1.25 90 100
M14 14.0 1.5 190 170
M6 6.0 1.0 11 13.5
1.25 28 35
M8 8.0
1.0 28 35
1.5 55 80
9T M10 10.0
1.25 55 80
1.75 100 130

M12 12.0
1.25 100 130
M14 14.0 1.5 170 210
*: Nominal diameter
1. Special parts are excluded.
2. This standard is also applicable to bolts having the following marks embossed on the bolt head.
M 6
Nominal diameter of bolt threads (unit: mm)
Metric screw threads
Terminology
See the following chart for notes of the terms that appear in this manual:
Terminology List
DG Speed sensor
TF-W Coolant temperature sensor
ZSK Ignition coil
FPM Accelerator pedal
ECU Electronic control unit (commonly referred to as Computer)
GI-15
EKP Fuel pump
EMS Engine management system
EV Injector
LSH Heated oxygen sensor
KS Knock sensor
KSZ Fuel rail assembly
KVS Fuel rail
PG Phase sensor
RUV Distributorless ignition system
TEE Fuel pump bracket assembly
TEV Canister control valve
GI-16
J4 Workshop Manual Maintenance
MA Maintenance
Preparation
List of Commercial Service Tools
Tool name Description
Radiator cap tester adapter

Connecting radiator cap tester
to radiator cap and radiator
filler port
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm
Oil filter wrench
Removing and installing oil

filter
Radiator cap tester
Checking radiator and radiator

cap
Spark plug wrench
Removing and installing spark

plugs
MA-1
General Maintenance
General maintenance includes those items which should be checked during the normal
day-to-day operation of the vehicle. They are essential if the vehicle is to continue
operating properly. The owners can perform these checks themselves or have their JAC
dealers do them.
Outside the vehicle:
The maintenance items listed here should be performed from time to time, unless
otherwise specified.
Item
Check tire pressure (including spare tire) with a pressure gauge at a service station
Tires regularly. Adjust to the specified pressure if necessary. Check tires carefully for
damage, cracking or excessive wear.
Clean the windshield on a regular basis. Check the windshield at least every six
Windshield
months for cracks or other damage. Please repair or replace as necessary.
Windshield
Check for fracture or wear if they do not wipe properly.
wiper blades
Check that all doors as well as the engine hood and tail gate can be opened and
closed normally. Also make sure that all latches lock securely. Lubricate if
Doors and necessary. Make sure that the secondary latch keeps the hood from opening when
engine hood the primary latch of the engine hood is released.
When always driving in areas using road salt or other corrosive materials, check
lubrication frequently too.
Tire rotation Tires should be rotated every 8,000 km.
Make sure that the headlights, fog lights, stop lights, taillights, turn signal lights,
Lamps and other lighting are all operating properly and fixed securely. Also check
headlight aim.
Inside the vehicle:
Item
Warning lights
Make sure that all warning lights and buzzers are operating properly.
and buzzers
Windshield, Check that the wipers and washer operate properly and that the wipers do not
wipers and washer streak.
Windshield Check that the air comes out of the defroster outlets properly and that air is
defroster sucked in sufficient quantity when operating the heater or air conditioner.
Steering wheel Check that it has the specified free play (<35 mm); check it for hard steering or
MA-2
abnormal noise.
Check that buckles, anchor bolts, adjusters and retractors of seat belts operate
Seat belts properly and smartly and are installed securely; check seat belts for cracking,
fraying, wear or damage.
Check the pedal for smooth operation and make sure it does not catch or
Accelerator pedal require uneven effort.
Keep the undercover mat away from the pedal.
Check the pedal for smooth operation and make sure it has the proper distance
Brake pedal and
from the undercover when depressed fully. Check the brake booster function.
booster
Keep the undercover mat away from the pedal.
Parking brake Check that the pedal has the proper travel.
Under the hood and vehicle:

The maintenance items listed here should be checked periodically, e.g. each time you
check the engine oil or refuel.
Item
Windshield
Check that there is adequate fluid in the reservoir tank.
washer fluid
Engine coolant
Check the coolant level when the engine is cold.
level
Check the level after parking the vehicle on a level ground with the engine shut
Engine oil level
down.
Make sure that the brake fluid level is between the “MAX” and “MIN” lines on
Brake fluid level
the reservoir.
Battery Check battery terminal condition.
Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle
has been parked for a while. Water dripping from the air conditioner after use is
Fluid leaks normal.
If you should notice any leaks or gasoline fumes are evident, check for the cause
and repair it immediately.
Periodic Maintenance
The periodic maintenance section lists the minimum maintenance items required to
ensure trouble free operation of the vehicle roughly. Some additional maintenance
items may be required depending on areas and climates. For more detailed information,
please refer to your Warranty Manual.
MA-3
Recommended Oils and Lubricants

Table of Oils and Lubricants
Recommended oils/lubricants
Name
L
With oil filter SAE 5W-30 (winter in northern areas)

3.5
change
Engine oil SAE 15W-40 (year round in southern areas
drain and refill and summer in northern areas), SJ quality
Without oil
3 grade above
filter change
With reservoir
7.5 ELQ-L3 long life antifreeze
Cooling tank
system
Reservoir tank 1.9 ELQ-L3 long life antifreeze
2.1 (Top off to Hypoid gear oil SAE 75W~85W

Manual transmission fluid lower edge of
filler) API GL-4 grade above compliant
Power steering fluid 1.1 ATF-III
Brake fluid Just enough DOT4
Multi-purpose grease Just enough No. 2 general purpose lithium base grease
*1: For detailed instructions, please refer to “SAE Viscosity Numbers”.

*2: Please use original engine coolant for JAC B-Class MPV or products of equal quality so as to
avoid aluminum metal corrosion in engine cooling system caused by use of false and inferior engine
coolant.
Please note that the engine cooling system damage caused by use of false and inferior engine
coolant is not covered by the JAC warranty even within warranty period.
SAE viscosity number (gasoline engine):

SJ quality grade above SAE 5W-30 (winter in northern areas) and SAE 15W-40 (year
round in southern areas and summer in northern areas). If 5W-30 is not available,
please select the viscosity suitable for outside temperature range from the table.
Ambient temperature
MA-4
Specific gravity of engine coolant:

The engine cooling system is filled at the factory with a high-quality long life antifreeze
coolant. The coolant contains special corrosion and freeze inhibitors. Therefore,
additional cooling system additives are not necessary.
Caution:
 When adding or replacing coolant, be sure to use only original JAC engine coolant
or products of equal quality with the proper mixture ratio. Refer to the examples in
the following table.
Coolant Composition Table
Outside temperature down to Composition
℃ ℉ Engine coolant (concentrate) Distilled or demineralized water
-15 5 30﹪ 70﹪
-35 -30 50﹪ 50﹪
Use of other types of engine coolant solutions may damage your engine cooling system.
 When checking the engine coolant mixture ratio by the coolant hydrometer, use the
chart below to correct your hydrometer reading (specific gravity) according to
coolant temperature.
Coolant Specific Gravity Comparison Table
Coolant temperature ℃ (℉)

Engine coolant mixture ratio
15 (59) 25 (77) 35 (95) 45 (113)
30﹪ 1.046-1.050 1.042-1.046 1.038-1.042 1.033-1.038
50﹪ 1.076-1.080 1.070-1.076 1.065-1.071 1.059-1.065
Warning:
Never open the radiator cap when the engine is hot. Serious burns could be caused by
high pressure fluid escaping from the radiator. Wait and do not operate until the engine
and radiator cool down.
MA-5
Engine Maintenance
Checking drive belts:
Be sure to perform the following when engine is stopped.
1 Check belts for cracks, wear and oil trace. MA001

If necessary, please replace.
② Check drive belt deflection at a point on
belt midway between pulleys.
 Inspection should be done only when
engine is cold, or over 30 minutes after
engine is stopped.
 When measuring the deflection, apply 100 N at the marked point.

 Adjust if the belt deflection exceeds the limit.
 Specified value of belt deflection: 8.3~10.4mm.
Alternator Drive Belt Tension adjustment

1 Loosen alternator bolster nut. MA002
2 Loosen Drive Belt Tension lock nut.
3 Adjust tension by turning adjusting bolt.
Bolster nut
4 Tighten lock nut. MA003

Adjust bolt
Lock nut
5 Tighten alternator bolster nut.
MA-6
6 Detect drive belt’s flinch degree.

If there is a need, adjust it.
Specification:
Detect time
When install new belt When check
Detect method
Alternator drive
belt’s flinch
5.6～6.7(mm) 8.3～10.4(mm)
degree(Under 100N
force)
Alternator drive
785～981(N) 392～588(N)
belt’s tension
Engine coolant:
The semitransparent coolant expansion tank is installed in the engine compartment.
Keep the coolant level in this expansion tank between the “MIN” and “MAX” lines. Be
sure to check coolant level when engine is cold.
Coolant consumption is very small under MA002

normal conditions. When coolant level drops,
it indicates possible leaks. If this occurs,
immediately drive to a JAC approved service
station for inspection.
If the coolant level drops to below the level of
the “MIN” line on the coolant expansion tank,
please add coolant promptly.
Precautions:
 When coolant of other brand is to be used, be sure to drain original coolant and
clean. Hybrid use of coolants of different brands will cause damage to such
components as engine and radiator.
 Coolants are harmful to human health! The coolant should be kept properly in its
original container and particularly out of reach of children.
 Note that the expansion tank cap can not be opened during operation when engine
is hot. A certain pressure exists in cooling system of a hot engine. Serious burns
will be caused when hot coolant ejects.
 Do not spill fluid when filling coolant. Otherwise wipe up the spillage with a cloth
immediately.
MA-7
 The coolant contains harmful corrosion inhibitors. Therefore, flush clean with clear
water immediately if the fluid spills on your body inadvertently.
 Never open radiator cap before engine cools down completely. Serious burns could
be caused by high-pressure fluid spilling from radiator.
 Wrap a thick cloth around radiator cap. First turn radiator cap 1/4 turn to release
built-up pressure in radiator, and then screw off radiator cap all the way.
1. Changing engine coolant
Hybrid use of coolants of different brands is not allowed. When changing to a different
coolant, you need to drain the original antifreeze coolant in the engine radiator and
engine completely as follows:
① Remove radiator cap.
② Remove radiator drain valve (from lower left part of radiator), and drain coolant in
radiator and engine water jacket.
③ Remove expansion kettle and drain coolant in it.
④ Loosen radiator inlet pipe clamp and pull out the pipe. Clean engine coolant lines
by pouring clear water through radiator inlet until clean water is drained. Then
install radiator inlet pipe and clamp it.
⑤ Tighten radiator drain valve firmly.
⑥ Pour coolant designated by JAC Motors in radiator slowly until it is topped off.
Start engine and then liquid level in radiator should drop. Wait until radiator is
filled with coolant, and then install radiator cap.
⑦ Fill expansion tank with coolant until liquid level reaches line “MAX” (full).
⑧ Install expansion tank cap.
⑨ Start engine and warm it up until thermostat opening.
⑩ After thermostat opening, run engine at full speed for several times and then shut it
down; wait until engine cools down, and then fill expansion tank with engine
coolant until liquid level reaches line “MAX” (full).
2. Coolant
The engine coolant contains corrosion inhibitor-ethylene glycol. The cylinder head and
water pump are aluminum alloy die castings. To prevent these components from
corrosion, be sure to change engine coolant regularly.
The coolant contains corrosion inhibitors, so do not replace it by light water even in
summer.
Content of the required coolant varies with ambient temperature used:
Contrast Table of Coolant Content and Ambient Temperature
Minimum ambient temperature (℃) -10 -20 -35 -45
MA-8
Ethylene glycol content (%) 25 30 35 40
3. In cold seasons
When the air temperature in the location of your vehicle drops to below 0℃, the
coolant in the engine or radiator may have the risk of freezing causing serious damage
to them. To prevent coolant from freezing, add sufficient quantity of coolant in it. The
engine coolant filled at delivery of the vehicle has an antifreeze effect even at a low
temperature of around -35℃. Before start of each cold season, check coolant content
and add coolant to the system in time when necessary.
Flushing cooling system:
① Install reservoir tank and radiator drain plug if removed.
Caution:
 Be sure to clean drain plug and install with new O-ring.
 If water drain plugs on cylinder block are removed, please install and tighten them.
② Remove air duct component.
③ Disconnect heater hose.
 Raise heater hose as high as possible.
④ Fill radiator and reservoir tank with water, and install radiator cap.
 Disconnect when engine coolant overflows heater hose, and then reconnect heater
hose and continue filling engine coolant.
⑤ Install air duct component.
⑥ Run engine and warm it up to normal operating temperature.
⑦ Rev engine 2 or 3 times under no-load.
⑧ Stop engine and wait until it cools down.
⑨ Drain water from the system.
⑩ Repeat steps 1~9 until clear water begins to drain from radiator.
Checking cooling system:
MA-9
1. Checking cooling system hose MA003

Check hose for improper attachment, leaks,
cracks, damage, loose connections, wear or
aging. If necessary, please repair or replace
damaged parts.
2. Checking radiator cap
① Pull out negative-pressure valve to open
it, and make sure that it closes
completely after pressure release.
 Make sure that there is no dirt or damage MA004

on the valve seat of radiator cap
negative-pressure valve.
 Make sure that there are no unusualness
in the opening and closing conditions of
negative-pressure valve.
② Check radiator cap relief pressure.
 When connecting radiator cap to the radiator cap tester (commercial service tool)
and the radiator cap tester adapter, apply engine coolant to the cap sealing surface.
Please replace radiator cap if negative-pressure valve operates abnormally or relief
pressure drops to below the limit.
3. Checking radiator
Check radiator for mud or clogging. If necessary, clean radiator as follows.
 Be careful not to bend or damage radiator fins.
 When radiator is cleaned without removal, please remove all surrounding parts
such as cooling fan, cowl and horns. Then tape harness and electrical connectors to
prevent water from entering.
① Apply water by hose to flush the back side of the radiator core vertically
downward.
② Apply water to flush all radiator core surfaces once per minute.
③ Stop washing if any dirt no longer flows out from radiator.
④ Blow compressed air into the back side of radiator core vertically downward.
 Use compressed air lower than 490 kPa and keep distance more than 30cm.
⑤ Blow compressed air into all the radiator core surfaces once per minute until no
water sprays out.
MA-10
4. Checking cooling system for leaks
 To check for leaks, apply pressure to the MA005

cooling system with the radiator cap tester Hose connector
(commercial service tool) and radiator cap
tester adapter.
Warning!
Do not remove radiator cap when engine is hot.
Otherwise serious burns could be caused by
high-pressure engine coolant escaping from
radiator.
Caution:
Higher test pressure than specified may cause radiator damage. In a case that engine
coolant decreases, replenish radiator with engine coolant.
 Maximum test pressure: 157 kPa.
 If any part is found damaged, repair or replace.
Checking fuel lines
Check fuel lines, filler cap and tank for improper attachment, leaks, cracks, damage,
loose connections, wear or aging. If necessary, please repair or replace damaged parts.
Changing engine oil:
Warning!
 Be careful not to burn yourself, as engine oil may be hot.
 Prolonged and repeated contact with used engine oil may cause skin cancer;
therefore, avoid direct skin contact with used engine oil. If skin contact is made,
wash thoroughly with soap or cleanser as soon as possible.
① Warm up the engine, and check for oil leakage from engine room.
② Stop the engine and wait for 10 minutes.
③ Loosen filler cap, and then remove drain plug.
④ Drain engine oil.
⑤ Install drain plug with new washer.
Caution:
Be sure to clean drain plug and install with new washer.
⑥ Refill with fresh engine oil.
Caution:
 When filling engine oil, do not pull out oil level gauge.
MA-11
 The refill capacity depends on the engine oil temperature and drain time.
 Always use oil level gauge to check for proper engine oil refill capacity.
7 Pull out the engine oil dipstick from the engine. Check whether the engine oil level
is at MAX and MIN.
8 Warm up the engine and check area around drain plug and oil filter for engine oil
leakage.
9 Check if the oil level is within the normal range.
10 Stop the engine and wait for 10 minutes. Check whether the engine oil level is
normal.
Chassis and body maintenance

Checking exhaust system:
Check exhaust pipes, muffler and mounting brackets for improper positions, cracks,
damage, loose connections or wear; if any part is found damaged, please repair or
replace.
Transmission:
Both poor lubricant quality and lubricant excess or lack will affect normal operation
and service life of the manual transmission. Use gear oil SAE 75W~85W as the manual
transmission fluid. Check oil volume as follows:
① Check oil volume after vehicle driving with transmission still hot.
② When checking, be sure to park your vehicle on a flat, level and good ground and
set parking brake. Do not proceed with the next operation until making sure the
vehicle has come to a full stop.
③ Set shift lever to neutral position.
④ Screw off filler plug at left side of transmission and wipe up filler with a clean
cotton cloth. Check that the fluid level is within the range from lower edge of filler
to not lower than 5mm from the lower edge.
⑤ If the fluid is found dilute, gumming or too dirty, change immediately.
Caution:
 Do not spill fluid when filling. Otherwise wipe clean the spillage immediately.
■ Hybrid use of gear oils of different brands will damage transmission. Be sure
to use the designated hypoid gear oil SAE 75W~85W (API GL-4 grade above
compliant).
Brake system:
Check brake fluid level in reservoir tank. The level must be between the “MIN” and
“MAX” lines on the tank. Brake fluid level will slightly drop when brake pad is worn.
MA-12
If brake fluid level drops significantly in a short period of time, it indicates oil leaks in
brake system. If this occurs, immediately drive to a JAC approved service station to
have your vehicle serviced.
Use DOT 4 brake fluid. Brake fluids are water absorbing liquids. Braking performance
will be reduced if the brake fluid contains excessive moisture. In addition, the brake
fluid cup is provided with a special sealing gland in order to prevent air entry. This
gland can not be removed at will.
Brake fluid level is monitored by a float. When brake fluid level drops to below the
“MIN” line, the brake fluid warning light will come on.
1. Changing brake fluid
The brake fluid can absorb moisture, so it will absorb the moisture in the surrounding
air as time elapses. However, excessive water content in the brake fluid could cause
corrosion damage to the brake system. In addition, boiling point of the brake fluid will
drop significantly. Therefore, be sure to change the brake fluid every 2 years.
Caution:
 If the brake fluid has been used for an extended period of time, bubbles will be
produced in the brake system under extremely high braking load, thus impairing
braking efficiency and driving safety seriously.
 Use DOT 4 brake fluid approved by JAC only at brake fluid change. In addition, it
is required that brake lines be cleaned thoroughly. Ensure hybrid use of 2 types of
brake fluid will not occur.
Caution:
 Brake fluids are harmful to human health! Therefore, the coolant should be kept
properly in its original sealed container and particularly out of reach of children. In
addition, take care to prevent brake fluid from corroding automobile finish.
 Pay attention to disposal of brake fluid. It will impair both eyes and skin and
spray-painted surfaces. Flush clean with clear water immediately if the fluid spills
on your body inadvertently.
 Be sure to keep brake fluid cup clean. Its gland must be tightened to prevent dirt
entry.
 When filling brake fluid, wipe clean brake fluid cup gland and filler with a clean
rag first and then refill with designated clean brake fluid.
 If the brake fluid is found deteriorated, drain the fluid in brake system and then
refill with clean designated brake fluid.
2. Checking brake lines and cables
Check brake lines and parking brake cables for improper positions, leaks, wear, chafing
and aging, etc.
MA-13
3. Checking disc brake MA006

1) Brake disc
Check condition, wear, and damage.
2) Brake caliper
Check for oil leaks.
3) Brake shoe
Check for wear and damage.
(Refer to service data of Chassis section.)
Checking steering gear and linkage:

Steering gear:
1) Check gear housing and boots for looseness, damage and grease leakage.
2) Check connection with steering column for looseness.
Steering linkage:
Check ball joint, dust boots and other parts for looseness, wear, damage and grease
leakage.
Checking power steering fluid and lines:

Power steering fluid:
Check power steering fluid level in reservoir tank with engine idling.
Check power steering fluid level in reservoir tank. The level must be between the
“MIN” and “MAX” lines on the tank.
Please use the “recommended oil: PSF-3”. MA007

Caution:
 Please do not overfill.
 It is recommended that the oil designated
by JAC or equivalent be used.
 Check lines for improper attachment,
leaks, cracks, damage, loose connections,
wear or aging.
 Check rack boots for accumulation of
power steering fluid.
Axle and suspension parts:
MA-14
Check front and rear axle and suspension parts MA008

for excessive play, cracks, wear or other
damage.
 Shake each wheel to check for excessive
play.
 Check wheel bearings for smooth
operation.
 Check axle and suspension nuts and bolts
for looseness.
 Check strut (shock absorber) for oil MA009
leakage or other damage.
 Check suspension ball joint for grease
leakage.
 Check ball joint dust cover for cracks or
other damage.
Strut Ball joint
Tires:
For safe driving of your vehicle, type and size of tires must be suitable for the vehicle
model; in addition, tire treads must be in good condition and appropriate tire pressures
must be provided.
The way to service tires and the method for tire replacement are described below.
Warning!
 Use of excessively worn or under inflated tires will cause accidents resulting in
personal injury or death.
 All instruction regarding tire inflation and maintenance in the Operation Manual
must be observed.
Overview of inflation:
Keeping tires properly inflated provides the best combination of steerability, tread life
and driving comfort.
 Underinflation may cause uneven wear of tires and affect steerability and fuel
consumption, and much more likely result in air leaks due to overheating.
 Overinflated tires will make your ride in the vehicle uncomfortable, are more likely
to be damaged by rugged roads, and are subjected to uneven wear.
Measure tire pressure with a tire gauge at least monthly. Even pressure of a tire in good
condition may decrease by 10~20KPa (0.1~0.2kgf/cm2) per month. Also check spare
tire each time all tires are checked.
MA-15
Measure tire pressure when tires are cold. This means that the measurement should be
made after your vehicle has been parked for at least 3 hours or when travel distance
does not exceed 1.6km. If necessary, inflate or deflate tires until their tire pressures
reach the value recommended for cold tires in the name plate on driver side door frame.
When pressure of a tire is checked when hot (after a travel of several kilometers), the
reading will be 30~40KPa (0.3~0.4kgf/cm2) higher than that when cold, which is
normal. Do not deflate the tire in order to reach the specified cold tire pressure reading,
otherwise tire underpressure will result.
When a tubeless tire is punctured, its self-seal function will be activated. If pressure of
a tire starts to drop, locate air leak carefully.
Checking tires:
Also check tires for wounds, punctures by foreign materials and other abrasions at each
tire inflation check.
 Damage and bulge on tread or sidewall. If any is found, replace the tire.
 Scratch, crack or fracture on sidewall. If tire fabric or cord can be seen, replace the
tire.
 Excessive tread wear.
Servicing tires:
In addition to proper inflation, correct wheel alignment also helps reduce tread wear. If
uneven tire wear is found, check wheel alignment.
If some kind of continuous vibration is felt during driving, check tires. Perform tire
balance as long as a tire has ever been removed from its wheel. When installing a new
tire, be sure to perform tire balance. This can increase ride comfort and prolong tire life.
Caution:
 Inappropriate wheel balance weights will damage aluminum alloy wheels.
Therefore, use original wheel balance weights of JAC to keep wheels balanced
only.
Tire rotation:
MA-16
To prolong service lives of tires and ensure

even tire wear, rotate tires every 8,000km. At MA010 Vehicle front
each rotation, move tires to the positions

shown by the figure at right. The figure at right
indicates how to rotate tires of a vehicle
provided with a standard spare tire.
If directional tires are used, swap tires on front
and rear wheels only at tire rotation. If a (Non-directional (Directional tire
standard spare tire is used at tire rotation, tire and wheel) and wheel)
please refer to the figure at right.
Replacing tires and wheels:

Select radial ply tires of same size, load range, rated speed and maximum cold pressure
(marked on sidewall) for replacement.
Hybrid use of radial ply tires and bias ply tires will reduce braking capacity, driving
force (ground adhesion) and steering precision of your vehicle.
Use of tires of different sizes or structures will MA011 Non-directional tire and wheel
result in anti-lock brake system (ABS) failure
Vehicle front
to work normally. ABS works by comparing
speeds of wheels. When replacing a tire, be
sure to use one of same size as original tires of
the vehicle. Size and structure of tires will
affect wheel speed and may result in
uncoordinated movements of the system.
It is preferable that the 4 tires be replaced at
the same time. If impossible or unnecessary,
replace 2 front or rear tires in pairs. Replacing Directional tire and wheel
only one tire will affect steerability of your Vehicle front
vehicle badly.
If a wheel replacement is required, ensure the
new wheel and the original one match in size.
Warning!
Installing with unsuitable tires will affect steering mobility and stability of your vehicle
and may result in accidents, causing casualty.
Always use the tires of the recommended size and type indicated in the tire name plate
affixed to the vehicle.
MA-17
For size of the tires applicable to this vehicle, please refer to the tire name plate affixed
to driver side door frame or consult a JAC authorized after service shop.
MA-18
J4 Service Manual Introduction
J4 Service Manual
Introduction General Content
The manual is to help service General Information and

technicians authorized by JAC MOTORS
to provide effective and proper Maintenance
Chapter 1 GeneralInformation
maintenance and repairing for J4 Series
cars. The passionate service and proper Chapter 2 Maintenance
operation of JAC MOTORS professional
service technicians is vital to assure the
high user satisfaction, for this reason, the Engine Register
service technicians must get fully
knowledgement about this manual. This Chapter 1 Engine Mechanical
manual should be placed in easy-to-reach
place, so that it can be used for reference Chapter 2 Engine Electrical
at any time.
All the contents including pictures, Chapter 3 Engine Electronic
technical parameters within this manual Control System
are the latest, and JAC MOTORS will Chassis register SD
provide technical information or
additional volume when the maintenance
Chapter 1 Transmission system
is affected due to products improvements.
For this reason, please pay close attention Chapter 2 Clutch system
for any relevant information on the latest
developments while using the manual. Chapter 3 Drive system
JAC MOTORS reserves the right to make 第三章悬架系统
design changes, additions or Chapter 4 Suspension system

improvements for JAC products. 第三章悬架系统
Without the authorization of JAC Chapter 5 Brake system

MOTORS, it’s forbidden to copy or 第三章悬架系统
modify this manual in any form, Chapter 6 Brake system

第三章悬架系统
including, but not limited to, electronic,
paper, audio-visual, mechanical, and Body electrical and Body
other methods.
The use of non-genuine spare structure register
Chapter 1 Body electrical
parts or unqualified fuel during the
maintenance and repairing for JAC Chapter 2 Body structure
products may cause damage to the
products. Chapter 3 Body data
Circuit Service Register
SM-1
J4 Service Manual Engine register directory
Engine Register
General Information and Maintenance……………………………… GI-1
General Information………………………………………………… GI-1
Precautions……………………………………………………………… GI-1
How to Use This Manual……………………………………………………… GI-6
Model Identification Information………………………………… GI-7
Lifting Points………………………………………………………………… GI-11
Tow Truck Towing……………………………………………………………… GI-13
Tightening Torques of Standard Bolts………………………………………………… GI-13
New vehicle management……………………………………………………………… GI-14
Acronyms……………………………………………………………… GI-26
Maintenance…………………………………………………………… MA-1
Preparations……………………………………………………………… MA-1
General Maintenance……………………………………………………………… MA-2
Periodic Maintenance……………………………………………………………… MA-3
Engine Maintenance…………………………………………………………… MA-5
Chassis and body maintenance……………………………………………………… MA-15
Engine Mechanical………………………………………………… EM-1

Engine Itself…………………………………………………… EM-1
General precautions………………………………………………………… EM-1
Sealant Precautions……………………………………………………… EM-2
Preparations……………………………………………………………… EM-3
Engine Assembly…………………………………………………………… EM-6
Engine belt…………………………………………………………… EM-10
Intake manifold and exhaust manifold………………………………… EM-11
Timing Chain-Wheel system………………………………………………………… EM-14
Camshaft Assembly…………………………………………………………… EM-16
Cylinder head…………………………………………………………………… EM-19
Valves…………………………………………………………………… EM-24
ER-1
Cylinder Block Assembly…………………………………………… EM-28
Common Symptoms Diagnostics…………………………………………………… EM-42
Service Parameters……………………………………………………………… EM-43
Lubrication System……………………………………………………… LU-1

Precautions……………………………………………………………… LU-1
Preparations……………………………………………………………… LU-2
Lubrication System Illustrative Diagram………………………………… LU-3
Engine Oil…………………………………………………………… LU-3
Oil Filter…………………………………………………………… LU-6
Oil sump and oil pump……………………………………………………… LU-7
Cooling system……………………………………………………… CO-1

Cooling circuit……………………………………………………………… C0-1
Engine Coolant………………………………………………………… C0-1
Radiator………………………………………………………………… C0-4
Radiator Cooling Fan……………………………………………………… C0-6
Water Pump…………………………………………………………………… C0-6
Thermostat Components…………………………………………………………… C0-8
Water Pipe components……………………………………………………………… C0-9
Failure analysis……………………………………………………………… C0-10
Service Parameters……………………………………………………………… C0-11
Fuel Supply System………………………………………………… FL-1

Precautions……………………………………………………………… FL-1
Preparations……………………………………………………………… FL-2
Fuel Supply System Components………………………………… FL-2
Fuel Tank………………………………………………………………… FL-2
Fuel Filter…………………………………………………………… FL-4
Fuel Pump Assembly…………………………………………………………… FL-6
FuelEvaporative Emission Control System……………………………… FL-9
Accelerator Control Device……………………………………… FL-11
ER-1
Service Data and Specifications…………………………………… FL-12
Emission Control System…………………………………… EES-1
Fuel Evaporative System……………………………………… EES-1
Positive Crankcase Ventilation Syatem…………………………… EES-4
Engine Electrical………………………………………………… EI-1
Start charging system……………………………… EL-1
Start charging system Illustrative Diagram ………………… EL-1
Battery………………………………………………………………… EL-1
Start System……………………………………………………………… EL-3
Charging system……………………………………… EL-8
Engine Electronic Control System……………………… EC-1
Precautions……………………………………………………………… EC-1
Supplemental Restraint System Precautions ... ... ... ... ..... ... ... ... ... ... ...
EC-1
General precautions…………………………………………………………
EC-1
Precautions during maintaining……………………………………………………
EC-2
Engine Control System structure and Service ... ...... ... ... ... ... EC-3
System description……………………………………………………………… EC-3
Fuel multi-point injection system……………………………………… EC-3
Onboard Diagnostic System………………………………………………………… EC-6
Engine Trouble Diagnosis……………………………………………………… EC-8
Engine Control System structure and Service………………… EC-14

Intake air pressure/temperature sensor……………………………………… EC-14
Engine coolant temperature sensor…………………………………………… EC-15
Electronic Throttle…………………………………………………………… EC-18
CKP sensor and Camshaft position sensor……………………………… EC-20
Oxygen sensor……………………………………………………………… EC-22
Fuel injector………………………………………………………………… EC-24
Knock sensor………………………………………………………… EC-25
ER-1
A/C switch and Relay…………………………………………………… EC-26
Continuously Variable cam phase regulator and its control valve…… EC-27
EVAP Canister solenoid valve………………………………………… EC-29
Ignition coil……………………………………………………………… EC-30
Electric fuel pump…………………………………………………………… EC-31
Engine electronic control modules………………………………… EC-32
Engine Control System Trouble Diagnosis Flow………………… EC-37
Diagnosing according to DTCs………………………………………… EC-37
Engine anti-theft system………………………………………………… EC-67
System overview……………………………………………………………… EC-67
Components and their location map…………………………………… EC-67
Illustrative diagram………………………………………… EC-68
Components inspection…………………………………………… EC-68
The installation and removal of components…………………………………… EC-69
Diagnose and Match…………………………………………………………… EC-69
ER-1
J4 Service Manual- Engine B
Engine Mechanical
Engine Body
General precautions:
1、Precautions for drain engine coolant:
Drain engine coolant after the engine is cooled down.
2、Precautions for disconnecting the fuel line
1) Before the start of work, please confirm that within the work area, there is no
easily burning or sparks-producing objects.
2) Before disconnection and disintegration, please release the pressure of the
fuel.
3) Plug the openings after disconnecting the pipelines, in order to prevent fuel
leakage
3、 Precautions for disassembly and disintegration
1) When it requires using the special maintenance tools, please use them as
required. Always pay attention to the safe operation, and must follow the instructions.
2) Caution! Do not damage the mating surface or sliding surface
3) If necessary, use adhesive tape or the equivalents, to seal the openings of
engine system, for fear of the entry of foreign bodies.
4) Identify and put the disassembled components and parts in order, for ease of
troubleshooting and reassembly.
5) Loosen the bolt and nut is based on the principle that to release the outermost,
and then release the diagonal locations, and so on. If having specified a release order,
please operate in the specific order.
4、Precautions for Inspection, Repair, and Replace the parts
Inspect the components and the parts thoroughly before repairing or replacing
them. First of all, inspect the newly replaced components and parts as stated above, if
necessary, replace it.
5、Precautions for assembly and installation
1) Using a torque wrench to tighten nuts and bolts.
EM - 1
2) The principle of tighten the bolts and nuts is to tighten the center ones in the
same tightness by multi-steps, and then tighten those on inside and outside the
diagonal lines. If having specified the tighten order, please operate in the specific
order.
3) Replace with a new gasket, oil seal or "O" ring.
4) Thoroughly rinse, clean and dry each part and component. Carefully check the
pipelines of engine oil and engine coolant without blocking.
5) Be sure not to damage the sliding surface or the mating surface. Thoroughly
clean the dust and dirt, or other foreign bodies. Smooth the sliding surface with engine
oil before assembly.
6) After exhaust the engine coolant, when re-filling it, please release the air in
the pipe firstly.
7) After repair, start the engine and raise the engine in order to check the engine
coolant, fuel, engine oil or the tail-gas whether leak or not.
6、The components and parts needed to be tightened in the settled angle.
1) Use the angle wrench to tighten the following components and parts on the
engine finally.
- Cylinder Head Bolt
- Main Bearing Cap Bolt
- Connecting Rod Cap Bolt
2) Do not do the final tightening according to the torque value.
3) The torque value of the components and parts applicable to the pre-tightening
procedures.
4) Make sure the threads surface and the base surface clean, and then daub the
engine oil.
Precautions for Sealant:

1、Refer to “Removal of the sealant”， in page EM-2.
After disassembling the fixed nuts and bolts, use the scraper to separate the
mating surface, and disassemble the used sealant.
EM - 2
EM001
JAC-T1F017
Slide
a
Tap
T
A
Caution: P
p
Be careful not to damage the mating surfaces.
阿
婆
Insert the scraper, and then knock as shown in the figure
a
Slide it sideways.
a
In those areas where the seal cutter is hard to use, please use a plastic hammer to
lightly tap the parts and to disassemble it.
If for some unavoidable reasons,
EM002
Scraper tools such as a flat screwdriver have to
be used,
Please be careful not to damage the mating surfaces.

2、The application procedure of the sealant
1) Use the scraper to remove the used sealant adhering to the application surface
of the gasket and the used sealant adhering to the mating surface of the gasket
Caution:
Clear up the used sealant from the grooves on the application surface of it, from the set
bolts, as well as from the bolt holes.

2) use of unleaded gasoline to clean the application surface and the mating
surface of the sealant, clear the adhering water,lubricating grease, and foreign bodies.
EM - 3
3) Put the sealant with specified dimension fully in the specified location
If there is a groove to put the sealant,

EM003
please put it into the groove.
As for bolt holes, normally put sealant inside them，and occasionally outside
them.
Install the binding elements within 5 minutes after gluing the sealant
Components:
If the sealant has stains, please clean them off immediately.
EM004 Inner side
Groove Bolt hole
Inner side
Please do not re-tighten bolts or nuts after the installation.

After 30 minutes of the installation, please fill the engine oil and engine coolant.
Engine Coolant
Caution:
-- If there are special instructions in this manual, please follow the instructions.
Preparations
EM - 4
1、Service tools:
List of Special Tools
SN Tool Outline drawing Serial Number Description:
1 The fork The timing gear

clamp of the fixed
camshaft
JAC-T1D001
2 Pin Use
cooperatively
with fork clamp
3 Positionin Install and

g tools of disassemble
piston pin piston pin
JAC-T1F005
4 Guide Use
Bush cooperatively
with
positioning
tools of piston
pin,as well as
setting tool
5 Flywheel JAC-T1F011 Fixed flywheel

stop dog
6 Valve JAC-T1F012 Compressed

spring valve springs
compresso
r.
EM - 5
5)Disassemble
7 Oxygen JAC-T1F015 and install
sensor oxygen sensor
sleeve
8 Oil pan JAC-T1F017 Disassemble

and the oil pan
removal
tools
The
9 installer of JAC-T3F001 Install valve oil
valve oil seal
seal
The oil
10 seal JAC-T3F002 Install oil seal
installer of of engine
camshaft camshaft
It plays a
11 Front Oil JAC-T3F003 guiding role
Seal guide when installing
of the front oil
Crankshaft seal of
camshaft
Front oil
12 seal JAC-T3F004 Install front oil
installer of seal of engine
Crankshaft crankshaft
EM - 6
Rear oil
13 seal JAC-T3F005 Install rear oil
installer of seal of
Crankshaft Crankshaft
2、Engine assembly auxiliary materials table
SN Name Using position Specifications and Grades

5 W - 30 (NORTHERN
WINTER)15 W - 40 (northern
Engine Oil filling, assemble with the engine
1 summer and full year the south)
oil oil
Quality rating is on SJ level or
above
The oil pump, water pump, oil pan,
2 Silicone LT 5699 or equivalent products
crankshaft and rear oil seal shell
Oil pressure switch, drain screw plug,
3 Sealant: LT 243 or equivalent products
flywheel bolt
Coolant temperature sensor and Water
4 Sealant: LT648 or equivalent products
temperature warning switch
RON #93 and lead-free petrol
5 Petrol
above RON #93
6 Sealant: Stud bolt LT271 or equivalent products
3、Cylinder assembly auxiliary materials table
Cylinder assembly auxiliary materials table
SN Name The materials used and model Assembly Location
5 W - 30 (NORTHERN
WINTER)15 W - 40 (northern
Valve Head, camshaft, oil
1 Engine oil summer and full year the south)
seal of camshaft
Quality rating is on SJ level or
above
2 Sealant: LT271 or equivalent products Stud bolt
Spark plug guide bush,
cylinder block/cylinder
3 Sealant: LT962T or equivalent products
head Bowl-type plug
tablet, and filler neck
EM - 7
Engine Assembly
1、Precautions for disassembly and installation:
Warning:
Please operate as the following requirements; otherwise, it may result in personal
injury!
Park the car on a flat, solid ground.
Caution:
Always pay attention to the safe operation, and must follow the instructions.
Before the exhaust system and the engine coolant completely cool down, you
must not start work.
If the engine chapter does not contain the required items or work, please refer to
the relevant chapters.
Always use the dedicated support point for lifting, and choose the proper car
lifting machine according to the circumstances.
2、Preparation work for disassembling the engine and the transmission assembly
1) Summary
First of all, disassemble the engine and transmission assembly from the car, and
separate the engine and the transmission.
2) Preparation
① Release the fuel pressure please refer to "Release the fuel pressure"
② Drain engine coolant from radiator
Please refer to “Changing engine coolant”.
③ Drain the engine oil, transmission oil, and clutch oil. Please refer to "Engine
oil" and "Transmission oil" and "clutch circuit".
④ Recycle the refrigerant in the refrigerant lines.
⑤ Drain power steering fluid ，please refer to "power steering fluid":
Caution:
Do not perform this step until engine cools down.
Please do not spill engine coolant on drive belts.
EM - 8
⑥ Disassemble the following parts:

The engine trims cover. Please refer to "the intake manifold".
The Engine Hood Assembly， Please refer to the "Engine Hood".
The front wheels and tires. Please refer to the "Wheels and tires".
The engine deflector (left and right)
The air-duct and the air cleaner assembly
Please refer to the air-duct.
The battery, the battery holder, battery holder bracket Please refer to "Battery".
The radiator assembly and radiator fan. Please refer to the "radiator".
3、Disassembly of the related component in the engine compartment
① disconnect the following pipe lines and move aside
Caution:
When you disconnect them, use the plug to prevent leakage.
The fuel inlet line of the injector Please refer to the “Fuel Injectors”.
Vacuum hose of vacuum booster on the engine side please refer to the
"vacuum booster".
The PCV hose please refer to "Fuel evaporation control system".
Inlet connectors of the clutch please refer to the "clutch hydraulic lines".
High-voltage and low-voltage tubes on the Air Conditioning Compressor Please
refer to "A/C compressor".
② Disassemble steering fluid reservoir.
③ Disassemble the wire drawing of the selecting shifts. Please refer to "the
operation mechanism of the selecting shifts".
④ Disconnect the the following wiring harness and connect the plug-in
components, as well as the wire harness retainer, and remove.
Oxygen sensor
Engine coolant temperature sensor
Crankshaft position sensor:
Camshaft position sensor:
Vehicle speed sensor
EM - 9
The VVT Oil Control Valve wiring harness

Throttle valve position sensor:
The Air Inlet Absolute Pressure Sensor
Ignition coil
Fuel injector
Knock sensor
The generator
The starter motor
A/C switch
4、Disassembly of related element on Automobile Chassis
① Disassemble the front drive shaft. Please refer to the front drive shaft.
② Disassemble the forepart of the exhaust pipe please refer to the "exhaust
system".
③ Disassemble the engine support beam. Please refer to the "Engine support
beam".
5、Disassembly work
① Hang the lifting hook on the lifting ear of the Engine
② Raise the engine and fix it in place.
③ Use the manual lift table or equivalent tools to firmly support the engine and
the bottom of the transmission assembly and at the same time adjust the lift tensity.
Caution:
Put the pads at the support surface, and to ensure it in a steady state.
④ Separate the left and right, front and rear suspension of the engine. Please
refer to the "Engine Suspension".
⑤ Lower the engine and the transmission assembly. When carrying out the
work, please read the following precautions:
To confirm that they do not interfere with vehicles
To make sure that all connections have been disconnected
To remember the vehicle's center of gravity will change, and if necessary, please
use the jack to support rear lifting point to avoid falling off.
EM - 10
6、Separation work
① The engine and transmission assembly, the air conditioning compressor
assembly.
② Disassemble the starter motor.
③ Use the lifting jack to raise, and separate the engine and the transmission.
Caution:
Always confirm that there is no wiring harness before lifting and during the
process of lifting.
7、Installation
Please read the following precautions and install them in the reverse order of
disassembly.
1) Do not damage the engine suspension bolsters. Avoid engine oil spilling over
the cushions.
2) Confirm that all engine suspension are properly fixed, and then tighten the
nuts and bolts.
8 Inspection after installation:
1) Check for leaks.
The following is to check the fluid leaks step, oil leaks step and exhaust leaks
step.
Before starting the engine, please check engine coolant and engine oil level. If it
is less than the required amount, please fill till the assigned position.
Use the following steps to check for fuel leaks.
- turning the ignition switch to the "ON" position, check for the fuel leak in the
connections.
Start engine, and check for fuel leaks at connections again when the engine
speeds up.
Run the engine to check for abnormal noise and vibration.
To warm-up then engine thorough, confirm that there is no fuel, exhaust or any
fluid leaks (including the engine coolant and engine oil leak).
Bleeding or fill from the corresponding line pipes and hoses.
EM - 11
After the engine cools down, please re-check the oil level (including the engine
oil and engine coolant). If necessary, re-fill to the assigned level.
2) Check the project overview
Check for leaking item list
Project Before starting Engine running After the engine is
the engine shut off
Engine coolant: Fluid Level Leakage Fluid Level
Engine Oil Fluid Level Leakage Fluid Level
Transmission Oil, brake Fluid Leakage Fluid Level
fluid, power steering Level
fluid, Clutch Fluid
Fuel Leakage Leakage Leakage
Exhaust - Leakage -
Engine belts
1、Check the drive belt:
Warning:
To make sure that performing operations after the engine has been shut off.
1) Check the belt for aging, cracks, wear and traces of oil. If necessary, replace
it.
2、Tensity adjustment
Tensity adjustment table
Position Adjustment Method
Alternator belt. Adjust the adjusting bolt on the generator.
Caution:
Please do not allow the engine oil and engine coolant to spill on the belt.
-- Do not excessively twist or bend belt.
3、The disassembly of generator's belt
1) Loosen the generator's adjustment nut and its support nut. Use the adjusting
screw to adjust tensity.
2) Tighten the generator's adjustment nut and its support nut.
Tighten the torque: generator adjustment nut: 22.5 ±2.5 N ·M
generator support nut: 47 ±5 N·m
EM - 12
4、The Installation of generator's belt

1) Install the belt on the pulley according to the reverse order of removal.
2) Verify that the belt tensity is in the standard range (450 - 550 N·M).
The intake manifold and exhaust manifold
The intake manifold and exhaust manifold breakdown drawing.
1、The intake manifold

1) Disassembly
Warning:
Please do not drain the engine coolant when the engine warms up, in order to
avoid burns.
① Drain engine coolant: Please refer to “Changing engine coolant”.
② Release the fuel pressure， please refer to "Release the fuel lines pressure"
③ Disassemble the engine trim cover.
Tighten the torque: 8 to 12 N M.
EM - 13
④ Disassemble the air cleaner assembly. Please refer to the "air cleaner
assembly".
⑤ Disconnect the the following wiring harness and connect the plug-in
components:
The Air Inlet Absolute Pressure Sensor
Fuel injector
Electronic throttle valve position sensor:
Carbon canister control solenoid valve
⑥ Disconnect the following hose connections.
The water pipe fittings (please install the plug to prevent engine coolant leaking)
The PCV tube
Vacuum hose of vacuum booster on the engine side
Vacuum hoses in the carbon canister solenoid valve side.
Small loop pipes in the throttle body
⑦ Disassemble throttle body mounting screw and throttle body, remove throttle
body assembly.
⑧ Disassemble the injector assembly. Please refer to the “Fuel Injectors”.
Tighten the torque: 18.4 ±1.4 N M.
⑨ Disassemble the intake manifold and the bracket of the engine block.
Tighten the torque: 10 ±20 N M.
⑩ Disassemble the intake manifold mounting bolts and nuts.
Tighten the torque: 18 ±1.0 N M.
⑪ Remove the intake manifold and the intake manifold's gasket.
2）Inspection after Disassembly:
Check the air intake manifold for cracks or any other damages and for whether
the matching surface is deformed or not. Please repair or replace as necessary.
3）Installation
According to the reverse order of removal
Caution:
-- Do not re-use the components and parts that are no longer available.
EM - 14
Before starting the engine, please check engine coolant level. If it is less than the
required amount, please fill till the assigned position.
- turning the ignition switch to the "ON" position, check for the fuel leak in the
connections.
Start engine, and check for fuel leaks at connections again when the engine
speeds up.
To warm-up then engine thorough, confirm that there is no fuel, or the engine
coolant leak.
After the engine cools down, re-check the engine coolant level. If necessary,
re-fill to the assigned level.
2, Exhaust manifold
1) Disassembly
Warning:
After the exhaust system cools down thoroughly, perform this operation.
① disconnect the oxygen sensor harness connector; if necessary, use a special
tool to remove the Oxygen Sensor.
Caution:
-- Do not damage Oxygen Sensor.
-- Drops to hard ground from any place higher than 0.5 m , the oxygen sensor
will be not able to use, please replace it.
②Disassemble the mounting bolts of the exhaust manifold insulation mat and
remove exhaust manifold insulation mat.
③ disconnect the connection between three-way catalytic converters and
exhaust manifold.
④ disassemble the exhaust manifold bracket cap screws and remove exhaust
manifold bracket.
EM - 15
■ Tighten the torque: 20 ±1.0 N M.

⑤ disassemble the mounting bolts of the exhaust manifold and remove exhaust
manifold.
Tighten the torque: M8 35 ±2 N M.
2）Inspection after Disassembly:
Check to see whether the exhaust manifold mating surface is deformed or not.
3) Installation
Install them according to the reverse order of removal.
Caution:
-- Do not re-use the components and parts that are no longer available.
-- Please do not over-tighten Oxygen Sensor to avoid damaging Oxygen Sensor.
Timing chain wheel body

1、 Component description:
Timing belt diagram
2、 Disassembly and installation of timing chain:

1）Disassembly
a) Disassemble the fixed bolt of water pump pulley.
EM - 16
Tighten the torque: 7～ 8.2 N·m.

Note:
Disassemble it relying on the drive belt friction when the drive belt has not
yet been removed.
b) Disassemble the drive belt and check the drive belt for wearing, aging, and
cracks, and if the above phenomenon exists, please replace the drive belt.
c) Disassemble oil dipstick components
Tighten the torque: 7～ 8.2 N·m.
d) Disassemble vibration damper
e) Disassemble generator
f) Disassemble the oil pan and cylinder head cover.
Caution:
First, disassemble the oil pan and cylinder head cover, and then disassemble
the oil pump assembly.
g) Disassemble the pump assembly
h) Check the timing
Check whether the five timing points meet the requirement as shown in the
figure.
EM - 17
Exhaust camshaft Timing marks of Chain
chain wheel
Timing marks of Chain wheel

Timing marks
Timing marks of Chain
wheel
Timing marks of Chain
Automatic tension device Timing marks
of Chain
Timing marks
i) Disassemble automatic tensioner, as EM005

well as the orbit and the dynamic
rail of the timing chain. And check
to see if there is an exception.
Tighten torque:
Automatic Tensioner: 9 ~ 11 N M.
Orbit: 10~12 N·m
Dynamic rail: 19～28 N·m
EM006
j) Disassemble exhaust Camshaft

Sprocket bolt
Tighten the torque: 78～98 N·m
k) Disassemble the intake cam timing controller
Tighten the torque: 64.5 ±5.5 N M.
EM - 18
2）
Installation
Install it according to the reverse steps of disassembly as stated above.
During the installation process, pay much attention to the timing point and the
torque installation.
Camshaft assembly
1、Component description:
Camshaft breakdown drawing
2、 Disassembly and installation:

1）Disassembly
EM - 19
① Disassemble the engine trim cover. Please refer to "the intake manifold".
② Disassemble high pressure ignition coil. Please refer to "Ignition coil".
③ Fixation of power steering pump's pressure line
④ Disconnect PCV hoses and camshaft position sensor harness connector.
⑤ Disassemble valve cover from the cylinder head
⑥ disassemble the valve cover gasket from the valve cover, and remove spark
plug tube sealer from the spark plug tube.
⑦ Disassemble the timing chain wheel. Please refer to "Timing chain wheel
body".
⑧ Disassemble the timing gear of the camshaft
a. Fix the camshaft with a wrench
b. Tighten the timing gear bolts of the camshaft
Tighten torque: 59～70N·m
c. Remove the timing gear of the camshaft
⑨ Disassemble camshaft position sensor from the rear of the cylinder head end
Tighten the torque: 9～11 N·m.
Caution:
To be careful to avoid clashing
10 Use the appropriate tools to disassemble the front oil seal of camshaft.
Caution:
EM007
Do not damage the matching surface
between cylinder head and the camshaft.
⑪ Remove camshaft from the cylinder
head
2) Inspection after disassembly
①camshaft
The measure of Camshaft cam's height
Intake: 44.7054 ±0.1mm
Exhaust: 44.2836 ±0.1mm
If the value does not meet the above standard value, please change the camshaft.
EM - 20
②Mechanical followers
EM008
The measurement of thickness of the
mechanical followers
3) Installation
① Install mechanical followers
② Install the camshaft.
Caution:
Paint the engine oil on the camshaft journal and cam.
Pay attention to the installation direction of the camshaft.
③ Install camshaft position sensor:
Caution:
In the rear-end cover flange coated with a sealant.
Tighten the fixed bolt after the stand is fully seated.
④ Install the front oil seal of the camshaft.
⑤ Install the timing gear of camshaft
⑥ please read the following precautions and install them in the reverse order of
disassembly based on this step.
Before installing the valve cover, please eliminate all the sealant on the cylinder
head cover.
Verify that the valve cover gasket is in good condition, and has been put into the
slot of the valve cover.
4) Inspection after installation:
Examine that all components are installed.
Before starting the engine, please check engine oil level. If it is less than the
required amount, please fill till the assigned position.
After the thorough warm-up, confirm that there is no engine oil leak.
After the engine cools down, re-check the engine oil level. If necessary, re-fill to
the assigned level.
EM - 21
3、Valve clearance
1) Inspection
When disassemble or replace the related parts and components of the camshaft or
mechanical followers, or when the engine run abnormally due to the valve clearance's
change, please do the following inspection.
① Disassemble valve cover please refer to the “camshaft".
② Measure valve clearance in accordance with the following steps
a. Fix compression stroke TDC (1-Cylinder). Rotate crank belt pulley clockwise,
align the timing mark.
b. Use filler gauge valve to adjust the screw and stem head clearance
Valve clearance: intake valve 0.22 ±0.03 mm
Exhaust Valve 0.30 ±0.03 mm
c. Rotate crankshaft pulley for 1 ring
③If it exceeds the standard, please adjust. Please refer to the "Adjustments".
2) Adjust
① loosen the nut, loosen the adjusting screw.
② Insert filler gauge that has the equal magnitude with the valve clearance
between the adjustment screws and stem head.
③ Fix the adjusting nut and slowly tighten the adjusting screw until twitch the
filler gauge with a slight resistance, and then tighten the adjusting nut.
④ Verify again whether the valve clearance is in the standard range.
⑤ if not, repeat the steps 1 to 4 until valve clearance is in the standard value.
⑥ the manual rotation of crank, refer to the standard value to confirm cold valve
clearance in the standard value.
⑦ Install them in reverse order of disassembly. Install all the parts and
components that have been disassembled.
⑧ Engine warm-up, check to see if there is an abnormal noise and vibration.
Cylinder head cover
EM - 22
1、 the vehicle repair

1) Check the cylinder pressure.
① Warm-up thoroughly, and then shut down the engine.
② Release the fuel pressure please refer to "Release the fuel pressure"
③ Disconnect the fuel pump fuse to avoid fuel oil spray when measuring.
④ Use a special tool to disassemble ignition coil and spark plug. Please refer to
"Ignition coil"and "spark plug".
⑤ Disassemble the engine trim cover. Please refer to "the intake manifold".
⑥ Install the cylinder pressure gage with connector on the spark plug.
⑦ Step the accelerator pedal to the metal, turn the ignition switch to the
"START" position to start. When the instrument pointer stables, read compression
pressure, and engine rotate speed. Perform these steps to check the rest of the
cylinders.
Standard Pressure: 1500 kPa
The minimum pressure: 1200 kPa
The allowed values between the cylinders: not larger than 150 kPa
Caution:
Always use a fully charged battery to get the specified engine speed.
If the compression pressure is lower than the minimum value, please check valve
clearance, and other related components (valves, valve seat, piston, piston ring,
cylinder diameter, cylinder head and gasket). After checking, measure the
compression pressure again.
If some of the cylinders' compression pressure is low, please fill a small amount
of the engine oil to the spark plug hole of the cylinder, and re-check the cylinder
pressure.
-- If you add engine oil, the cylinder pressure has increased; the piston rings may
be worn or damaged. Check piston rings, if necessary, replace it.
-- If you add engine oil, the compression pressure is still low, the valve may be
faulty. Check valve for damage. Replace the damaged valve or valve seat.
If the two adjacent cylinder compression pressure is low, and after adding the oil
EM - 23
pressure is still low, may be the cylinder head gasket has the leaking. Replace cylinder
head gasket.
⑧when the inspection is completed, please install the parts and components that
have been removed.
⑨ Start the engine and verify engine running smoothly.
2、Disassembly and installation:

1）Disassembly
① Release the fuel pressure; please refer to "Release the fuel pressure"
② Drain engine coolant and the engine oil Please refer to “Changing engine
coolant”and "Changing engine oil".
Caution:
Do not perform this step until engine cools down.
Please do not spill engine coolant and the engine oil on driving belts.
③ Disassemble the following components and related parts and components.
Driving belts please refer to the "driving belt".
The oil pumps assembly and the timing mechanism. Please refer to "Timing
chain wheel body".
The engine trims cover. Please refer to "the intake manifold".
The valve cover, please refer to the"camshaft assembly".
The intake manifold, please refer to "the intake manifold".
Exhaust manifold. Please refer to the "exhaust manifold".
The thermostat shell, Please refer to the "thermostat subassembly".
The oil dipstick conduit
④ Loosen the cylinder head bolts.
Disassembly order reverses with the
EM009
shown in figure 11.043.
A: The air inlet side
B: Exhaust side
EM - 24
: Front of Engine
⑤ Disassemble cylinder head gasket

① Cylinder Head Bolt
Measure the length of cylinder head bolt.
The limits are: 143.5 ±0.7 mm, if it exceeds the threshold value, please replac it.
② Cylinder head cover
Check the cylinder head for cracks or other damages.
Check the the watercourse of the cylinder head, and the oil for restriction, if there
is restriction, please clean them.
Check the cylinder head flatness.
Note: Perform this check, and check the cylinder for flatness. Please refer to the
"Block Plane".
a. Wipe clean the oil on the cylinder cover, as well as clear the sealant and
carbon deposits, and so on.
Caution:
Take care and do not allow debris falling into the cylinder head watercourse and
oil passages.
b. Measure the orientation of 6 planes on the mutiple positions of the bottom
surface on of the cylinder head.
Standard Value: below 0.03 mm
Cylinder head height (new): 158 + /- 0.5 mm
If it exceeds the standard value, please grinding or replace it according to the
specifications.
Caution:
The total remaining amount that can be ground of the mating surface between
cylinder head and block is less than 0.2 mm.
EM - 25
3）Installation
EM010
① Install the new cylinder head gasket.
② Screw it in accordance with the
numerical order as shown in the diagram
on the right.
Tighten cylinder head cap screws, and install
cylinder head as the following steps.
A: The air inlet side EM011
B: Exhaust side
: Forepart of Engine
a. Install the gasket as shown in Figure

1.1.046.
b. Smear the threads and the gaskets of
the threads of the bolts with appropriate EM012
engine oil.
Timing belt side

c. Tighten the bolts in the sequential
order as shown in Figure 1.1.047., until each bolt torque reach to 24.5 ±2N·m.
d. Loosen the bolts entirely.
e.Re-tighten the bolts in the sequential order as shown in Figure 1.1.047, until
each bolt torque reach to 24.5 ±2N·m.
EM013
f. Smear the head of the cylinder cover bolt Painting mark
EM - 26
and cylinder cover with paint marks.

(As shown in Figure 1.1.048)
g. Tighten each bolt in the 90 angle according to the tightening sequence
h. Tighten each bolt in 90 angles again, and check whether paint marks on the bolt
head align with cylinder head.
Caution:
If the tightening angle of the bolts is less than 90 angles, they are not likely to
have sufficient forces to tighten cylinder cover.
If the tightening angle of the bolts is greater than 90 angle, they should be
completely disassembled, and then re-install them.
i. If replace the old cylinder cover bolts during the process of repair, please repair
them in accordance with the above steps a-h.
i. If do not replace the old cylinder cover bolts during the process of repair,
please repair them in accordance with the above steps a、b、e、f、g、h.
Installation is the reverse order of removal.
4 Inspection after installation:
The following steps are to check the fluid leaks step, oil leaks step and exhaust
leaks step.
Before starting the engine, please check engine coolant and engine oil/fluid level.
If it is less than the required amount, please fill till the assigned position.
- Turn the ignition switch to the "ON" position (when the engine shut down).
Check whether the connections has fuel leak or not.
Start the engine Start engine, and re-check for fuel leaks at connections again
when the engine speeds up.
To warm-up the engine thoroughly, confirm that there is no fuel, exhaust or any
fluid leaks (including the engine coolant and engine oil leak).
After the engine cools down, please re-check the oil level (including the engine
oil and engine coolant). If necessary, re-fill to the assigned level.
EM - 27
Valve
Valve components figure
1-Cylinder cover bolt 2-Cylinder cover bolt gasket 3-Cylinder cover assembly 4-Cylinder
cover gasket 5 - Intake valve clamp 6 - Intake valve spring seat 7 - Intake valve springs 8 - Intake
valve 9 - Exhaust clamp 10 - Exhaust valve spring seat 11 - Exhaust valve spring 12 - Exhaust
valve 13 - Intake valve seal 14 - Intake valve spring seat 15 - Exhaust Valve Seal 16 - Exhaust
valve spring seat 17 - Intake pipe 18 - Exhaust valve guide 19 - Intake valve seat ring 20 - Exhaust
valve seat ring 21 - Cylinder Cover
2、Disintegration and Assembly

1) Disintegration
① Use the spark plug sleeve to disassemble the spark plug.
② Disassemble valve locks, valve
EM014 JAC-T1F001
springs and valve spring seat.
Use the valve spring compressor to
compress valve spring.
EM - 28
Caution:
Pay attention to the position of top dead
center of the piston. EM015
JAC-T1F012
Make labels on the disassembled valve,
valve spring and other parts and
components,
Please note cylinder number and
location.
Store the components safely.
③ Disassemble the oil seal of the

EM026
valve.
④ If you must replace valve seat.
Please refer to the "replacement of valve
seat”, and disassemble them.
⑤ If you must replace valve seat.
Please refer to the "Valve guide pipe" to
disassemble.
2) Assembly
① Install valve guide, please refer to the "valve guide pipe".
② Install valve seat, Please refer to the "valve seat",
③ Install valve oil seal
a. Install valve spring seat.
B. Install the special tools as figure 1.1., 052 shows.
EM - 29
New valve oil seal. EM017
Caution: JAC-T3F001
The valve seal can not be re-used.

Must use the correct special tools to
install valve oil seal
④ Install valve
⑤ Install valve spring
Note: The valve and valve spring with paint mark should be installed upwards.
⑥ Install valve spring maintaining seat
⑦ Install valve locking plate
Use the valve spring compressor to install.
After installation, check it with a rubber hammer by gently tapping the edge of
valve stem.
⑧ Use the spark plug sleeve to assemble the spark plug.
3) Inspection after disintegration:
1. Valve
Check valve face whether it has correct touch or
EM018
not. If the touch is uneven, or is incomplete, Please
Well
refurbished valve seat surface.
Badness Badness
EM019 Badness
Check the thickness of the valve edge. If Touch (must on
the center of
it is not within the set values, please replace
the surface
Edge thickness
the valve.
Intake valve: 1.35 - 1.65 mm.
Exhaust Valve: 1.85 ±0.15mm
Check the overall length of the valve. If it is not within the set values, please
EM - 30
replace the valve.

Intake valve: 89.51 - 90.01 mm.
Exhaust Valve: 90.69 - 91.19 mm
2. Valve Spring
Check the free height of the valve spring. If it is less than the specified value,
please replace valve spring.
Standard Value: 43.1 mm
Limits: 50.37 mm
Check the verticality of the valve spring. If it exceeds limits, replace the valve
spring.
EM020 Verticality
Standard Value: 2°
Limits: 4°
4. Valve Seat Free height
Check the valve protrusion height between the

end face of the valve rod and the surface of the valve
spring seat. If it exceeds the limit value,
Please replace valve seat.
Standard value: EM021 Valve rod end
face
Intake valve: 53.21 mm Protrusion height
of the valve
Exhaust Valve: 54.10 mm
Valve spring
Limits:
seat face
Intake valve: 53.71 mm
Exhaust Valve: 54.60 mm
Cylinder block assembly

EM - 31
Cylinder block assembly breakdown drawing
1 - Flywheel bolts 2 - Signal wheel screws 3 - Flywheel 4-Crankshaft oil seal bolts 5 - Crankshaft
oil seal shell 6 - Bearing cap screws 7-Bearing cap 8 - The upper main bearing shell 9-Crank 10 -
The down main bearing shell 11 - Crank the cone piece, 12 - Crank signal wheel 13-Cylinder
block
2、Disintegration and Assembly

1) Disintegration
① disassemble the engine assembly from the vehicle, and then remove the
transmission from the engine. Regarding the specific separation process, please refer
to the engine assembly.
EM - 32
②Disassemble the engine accessories, about the specific disassembling process,

please refer to the relevant chapters.
The engine air intake manifold and the engine exhaust manifold
The generator belts
The generator
Timing chain wheel body of the engine
The water pump
The water pipe subassembly
The generator mounting bracket, air conditioning compressor mounting bracket
Ignition coil
③ Fix the overall engine.
④ Drain engine oil, please refer to "Changing engine oil".
⑤ Disassemble flywheel assembly, please use the special tool to fix flywheel,
and then disassemble the fixed bolts and spacer plate.
Tighten the torque: flywheel: 95～105N·m.
The spacer plate: 8～12 N·m.
Caution:
- Do not place the signal plate of the crankshaft position sensor on the flywheel
facedown.
The mounting bolts should be released in diagonal order.
⑥ Disassemble the following system. About the specific disassembling process,
please refer to the relevant chapters.
The cylinder cover
The oil pump shell
Oil pan
⑦ Disassemble knock sensor.
Tighten the torque: 16～24 N·m
Caution:
-- Do not fall or tap sensors.
EM - 33
⑧ Disassemble the rear oil seal holder.

Tighten the torque: 7.0～70N·m
Put the screwdriver between the crankshaft and the rear oil seal to disassemble.
Caution:
Once the rear oil seal has been disassembled, and cannot be used again, please
replace it with new parts.
⑨ Disassemble the piston and the connecting rod assembly.
Disassemble the piston and the connecting rod assembly; please check the
clearance of connecting rod big end. Please see below "Inspection after disassembly":
a. Turn crank, and put the crankshaft journal corresponding to the connecting rod
that to be disassembled in the middle of the bottom.
Note: In order to re-install, you can print
EM022
the cylinder serial number on the side face of
the connecting rod big end which could be
The cylinder
disassembled. number
b. Disassemble the connecting rod

cover.
Tighten the torque: 15±2N·m + 92°
～94°
c. Use a rubber mallet or similar tools to push the piston, and the connecting rod
assembly out of the cylinder cover side.
Caution:
Be careful not to let connecting rod big end damage the cylinder walls and
crankshaft journal.
⑩ Disassemble the connecting rod bearing shell from the connecting rod and
the connecting rod cover.
Caution:
Identify the location position, and place them on the right place, and do not get
EM - 34
confused.
⑪ Disassemble the piston rings from the piston.
Check piston ring side clearance before disassemble the piston rings. Please see
below "Inspection after disassembly":
Caution:
Use the piston ring expander.
⑫ Disassemble the piston from the connecting rod as EM023
the following methods: Piston ring expander
a. Insert push rod from the previous arrow marking

side
(Special tools), then install the guide sleeve D.
b. Put the front mark of the piston upwards, and assemble the connecting rod
assembly in the installed base of the piston pin
(Special tools)
c. Pinch out the piston pin by using the press machine.
d. Separate the connecting rod and the piston from the piston and the connecting
rod assembly.
Caution:
After disassembling the piston pin, put piston, piston pin, EM024 Push rod
and the connecting rod together.

Front Front mark
Must not put the cylinder piston, piston pin or connecting mark
Guide sleeve D
rod together
Base
⑬ Disassemble crankshaft bearing cover
Measure crankshaft end clearance before loosening
crankshaft bearing cover, . Please see below "Inspection after disassembly":
EM - 35
Loosen the crankshaft bearing cover

EM025 Bearing cover
bolts in the following order.
No.
Tighten the torque: 35±2 N·m＋60°～
64°
As the figure 1.1.065 shows:

Upper 4 8 10 6 2
Lower 1 5 9 7 3
As shown in Figure 1.1031, when disassembling, please use crankshaft bearing

cap bolts to waggle crankshaft bearing cap back and forth in order to disassemble
it.
EM026
⑭ Disassemble crankshaft
2）Inspection after disintegration:

① Crankshaft end clearance
EM027
When the crankshaft moves back and
forth toe the end the along with the dial
indicator,
Measure the main bearing shell in the center
and the clearance among the crank arms.
Standard: 0.05～0.18mm
Limit: 0.25 mm
If the measured value exceeds the limit, please replace the main bearing shell in
EM - 36
the center, and restart the measurement. If it is still exceed the limit, please replace the
crankshaft.
② Connecting rod big end clearance
Use a filler gauge to measure the EM028
clearance between the connecting rod and
crank arm.
Standard: 0.10～0.25mm
Limit: 0.4 mm
If the measured value exceeds the limit,
please replace connecting rod, and
re-measure. If it is still exceed the limit, please replace the crankshaft.
③The side clearance of piston ring
Use the filler gauge to measure piston ring and EM029 Badness
the side clearance of the piston ring groove.
Standard:
Filler gauge
The first groove: 0.03～0.07mm Well
The second groove: 0.02～0.06mm

Filler gauge
Limits:
Ring
The first groove: 0.1mm
The second groove: 0.1mm
If the measured value exceeds the limit, please replace the piston ring, and restart
the measurement. If it is still exceed the limit, you still have to replace the piston.
④ Piston ring end gap
Confirm that the cylinder inner diameter is within the assigned range.
Please refer to the "Cylindricity". Piston
EM030
Use the new oil to lubricate the piston, and piston rings Press and fix
Filler gauge
then insert the piston ring till the middle part of the cylinder, Piston ring
and use the filler gauge to measure piston ring end gap.
Piston ring
Measuring point
EM - 37
Standard:
The first groove: 0.15～0.30mm
The second groove: 0.30～0.50mm
Limits:
The first groove: 0.8mm
The second groove: 0.8mm
If the measured value exceeds the limit, please replace the piston ring, and restart
the measurement. If it is still exceeding the limit, and the bore the cylinder inner
diameter, please use the appropriate piston and piston rings.
⑤ The flatness of the block.
Clean the pad on the block surface, as well as engine oil, incrustation, carbon and
other contaminants.
Caution:
Be careful! Do not allow gasket sheet falling into the engine oil or the engine
coolant.
Use a straight ruler and a filler gauge in the different directions of 6 positions to
measure cylinder cover flatness.
Standard Value: below 0.03 mm
EM031 Straightedge
Limit value: below 0.1 mm

If it exceeds the limit value, please
replace cylinder block.
⑥ Cylindricity of the cylinder
Use the dial indicator to measure the Filler gauge
cylinder diameter at 6 different points of each

cylinder, to check for wearing, out-of-round and cylindricity.
Standard Values: cylinder inner diameter: 75.000 - 75.015 mm
Cylindricity: Less than 0.01 mm
⑦ Piston skirt diameter EM032
Use the outside micrometer to check
EM - 38
Micrometer
piston skirt is whether deform or not.

Standard Value: 74.973 ±0.005mm
⑧ The clearance between piston and cylinder diameter.

Calculate through the skirt of the piston and the cylinder innner diameter.
(Clearance) = (cylinder inner diameter) - (piston skirt diameter)
Standard Value: 0.02 ~ 0.04 mm
If calculated value exceeds the limit,
EM033 Micrometer
please replace the piston and piston ring
assembly.
⑨The diameter of the crankshaft main
journal
Use the outside micrometer to check the
diameter of the crankshaft main journal.
Standard: 46.009 - 46.029 mm
If it exceeds the standard, please replace main bearings.
⑩The journal diameter of connecting rod
Use the outside micrometer to measure the main journal diameter of the
connecting rod.
Standard Value: 39.975 - 40.0 mm, if it exceeds the standard, please replace
connecting rod. Divide the main shaft of the connecting rod as the following table:
Group Mark Size (mm)

Number
1 1 46.024-46.029
2 2 46.019-46.024
3 3 46.014-46.019
4 4 46.009-46.014
EM - 39
5 5 46.004-46.009
⑪The clearance of the connecting rod bearing shell EM034

Note: Use a plastic wire gauge to measure.
a. Wipe off all the engine oil on the connecting rod
journals and connecting rod bearing shell.
b. Put the plastic wire gauge on the rod journals, it can
be cut in length the same with the width of the bearing shell.
Plastic wire rails must be located in the center of the
connecting rod journals, and parallel with its axis
c. Gently place the connecting rod covers on their positions, and tighten the bolts
to the specified torque.
d. Disassemble the bolts, and slowly remove the connecting rod cover.
e. Use the ruler printed on the plastic wire gauge bag, to measure the extrusion
part at the widest point.
Standard Value: 0.02～0.04mm
Limit value: 0.1mm
⑫ Out-of-roundness of the crank and
cylindricity EM035
As shown in the figure, use the outside

micrometer to measure each crankshaft
main bearing journals and 4 different
points' size of the connecting rod
crankshaft main journal.
Use the different sizes to show the out-of-roundness among the "A” and” " B 's
"X " and " " Y.
Use the different sizes to show the cylindricity among the "X" and "Y”‘s "A" and
" B".
Limits: Out-of-roundness: no more than 0.05 mm
EM - 40
Cylindrical degrees: Less than 0.05 mm

If the measured value exceeds the limit, EM036
please correct or replace the crankshaft.

⑬ Crankshaft clearance
a. Wipe off all the engine oil on the
surface of crankshaft journal and
inside the bearing shell.
b. Install the bearing shell.
c. Cut the plastic wire gauge into the
length that matching with the bearing shell. EM037
Plastic
Put it on the bearing journal along the axis of wire gauge
the bearing journal.

d. Gently assemble the crankshaft
bearing cover, and tighten the bolts to the
specified torque.
e. Disassemble the bolts, and gently remove the crankshaft bearing shell.
f. Use the ruler printed on the plastic wire gauge bag, to measure the extrusion
part at the widest point.
Standard Value: 0.02～0.04mm
Limit value: 0.1mm
Caution:
The crankshaft rod journals and crankshaft main journal have been rolled down,
and don't have to process to the reduced size.

⑭ Flywheel
Check the flywheel and signal plate for deformation or cracks.
Caution:
-- Do not disintegrate flywheel.
- Do not place the flywheel's signal plate facing down.
When processing the signal plate, be careful not to damage or scratch it.
EM - 41
Do not magnetize the signal plate when processing it. If it is magnetized, please
change the flywheel.
3) Assembly
① Blown out the crankcase engine coolant and engine oil in the cylinder block,
cylinder diameter, and crankcase.
Caution:
To use safety goggle to protect your eyes
② Install the main bearing shell and the middle bearing shell as shown below.
Caution:
Select bearing shell in accordance with the identification mark or color code of
the crankshaft (refer to the following table). If they can not be recognized, you should
measure the shaft diameter of crankshaft, and select the appropriate bearing bush to
match.
Print the packet mark on K face of

EM038
crankshaft (seen as figure 1.1.043), the packet
marking has 10 digits, the first five digits
respectively corresponds from the first main
journal to the fifth; the sixth digit is printed
"B", showing that the packet is finished. The
packet of rod journal starts;
From the seventh digit to the tenth digit respectively corresponds the first rod journal
to the fourth.
The size of spindle hole is labeled on exhaust back-end on the lower part of the
engine block.
Mark (refer to Figure 1.1.044), respectively,
EM039
corresponding from the first spindle hole size,
to the fifth spindle hole size.
The main bearing shell should be
EM - 42
selected and matched as the table stipulate.
Packet marking pf Crankshaft

Packet marking of Main
bearing bore
0 (up/down) Black/Black Black/Yellow Black/Red Black/White Black/Purple
1 (up/down) Yellow/Black Yellow/Yellow Yellow/Red Yellow/White Yellow/Purple
2 (up/down) Red/Black Red/Yellow Red/Red Red/White Red/Purple
When installing, align the bulge of the bearing bush with the kerf of the main
bearing shell.
Confirm that the oil holes in the cylinder block have been aligned with the oil
hole on the bearing shell.
③ Crankshaft is installed on cylinder block. When turning crankshaft by hand,
please check whether the turning is flexible.
Arrow pointing to timing side of the engine

Bearing cover No
EM040
④ Install the main bearing shell.
Through the identification mark can
identify main bearing shell.
From the timing belt side, install the main
bearing shell in accordance with the sequence.
The arrow must point to timing belt side.
⑤ Tighten main bearing bolts as the right digitals show in the diagram.
a. Use the new engine oil smear the threads and mounting surface of the main
bearing shell bolts.
b. Tighten main shell bolts by multi-steps.
Tighten the torque: 35±2N·m
c. Turning all bearing shell bolts in clockwise order of 30°.
EM - 43
After installing the main bearing cap bolts, confirm that the crankshaft can be
rotated flexibly by hand.
Check crankshaft end clearance Please refer to" crankshaft end clearance".
⑥ Install piston onto the connecting rod as shown below

a. Measure the length (as shown in the
EM041
following figure)
A: The dimension from the piston to
Connect Pis
piston boss outside face. ing ton
B: The dimension from the piston to Pis rod
ton
piston boss inside face. pin
C: Piston pin length
D: Connecting rod small end thickness
b. Put the measurement value into the following formula:
L= [（A-C）-(B-D)]/2
c. Insert the push rods (special tools) into the piston pin, and then put it into the
guide sleeve A (special tools)
d. The front mark should be on the same side, when installing of the piston and
connecting rod.
e. Smear the engine oil on the out circle of the piston pin.
f. From the guide sleeve A, press the guide sleeve A, piston pin and push rods in
the the front side marker of piston.
g. Tighten guide sleeve B into A, between the two guide sleeves, the clearance
of it is equal to 3mm plus L value that calculated in the second step.
h. In the state of the piston front marker facing down, install the piston and
connecting rod assembly into the piston pin installed base. EM042
i. Install the piston pin by press machine.
EM - 44
Guide Sleeve B Guide Sleeve A

Caution:
If the press-fit load exceeds requirements, replace the piston pin and piston
assembly and connecting rod, or both.
Standard Value: 108±54N·m.
⑦ Install piston ring, the installation position of piston ring seen as the figure
shows
Piston ring sketch map

The first compression ring The opening direction of
opening direction the downward blade of oil
ring
Grommet of oil ring
opening direction
The opening direction of The second compression ring

the upper blade of oil ring opening direction
Front part of the engine
Caution:
When installing the piston ring, be careful not to damage the piston ring.
Be careful not to damage the piston ring due to the over-expansion.
EM - 45
⑧ Install the connecting rod bearing shell onto the rod and the rod cap.
Read the connecting rod packet marking as the figure shows identification, select
bearing shell as shown in the following table.
Crankshaft rod journals The selection of connecting rod bearing

shell
Mark Size (mm) Mark Thickness (mm)
1 39.992 - 40 1 (yellow) 1.487 - 1.490
2 39.984 - 39.992 2 (black) 1.490 - 1.493

3 39.975 - 39.984 3 (red) 1.493 - 1.496
■ Before installing connecting rod bearing shell, please use the engine oil to
smear the bearing surface. Do not use the engine oil.
Smear the back, but to thoroughly clean the back.
⑨ Disassemble the piston and the connecting rod assembly onto the crankshaft.
a. Put the crankshaft journal corresponding to the connecting rod that to be
disassembled, in the middle of the bottom.
Use the enough engine oil to smear the cylinder diameter, piston and crankshaft
journal.
-- As 1.1.049 figure, aligned with the opening of the air ring and oil ring.
When installing the cylinder, please correspond to the position of it with the
connecting rod mark which is to be installed.
Make sure the previous mark of the piston top facing toward timing chain side;
press the piston and the connecting rod in the cylinder from the above head of the
cylinder.
Use a piston ring compressor or a suitable tool
Install the piston with the front marks toward the front of
engine to the head of the piston. EM043
Caution:
EM - 46
Be careful not to let connecting rod big end damage the cylinder walls and
crankshaft journal.
⑩ Install the connecting rod cap.
⑪ Tighten connecting rod bolts, in accordance with the method of
“5N.m->10N.m->13N.m+ 45°+ 45°”, alternately tighten them. Connecting rod cap
can be used only for once, it cannot be re-used.
Caution:
-- If before installing the connecting rod nut, a cylinder cover has been
previously installed, you must first disassemble the spark plugs.
When the bolts are re-used, you must check for scratches. When the nut can
smoothly tighten all the threads, which can illustrate there are no scratches on the
threads of the bolts, otherwise the bolts must be replaced.
Before installing the nuts, please smear the engine oil in the threads of it and its
seat surface.
Caution:
If the nut rotation angle is less than 90°, the fasten force of the connecting rod
may not be sufficient.
If the nut rotation angle is greater than 94°, they should be completely loosened,
and re-tighten.
After tightening the connecting rod nuts, confirm the rotation flexibility of
crankshaft.
⑫ Install the rear oil seal shell, which has been installed the crankshaft rear oil
seal, into the cylinder block.
Use the special tools as shown in the figure; press
the rear oil seal into the block. Oil Seal
EM044 JAC-T3F005
Oil seal housing

EM - 47
When installing the crankshaft rear oil seal bracket, ensure that the gluing surface
clean, and free of oil, dirt, and so on, and as shown in figure 1.1 .051, smear Dow
Corning 3-0115 sealant or equivalent product in the rear mounting surface of the
cylinder block, sealant can also be smeared in the corresponding part of the crankshaft
rear oil seal bracket. Adhesive diameter 2±0.5mm, smear the lubricating oil on the oil
seal lip and the jointing part of crankshaft.
Section A- A Section B-B
⑬ Install the knock sensor

Caution:
-- Do not tighten the nuts, when holding the connector.
If the knock sensor has been shaken, please replace with a new one.
Note: Be sure that there are no foreign bodies on the matching surface and on the
back of the knock sensor.
⑭ please read the following precautions, and install them in the reverse order of
disassembly after finishing this step.
The flywheel
Cross-tighten the fixing bolts to specified torque.
Common fault phenomenon diagnosis

Common fault phenomenon diagnosis
The possible reason of fault
Fault phenomenon Troubleshooting.
phenomenon
EM - 48
Cylinder head gasket Replace cylinder head

leaking gasket
The cylinder pressure is Piston rings are worn or damaged Replace piston rings
low Repair or replace the piston or
Cylinder or piston worn
cylinder block
Valve seat damaged or worn Repair or replace valve seat
Engine oil quantity is less Check the engine oil quantity
Oil Pressure Sensor Fault Replacement
Oil filter block Replacement
The oil pump gear or cover damage Replacement
Engine oil pressure is low
Engine Oil Viscosity is low Check and replace oil
Oil pressure switch plunger normally
Repair
open
Bearing Clearance is large Replacement
Oil pressure switch plunger normally
Engine oil pressure is high Repair
close
Engine mounting bolts loose Tighten
Transmission Mounting Bracket is
Tighten
loose
Engine stand looses Tighten
Engine jitters Engine heat resistant pad damage Replacement
Engine support heat resistant pad
Replacement
damage
Transmission heat resistant pad
Replacement
damage
Oil is watery, (oil pressure is low) Replacement
Valve noise Valve or valve guides worn or
Replacement
damaged
Check the engine oil quantity is
Oil quantity is low
connecting rod bearing and enough
spindle bearing noise Oil is watery, (oil pressure is low) Replacement
Bearing Clearance is large Check and determine the reason
Toothed belt noise Tensioning force is not correct Adjust tension force.
Heat sink or pipe leaky Repair or replace
Water tank lid does not seal Tighten or replace
Cooling effect is poor. Thermostat leak Replace thermostat gasket
Radiator leak Repair or replace
Water Pump Leak Replacement
Heat sink is blocked Coolant has contamination Replacement
Engine coolant temperature Water tank lid is not sealed tightly Replacement
EM - 49
is high Cooling system is blocked Clean or replace.

Thermostat malfunction Replacement
Belt slip Adjust or replace.
Water pump malfunction Replacement

Sensor malfunction Repair or replace
Fan malfunction Repair or replace
Insufficient engine coolant Add coolant:
Engine coolant temperature Thermostat malfunction Replacement

is low Sensor or wiring harness malfunction Repair or replace
Sensor or starter damage Repair or replace
Fan does not work
Fan relay or wiring harness damaged Repair or replace
Connecting points loose Tighten
Exhaust air leaks
Exhaust Pipe or muffler damage Repair or replace
The muffler looses Replacement
Rubber pads falling off Replacement

Abnormal noise Exhaust Pipe or muffler is connected
Correction
with car body
Exhaust pipe or muffler damage Repair or replace
Service Parameters
1、Tighten torque
Name Quantity Tighten torque (N ·M)
Main Bearing Shell Bolt 10 (35±2)N.m+60°～64°
Connecting Rod Bolts 8 5N.m->10N.m->13N.m+ 45°+ 45°
Camshaft Bearing shell bolts 16 11±1
The front bearing shell bolts of 3 20±1
camshaft
Cylinder Head Bolt 10 （24.5±2） N.m +180°～ 184°
Crankshaft pulley bolt 1 （50±2） N.m +60°±2°
Flywheel bolts 6 100±5
Exhaust Camshaft Sprocket Bolt 1 88±5
Valve timing adjusting bolt 1 70±5
EM - 50
Crankshaft Rear Oil Seal Bolts 6
The rear lifting lug bolts 2 18.4±1.4
The intake manifold bolts 5 18±1
Oil pan bolts 14 11±1
Sprocket Cover Bolts I 2 39.5±3.0
Sprocket Cover Bolts II 2 39.5±3.0
Sprocket Cover Bolts III 2 8.4±0.6
M 6 * 20 E 10 model bolt 6 8.4±0.6
M 6 * 12 E 10 model bolt 7 8.4±0.6
When the above two bolts securing oil filter 11.5±1.1
bracket
Cylinder Head Bolts and 10 9±1.0
Bracket Bolts
M 6 * 45 E 10 model bolt 2 8.4±0.6
M 6 * 25 E 10 model bolt 9 8.4±0.6
M 6 * 12 E 10 model bolt 1 8.4±0.6
Oil filter braclet bolts 3 20±1
warm water steel tube bolts 2 7.6±0.6
Oil pressure rail bolt 2 18.4±1.4
Main oil galley plug I 2 60±5
Main oil galley plug II 1 35±5
Drain plugs 1 25±5
Oil Galley Plug 1 20±5
VVT oil blockage 1 44±5
Oil drain plug 1 39±5
The rail bolt components 2 10±2
The rail bolt components 1 23.5±4.5
Starter bolts 2 24±3
Oil pressure switch 1 10±2
EM - 51
Spark plugs 4 25～30
Exhaust manifold dual-head stud 6 12±2
Catalytic convert heat shield 3 10±1
nuts
Crank signal wheel bolts 3 12.5±2.5
Water temperature sensor 1 20±4
Hall sensors bolt 1 8.4±0.6
Knock sensor bolt 1 20±4
Exhaust manifold bolt 5 35±2
Throttle self-tapping screws 4 6±0.5
Absolute pressure sensor 6±0.5
self-tapping screws
Square head bolt 1 47±5
Idler Wheel Bolts 1 49±9
Oxygen sensor 2 35±5
Oil Filter 1 11±01
The standard parts and the threaded connections that the ablve table is not
provided for:
M6 ： 9 ～ 11N.m M8: 20 ～ 25N.m M10: 30 ～ 50N.m
M12：60～80N.m
2. Technical Parameter
Limit
Project Standard value
value
Camshaft
The air intake 44.7054±0.1mm
Camshaft height (mm)
Exhaust 44.2836±0.1mm
Cylinder Head and Valves
Cylinder head gasket surface flatness (mm) Below 0.03 0.1
Cylinder head cover total height (mm) 112.9～113.1 -
The thickness of the valve Intake valve 1.35 0.85
EM - 52
edge. Exhaust Valve 1.85 1.35

Valve stem diameter (mm) φ5.5 -
Clearance between valve The air intake 0.020～0.036 0.10
stem and valve guide (mm) Exhaust 0.030～0.045 0.15
Valve cone 45°～45.5° -
Valve stem overhang (mm) Intake valve 53.21 53.71
Exhaust Valve 54.10 54.60
The overall length of the Intake valve 89.61 89.11
valve. Exhaust Valve 90.94 90.44
Valve spring free height (mm) 43.1 42.7
Valve spring load/mounting height (N) / (mm) 152/33.4 -
310/25.2 -
Valve Spring verticality Less than 2° 4°
Valve seat contact width (mm) 0.9～1.3 -
valve guide inner diameter (mm) φ5.5 -
Valve guide overhang (mm) 13±0.3 -
Oil pump gear top clearance (mm) 0.06～0.18
Side clearance of the pump (mm) 0.04 ～0.11
Shell clearance of oil pump (mm) 0.10～0.18
Out diameter of piston skirt (mm) 74.968～74.978
The first air ring side clearance (mm) 0.03～0.07
The second air ring side clearance (mm) 0.02～0.06
The first piston ring gap clearance-compression 0.15～0.30
(mm)
The second piston ring gap clearance-compression 0.30～0.50
(mm)
Combination oil ring gap clearance (mm) 0.20～0.50
Piston pin out diameter(mm) 18.0
Piston pin out diameter(mm) 4900～14700
Connecting rod journal clearance (mm) 0.02～0.04 0.1
Rod head side clearance (mm) 0.10～0.25 0.4
Crankshaft end clearance 0.09～0.27
Crankshaft main journal diameter (mm) 46.009-46.029
Connecting rod journal diameter (mm) 39.975～40.0
Crankshaft main journal to clearance (mm) 0.02～0.04
Cylinder head gasket surface flatness (mm) Below 0.03
Cylinder block total height (mm) 256
Cylinder Block cylindricity (mm) Below 0.01
Cylinder bore inner diameter 75.000～75.015
Clearance between piston and cylinder (mm) 0.02～0.04
EM - 53
J4 Service Manual Lubrication System
Lubrication System
Precautions
Sealant Application Procedure: 001 LU
scrapers
1, Using a scrapers, Clear old sealant
adhering to the application surface and
the mating surface.
Note:
■Clear sealant completely from the groove of the sealant application surface, mounting bolts
and bolt holes
2, Clear the sealant application surface and the mating surface with unleaded
Petrol to remove adhering moisture, grease and foreign materials.
3, Locate sealant completely to the specified position with the specified
dimensions
1) Within 5 minutes after liquid gasket application, install the mating
component.
2) If sealant has stains, please clean them off immediately.
3) Please do not re-tighten bolts or nuts after the installation.
4) Refill engine oil and engine coolant in 30 minutes after the installation,
Preparations
1、Service tools:
List of Service Tools
SN Tools Outline drawings Descriptions
LU-1
1 Oil Measuring oil

pressure pressure
gauge
2 soft hose Connecting oil

pressure gauge to
cylinder block
3 Oil Removing and

pressure installing oil
switch pressure Switch
socket
Lubrication System Illustrative Diagram
LU-2
Engine Oil
1, check
1) The level of Engine Oil
Note: Before starting engine, park vehicle horizontally and firmly, check the
engine oil level. If engine is already started, stop it and check it 10 minutes later
○1 pulls out the Engine Oil 002 LU
Dipstick and wipe it clean.
○2 Insert Engine Oil dipstick and

Confirm engine oil level with the range
shown in the figure. Confirm engine oil level between “L”and “H”
○3 please adjust, if it's out of the range

2) Engine oil appearance
○1 Check the engine oil for white turbidity or heavy contamination.

○2 If engine oil appears cloudy or contaminated, it is highly probable that it is
contaminated with engine coolant. Repair or replace the damaged parts.
3) Engine Oil leakage
Check for engine oil leakage around the following areas:
■Oil sump
■Oil sump draining bolt
■Oil pressure switch
■Oil filter
■Mating surface between cylinder block and cylinder head
■Crankshaft oil-seals (front and rear)
■The mating surface between Oil Pump and Cylinder Block
■Mating surface between valve vocer and cylinder head
■Front camshaft oil seal
4) Oil pressure check:
Note:
LU-3
■Be careful not being burnt, as engine oil may be very hot
■Oil pressure check should be done after
003LU00
parking
2 LU
○1 Check engine oil level Please refer
to"The level of Engine Oil"
○2 Lift the vehicle and disconnect the oil 003LU002 LU

pressure switch
Disconnect harness connector at oil pressure switch, and remove the switch.
○3 Install oil pressure gauge and soft hose

○4 Start the engine and warm it up to normal operating temperature.
○5 Check the oil pressure when the
engine is idling. 004 LU
Note: the engine oil pressure is high

when the engine oil temperature is low.
■If difference is distinct; please check
engine oil passage and oil pump for engine
oil leakage
○6 After inspections install oil pressure switch as follows:

a. Clear old sealant adhering to oil pressure switch and engine
b. To use sealant as required and tighten pressure switch
■Please use appointed sealant: A New 1243 threads sealant or its equivalent.
■Tightening torque: 8-12N.m
c. After warming up engine, make sure there is no leakage of engine oil when
engine is running normally.
2, Change engine oil:
Note:
■Be careful not being burnt, as engine oil may be very hot
LU-4
■Avoid long-time direct skin contact with used engine oil

If skin contact happened, you should wash thoroughly with soap or cleanser as
soon as possible.
○1 Warm up the engine, and check for oil leakage from engine compartment
please refer to “The leakage of Engine Oil"
○2 Shut off engine and wait for 10 Mins.

○3 Open engine oil filler cap, and then remove the oil draining bolt.
○4 Drain the engine oil
○5 Install oil draining bolts with new gasket
Note:
■Be sure to clean draining bolts and install with new gasket
■The tighten torque for draining bolts: 34 ~ 44 N M.
○6 Fill with new engine oil.

The specifications and viscosity of engine please refer to "Maintenance".
■The oil quantity: 4.5 L
Note:
■When filling engine oil, do not pull out oil dipstick.
■The refill capacity depends on the engine oil temperature and draining time,
above is only for reference.
■Always use oil dipstick to check for proper engine oil refill capacity.
○7 Warm up the engine and check the area around draining bolts and oil filter for
engine oil leakage.
○8 Shut off engine and wait for 10 Min.

○9 Check engine oil level please refer to “The level of Engine Oil"
Oil Filter
1, Removal and installation:
LU-5
1) Removal
Using oil filter wrench to remove oil filter
LU005
LU
Wrench
Note:
■Use the original oil filter provided JAC vehicles or its equivalent.
■Be careful not is being burnt, for engine and engine oil may be very hot.
■When removing, prepare a shop cloth to absorb any engine oil leakage or
spillage.
■Please do not let engine oil adhere to driving belts.
■Completely wipe off any engine oil that spills onto engine and vehicle.
2) Installation.
○1 Remove foreign materials adhering to LU006 LU
oil filter.
○2 Smear just enough engine oil to the
oil seal surface of new oil filter.
○3 Tighten oil filter until O-ring is seated on mounting surface, and then screw oil
filter for another turn to make the tighten torque within 10-12N·m.
Note:
■Oil filter must be tightened with oil filter wrench.
■Hand-tightened filter will result in oil leakage due to insufficient tightening
torque.
LU-6
2, Inspection after installation:

1) Check the engine oil level. Please refer to"Engine Oil"
2) Start the engine, and check whether there is engine oil leakage or not.
3) Shut off engine and wait for 10 Min.
4) Check the engine oil level, and fill with engine oil. Please refer to"Engine Oil"
Oil Sump and Oil Pump

1, Component
12
13
6
14 10 8
7 2
41
5
11
15 4 3
Exploded view of Oil Sump and Oil Pump
1 - Engine Oil Filter support pad 2 - Oil filter support bolts 3 - Oil Filter 4 - oil sump bolts 5 - Oil
Sump 6 - Oil strainer 7 - Oil Strainer bolts 8 - Oil strainer support 9 - Oil Drain bolt 10 - Oil Drain
bolt pad 11 - water pump pad 12 - oil pump assembly 13 - Automatic Tensioner cover 14 - Front
Oil Seal 15 - water pump
LU-7
2, Removal
Warning:
■Do not drain engine oil when engine is
LU007 LU
hot, in case of being burnt.
1) Drain the engine oil Please refer to"
Changing Engine Oil"
2) Removing oil sump
a. Following the order that medium first
then two sides to loosen the bolt.
■Tightening torque: 7-8.2N.m
b. As shown in the1.2.007 figure,
between the oil sump and cylinder block LU008 LU
Insert special tools.

c. Tap the side of special tools to move
the tools along the sealing surface of oil
sump and cylinder block, and then remove
Oil sump
Caution:
■Be careful not to damage the mating surfaces.
3) Remove oil strainer.
Note:
■Do not drop pads.
4) Remove oil pump housing.
5), Remove mounting bolts on oil pump housing, and take away oil pump cover
and gear.
6) Remove crankshaft front oil seal, pressure reducing valve and oil filter from
the pump housing,
LU-8
3, Inspection after removal

1), Oil strainer
■Clean any materials adhering to oil strainer
2), Oil pumps housing.
■Check whether the holes of oil pump housing are clogged or not, if yes, please
clean it.
■Check oil pumps housing for cracks and other damage. If any, please replace.
3), Oil pump
Note:
LU009
■To check the clearance among oil
pumps, if it is not within required range,
please replace it.
■Before check please put the rotor into
Front Cover.
1 Check the clearance among gear tips.

010lu
Standard value: 0.06~0.18mm
2 check the side clearance.
LU011
3 Check the housing clearance.

Limit value: 0.35mm
LU-9
4. Installation.
1), Install oil pumps housing.
■Clean the seal surface and the front oil seal housing of cylinder block.
■Please refer to figure 1.2 .0 13, the diameter of adhesive at A point is 2+/-0.5
mm; the diameter of adhesive at B ponit is 1.5 + /- 0.5 mm.
■Appointed sealant: A New 1590 thread sealant or its equivalent.

2), Install crankshaft front oil seal
■Put the special tool on front end of crankshaft and apply engine oil to its outer
circumference. lu012
JAC-T3F003
LU-10
■Smear engine oil onto the sealing lip,

lu013
and then push oil seal in along its guide by JAC-T3F004
3
hand, until it comes into contact with front oil
seal housing
Using special tool to tap oil seal to snap
into place
3) Install the pressure reducing valve assembly.

4) Install oil Filter.
■Please refer to"Oil Filter"
5) Install oil sump. lu014
■Clean mating surfaces of cylinder
block and oil sump.
■Smear 2.5+/-1mm wide edge-curled
sealant around entire outer circumference of
oil sump flange
■The appointed sealant: Dow Corning 3 - 0115 flat seal or its equivalent.
6) Install oil sump draining bolt.
■Install oil sump draining bolt pad as lu015
shown.
Oil sump
Note:
■Fill engine oil in at least 30 Mins after
the installation of oil sump

1) Check the engine oil level, and fill with engine oil. Please refer to"Engine
Oil".
2) Start the engine, and make sure that there is no engine oil leakage.
LU-11
3) Shut off engine and wait for 10 Min.

4) Re-check the engine oil level. Please refer to"Engine Oil".
LU-12
J4 Service Manual Cooling System
Cooling system
Cooling circuit
Cooling Illustrative diagram
Radiator
Expansion tank
Thermost Thermostat
at housing
Heate Thro
r ttle
Water pump
excha Body
nger
Cylinder block
Thermost on
Thermost off
Cylinder cap
Cooling Illustrative diagram

Engine Coolant
1, check
1) Level check:
Check whether the engine coolant level of reservoir tank is within the “MIN” to
“MAX” after the engine cools down.
■Adjust the engine coolant level if necessary.
001 CO
CO -1
2) Leakage check:
Using Radiator cap tester to check for leakage though increasing pressure to the
cooling system.
002 CO
3) Test pressure
Warning:
■Do not remove radiator cap when engine is hot. Otherwise serious burns could
be caused by high-pressure engine coolant escaping from radiator.
Note:
■Higher testing pressure than specified may cause radiator damage.
■In a case that engine coolant decreases, please replenish radiator with engine
coolant. If any part is found damaged, please repair or replace.
2, changing engine coolant
Warning:
■To avoid being scalded, please do not change engine coolant when the engine is
hot.
■Wrap a thick cloth around radiator cap and carefully remove the cap. Release
the pressure in radiator first. Then turn radiator cap all the way.
■Be careful not to spill engine coolant on drive belts
1), Drain engine coolant:
○1 Remove the right engine shroud.
○2 Open the drain plug at the bottom of radiator, and then open the radiator cap.
○3 If necessary, please remove the coolant reservoir to drain engine coolant and
clean it before re-install.
CO -2
○4 Check whether there is rust, debris or discoloration in the drained engine
coolant,
■If contaminated, please flush the engine cooling system. Please refer to
"Flushing cooling system".
2) Refilling with engine coolant:
○1 Install the removed reservoir tank and radiator drain plug.
Note:
■Be sure to clean drain plug and install with new O-ring
○2 Make sure that each soft hose clips are firmly tightened.
○3 Remove the air cleaner cover and air intake hose. Please refer to" Remove air
cleaner assembly".
○4 Disconnect warm water outlet pipe. Please raise hose high enough.
○5 add coolant to radiator and coolant reservoir to the required level. Fill engine
coolant slowly, so as to emit the air in the system.

Note:
■Please use JAC genuine engine coolant. Please refer to"Recommended Oils and
Lubricants"
■Disconnect when engine coolants overflow warm-water hose,
And then reconnect warm-water hose and continue filling engine coolant.
○6 Install the air cleaner cover and air intake hose. Please refer to" Remove air
cleaner assembly".
○7 Install radiator cap
○8 Warm up till the thermostat opens.
Touch the radiator down-hose and feel that whether there is a heated flow to
confirm whether the thermostat opens or not.
Note:
■Check the Engine Water Temperature Gauge, avoid engine overheating.
CO -3
○9 Shut off engine to reduce the temperature
1○0 Add the engine coolant level of reservoir tank within the “MIN” to “MAX".
1○1 Install the radiator cover and repeat steps 3 to steps 9 two or more times until
the engine coolant level no longer drops.
1○2 Start the engine and check cooling system for leakage.
3) Flushing cooling system:
○1 Install the removed radiator drain plug and reservoir tank.

Note:
■Be sure to clean drain plug and install with new O-ring
○2 Remove the air cleaner cover and air intake hose. Please refer to" Remove air
cleaner assembly".
○3 Disconnect warm water outlet pipe. Please raise hose high enough.
○4 Fill radiator and reservoir tank with engine coolant, and install radiator cap.
Disconnect when engine coolant overflows warm-water hose, and then reconnect
warm-water hose and continue filling engine coolant.
○5 Install the air cleaner cover and air intake hose. Please refer to" Remove air
cleaner assembly".
○6 Run engine and warm it up to normal operating temperature.
○7 Speed engine up several times under no-load.
○8 Shut off engine and wait for cooling down.
○9 Drain water from the system please refer to “Draining engine coolant"
1○0 Repeat steps 1~9 until clear water begins to drain from radiator.
Radiator
CO -4
Warning:
■Do not remove radiator cap when engine is hot. Otherwise burns could be
caused by high-pressure engine coolant. Wrap a thick cloth around radiator cap and
slowly turn this cap to release air pressure inside. Wait until pressure is completely
released, then screw off radiator cap and take it off carefully.
1) Removal
○1 Remove engine shroud
○2 Drain engine coolant from radiator

Note:
■Do not operate this step until engine cools.
■Please do not spill engine coolant on drive belts.
○3 remove the air intake, and take it off.
○4 Disconnect the harness connector of radiator fan motor, and put it aside.
○5 remove the water inlet and outlet hoses of radiator and the water inlet hose of
reservoir tank.
○6 Remove radiator's installation support and take off radiator and radiator
cooling fan component.

Note:
■When removing, please do not damage or scratch radiator core
○7 Take off cooling fan component from radiator.
2).Installation.
Install according to the reverse order of removal.
3) Inspection after installation:
■Use radiator cap tester to check for leakage of engine coolant
Please refer to"Leakage check".
■Start the engine and warm it up. Visually check for leakage of engine coolant.
CO -5
2, Check radiator cap

003 CO
1) Pull out negative-pressure valve to
open it. Make sure that it closes completely
after pressure release.
■Make sure that there is no dirt or
damage on the valve seat of radiator cap
negative-pressure valve
■Make sure that there are no 004 CO
unusualness in the opening and closing of

negative-pressure valve
2) Check radiator cap and release pressure.

Standard value: 78~98KPa
Limit: 59 KPa
Connect radiator cap to the radiator cap tester, and please smear engine coolant
onto the cap seal surface.
Please replace radiator cap if negative-pressure valve operates abnormally or
relief pressure drops to below the limit.
3, Check radiator
■Check radiator for mud or clogging
If necessary, please clean radiator surface as follows.
■Be careful not to bend or damage radiator fans
■If the radiator needs to be cleaned without removal, please remove all
surrounding parts such as cooling fan, cowl and horns. Then tape harness connectors
to prevent water from entering.
1) To flush the back side of the radiator core vertically downward by water hose.
2) To flush all radiator core surfaces per minute.
CO -6
3) Stop flushing when no dirt flows out from radiator.

4) Blow the back side of radiator core vertically downward by compressed air.
Use compressed air which is lower than 490 KPa and keep distance more than 30cm.
5) Blow all the radiator core surfaces per minute with compressed aird, until no
water sprays out.
Radiator Cooling Fan

1) Removal
○1 Remove the air intake hose, and take it off.

○2 Disconnect the harness connector of radiator fan motor, and put it aside.
○3 Remove cooling fan component from radiator.
Note:
■When removing, please do not damage or scratch radiator core
2) Installation.
2, Disassembly and Reassembly
1) Disassembly
○1 Remove the cooling fan from fan motor.
○2 Remove the fan motor from shroud.
○1 Cooling Fan
Check cooling fan for cracks or unusual bend. If any is found, please replace
cooling fan.
○2 Fan motor
Check the motor for seizure.

3) Assembly
CO -7
Assemble according to the reverse order of disassembly.

Water Pump
Note:
■When removing water pump, be careful not to get engine coolant on drive belts
■Water pump cannot be disassembled and should be replaced as a unit.
■After installing water pump, connect hose and secure with clamp, then check
for leakage by radiator cap tester
1) Removal
○1 Drain engine coolant from radiator
○2 Loosen the mounting bolts of tensioner nut.
○3 Remove drive belts
Please refer to “Drive belts".
○4 Remove the mounting bolts of water pump
Note:
■Please distinguish the position of mounting bolts.
2), Inspection after removal
■Check the water pump assembly for serious corrosion, water-seal leakage or
corrosion.
■Check for excessive play which will result in malfunction
■Check the water pump bearing for seizure or other damage. If necessary, please
replace.
3) Installation.
○1 Clean the sealant on water pump mount and the water pump side hose.
CO -8
○2 Install the new O-ring on the side

005 CO
hose of water pump.
Note: Smear engine coolant onto
O-ring.
○3 Smear 3 mm wide edge-curled
sealant onto the surface of installed water

Pump
■Appointed sealant LT5699 or its equivalent
○4 Install water pump
Note:
■When install, please do not drop pad.
■Tighten the mounting bolts into water pump alternately and evenly.
a) Install water pump tensioner nut.
b) Install the drive belt, and adjust to required tension. Please refer to"Drive
belts".
c) Fill with engine coolant Please refer to"Refilling with engine coolant".
Thermostat Components
1) Removal
○1 Drain engine coolant from drain plug of radiator.

Note:
CO -9
■Please do not spill engine coolant on drive belts.
○2 Disconnect the water inlet and outlet pipes and minor cycle water pipe of
radiator at thermostat housing side
○3 Disconnect harness connectors of coolant temperature sensor and coolant
temperature warning switch and bolts securing mounts of harness connectors of front
and rear oxygen sensors, and move them away.
○4 Remove mounting bolts Heater's water-return pipe and remove warm air
return pipe.
○5 Remove mounting bolts on thermostat upper cover, and take out thermostat.
2) Inspection after removal:
○1 Thermostat
■Check thermostat valve-opening

006 CO
condition under normal room temperature
Thermostat Opening Temperature ：
82C （begin to open）
95 C (Completely open)
The maximum lift of valve stem: ≥ 8mm
Thermostat closing temperature: > 77 C
If the massured value is outside the specified range, please replace thermostat.
○2 Thermostat upper cover and Thermostat housing
Check for cracks and other damage.

3) Installation.
Please note the following items and install in the reverse order of removal.
○1 Be careful not to spill engine coolant on drive belts. Use rag to absorb engine
coolant.
○2 Replace the water pipes' O-ring with a new one, and then smear coolant onto
the O-ring, so that they can be easily embedded in the water-pump thermostat
CO -10
housing.
Note:
■Never smear the O-ring with engine oil or other oil material.
■The pipes at the back of thermostat housing must be installed firmly.
If engine coolant temperature sensor needs to be reused,
Please smear the thread with appointed sealant.

■The appointed sealant: LT648 or equivalent
Water Pipe components
1, Removal
○1 Drain engine coolant from drain plug at the bottom of radiator. Please refer to
“Changing engine coolant”.

Note:
○2 remove air cleaner assembly
Please refer to" Remove air cleaner assembly".
○3 Remove the water hose of radiator.
○4 Remove warm-water hose and minor cycle water pipe.
○5 Remove mounting bolts of inlet water pipe, and then remove the water inlet
pipe from the back of water pump.

Note:
■Before removing, please remove the battery negative terminals.
2. Installation.
Please note the following items and install in the reverse order of removal.
1) Firmly install each pipe. Install the clamp and make sure that clamp will not
CO -11
hold the bump of water pipes.

2) Replace the water pipes' O-ring with a new one, and then smear coolant onto
the O-ring, so that they can be easily embedded in the water-pump thermostat
housing.
Note:
■Never smear the O-ring with engine oil or other oil material.
■The pipes at the back of thermostat housing and water pump must be installed
firmly.
1) Check for leakage of engine coolant using the radiator cap tester. Please refer
to"Leakage check".
2) Start the engine and warm it up. Visually check for leakage of engine coolant.
Failure analysis
Analysis list of over-heating
Symptoms Check items
Water pump Worn or excessive
malfunction loosing drive belt
Thermostat stuck at
OFF position
Poor heat
Damaged Mud or paper clogging -
radiation
radiator fans Mechanical damage
Excessive foreign
Radiator cooling
materials (erosion, dirt,
clogged
sand, etc.)
Parts Cooling fan does
malfunction not operate.
Inadequate
of cooling Excessive resistance Fan assembly -
air flow
system to fan rotation
Damaged fan blades
Shroud damage - - -
Improper
coolant mixture - - -
ratio
Poor engine
- Viscous engine coolant
coolant quality
Insufficient Engine coolant Clamps loosen
Coolant hose
engine coolant leakage Cracked hose
CO -12
Poor sealing
Water Pump
effect
Loosened
Radiator cap Poor sealing
effect
O-ring for
damage, aging
or improper
installing
Radiator Radiator water
tank
Cracked
Radiator core
cracks
Reservoir tank
Reservoir tank
breaks
Cylinder head
Overflowing Exhaust gas leaks into aging
reservoir tank cooling system. Cylinder head
pad aging
Engine rpm is
excessive when
unloaded
Drive for
In addition - Engine overloads Drive improperly
extended time
Drive at
extremely high
speed
Powertrain system
malfunction
Installed with wheels

and tires of improper
Malfunction sizes
s of parts Retardant brakes
out of Incorrect ignition
cooling timing
system Blocked bumper
-
vent
Blocked air Blocked radiator Installed car hood
-
flow grille Mud or paper clogging
Clogged radiator -
Blocked condenser Blocked air flow
CO -13
Service Parameters
Specifications table of cooling system
Thermostat Opening Temperature 82C（begin to open） 95C（completely）
Thermostat closing temperature ≥77C
The maximum lift of valve stem >8mm
CO -14
J4 Service Manual Fuel Supply System
Fuel Supply System

Precautions
Warning:
When replacing or removing fuel system parts, be sure to observe the following
tips.
■Put a “NO FIRE” signs in the operation position.
■Be sure to work in a well ventilated area and equip operation position with CO2
fire extinguishers.
■Be sure to put drained fuel into a container and well-caped
Keep the container in safe area.
■When removing fuel line parts please operate the following procedures:
Release fuel pressure inside the fuel pipelines.
Disconnect the negative cable of battery.
■Please do not twist fuel pipes when install.
■Please operate at a flat place.
■After connecting fuel pipes connectors, make sure they are connected firmly.
Ensure that connector and resin tube not touch with any adjacent parts.
■Please do not tighten hose clamps excessively to avoid damaging hoses.
■After installing fuel pipes please make sure there are no fuel leakage at all
junctions by operating the following steps.
Increase fuel pressure to fuel lines by turning ignition switch “ON”. (Do not start
engine!)
Then check for fuel leakage at junctions.
Start engine and rev it up and check for fuel leakage at junctions.
■Please get a container and rag ready in advance as fuel may leak.
■Avoid open flames and sparks
■Please keep removed parts away from any fire source.
■Be sure to keep junctions clean and avoid damage and entry of foreign material
Please cover them completely with plastic bags or similar articles
FL-1
.
■Please use genuine fuel system spare parts provided by JAC.
Preparations
Special tools:
SN Tool Outline drawings Number Descriptions
1 Fuel JAC-T1F018 Measure fuel

pressur pressure
e gauge
Fuel Supply System Components 7
5 6
3
2
1
Fuel System Assembly Drawing
1.Fuel tank assembly 2.Fuel tank band 3.Canister assembly 4.fuel filler pipe assembly
5.fuel filler cap 6.Fuel supply line 7.Fuel transfer pump assembly 8.Fuel pump
access cover 9. Fuel filter
FL-2
Fuel Tank
1, Removal
1) Release left fuel pressure inside the fuel pipelines.
2) Open fuel filler cap to release the pressure in fuel tank.
3) Remove rear seat.
4) Remove fuel tank service-cover. FL001
■Pry off with a flat screwdriver directly
5) Disconnect the harness connector on

the fuel pump.
6) Remove the sub-frame assembly.
FL002
7) Disconnect the connections of fuel
lines, fuel tank and canister.
8) Disconnect the pipe on fuel tank and

the pipe installed under the protection cover. FL003
FL-3
9) Support the fuel tank with bracket

FL004
mount, remove mounting bolts and nuts of
fuel tank strap so as to remove the fuel tank
strap.
Note:
■The support points should not intervene the fuel tank strap
10) Take off the fuel tank, if necessary; take the needed parts and components
from it.
2, Inspection after removal:
■Check the surface of fuel tank assembly for scratch or serious distortion
3, Installation
■When install the fuel tank strap, the tighten torque of bolt and lock nut is from
40 N. m ~50 N. m.
4) Inspection after installation
Check for fuel leakage according to the following procedure.
Turn ignition switch to “ON” position (do not start engine), and check the
junctions of fuel pipes for leakage.
Start engine and rev it up, to confirm there is no leakage at junctions of fuel
system hose and pipes.
Fuel Filter FL005
1, Removal
Note:
■Fuel filter should be replaced regularly
according to the maintenance guide in the
“Operation Manual”.
1) Remove fuel tank assembly; please see detailed procedure"Fuel Tank
FL-4
Removal".
2) Disconnect the fast plug between fuel pipes and fuel filter.
Note:
■Wrap fuel filters with a towel or similar article to avoid ejection of fuel caused
by residual pressure.
3) Pull out the fuel filter from the filter mounting bracket along the line direction
on the surface of fuel tank.
2, Inspection after removal:
■Check filter assembly surface for scratch or serious distortion.
3, Installation
Please note the following and install according to the reverse order of removal.
1) Fuel filter
■Pay attention to installation direction
of fuel filter FL006
Toward the fuel outlet line
2) Connect the fast plug connector

Connect fuel pipe connector as followed:
Check the junctions for foreign materials or damage.
Align the connector with resin tube at the two end of filter, and then insert the
connector straight into the tube until a click sound is heard.
After installation, check for fuel leakage according to the following procedure.
Turn ignition switch “ON” (with engine stopped) after lifting the vehicle to a
certain height, and then check fuel filter line junctions for leakage.
Start engine and run it at idle speed and high speed, and make sure again there
FL-5
are no fuel leakages at the fuel filter junctions.
Fuel Pump Assembly

FL007
Fuel Pump Assembly Drawing
1, Removal
Warning:
■Be sure to read the "General Considerations"
1) Check the readings on fuel gauge. If fuel gauge indicates a “FULL” or close to
“FULL” position, then drain the fuel in fuel tank until the level indicated by fuel
gauge is below “E”.
2) Release fuel pressure in the fuel pipelines.
3) Open fuel filler cap to release the FL008
pressure in fuel tank.
4) Remove rear seat cushion.
5) Remove fuel tank service-cover.
■Pry off with a flat screwdriver directly
FL008
6) Disconnect the fuel pump harness

connector and fuel lines connector.
FL-6
Note:
■Do not use any tools to disconnect connector.

■Keep junctions clean and avoid damage and entry of foreign material. Please
cover them completely with plastic bags or similar articles.
7) Using special lock nut retainer to
FL009
loosen lock nut and take it off.
8) Remove Y-ring seal.

FL010 Figure1.4.015
9) Pull out fuel pump.

Note:
■When pulling it out, tilt fuel pump to avoid damage to fuel level sensor.
■To avoid contamination with residual fuel, please wrap the fuel pump with rag
and pull it out straightly.
FL011

1) Fuel pump:
■Check for breakage and impurities in fuel
FL-7
If any, please replace or clean.

■Resistance check
Measure the resistance between 2 terminals of fuel pump. Its value should be
approx. 2~30Ω.
■Fuel supply pressure check. Connect a 12V power source and test it while
running in gasoline.Observe whether fuel is output from delivery pipe of fuel pump,
check whether fuel supply pressure can be built up.
■Please do not run it for extended time so as to avoid damage to pump core.
2) Y-ring seal
■Check for starving and breakage
3) Lock nut
■Check for deformation, cracks, starving, breakage, and mounting thread
damage.
4) Fuel level sensor
■Check fuels float for interference and check its surface for oxidation.
3, Installation
Please note the following and install according to the reverse order of removal.
1) Fuel Pump Assembly
■When install, make sure the Y- ring match with the fuel tank completely.
■The fuel pump should be tilted into, and please note the installation direction of
fuel pump assembly.
■When install fuel pump, make sure that the Y-ring is not edged.
■Pre-tighten the lock nut then install, then install the horizontal lock, the tighten
torque is 75 N. m±5 N. m
2) Fast plug connector
○1 Check the junctions for foreign materials or damage.
○2 Align the connector with resin tube, and then insert the connector straight
into the tube until a click sound is heard.
○3 After connecting, make sure that the connection is secure by following
FL-8
method.
■Pull the resin tube and the connector heavily to confirm that they are ecurely
connected.
Check for fuel leakage according to the following procedure.
1) Turn ignition switch to “ON” position (do not start engine), and check the
Start engine and rev it up, and re-confirm that whether there is leakage at
connections of fuel system or not.
Fuel Evaporative Emission Control System

System description:
Intake
Manifold
Air Cleaner Fuel Evaporative System Drawing
EVAP.Canister
solenoid
valve.
Fuel
Air
Vapor
EVAP
Canister
Fuel
Tank
Fuel Evaporative System Illustrative Diagram
○1 The fuel evaporative system is used to reduce the hydrocarbons emitted into
the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished
effectively by applying activated charcoals in the canister.
FL-9
○2 The fuel vapor evaporated from the sealed fuel tank is led into the canister
which contains activated carbon and stored there, when the engine is not operating or
when refueling to the fuel tank.
○3 The fuel vapor in the canister is routed into the intake manifold through purge
pipelines when the engine is operating. Canister purge volume control solenoid valve
is controlled by ECU. When the engine operates, the flow rate of vapor controlled
by canister purge volume control solenoid valve is proportionally regulated as the air
flow increases.
○4 Canister purge volume control solenoid valve also shuts off the vapor purge
pipes during decelerating and idling.
○5 Riveted on fuel tank, fuel vapor control valve can prevent fuel vapor from
being excessively emitted into canister.
2, Fuel evaporative emission pipeline drawings
2
1
1. Canister Assembly 2, Fuel pipeline Assembly
Note:
■Please do not use soapy water or any type of cleanser while installing vacuum
hose or purge pipelines.
3, Components inspection:
FL-10
2
1) Canister:
○1 The location of canister: Located on the mounting suuport of the canister on
fuel tank.
FL012
○2 canister removal
1) Release left fuel pressure inside

FL013
the fuel pipelines.
2) Open fuel filler cap to release the
pressure in fuel tank.
3) Disconnect the connection of the
pipelines in connector box on canister.
4) Pull upward the holder of the
support of canister.
Pull out the canister from installing support.
5) Fuel filler cap
The fuel filler cap is provided with a vacuum relief valve. When pressure in fuel
tank is high (much fuel vapor), the vacuum reducer valve will close to prevent fuel
vapor from emitting into the atmosphere. When pressure in fuel tank is low (negative
pressure), the vacuum reducer valve will open to allow outside air to enter fuel tank.
Accelerator Control Device

1. Components: Electronic accelerator pedal
FL-11
2, Removal
1) Disconnect the harness connector on electronic accelerator pedal.
2) Remove the 3 mounting screws on the FL014
pedal.

Check pedal for cracks and mobility of movable joint.
4, Installation
■Check whether accelerator pedal can operate smoothly or not.
Service Data and Specifications

Specification Table of Fuel System
Items Descriptions
Fuel tank capacity 45L
Fuel pump
FL-12
Working voltage 6～15 V
Rated working voltage 12 V
System pressure 350 kPa
Range of permissible -30℃～+70℃
operating temperature
Radio disturbance Requirements of clause 6.2,6.4 in GB/18655
characteristic
FL-13
J4 Service Manual Emission control System
Emission Control System

Fuel Evaporative System
1, System description:
Intake
Manifold
Air
Cleaner.
Fuel Evaporative System Drawing
EVAP
Canister
solenoid
valve.
Fuel
Air
Vapor
EVAP
Canister
Fuel
Tank
Fuel Evaporative System Illustrative Diagram
The fuel evaporative system is used to reduce the hydrocarbons emitted into the
atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by
applying activated charcoals in the canister. The fuel vapor evaporated from the
sealed fuel tank is led into the canister which contains activated carbon and stored
there, when the engine is not operating or when refueling to the fuel tank. The fuel
vapor in the canister is routed into the intake manifold through purge pipelines when
the engine is operating. EVAP Canister solenoid valve is controlled by ECU. When
the engine operates, the flow rate of vapor controlled by EVAP Canister solenoid
valve is proportionally regulated as the air flow increases. EVAP canister control
solenoid valve will shut off the vapor purge pipes during decelerating and idling.
EES-1
2,Fuel evaporative emission pipeline drawings
1
6
Fuel Evaporative System Line Drawing
1- Canister Assembly2 - Engine Oil Inlet Hose 3 - Canister to solenoid valve hose
4- Canister to solenoid valve hose 5 - Engine Oil Tube 6 - Fuel Filter
Note:
■Please do not use soapy water or any type of cleanser while installing vacuum
hose or purge pipelines.
1) P Canister
EES001
○1 Check EVAP canister according to 2

1 3
the following procedure
a. block port 1, and blow from port 3,
Confirm that air flow out from port 2
smoothly.
b. block port 3, and blow from port 1,
EES-2
Confirm that air flow out from port 2 smoothly.
○2 Vacuum hose removal
Using slip-joint pliers to loosen the clamps connecting canister to fuel tank and
canister solenoid valve, and pull off vacuum hose.
○3 canister removal
Lift up the canister from the left EES002 Left

daughter board lining front
frame
Remove it from its holder.
2) EVAP Canister solenoid valve.

The changes of the openning of vapor bypass line in canister solenoid valve
controls air flow rate. Canister solenoid valve repeats ON/OFF operations according
to signals sent by ECM and the opening of the valve changes in order to achieve the
best of engine control. The optimal values stored in ECM depend on different engine
conditions. When engine is running, air flow rate of fuel vapor from canister is
regulated with changes of airstream.
○1 Component description:
EVAP Canister solenoid valve uses ON/OFF duty cycle to control THE flow rate
of fuel vapor flowing out of EVAP canister. EVAP canister solenoid valve is driven
by the on/off (ON/OFF) Duty Cycle signal sent from ECM. The longer the pulse
width is, the more fuel vapor flow through the valve.
○2 Remove
a, Disconnect EVAP canister solenoid valve vacuum hose.

b, Disconnect EVAP canister solenoid valve harness connector.
c, Take off EVAP canister solenoid valve from its holder.
EES-3
3) Fuel filler cap

The fuel filler cap is provided with a vacuum relief valve. When pressure in fuel
tank is high (much fuel vapor), the vacuum reducer valve will close to prevent fuel
vapor from emitting into the atmosphere. When pressure in fuel tank is low (negative
pressure), the vacuum reducer valve will open to allow outside air to enter fuel tank.
Positive Crankcase Ventilation Syatem

3
1 2 4
5
6
8
7
Positive Crankcase Ventilation System Diagram

1 - Air Cleaner 2-air intake hose 3 - throttle valve 4 - Purge tank 5-PCV valve
6 - Air Hose 7 - Air Intake Manifold 8 - Fuel Injectors
The function of Positive Crankcase Ventilation System is to make the blowby air
from cylinder flow back to the intake manifold.
Crankcase Ventilation VALVE (PCV) in the crankcase makes the blow by air
from cylinder in crankcase flow back to the intake manifold. With the engine TPS
circuit turning on, the intake manifold can draw the blowby air in crankcase through
PCV valve. Under normal circumstances, the ventilation ability of PCV valve is
adequate to draw the crankcase blowby air and a small volume ventilation air.
Ventilation air is drawen from the air intake hose into crankcase. In this process, air
will go through the air intake hose and the hose of rocker arm cover. When TPS
EES-4
circuit fully opens, the vacuum of intake manifold is insufficient to open PCV valve
and draw the blowby air in crankcase. Air will flow through hose connections in the
opposite direction. PCV valve can't meet requirements if air blowby situation is very
seirous. Because, in any case, there will be some gas goes through the hose and gets
into the air intake hose.
Check Positive Crankcase Ventilation as follows:
1) Operation Principle
PCV Valve Operation Principle Diagram
High
No vacuum
vacuum
Valve Chamber Valve Chamber

Cover Side Cover Side
Engine working Not running Engine working Idling or deceleration
condition condition
PCV valve Not Work PCV valve Fully open
Vacuum change Limit Vacuum change Slight
EES-5
No
Vacuum
vacuum
medium
Valve Chamber Valve Chamber

Cover Side Cover Side
Engine working Working normally Engine working Acceleration and
condition condition high-speed negative
PCV valve Working normally PCV valve Working trady
Vacuum change Large extent Vacuum change Very large
3, Removal and installation
○1 Removal
a. Disconnect PCV valve hoses and cylinder head cover.

b. Remove PCV valve from the cylinder head cover.
○1 PCV valve
When the air stream flows though,

EES003
functional valve will come out with hissing
noise. When put your finger on the valve
inlet, you will feel a strong vacuum pressure.
○2 PCV valve ventilation hose
a. Check the hoses and hose connections for leakage.

b. Disconnect all hoses and use compressed air to clean them. If you cannot
EES-6
clear obstructions in the hose, please replace it.
EES-7
J4 Service Manual Start charging system
Engine Electrical
Start charging system
Start charging system Illustrative Diagram
Start charging system Illustrative Diagram
Batter
y
Battery
1, How to use the battery
Note:
■If it is necessary to use auxiliary battery and cross-wire to start the engine, be
sure to use 12 V auxiliary batteries.
■After connecting the battery, confirm that cross-wire is clamped to the battery
terminals and good contacted.
2, Methods to prevent the battery from over-discharging
To prevent battery from over-discharging, the following precautions should be
attached great importance to.
■Always keep the battery surface (especially the top) clean and dry.
EL-1
■The port of the connecting part should be cleaned and tightened.

■If the vehicle is not in operation for a long period, please disconnect the
negative battery terminal.
■Check the battery for charge status
3, check
1) Visually check
■Check the battery terminals for damage, fluid leakage, if any, please replace it.
2) Check voltage (U)
○1 If U > 13.2 V, please check the electrical system.
○2 If 12.5 V <U <12.9 V, It means the system is working normally.
○3 If 11 V <U <12.4 V, please check the charging system.
○4 If U <11 V, it means the battery is damaged or there is a problem with the
charging system, please check the charging system and the battery.
1) Removal
■Turn ignition switch to “OFF” position
○1 Disconnect negative terminal.
○2 Remove the battery positive terminal and the battery plate mounting bolts,
then take out the board.
○3 Remove the battery.
○4 Remove the battery carrier. Figure2.2.0

02
○1 Battery carrier
■Check for corrosion

If any, please clean it with hot water.
○2 Battery harness
EL-2
■Check for wear or damage 4
If any, please replace.

3) Installation
Note:
■When connecting, please connect the battery positive terminal first.
■After installation, please smear mineral oil on terminals.
Start System
When starter solenoid switch is closed, there is a closed line between the battery
and starter motor. Connect starter to engine block. After being provided with power,
starter turns crankshaft, then the engine will start.
Starter Motor Components Figure
1 - M port 2-S port 3-B port
1) Removal
○1 Disconnect negative battery terminal.
Note: Before disconnecting negative battery terminal,
EL-3
please take out the vehicle key first.
○2 Disconnect starter wiring harness connector
○3 Remove mounting bolts of starter, take off starter.
2) Installation
Note:
■Be sure to tighten the B “end nut
3, Disassembly and Reassembly
1) Disassembly
EL-4
4
1
11
10
8 9
16
3
2
15
14
13
12Exploded view of starter
1 - Screw 2 - Front support 3 - Retaining Ring 4-Ring 5-Pinion gear 6-Ring 7-Solenoid Switch
8-Stars gear 9 - Planetary gear 10-Ball 11-Gasket 12 - Stator 13 - Armature 14 - Brush holder
15 - Rear support 16 - Tighten bolts
2) Check
○1 Check solenoid switch
EL-5
■Before checking, please disconnect negative battery terminal first.

■Disconnect "M" port of starter.
a. Test whether the "S" port and switch is EL001
connected or not.
■If not, please replace the solenoid
switch.
b. Test whether the "S" port and "M" port is connected or not.
■If not, please replace the solenoid EL002
switch.
○2 Check pinion gear
a. Visually check engaged gear's gear

■If the gear is worn or damaged, please replace it (please check gear of flywheel
at the same time).
b. Check the gear of pinion gear.
■If the gear is worn or damaged, please replace it (please check the gear of
Armature shaft at the same).
c. Check whether the pinion gear locks in one direction rotates smoothly in
another direction.
■If the pinion gear can lock or rotate in both direction, or if there is no normal
resistance, please replace it.
EL-6
3) Assembly
When assembling the starter, please add high temperature grease to lubricate
bearings, gears and friction surface. Do as the following instructions.
○1 Gear Clearance Adjustment
■Push the pinion gear out when the

EL003
magnetic switch is powered on
Using a feeler gauge to check the clearance
between pinion gear and thrust block.
■If the clearance is not within the specified EL004

range, please use adjustment shims to adjust.
4, Common trouble diagnosis flow (if any abnormalities are found, please quickly
disconnect the negative battery)
EL-7
Start System common trouble diagnosis flow
Starter motor does not stop Replace the solenoid

switch.
Engine does not start
Y Y
Does the engine start after Is engine running normally? Check Ignition/fuel
crankshaft rotates? system
Check the battery in the

Abnormal
following items: Normal
Repair Starter
A 1.Charge status
2.Terminal connections status
3.Terminal corrosion
Y
Starter motor is running? Y Gear shaft is running? Check pinion gear clutch
N
Check the reducer, armature and gear shaft
N
N
Abnormal
Check safety wire and fuse wire Replacement
Check the battery in the 1.Battery charge

Abnor
following items: 2.Repair bad connections and
mal A
1.Charge status corrosion of the battery
2.Terminal connections status terminals
3.Terminal corrosion
Normal Abnormal
Check Start System lines Repair.
Normal
Solenoid Switch is operating N

Repair Starter
with noises?
Check the engagement between Y

Whether the starter rotates or not?
Replace the solenoid
pinion gear and ring
when connected without load. switch.
Abnormal
1. Adjust the pinion gear shift
2. Check the pinion gear

N
Repair Starter
operates train
Charging system
3. Check the ring
EL-8
Generators provide DC voltage to automotive electrical system and keep the
battery charging status. Voltage output is controlled by IC regulator.
Port "B" is used to supply power to automotive electrical system and to provide
power source for battery. IC regulator check the input voltage at Port 4 (the "S" port),
and so as to control output voltage.
After being powered and grounded, charge warning lights will light on. When
generators are able to provide sufficient high-voltage, ground line open, the charge
warning light will light off. If the charge warning light remains on when the engine is
running, that indicates a failure.
2, Charge warning light
If the generator works with the following occurs, the warning function of IC
regulator will start and illuminate the charge warning light.
■No voltage or excessive high voltage
Figure2.2.0
17
EL-9
1) Removal
○1 Disconnect negative battery terminal.
○2 Disconnect generator wiring harness connector
○3 Loose generator adjusting nut and support nut
Then use the adjusting nut to adjust tension.

■Tightening torque: Generator adjusting nut: 22.5 ±2.5 N. M
Generator support nut: 47 ±5 N m.
○4 Remove generator belt
○5 Remove the generator from the vehicle.
2) Installation
■Install according to the reverse order of removal
■Install generator, please check the generator belt tension. Please refer to"Drive
belts".
Note:
■Tighten the B “port nut
Tightening torque: 10～12N.m
5, charging system trouble diagnosis
Before testing the generator, please confirm the battery is fully charged. Please
use a 30V-voltmeter and suitable testing probe while testing. Reference to checking
list will facilitate generator check.
■Before starting, please check fuse wire.
■Use a fully charged battery
EL-10
Charging System trouble diagnosis flow
Ignition Disconnect Check the following:1Warning

Warning Warning
switch"N" connectors, light bulb 2Warning light
lights lights
pairs L safety wire
off off
Harness Check the
Warning
Ground following: Damaged IC regulator,
lights on
Warning 1.rotor Please replace it
lights on 2.rotor
Check the slip
Engine starts, following: 1. rings
engine speed Warning Drive Belt 2. Engine
3.brush is Warning
1500 RPM lights on Generator "S" idling
lights
port 3.
off
Connector Normal
Warning Normal Warning
lights off lights on

Damaged IC regulator,
Engine speed 2500 Higher than 16.0 V
Please replace it
RPM, measure the
voltage at B port
Lower than 13.0V
Damaged IC
2.Checkthefollowing:1.r
regulator or 2a
otor 2.rotor slip rings
diode assembly,
Warning Lights: "charging" warning 3.brush 4.stator
Please replace it
light in the instrument cluster
Note:
■If there is a problem with the charging system while the test result is normal;
please check "B" port connection (check tightening torque and voltage).
■Check the condition of rotor coil, rotor slip ring, brush and stator coil
If necessary please replace the faulty parts.
EL-11
J4 Service Manual Electronic Control System
Engine Electronic Control System

Precautions
Supplemental Restraint System Precautions
The supplemental restraint system (SRS) such as “air bag” and (SB) “seat belt
pre-tensioner”, used along with the front seat belt, help reduce the risk or severity of
injury to the driver and front passenger in the event of a vehicle collision. For the
information of the proper maintenance of the system, please refer to the air bag
section in the service manual.
Warnings:
■To avoid rendering the SRS inoperative, which could increase the risk of
personal injury or death in the event of a collision, all maintenance operations must be
performed by an authorized JAC dealership.
■Improper maintenance, including incorrect removal and installation of the SRS,
can cause unintentional activation of the system which will lead to personal injury or
death.
About the removal methods of clock spring (gossamer webs) and air bag
controller, please refer to the airbag section.
■Do not use electrical test equipment on any circuit related to the SRS unless
under the instruction of this manual. Airbag circuit wiring harness can be identified by
the harness connectors.
General Precautions:
1、When checking the electrical control system, only the use of digital millimeter
is allowed.
2、During maintenance operation, please use JAC genuine parts. Otherwise the
normal operation of the system cannot be ensured.
3、Only unleaded petrol is allowed to use during maintenance and use.
4、 When performing maintenance operation, please observe the standard service
and diagnostic flows.
EC-1
5、 During maintenance, it is forbidden to disassemble and remove the parts of

the system.
6 、 During maintenance, please be cautious when take and put the electronics
components (electronic control modules, sensors, etc.) to avoid dropping.
7、Establish a sense of environmental protection and effectively dispose of the
wastes produced during maintenance.
Precautions during Maintenance

1、When performing simulation of thermal conditions of a malfunction or other
maintenance operation that may make temperature rise, Do not allow temperature of
the electronic control module to exceed 80℃.
2、For the fuel pressure of the fuel injection system is high (350 kpa), all the oil
pipes used in the system must be able to withstand high pressure. Even when the
engine is not in operation, the oil pipes still have maintained a quite high pressure.
Therefore, during maintenance please note that do not easily remove oil pipes. if it is
necessary to maintain the fuel system, please make sure that release the pressure in the
fuel system before you remove oil pipes.
3、Removal of oil pipes and replacement of fuel filter should be performed by
professional maintenance personnel at a well-ventilated place.
4、Do not energize the fuel pump when removing the electric fuel pump from the
fuel tank so as to avoid producing electric sparks which will cause fire. Operation test
of the fuel pump is not allowed with the pump dry or in water; otherwise service life
of the pump will be reduced. In addition, never connect positive (+) and negative (-)
of the fuel pump inversely.
5、When checking the ignition system, perform spark test only when necessary
and for a duration as short as possible. During inspection, do not open the throttle;
otherwise a large amount of unburned gasoline will enter the exhaust pipe causing
damage to the three way catalyst.
6、 Idle speed adjustment is completely accomplished by the electronic control
system, so no manual regulation is required. The throttle stop screw of the throttle
EC-2
body has been adjusted properly by the manufacturer at factory. Users are not allowed
to change its initial position optionally.
7、 When connecting the battery, do not misconnect its positive (+) and negative
(-) so as to avoid damage to electronic components. This system uses negative ground
(minus earth).
8 、 It is not allowed to remove the battery cable when the engine is running.
Before on-vehicle welding operation, be sure to remove battery positive and negative
cables and the ECU.
9、Do not detect input and output electric signals of parts by piercing wire skins.
EC-3
Structural Principle and Maintenance of Engine Control System
System Description
1- Canister 2-Canister Control Solenoid Valve 3 - Electronic Throttle Body

Assembly 4 - Intake Air Pressure/Temperature Sensor 5 - Injector 6-Camshaft
Position Sensor 7-Ignition Coil 8-Front Oxygen Sensor 9-Three Way Catalytic
Converter 10-Rear Oxygen Sensor 11 - Engine Coolant Temperature Sensor 12 -
crankshaft position sensor 13 - Fuel Filter 14 - Electric Fuel Pump 15 - Fuel Tank 16
- Diagnostic Interface 17 - Engine Control Module
Note:
■ This is the diagram of control system. If the sensor location is not in
conformity with the entity, please refer to the entity.
Multi-point Fuel Injection System
1、 System Description
Multi-point fuel injection (MPI) system consists of the engine's electronic
control module (ECM) and the sensor that detects the engine performance.
EC-4
The control of the system is based on the sensors' signals.Each actuator

operates under control of the ECM. The functions of ECM are to control fuel
injection , idle speed and ignition timing,etc. Also, ECM has several diagnosis
methods that can simplified the troubleshooting process when malfunctions occur.
2、Input/Output Signal
Input/Output Signal table
Sensor Input signal to ECM ECM Actuator

Crankshaft position Engine speed piston position Functions
sensor(position)
Camshaft position sensor(phase
position)
Intake air pressure sensor
Air intake flow Fuel Injection
Intake air temperature sensor Fuel
Oxygen sensor Oxygen concentration of exhaust gas and mixture injector
Electronic throttle position sensor Throttle position ratio control
Knock sensor Engine Knock conditions
A/C switch A/C pressure
Wheel speed sensor Speed
Engine coolant temperature sensor Engine coolant temperature
3、 Start Control
During start-up, special calculation method should be taken to control the air
intake flow, fuel injection and ignition timing. At the beginning of the start-up, the
air in the intake manifold is still while the pressure is same as the atmospheric
pressure. When the throttle is switched off, the electronic throttle is specified as a
fixed parameters based on the starting temperature. In a similar process, the specific
"injection timing" is specified as the initial jet pulse. The fuel injection flow varies
with the engine temperature so as to facilitate an oil film formation on the wall of
the intake manifold and cylinder. Therefore, when the engine reaches a certain
speed, the rich mixture shall be added. As soon as the engine starts running, the
system immediately begins to reduce the cranking enrichment until it completely
stops the cranking enrichment when the starting status is finished. (600 to 700 rpm)
At the start-up, the ignition advance angle is also adjusted constantly, varying with
the engine temperature, intake air temperature, and engine speed.
EC-5
4、Heating control of the heater and three-way catalytic converters
After the engine is started at low temperatures, the air intake flow in cylinder,
fuel injection and electronic ignition are adjusted to meet the requirement of higher
torque; The process continues until the temperature reaches to the appropriate one.
In this phase, the quick heating of three-way catalytic converters is the most
important because exhaust emissions can be significantly reduced by the quick
transition to the operation of three-way catalytic converters. In this condition, make
use of the exhaust emissions to heat the three-way catalytic converters by
moderately delaying the ignition advance angle.
5、 Acceleration/deceleration and motoring with fuel cut-off control
Some of the fuel that injected to the intake manifold will not be delivered to the
cylinder in time to participate in the follow-up process. Instead, it forms a thin oil
film on the wall of the intake manifold. With the workload increasing and the fuel
injection lasting, the volume of fuel that stored in oil film will increase sharply.
When the throttle opening is increased, some of injection fuel will be absorbed by oil
film. Therefore, it is necessary to add appropriate fuel as compensation, and prevent
gas mixture from thinning when accelerating. Once the load factor decreases, the
additional fuel contained in the oil film on the wall of the intake manifold will be
released, then during deceleration, there is a must to reduce the injection duration.
Motoring or traction condition refers to the situation where the value of the engine
power that provided to the flywheel is negative. In this case, the friction of engine
and pumping losses are available to the vehicle deceleration. When the engine is in
motoring or traction condition, the fuel injection is cut off to reduce consumption
and emissions, and more importantly, to protect the three-way catalytic converters.
Once the speed drops to a specific speed which is higher than idle speed and suitable
for fuel supply, the fuel injection system restarts supplying. In fact, there is a speed
range of recovery in ECM procedures. The range varies with the engine temperature,
dynamic changes of engine speed and other parameters, and prevents the engine
speed from decreasing to the specified minimum speed by calculating. Once the
EC-6
injection system starts supplying fuel, the system starts the initial injection pulse to
supply additional fuel, and reforms oil film on the wall of the intake manifold. After
recovery of fuel injection, a torque-based control system makes the engine torque
increase slowly and smoothly (smooth transition).
6、 Idle Control
When the engine is idling, it does not provide torque to flywheel. To ensure
that the engine has a stable operation when the idle speed is as low as possible, the
closed loop idle control system must maintain the balance between the torque
produced by engine and the "power consumption" of engine. The idling needs a
certain power to meet the load requirements. The load comes from the engine
crankshaft, valve mechanism and accessories, such as internal friction in water
pump. The torque-based system controls strategy. Based on closed-loop idle control,
it decides the output torque for maintaining the required idle speed in any operation
conditions. The output torque increases as the engine speed decreases, and
decreases as the engine speed increases.The system responds to the new
"interference factors" by requiring greater torque, such as the start and stop of the
air conditioning compressors. When the engine temperature is low, the torque also
increases to compensate for greater loss from internal friction or maintain a higher
idle speed. All the requirements for output torque is passed to the torque
coordinator. Then the torque coordinator figures out the gas density, the mixture
composition and ignition timing by calculating.
7、Closed-loop Control
The exhaust reprocessing of three-way catalytic converters is effective to
reduce the concentration of harmful substance from the emissions. Three-way
catalytic converters can reduce the hydrocarbon (HC), carbon monoxide (CO) and
nitrogen oxides (NOX) with 98 per cent or more, and converts them into water
(H2O) , carbon dioxide (CO2) and nitrogen (N2). However, only when the engine
excess air coefficient =1 and with a very narrow near range, can it attain such a
high efficiency. The purpose of the closed-loop control is to ensure that the mixed
EC-7
gas density is within this range. Closed-loop control system only works when it is
equipped with oxygen sensors. Oxygen sensors installed at the side of three-way
catalytic converter detects oxygen content from emissions. Thin gas mixture（1）
generates about100 mV sensor voltage, while thick mixture（1) generates about
900 mV sensor voltage. When  =1, the sensor has a voltage leap.  Closed loop
control responds to the input signal (1= thin gas mixture, 1= thick gas mixture)
by modifying the control variable and outputting correction factor as a multiplier to
correct fuel injection duration.
8、Evaporative Emission Control
Due to the heat delivery of external radiation and the oil return, the fuel in fuel
tank is heated which results in the fuel vapor. According to evaporative emissions
regulations, the fuel vapor which contains much HC composition is not allowed to
directly pump into the atmosphere. In the system, fuel vapor is collected in the
charcoal canister through conduit, and flushed into the engine for combustion
processes in due course. The flush air flow is achieved by ECM's control of the
canister control valve. That only works, when the  closed-loop control system is
under operation.
9、Fuel Injection Control
The control of fuel injection timing and fuel injection pulse width supplies the
engine with the best air/air-fuel ratio to keep pace with the changing operating
condition of engine. Each of the cylinder inlets is installed with the injector. Fuel is
pumped out from the fuel tank by fuel pump and sent to each fuel injector. Under
normal circumstances, the crank operates every two circles while fuel is injected
once to each cylinder. The working order of each cylinder is 1-3-4-2.
10、Ignition Timing Control
The power transistor of ignition primary circuit controls the ignition timing by
switching on or off the primary current that flows to the ignition coil, and provide
the best ignition timing based on engine operating condition. Ignition timing is
controlled by ECM according to the engine speed, air intake flow, engine coolant
EC-8
temperature and pressure of the atmosphere.
11、 Self-diagnostic Function
When abnormalities are detected by the sensor or actuator that related to the
emission control, the engine warning light (the check engine light) is lit to inform
the driver. That the abnormalities are detected by the sensor or actuator is
equivalent to that the diagnostic trouble code of the abnormal situation will be
outputted. RAM data in ECM which is related to sensors and actuators, can be read
by diagnostic equipment. And in some circumstances, the actuators can be forced to
drive.
12、Other Control Functions
1）Fuel Pump Control
Connect the fuel pump relay, and then it supplies electricity to the fuel pump
when the engine crankshaft is running.
2) Fan Relay Control
The speed of radiator fan and condenser fan is controlled based on the engine
coolant temperature, vehicle speed and switching signal of air condition (AC).
On-Board Diagnostic System

1、Description
The on-board diagnostic system (for short, OBD system) refers to a diagnostic
system integrated in the engine control system for monitoring faulty parts affecting
exhaust emission and main functions of the engine. It has the functions of
identifying, storing and displaying [through self-diagnosis malfunction indicator
light (MIL)] fault messages.
2、Fault Messages Record
The ECU continuously monitors sensors, actuators, related circuits, MIL,

battery voltage and so on and even the ECU itself. Also it inspects credibility of
output signals of sensors as well as driving signals and internal signals of actuators
EC-9
(e.g.  closed-loop control, coolant temperature, idle speed control, and battery
voltage control, etc.). The ECU will set a fault message record in the RAM fault
memory immediately once a link is found out of order or a signal value incredible.
The fault message records are stored in the form of diagnostic trouble codes (DTCs)
and are displayed in the order of appearance of faults.
Faults can be divided into “steady faults” and “incidental faults” (e.g. those
caused by brief open circuit in harness or poor contact of connector) by frequency
of occurrence.
3、Description and control strategies of malfunction indicator light
1）Malfunction Indicator Light （MIL): Indicates the removal of related parts

or system failure according to law and regulations. MIL is generally an indicator
light that can be displayed on the instrument panel and has a shape conforming to
requirements of laws and regulations and standards.
2）MIL activation abides by the following principles:
①When ignition switch is turned ON (without starting the
engine), the MIL will keep lighting up.
②If there is no fault request for MIL lighting up in the fault memory 3
seconds after engine start, the MIL will go out.
③When there is a fault request for MIL lighting up in the fault memory or a
same request outside the ECU, the MIL will light up.
④When there is a MIL flashing request outside the ECU, or a misfire cause
requiring MIL flashing, or a fault request for MIL flashing in the fault memory,
the MIL will flash at a frequency of 1Hz.
4、 Troubleshooting Steps
1）For vehicles with OBD functions, their troubleshooting should generally
follow the procedure below:
Service Procedure Chart for OBD Malfunctions
EC-10
1.Connect diagnostic test

equipment to diagnostic interface, and turn on
the equipment.
2.Turn ignition switch ON.
3.Read fault-related information

[DTCs, freeze frames (FFs), etc.]; refer to the
service manual and recognize faulty
components and fault types; prepare
maintenance scheme according to fault-related
information and experience.
4. Perform troubleshooting.
5.Clear fault memory; drive your

vehicle appropriately with driving patterns
satisfying corresponding trouble diagnostic
criteria; read fault information and make sure
the trouble has been cleared.
Engine Troubleshooting
1、Troubleshooting overview of engine control system
If the electronic engine control system components (e.g. sensors, ECM, injectors,
etc.), Have malfunctions, fuel supply interruption, or wrong supply of fuel capacity
for the engine in different conditions, the followings will occur.
a.Difficult or completely unable to start the

engine
b.Unstable idle speed
EC-11
c.Poor driving performance
If any of the above occurs, firstly carry out the routine tests including the engine
basic checks (ignition system failure, engine correct adjustment etc.). Then check the
engine electronic control system components with fault diagnosis instruments.
Note:
■ Read the diagnostic trouble codes first before removing or installing any parts,
and then disconnect the negative battery terminal.
■Please disconnect the wiring harness to the battery terminal before you turn
off the ignition switch. If the engine is running or the ignition switch is turned on,
the disconnection of the battery harness will cause damage to ECM.
■The harness between ECM and sensors should be shielded by the shielded
ground wire that connected to the car body, which aims to prevent the ignition
system interference and radio interference. If the shielded wiring harness
malfunctions, wire harness must be replaced.
■Check the alternator charging status, and do not disconnect the battery positive
to avoid ECM damage.
■When using an external charger to charge the battery, please disconnect the
battery terminals to avoid ECM damage.
EC-12
2、Trouble Diagnosis Flowchart
EC-13
3、Fault symptom check list
Fault symptom check list
Fault Symptom Check

Unable to communicate with Unable to communicate with all system Sequence
1
Number
the diagnostic scanner
Only unable to communicate with ECM 2
When the ignition switch is turned on ,the engine

3
warning light does not light up immediately
Engine warning light and the
corresponding components Engine warning lights light up simultaneously and 4
do not go out
No initial ignition (unable to start) 5
With initial ignition, but not completely burned 6

Start
(unable to start)
Long start-up time (unable to have a normal start) 7
Unstable idle speed (idle speed fluctuations, 8

hunting)
Idle speed stability (idle speed High idle speed (idle speed abnormality) 9
abnormality）
Low idle speed (idle speed abnormality) 10
When engine is cold, flameout occurs during 11

idling (flameout in deceleration)
Idle speed stability (engine When engine is hot, flameout occurs during 12
flameout) idling (flameout in deceleration)
Engine flameout occurs in start (flameout in 13

acceleration)
Engine flameout occurs in acceleration 14
Surge in vehicle and decrease or instability of 15

vehicle speed
There is an impact or vibration when accelerating 16
Driving There is an impact or vibration when slowing 17

down
Poor acceleration performance 18
Surge 19
Cylinder knocking 20
Unable to stop 21
High CO and HC concentration during idling 22
EC-14
Low alternator voltage 23

Idle speed is abnormal when the air conditioning is turned on 24
Fan is not functioning properly 25
4、Fault symptom list
Fault symptom list
Items Symptoms
No start Starter drag engine, but if no combustion in the cylinder, the
engine will not start
Start Engine stops after There is combustion in the cylinder , but the engine stops
combustion immediately
Hard starting Engine starts after crankshaft operates for a few minutes
Hunting Engine speed is not constant and changes within idle speed
range
Idle speed Idle speed fluctuations Usually, it can be judged by the swing of tachometer
stability pointer, as well as the vibration that is passed to the steering
wheel, shift lever, and body, etc.
Idle speed is not correct Engine is idling in the incorrect speed
Flameout occurs (flameout When the foot is off the accelerator pedal, engine stops no
in deceleration) matter whether the vehicle is moving or not.
Flameout occurs (flameout When accelerator pedal is hit or stepped on, the engine stops
in acceleration)
"Surge phenomenon " is a phenomenon that the motor
speed (engine speed)is slower than the current speed when
Surge in vehicle and
speed pedal is hit to speed up, or there is a temporary speed
decrease of vehicle speed
(engine speed) decline during acceleration
Poor acceleration performance refers to that the vehicle
cannot obtain a throttle opening to change the speed, which
Poor acceleration
is still a fault even accelerating smoothly; or refers to the
performance
Driving incapability to achieve the maximum speeds
Instability Engine speed increases slowly when first hitting the
accelerator pedal to speed up
Impact A large impact or vibration can be sensed when the engine
speed up or slow down
Surge There is a repeated surge forward when driving at a constant
speed or variable speed
Cylinder knocking A strong voice which is like a hammer striking against the
cylinder wall during driving, is harmful to driving
EC-15
Parking Continuous running (Unable

to stop)
5、Basic Fault Check
When check the engine failure, the first should be the basic system check in
terms of order. If there are the phenomena of engine failure to start, unsteady idle
speed and insufficient fuel supply, please check the following basic systems:
a. Power Supply: battery, fusible line and blown fuse.
b. Earth wire
c. Fuel supply: oil tube, fuel filter and fuel pump.
d. Ignition system ignition plug, high-tension and line ignition coil.
e. Emission Control System: vacuum leaks
f. Others: ignition timing and idling.
The Electronic Engine Control System failure is usually caused by poor

contact of the harness connector; therefore check all the wiring harness connector
to verify that they are properly connected.
6、Idle Speed Check
1）Check Conditions
Note:
■First of all, check the general projects including ignition plug, fuel injector,
and cylinder compression pressure and so on.
①Engine warms up.
② Lights, electronic fan and all of the other accessories are turned off.
③ the transmission is in neutral.
④ Steering wheel is in the middle (with power steering system).

2） Connect diagnostic apparatus
3）Start engine and make it run at the minimum idle speed.
4) Make the engine run for 5s or more at the speed of 2000 to 3000 r/min.
Then, make the engine idle for 2 minutes.
EC-16
5) Read the idle speed (750±30r/min).
7 、 Fuel Pressure Test

Note:
■Release the pressure in fuel line first to eliminate dangers before
disconnecting the fuel line
■Always use the" O" ring to maintain good sealing performance of the
connector of fuel hose.
■Please do not operate electric system when you check.
Note: Prepare a container to avoid fuel spills before disconnecting the fuel lines.
1 ） Release the fuel pressure to zero. Please refer to "Release fuel pressure"
section.
2) Remove the fuel pressure check nut from the fuel injector rail.
3）Connect the fuel pressure gauges.
4) Turn the ignition switch to the "ON" position and check whether there is a
fuel leak.
5) Start the engine and male it idle, and check whether there is a fuel leak.
6) Take the reading on the fuel gauge.
■The fuel pressure：350KPa
Note:
■Do not perform Fuel Pressure Check when the system is running.
■During checking the fuel pressure, always make sure to check the junctions of
fuel pipes for leakage.
7) If the measurement of the fuel pressure is beyond the standard value,

analyze the possible cause in accordance with the following table, then carry
out necessary maintenance
Fuel System
Troubleshooting
table 1
Trouble Possible causes Solutions to troubles

Symptoms:
EC-17
Fuel filter is blocked Replace the fuel filter

Oil pressure is too
low
Pump damage or fuel leak in the fuel return pipe at Replace fuel pump.
the side of oil pressure regulator
Oil pressure regulator cementation Replace fuel pump.

Oil pressure is too
high
Fuel return pipe is blocked or bent Repair or replace fuel

pipe.
8) Stop the engine and check the reading changes of fuel pressure gauge for 5
minutes. If oil pressure gauge reading drops, observe the lower rate. Analyze and
perform troubleshooting according to the following table.
Fuel System
Troubleshooting
table 2
Trouble Symptoms: Possible causes Solutions to troubles

Oil pressure declines slowly after engine Fuel injector leakage Replace fuel injector
stopped
Oil pressure declines completely after Fuel pump faults Replace fuel pump.
engine stopped
9) Reduce the pressure in the fuel line.

10) Disconnect the fuel pressure gauge and install the check nut.
11) Check whether there is a fuel leak or not by the following steps.
①Turn ignition switch to “ON” position (do not start engine), and check the
②Start engine and rev it up, and re-confirm that whether there is leakage at
connections of fuel system or not.
EC-18
Structural Principle and Maintenance of Engine electronic
components
Intake Air Pressure/Temperature Sensor（MAP/MAT）
1、Component Description
Intake air pressure/temperature sensor is used to measure the absolute pressure
and intake air temperature of the intake manifold, providing the information of engine
load and intake air temperature. The piezoelectric to measure intake air pressure can
provide "the load signal" to the controller according to the differential between
atmospheric pressure and the intake manifold pressure; 5 V voltages is provided by
the controller. And 0-5 V voltage is back fed to the controller in accordance with the
intake air pressure.
NTC (negative temperature coefficient) sensor whose resistance changes with the
intake air temperature to measure the intake
temperature, transmit the voltage that EC001
indicates the temperature change to ECU.

2、Installation Positions of Components:
It is mounted behind the throttle body;
please refer to the diagram at the right.
3、Terminal Definition
Terminal 1 (grounded): By ECU (17 #
EC002
pin) grounded
Terminal 2 (temperature signal: output
temperature signal to ECU (42#pin)
Terminal 3 (5V power supply): ECU (33#
pin) provides 5V voltage
EC-19
Terminal 4 (temperature signal: output temperature signal to ECU (37#pin)
Working voltage：5±0.1V
3、Trouble Diagnosis
 No signal fluctuations；
 Sensor signal improper
 The intake air pressure detected by sensor is above the upper limit.
 The intake air pressure detected by sensor is below the lower limit.
 The voltage of temperature signal is too low.
 The voltage of temperature signal is too high.
4、Troubleshooting
 Check whether there is a short circuit or open circuit in the connection
between the ECU and 4 wires of the sensor.
 Whether the sensor inspection holes are blocked.
 Whether there is a short circuit, open circuit or grounded circuit among the
sensor harness.
 Disconnect the sensor harness and turn on the ignition switch, and the
voltage value of terminal 3 should be 5V.
 To measure the temperature sensor's characteristics: disconnect the sensor
harness, and measure the sensor's resistance between terminal 1 and terminal
2. (Resistance Reference Value: 0℃-5280～6570Ω，20℃-2280～2740Ω，
40℃-1060～1300Ω，60℃-530～660Ω）
 Measure the voltage of the pressure signal. (Pressure Signal Reference
Value：20kPa-0.40V,35kPa-1.10V,
95 kPa - 3.80 V, 115 kPa - 4.65 V)
 Check whether the sensor has been exposed to a impact that can cause a
sensor failure.
EC-20
 Range of working pressure : 10kPa～115kPa

 Range of operating temperature：-40～125℃
5、Removal and Installation
1) Removal
① Disconnect the harness connector of the intake air pressure/temperature
sensor.
Note:
■Make sure ignition switch is in OFF position.
② Remove the mounting screws of the intake air pressure/temperature sensor,
and take off the sensor with crosshead screwdriver.
2）Installation.
Please note the followings and install in the reverse order of removal.
■Apply a little engine oil to sensor seal ring for easier installation.
■Make sure sensor and intake manifold have fitted perfectly.
■Make sure harness connector is installed securely.
Engine Coolant Temperature Sensor

1、Component description
The engine coolant temperature sensor detects the coolant temperature of the
engine, and then sends the signal to ECM for the control of starting, idling,ignition
timing during normal operation and the pulse width of fuel injection. Simultaneously
the sensor provides water temperature signal to the gauge for displaying temperature.
It uses a negative temperature coefficient thermistor whose resistance value decreases
with temperature rise.
2、Installation Positions of Components
As the installation positions, please refer to the diagram.
EC-21
Terminal A (water temperature signal): EC003
Outputs cooling water temperature signal

To the ECU (39#pin);
Terminal B: connected to water
thermometer.
Terminal C (grounded): grounded by
ECU (17 # pin)
 The signal of water temperature is above the limit.
 The signal of water temperature is below the limit.
 Water temperature sensor with short circuit or open circuit
Data of normal temperature resistance value：2.5±5% k。
Characteristics of the sensor's temperature-resistance:
I - ECU II - Gauge
Temperature Standard Temperature Standard
°C resistance kΩ °C resistance Ω
EC-22
-20 13.71 - 16.49 60 100-120

25 1.825-2.155 90 41-46
80 0.303-0.326 115 24-26
110 0.1383-0.1451 120 20.5-23.5
5、Troubleshooting
 Check whether there is a short circuit or open circuit in the connection
among the 3 wires in the sensor, the ECU and the gauge .
 Whether there is a short circuit,open circuit or grounded circuit among the
sensor harness；
 The wires poorly grounded will easily lead to a high indication of the water
temperature gauge of the engine;
 Working voltage：5V；
 Range of operating temperature：-40～135℃.
6、Removal and installation
1) Removal
① Drain engine coolant from the radiator
② Disconnect the harness connector of engine coolant temperature sensor.
③ Remove engine coolant temperature sensor
2）Installation
■Smear threaded portion of the sensor with plane seal gum, and tighten it as
required.
Tightening torque：11-16N.m
Start the engine and turn it to idle running. Visually check for engine coolant
leakage.
EC-23
Electronic Throttle
Electronic Throttle body assembly is one of the key parts of the intake control
management system in modern engine management systems. It has direct control over
the engine air intake volume, which in turn controls the speed of the engine and the
output power.
The mechanical control system that control the throttle body mechanically is
removed from electronic throttle body while the drive motor and drive gear
mechanism are added as well as necessary mechanical drive components and the
special throttle position sensor that is more powerful in terms of functions and
reliability.
EC004
It is mounted on the intake manifold.
3、 Throttle Terminals Definition

Terminal 1 (motor negative): connected
EC005
with ECU (66 #、67# pin);
Terminal 2 (sensor grounded): By ECU
(78# pin) grounded
Terminal 3 (sensor supply): power
supplied by ECU (32# pin)
Terminal 4 (motor positive): connected
with ECU (64#、65# pin)
Terminal 5 (signal 2): connected with ECU (38# pin)
Terminal 6 (signal 1): connected with ECU (40# pin)
EC-24
 Drive motor failure of the throttle body:
 Open circuit of drive motor assembly;
 Short circuit of the internal coil in drive motor assembly;
 The internal line of drive motor assembly is burned out;
 Excessive wear or damage inside the drive motor assembly.
 Riveting failure of the throttle body:
 Excessive wear and damage of the throttle body gear.
 Bearing seizure and damage of the throttle body gear ;
 Poor contact of throttle position sensor; instable output signal;
 Valve that clogged by debris or sludge should be given periodic
cleaning.
5、Troubleshooting
 Mainly check whether there is a short circuit,open circuit or grounded
circuit between the sensor and ECU harness;
 Use multimeter to detect whether there is a beating between the sensor signal
port and ground wire when the throttle is switched on or switched off;
 Adaptive temperature to working conditions:-40～125℃;
 Throttle Response Time:≤100ms (fully open to fully closed), ≤150ms (fully
closed to fully open)
Throttle position sensor measurement range:
Voltage division ratio Angle sensor 1 Angle sensor 2
New State BDC 10%±4% 90%±4%

TDC 93%±4% 7%±4%
Old State BDC 10%±5% 90%±5%
TDC 93%±5% 7%±5%
6、Removal and installation of throttle position sensor

1) Removal
EC-25
① Disconnect TPS harness connector.

Note: Make sure ignition switch is in OFF position.
 Remove throttle body assembly.
③ Remove bolt securing TPS, and take off the sensor.
2）Installation
Please note the following procedure and install in the reverse order of removal.
■Tightening torque：5.5～6.5 N·m
Crankshaft Position Sensor and Camshaft Position Sensor

The Camshaft Position Sensor and Crankshaft Position Sensor belong to the
category of Hall Sensor.They operate with the camshaft and crankshaft signal wheel
which is corresponding to a specific location of the engine.According to the sensor's
digital voltage signal ECU determines the working conditions of engine, and
implements a one-to-one control.
Performance: EC006
Operating temperature: -40～150℃

System Input voltage: 5.0 V (power
supplied by the controller)
The clearance: 0.1 - 1.5 mm
Crankshaft Position Sensor
Crankshaft
2、Installation Positions of Component
Separately installed near the camshaft and crankshaft
EC007
Camshaft Position
Camshaft Sensor
position
EC-26
EC008
Crankshaft position sensor: ① ② ③
Terminal 1: power supplied by ECU

(33# pin) （5V）
Terminal 2: signal outputted to ECU
(15#pin)
Terminal 3: grounded by ECU (17#pin)
Camshaft position sensor:

EC009
Terminal 1: power supplied by ECU
(32# pin) （5V）
Terminal 2: signal outputted to ECU ① ②
(79#pin)
Terminal 3: grounded by ECU (36#pin)
The ECU carries out real-time monitoring on sensor and wires
 Sensor open circuit;
 Sensor Internal short circuit
 Line-to-ground Sensor Hall elements;
 Short circuit between the Sensor Hall elements and system reference voltage
signal line.
5、Troubleshooting
 Check whether the sensor line is normal or the line is shorted to ground.
 Use Tee connecting sensor and the harness connector for to check whether
the power, ground wire and signal lines are connected properly.
EC-27

1) Removal
① Disconnect Crankshaft position sensor and harness connector of the Camshaft
Position Sensor
② Remove bolt securing CKP sensor, and take off the sensor.
2）Installation
■Pay attention to mounting clearance
Standard value: 0.1～1.5mm
■Tightening torque: 8～10 N·m
Oxygen sensor
Oxygen sensor is used to provide the information that whether oxygen is excess
after complete combustion of intake air and fuel that injected into the engine cylinder.
Based on this information, ECU takes a closed loop control of fuel amount to ensure
that the three main toxic ingredients in engine exhaust can achieve maximum
transformation and purification from the operation of three-way catalytic converter.
The sensing component is a kind of ceramic tube with pores.The outside tube
wall is surrounded by engine while the inside is open to the atmosphere. The sensor
indirectly calculates pulse width of fuel injection according to the difference of
oxygen concentration outside and inside and deliver the difference to ECU which in
turn controls fuel injection again. Also test the data outputted by rear Oxygen Sensor,
and make a comparison between the data outputted by front oxygen sensor and the
rear one to monitor whether three-way catalytic operates well.
Oxygen Sensor operating voltage fluctuates between 0.1v and 0.9 V with the
frequency of 5 to 8 times in 10s. Those aged sensor whose frequency is below that
value needs to be replaced. And the sensor cannot be repaired.
EC-28

The front (upstream) oxygen sensor is mounted on the exhaust manifold portion
in front of three way catalytic converter (catalyst).
The rear (downstream) oxygen sensor is
EC010
mounted behind three way catalytic
converter.
Front oxygen sensor
Terminal 1 (heater wire +): power supplied by main relay;
Terminal 2 (heater wire -): connected with ECU (26# pin);
Terminal 3 (grounded): grounded by ECU (36# pin);
Terminal 4 (signal): output signal to ECU (18#pin).
Rear oxygen sensor
Terminal 1 (heater wire -): connected with ECU (28# pin);
Terminal 2 (signal): output signal to ECU (55#pin).
Terminal 3 (heater wire +): power supplied by main relay;
Terminal 4 (grounded): grounded by ECU (36# pin).
The ECU detects the oxygen sensor line, ECU internal power amplification
circuit and detection circuit. Once one of the following situations is found, oxygen
sensor fault location is set:
 The battery voltage is not credible
 The manifold absolute pressure signal is not credible
 Engine coolant temperature signal is not credible
 Drive fault of fuel injector
EC-29
After oxygen sensor fault location is set, the closed loop control of fuel amount is
turned off and fuel amount is determined by the basic fuel injection time that stored in
the ECU.
 Mainly check whether there is a poor plug connection between the wires of
the sensor ,a short circuit or open circuit;
 Sensor damage is generally caused by the lead and phosphorus poisoning,
therefore pay attention to the quality of oil products, as well as the engine
excessive oil consumption which is also likely to lead to sensor failure.
 The frequency of oxygen sensor changes should not be less than a certain
number of times in a certain period.
1) Removal
① Disconnect oxygen sensor harness connector
② Using oxygen sensor special socket to remove oxygen sensor
Note:
■Seal mounting hole of oxygen sensor with lint-free cotton yarn to prevent
foreign materials or oil/water from entering exhaust manifold
■Visually check oxygen sensor appearance.
Brownish red: lead poisoning
Off white: normal
Black: carbon deposition
2）Installation
 Pay attention to the route of oxygen sensor harness.
 Tightening torque：40～60 N·m
 After replacing the oxygen sensor, rust inhibiting oil should be smeared on
the Oxygen Sensor to prevent rust which can be an obstacle of removal.
EC-30
Fuel injector
The fuel provided by injection pump is stored and allocated by fuel pressure rail
component, which provides a more stable pressure environment for fuel system,
balancing the cylinder pressure and fuel supply to make the engine running smoothly.
The fuel injector injects fuel according to injection signals transmitted from the ECU
and determines fuel injection flow by the opening time of fuel injector solenoid valve.
They are installed on the fuel rail.
Terminal 1 (power supply): after relay power supply;
Terminal 2 (signal): connected with the ECU (first cylinder 27#pin, second
cylinder 6#pin, third cylinder 7 #pin, fourth cylinder 47#pin).
Note:
■Please clean and analyze fuel injectors using the special fuel injector cleaner
and analyzer within a certain period.
1）Check resistance
Note: Check after harness connector is disconnected.
■Standard resistance value: 11-16Ω
2） Use trouble diagnostic tester to check the working time of fuel injector
■Standard working time: 2.0～3.0ms at idle (increased at acceleration).
3）Check operating sound of each fuel injector
Note:
■Listen to click sound of fuel injector at idle with stethoscope, or check the vibration of fuel
EC-31
injector with fingers.
If no vibration is perceived, check harness connector, injector, or ECU signal

controlling fuel injector.
Please refer to "Fuel System" section.
Knock sensor
Knock Sensor is installed at the side of the cylinder typically between Cylinder-2
and Cylinder-3, which is conducive to engine knock balance. ECU makes use of the
vibration frequency signal outputted from of the knock sensor to pass through its
internal filtering, which in turn determines whether there is an engine knock. When a
knock signal is detected, ECU will gradually decrease until there is no knock, and
then recovers gradually until to the knock edge,and so forth.
They are mounted at the side of cylinder. EC011
3、Components inspection
1）Terminal Definition
Terminal 1(Knock sensor signal A):
sends signal to ECU (19#pin);
Terminal 2(Knock sensor signal A):
sends signal to ECU (20#pin);
Terminal 3 (shield)
2）Check resistance
EC-32
Resistance values: >1MΩ（25±5℃）

4、Trouble Diagnosis:
The ECU detects the knock sensor, power amplification circuit and detection
circuit. Once one of the following situations is found, knock sensor fault flag bit is set:
 Knock sensor fault;
 Knock control data processing circuit fault;
 Sub-cylinder signal is not credible;
 Sensor line fault.
After the knock sensor failure position is set, knock closed loop control is turned
off, and the ignition advance angle stored in the ECU is fixed in a safety angle by the
software application. When the error frequency of drops below the set value, fault flag
bits are reset
1) Removal
① Disconnect knock sensor harness connector.
② Remove knock sensor lock bolt, and take off the sensor.
Note:
■Do not drop or damage the sensor.
2）Installation
■Tightening torque: 16～24N·m
A/C Switch and Relay

When Air conditioning is on, A/C switch transmit the battery voltage signal to
ECM. After the signal that A/C is switched on is inputted, the ECM drive electronic
throttle raises the engine idle speed, and corrects the ignition advance angle.
Meanwhile ECM controls the operation of A/C relay to make the compressor
electromagnetic clutch operate.
EC-33
2、Components Inspection
When the engine is idling, use the fault diagnostic apparatus to check whether
the air conditioning switch operates well
A/C switch checklist
Check items A/C switch Normal instructions

Off Off
A/C switch
On On
Off Off(compressor clutch does not work)
A/C compressor
On On(compressor clutch works)
Continuously Variable Cam Phase Regulator and its Control Valve

Continuously Variable cam phase regulator is used for changing the timing of
valve mechanism. It can continuously adjust the phase relationships between camshaft
and crankshaft according to the system requirements to achieve the control of timing
phase.
VVT pressure regulating valve is a four path pulse-width control solenoid valve
with two-way movement, it can achieve the oil flow control through the axial
movement of plunger valve. According to the duty cycle signal of the adjustable
pulse-width , Engine ECU changes the oil flow leading to both sides of the rotor
blades, so as to control the cam timing and phases that relative to crankshaft .
Main functions of the system：
 Improve the intake efficiency:
 Improve dilution control to get better fuel economy when there is partial
load.
 Being as an alternative to Exhaust Gas Recirculation (EGR) system with the
ability to reduce equivalent amount and NOx emission, it also has the
potential to reduce HC emissions and heat radiation;
 The use of the default variable cam phase system return helps improve the
EC-34
cold start performance and reduce HC emission.

EC012
EC003
3、Component Circuit Diagram

Terminal 1 (control signal): ECU (48# pin)
provides a control signal.
Terminal 2: main relay control.
Diagnostic system is one of the most complex parts of the Cam Phase Adjust
control system. The cam sensor, target wheel and oil control valve must be possessed
with a component-level diagnostic capabilities and must constantly confirm the
integrity of cam signal to ensure the cam phase measurement. The drive signal of oil
control valve needs a check as well as the fuel injection nozzles and ignition coil
driver. But for the oil control valve and the phaser, usually there is more responsible
diagnosis. The phase regulator and oil control valve circuit are detected by ECU for
the following problems:
EC-35
 Slow response of the air intake VCP phase.

 Phase error of the air intake VCP camshaft.
 The air intake VCP and cam teeth learning are out of range.
 The air intake VCP hydraulic control valve is clamped.
5、Troubleshooting
 Check whether there is a short circuit or open circuit of sensor signal.
 Check whether there are crossed lines between the harness.
 Check whether there is a short circuit between the sensor line and the power.
 Check whether there is a blockage or good ventilation inside the VCP and
oil control valve.
 Check VCP working conditions as follows:
Items Value
Input voltage 11.5 - 18.0 VDC; nominal 13.5 ±1.0
VDC
The average working current 1.0 AMP
when remain in position *
The maximum current Duty cycle when 100%, 2.5 AMP when
- 40ºC,15.5V
Ambient temperature -40ºC to 150ºC
Under-the-hood temperature -40ºC to 150ºC
Solenoid valve temperature -10ºC to 150ºC
 Check the oil control valve working conditions as follows:
Type Oil control solenoid valve
Coil impedance Nominal: 7.0 Ω@20 ºC
5.6Ω@-30 ºC
10.6 Ω@150 ºC
Coil inductance 18mH@1KHz
The minimum current for 1.07 AMP
complete route of plunger valve
Input voltage(by coil) Nominal: 13 ± 0.5V
Minimum: 11.0V
Maximum: 18.0 volts (CARB
requirements)
Start the response in normal <50ms in Tcoil <65ºC
EC-36
input voltage
Turn off the response <50ms in Tcoil <65ºC
Please refer to the "timing chain wheel system”
Canister solenoid valve

Control the cleaning air flow from the canister to the intake manifold. Because
the canister has a limited adsorbing capacity, if gasoline volatilizes to the outside, it
will cause atmospheric pollution and add additional insecurity factors.
Inside the canister solenoid valve is a solenoid valve structure whose opening
control is determined by the digital control square pulse outputted by ECU .The
canister solenoid valve opening varies according to the different engine working
conditions.To ensure the output of engine power when there is heavy engine load and
idling, the canister solenoid valve refuses to work.

EC013
Terminal 1: main relay output end.
Terminal2 (control signal): ECU (46# pin)
EC-37
provides a control signal.

 Short circuit between sensor line and ground
 Short circuit between sensor line and power supply
 Open circuit of sensor line
5、Troubleshooting
 Check whether there is a short circuit or open circuit of sensor signal.
 Check whether there are crossed lines between the harnesses.
 Check whether there is a short circuit between the sensor line and the power.
 Check whether there is a blockage or good ventilation inside the canister
control solenoid valve.
 Operating temperature: -40～120℃;
 Coil resistance: 20.5±1.5Ω（20℃）；
Working voltage：8～16V；
 Rated operational voltage：12V.
1) Removal
① Disconnect the horse at the side of canister solenoid valve.
② Disconnect the canister solenoid valve harness connector.
③ Take off canister solenoid valve from its holder.
2）Installation
■When installing, ensure that the air flow direction is within the specification
and check whether canister solenoid valve has wears or cracks.
■During removal and installation, avoid entry of such fluids as water and oil into
the valve.
Ignition coil
Ignition Coil transforms the low voltage of primary winding into the high voltage
EC-38
of the secondary winding, and the spark plugs discharge sparks to ignite the fuel air
mixture in the cylinder.
 Ignition Coil Voltage Range:6～16V

 Ignition Coil secondary resistance: 8.7±0.87 KΩ
Installed on the top of the cylinder head cover
Terminal 1 (control signal): ECU (NO.1 cylinder
corresponds to 27# pin, NO.2 cylinder corresponds to 6# pin,
NO.3 cylinder corresponds to 7#pin, NO.4 cylinder corresponds
to 47# pin) transmits control signal;
Terminal 2 (power supply): main relay control;
Terminal 3 (grounded): engine grounded.
As ECU does not have a function of fault diagnosis on ignition coils, if the
ignition coil has any fault, ECU would output no trouble codes. Only by checking the
ignition coil resistance can determine whether the ignition coil is working
properly.Under normal circumstances,the heat given by working ignition coil is
relatively large,which will lead to increasing resistance value of ignition coil.As a
result, the faults like unsteady engine operation and auto shut-off may occur. However,
the control line of the ignition coil can be monitored by ECU. When ECU detects an
ignition coil fault, it will turn off the injector that corresponding to the cylinder.
EC-39
 Short circuit between control lines and ground.

 Short circuit between control lines and power supply circuit.
 Open circuit of control line.
 Short Circuit and/or Broken Circuit inside coil
 Coil leakage and shell cracks;
 Aging coil causes inadequate ignition energy.
Refer to “Ignition System” for removal and installation.
Electric Fuel Pump

The fuel is delivered from the fuel tank to the engine fuel manifold in terms of a
certain oil pressure and flow, and a stable oil pressure is maintained (by the pressure
regulator).
They are installed inside the fuel tank.
3、Component circuit diagram
Pin description: electric fuel pump has two pins, beside which is the fuel pump
housing carved with a “+" and " -" sign, which respectively means the positive (pump
relay) and ground connection.
EC-40
4、Components Inspection:
1) Check the internal resistance of the fuel pump.
The internal resistance is not zero or infinite.
2) Check the fuel pressure.
Please refer to "Fuel System".
Please refer to "Fuel Pump Assembly" section.
Note:
■In order to prevent the fuel pump accidental damage, please do not operate in
oil-free status.
■If fuel pump needs to be replaced, please note that rinse the fuel tank and fuel
lines and replace the fuel filter.
Engine Electronic Control Module （ECM）

1、System Description
M (E) 7 system is the EMS system that based on engine theoretical model:
- Air Inflation Calculation Model: through the residual exhaust sub-model, the
exhaust back pressure sub-models and intake air temperature sub-models, it can
accurately calculate the actual mass of intake air of each cycle, which serves as a
basis for torque control and fuel injection calculation.
- Load forecast model: based on gradient changes of the intake manifold pressure,
it can calculate the actual mass of intake air in a circle which serves as a basis for
oil film calculation in dynamic working conditions before fuel injection,
- Torque Calculation Model: It is a torque model that is based on a real-time test
EC-41
and consists of ignition timing and fuel-air ratio changes, and it is a main line
running through this system.
- Temperature Protection Model: It is a exhaust temperature model that is based
on a real-time test and consists of fuel-air ratio changes, ignition timing and the
influence of ambient temperature changes. It is able to achieve a better balance
between catalytic converters protection and fuel consumption.
1) Function
 Main power supply relay control of fully built unit car
 Speed and density of air flow
 Closed-loop control of multi-point sequential fuel injection (including MAP
CID pressure to judge cylinders)
 Closed-loop control of multi-point sequential fuel injection
 Different ways of fuel supply such as fuel return, no fuel return , half fuel
return and so on
 Fuel Pump Operation Control
 Direct ignition without distributor and ECU built-in ignition module with
sequential ignition order of 4 cylinders
 Use Electronic Throttle to control the quick response and accuracy of the air
intake flow and use ECU to achieve torque control and improve reliability
 VVT - I (Electronically controlled air intake phase variable Cam Control
Unit) controls the engine air intake charge, torque and increases power
 Knock control
 Canister solenoid valve control
 Air-conditioning and cooling water tank fan control
 Mileage memory
 Over voltage protection
 Electron security
 CAN - BUS communication interface can communicates with automatic
transmission control module or ABS system
 Open and modular C language programming and so
EC-42
2) ECM Pin Definition:

ECM pin Definition Table
Pin Function Pin Function
1 Ignition coil （NO.2 cylinder） 12 UPS
2 Ignition coil （NO.3cylinder） 13 Ignition switch
3 Ignition 14 Main relay
4 Ignition coil （NO.4cylinder） 15 Engine speed sensor
5 Ignition coil （NO.1cylinder） 16 Accelerator pedal sensor
6 Fuel injector 4 (No. 2 cylinder) 17 Sensor 1
7 Fuel injector 4 (No. 3 cylinder) 18 Upstream Oxygen sensor
8 Engine speed output 19 Knock sensor terminal A
9 Water temperature output 20 Knock sensor terminal A
10 Fuel consumption output 21 Brake light
11 SVS light 22
23 62
24 63 Non-continuous power supply
25 64 Throttle actuator
26 Upstream Oxygen sensor heating 65 Throttle actuator
27 Fuel injector 1 (No. 1 cylinder) 66 Throttle actuator
28 Downstream Oxygen sensor heating 67 Throttle actuator
29 68 Fan Control 2
30 69 Fuel pump relay
31 MIL light 70 A/C compressor relay
32 5V power supply 2 71 Diagnostic K-line
33 5V power supply 1 72 High Knock sensor
34 73
35 Sensor 3 74 Clutch Switch
36 Sensor 2 75 A/C switch
37 Intake air pressure sensor 76 Power steering switch
38 Throttle position sensor 2 77 Headlight switch
39 Engine coolant temperature sensor 78 Sensor 4
40 Accelerator pedal sensor 79 Phase sensor
41 80 Power
42 Intake air temperature sensor 81
43
44 Non-continuous power supply
45 Non-continuous power supply
46 Carbon tank valve
47 Fuel injector 3 (No. 4 cylinder)
48 Variable camshaft timing (intake air)
49
EC-43
50 Fan Control 1
51 Electronic 2
52
53 Electronic 1
54 Throttle position sensor 1
55 Downstream Oxygen sensor
56
57
58 Brake switch
59
60 A/C medium voltage switch
61 Power 1
* Specific pin numbers are subject to harnesses schematic. (Spare terminal definition means
“NC”.)
EC-44
3) Electrical Schematic
EC-45
4、Components Inspection
1) Read the engine failure based on the engine data from K-line.
2) Check whether ECM connection line is intact, with a focus on whether the ECM power
supply and ground line is normal.
3) Check whether the external sensor is working properly, the outputted signal is credible and
whether its line is intact.
4) Check whether the actuator is working properly and whether its line is intact.
5) Finally replace ECM and carry out experiment.

1) Removal
① Turn the ignition switch to "OFF" position, and remove the battery negative terminal.
② Remove the bottom parts of instrument panel. Please refer to the “Instrument Panel".
③ Disconnect the ECM port harness connector. Please refer to the "Precautions".
④ Remove bolt securing ECM and remove ECM.
2）Installation
■Install in the reverse order of removal
■As the installation precautions, please refer to the "Precautions"
EC-46
J4 Service Manual Electronic control System
Engine Control System Trouble Diagnosis Flow

Diagnosing according to DTCs
1, Descriptions
1) Operate the following servicing only when confirm it is a current steady fault,
otherwise it may result in diagnostic errors.
2) It is forbidden to check electronic control system lines with an analog
multimeter, the “multimeter” mentioned hereunder refers to a digital multimeter.
3) When servicing a vehicle with anti-theft system, if“Replace ECU” appears in
“Next step” column, please pay attention to ECU programming after replacement
4) If a DTC indicates too low voltage in a circuit, it means that short/open to
ground may exist in the circuit; If a DTC indicates too high voltage in a circuit, it
means that short to power may exist in the circuit; if a DTC indicates a circuit fault, it
means that open or several kinds of improper wiring may exist in the circuit.
2, Seek for diagnosis help
1) A DTC can not be cleared is a steady fault; in the case of an incidental fault,
check harness connector for looseness carefully.
2) Inspection has been made with the above procedure. No abnormality is found.
3) During servicing, do not overlook the effects of maintenance condition,
cylinder pressure, and mechanical ignition timing of the vehicle to the system.
4) Replace the old ECU with new one and test.
■If the DTC can be cleared, and then the fault is located in the ECU; if the DTC
still can not be cleared, change back with the old ECU and repeat the flow to operate
another servicing.
3, Diagnose DTCs
■All related ECU pins mentioned hereunder are subject to actual wiring
diagrams.
EC-40
DTC P0010 VVT Intake Control Valve Circuit Fault

Set up emergency control
programs. Light on malfunction indicator light till the fault disappears
Normal
Terminals: ME7 VCP control
Measurement signal
Variable timing control
signal. E48 1 0～1000mV
Main relay: 143 2 12V
Possible source of trouble Reference troubleshooting solutions
1. Poor connection of Connector 2. Open of circuit
of variable timing control signal 3. Short to ground 1. Re-connect 2. Repair harness 3. Repair
of variable timing control signal circuit 4. Improper harness 4. Repair harness 5. Replace Sensor 6.
wiring of main relay 5.Sensor damage 6. Timing Replace ECM
control signal input interface failure of ECM
DTC P0016 The installation position of camshaft and crankshaft is improper

Set up emergency control Light on malfunction indicator light till the fault disappears
programs. torque limitation
Possible source of trouble Please refer to troubleshooting solutions
1. Mechanical timing errors (timing errors, chain
skip gear or chain elongation)
1. Check Timing and Chain 2. Replace ECM
2. ECM failure
DTC P0030 Upstream oxygen sensor heater control circuit open

Set up emergency control Light on malfunction indicator light till the fault disappears turn
programs. off heater
Normal
Terminals: ME7 Pins of Sensor
Measurement signal
Heating control signal: E26 2 Low-voltage
1, An open exists between the circuit connected to
1. Measure Resistance and repair wiring
ECU pin and 2# pin of upstream oxygen sensor.
harness
2, The circuit connecting 1# pin of upstream oxygen
sensor to main relay open.
harness
3, Circuit between 1# and 2# pins of upstream
Replace the Oxygen sensor.
oxygen sensor open.
EC-41
The voltage of upstream oxygen sensor heating control circuit is

DTC P0031 too low
Normal
Measurement signal
1,The circuit connecting 2# pin of upstream

1,The circuit connecting 2# pin of upstream oxygen
oxygen sensor to pins of ECU is open to ground
sensor to pins of ECU is short to ground
Note: It may be an intermittent fault

DTC P0032 too high
Normal
Measurement signal
1. Measure the voltage of 2# pin
2． Measure resistance between ECU pins and
sensor to pins of ECU is short to power source
1# pin of sensor
2. The circuit connecting ECU pins and 1# line short
EC-42
DTC P0036 Downstream oxygen sensor heating control circuit open

Normal
Measurement signal
1, An open exists between the circuit connected to
ECU pin and 2# pin of upstream oxygen sensor.
harness
2, The circuit connecting 1# pin of upstream oxygen
sensor to main relay open.
harness
3, Circuit between 1# and 2# pins of upstream
Replace the Oxygen sensor.
oxygen sensor open.
The voltage of downstream oxygen sensor heating control circuit

DTC P0037 is too low
Normal
Measurement signal
1,The circuit connecting 2# pin of upstream

oxygen sensor to pins of ECU is open to ground
sensor to pins of ECU is short to ground
EC-43

DTC P0038 too high
Normal
Measurement signal
1. Measure the voltage of 2# pin
2． Measure resistance between ECU pins and
sensor to pins of ECU is short to power source
1# pin of sensor
2. The circuit connecting ECU pins and 1# line short
DTC P0053 Upstream oxygen sensor internal heating resistance improper

Normal
Measurement signal
1,Oxygen sensor heating resistance is

abnormal,function is disabled. 1,Replace the Oxygen sensor.
DTC P0054 Downstream oxygen sensor internal heating resistance improper

Normal
Measurement signal
1, Oxygen sensor heating resistance is abnormal,

function is disabled. 1, Replace the Oxygen sensor.
EC-44
DTC P0105 IAP sensor signal unchanged

Normal
Measurement signal
Power-supply wire: E33 3 5V
Ground wire: E17 1 0V
Signal wire. E37 4 0～5V
1. Re-install the sensor at normal room
temperature after the ice in the sensor
1,IAP sensor frozen or clogged
melted or clearing the carbon fuel on
2,IAP sensor serious aging
surface, please replace the sensor if faults
cannot be eliminated
2. Replace the intake air pressure sensor
DTC P0106 IAP sensor signal improper

Light on malfunction indicator light till the fault disappears
programs.
Normal
Measurement signal
1. Re-install the intake air pressure sensor,
1,The components of IAP sensor leaks air
repair air leakage of junctions of air intake
2． Pressure sensor damaged
pipes
3． Installation position of the sensor leaks air
2, Replace the intake air pressure sensor
4． Migration characteristics of the pressure sensor
EC-45
DTC P0107 The signal voltage of IAT sensor is too low

programs.
Normal
Terminals: ME7 Pins of Sensor Measurement
signal
1. Poor connection of Connector
2. Harness pressure signal circuit open 1. Re-connect
3. Harness pressure signal circuit short to ground 2. Repair harness
4. 5V reference voltage circuit break 3. Repair harness
5. Sensor signal ground circuit break 4. Repair harness
6. Harness 5V reference voltage reverses to 5. Repair harness
reference ground harness(This failure may result 6. Repair harness
in damage of sensor) 7. Replace sensor.
7. Sensor damage 8. Replace ECM
8. MAP signal input interface on ECM failure
DTC P0108 The signal voltage of IAT sensor is too high

programs.
Normal
signal
1. Pressure signal circuit short to 5 V reference
1. Repair harness
voltage or power positive.
2. Replace sensor
2.Sensor damage
3. Replace ECM
3. Pressure signal input interface failure on ECM
EC-46
DTC P0112 The voltage of intake air temperature sensor is low

programs.
Normal
signal
1. Re-connect
1.Poor connection of Connector
2. Repair harness
2.Temperature signal circuit open
3. Repair harness
3. Sensor signal ground circuit open 4.Temperature
4. Repair harness
signal circuit short to ground 5. Sensor damage
5. Replace sensor.
6. ECM Signal input interface failure
6. Replace ECM
DTC P0113 The voltage of intake air temperature sensor is high

intake air temperature equals to the coolant temperature, but not
programs.
more than 44.25 degree.
Normal
signal
1. Temperature signal circuit short to ground 2. 1. Repair harness

Sensor damage 2. Replace sensor.
3. ECM Signal input interface failure 3. Replace ECM
EC-47
DTC P0117 The voltage of coolant temperature sensor is low

apply the intake air temperature when start, fix it when the
programs.
temperature increase to 79.5 degrees with time going by
Normal
signal
ECU signal wire: E39 A 0.5～4.5V
ECU ground wire. E17 B 0V
Instrum
Instrument signal wire: c
ent
1.Poor connection of Connector 1. Re-connect
2. Temperature signal circuit open 3. Sensor 2. Repair harness
signal ground circuit open 3. Repair harness
4.Sensor damage 4. Replace sensor.
DTC P0118 The voltage of coolant temperature sensor is high

apply the intake air temperature when start, fix it when the
programs.
temperature increase to 79.5 degrees with time going by
Normal
signal
ECU signal wire: E39 A 0.5～4.5V
ECU ground wire. E17 B 0V
Instrum
Instrument signal wire: c
ent
1.Temperature signal circuit short to power positive 1. Repair harness

2.Sensor damage 2. Replace sensor.
EC-48
Electronic throttle sensor signal 1 is improper (signal voltage is

DTC P0121
out of the normal range)
Light on malfunction indicator light till the fault disappear ECM
cut throttle actuator current, and the return valve back to 6
degrees of throttle position though spring. And then, according
to opening of the accelerator pedal, ECM adjust the engine
programs.
power output through control of fuel injection (intermittent fuel
shut off) and ignition timing, to allow vehicles to continue to
maintain a minimum speed.
Normal
signal
Sensor ground E78 2 0V
Sensor power E32 3 5V
Sensor 1 signal E54 6 0.65～-4.65V
1.Throttle seizure 1. Replace throttle
2.Throttle body damage 2. Replace throttle
3.Signal circuit open 3. Repair harness and terminals
4.Position sensor damage 4. Replace throttle
DTC P0122 The voltage of electronic throttle sensor signal 1 is too low
programs.
Normal
signal
1. Reconnect the sensor or repair harness
1. Sensor harness circuit open or short to ground
2. Replace throttle
2.Position sensor damage
3. Check the power voltage circuit for open
3. Sensor signal circuit open
Repair or replace throttle
EC-49
DTC P0123 The voltage of electronic throttle sensor signal 1 is too high
Light on malfunction indicator light till the fault disappear
ECM cut throttle actuator current, and the return valve back to 6
programs.
Normal
signal
Sensor power supply E32 3 5V
1. Sensor harness short to power 1. Reconnect the sensor or repair harness

2． Sensor harness short to power source 2. Repair harness
3.Position sensor damage 3. Replace sensor
DTC P0130 Upstream oxygen sensor signal improper

programs. System stops controlling the oxygen signal closed-loop
Normal
signal
Signal negative E36 3 /
Signal positive E18 4 0～1V
1. Upstream oxygen sensor signal continuously in
the lower range (0.1 - 0.4) V, but Downstream
oxygen sensor signal continuously above 0.5V
2. Check the air-fuel ratio, after
2. Upstream oxygen sensor signal continuously in
troubleshooting, replace oxygen sensor
the lower range (0.5 - 0.4) V, but Downstream
3. Repair harness
oxygen sensor signal under 0.1V
Upstream oxygen sensor signal circuit and heater
circuit are coupled
EC-50
DTC P0131 The voltage of upstream oxygen sensor signal is low

programs.
Normal
signal
The voltage of upstream oxygen sensor signal is

1. Check and repair fuel problems or
negative
Replace oxygen sensor
1. Oxygen Sensor is contaminated by water, fuel or
2. Repair harness
other materials
2. Signal wire ground.
DTC P0132 The voltage of upstream oxygen sensor signal is high

Normal
signal
The voltage of upstream oxygen sensor signal is

1. Repair harness
bigger than 1.5V
2. Repair harness
1. Circuit short to the heating power
2. Circuit short to the power
EC-51
DTC P0133 Upstream oxygen sensor aging (hop frequency is too small)
Normal
signal
Upstream oxygen sensor aging, oxygen signal hop Check and repair fuel problems and
frequency is smaller than critical limits. Replace oxygen sensor
DTC P0134 Upstream oxygen sensor circuit malfunction (open)

Normal
signal
Upstream oxygen sensor signal always change
within 0.4 - 0.6 V system determines the circuit open 1. Repair harness
1. Signal to ECU circuit open 2. Repair connector
2. Poor connection of connector, pin oxidation
DTC P0136 Downstream oxygen sensor signal improper

programs.
Normal
signal
1.Upstream oxygen sensor signal circuit and heater

1. Repair harness
circuit are coupled
EC-52
DTC P0137 The voltage of downstream oxygen sensor signal is low

programs.
Normal
signal
The voltage of downstream oxygen sensor signal is

1. Check and repair fuel problems or
negative
Replace oxygen sensor
1.Oxygen Sensor is contaminated by water, fuel or
2. Repair harness
other materials
2.Signal wire ground.
DTC P0138 The voltage of downstream oxygen sensor signal is high

programs.
Normal
signal
The voltage of downstream oxygen sensor signal is
bigger than 1.5V 1. Repair harness
1. Circuit short to the heating power 2. Repair harness
Circuit short to the power
EC-53
DTC P0140 Downstream oxygen sensor circuit malfunction (open)

Normal
signal
Downstream oxygen sensor signal always change
within 0.4 - 0.6 V system determines the circuit open 1.Repair harness
1.Signal to ECU circuit open 2.Repair connector
2.Poor connection of connector, pin oxidation
DTC P0201 Control circuit of fuel injector in No. 1 cylinder malfunction

programs.
Normal
signal
Control wire E27 2 1～10V
Main relay 132 1 12V
1. Control circuit of fuel injector open
1. Repair harness
2. Fuel injector connector to the main relay circuit
2. Repair harness
open
3. Replace fuel injector
3.Fuel injector coil open
DTC P0202 Control circuit of fuel injector in No.2 cylinder malfunction

programs.
Normal
signal
1.Control circuit of fuel injector open
1. Repair harness
2.Fuel injector connector to the main relay circuit
2. Repair harness
open
EC-54

programs.
Normal
signal
1. Control circuit of fuel injector open
1. Repair harness
2. Fuel injector connector to the main relay circuit
2. Repair harness
open

programs.
Normal
signal
1.Control circuit of fuel injector open
1. Repair harness
2.Fuel injector connector to the main relay circuit
2. Repair harness
open
EC-55
Electronic throttle sensor signal 2 is improper (signal voltage is

DTC P0221
out of the normal range)
programs.
Normal
signal
Throttle2 signal bigger than 4.65 V
1. Replace throttle
1.Throttle seizure
2. Replace throttle
2.Throttle body damage
3. Repair harness and terminals
3.Signal circuit open
4. Replace throttle
DTC P0222 The voltage of electronic throttle sensor signal 2 is too low
programs.
Normal
signal
1. Sensor harness circuit open or short to ground
2. Replace throttle
3. Check the power voltage circuit for open
3. Sensor signal circuit open
Repair or replace throttle
EC-56
DTC P0223 The voltage of electronic throttle sensor signal 2 is too high
programs.
Normal
signal
1. Sensor harness short to power 1. Reconnect the sensor or repair harness

2． Sensor harness short to power source 2. Repair harness
3.Position sensor damage 3. Replace sensor
DTC P0261 Control circuit of fuel injector in No. 1 cylinder is too low
programs.
Normal
signal
1． Control circuit of fuel injector short tp ground 1. Repair harness
EC-57
DTC P0262 Control circuit of fuel injector in No. 1 cylinder is too high
programs.
Normal
signal
1． Control circuit of fuel injector short to power 1. Repair harness
DTC P0264 Control circuit of fuel injector in No.2 cylinder is too low
programs.
Normal
signal
1.Control circuit of fuel injector short to ground 1. Repair harness
DTC P0265 Control circuit of fuel injector in No.2 cylinder is too high
programs.
Normal
signal
1.Control circuit of fuel injector short to power 1. Repair harness
EC-58
DTC P0267 Control circuit of fuel injector in No.3 cylinder is low

programs.
Normal
signal
Control circuit of fuel injector short tp ground Repair harness
DTC P0268 Control circuit of fuel injector in No.3 cylinder is high

programs.
Normal
signal
Control circuit of fuel injector short to power Repair harness
DTC P0270 Control circuit of fuel injector in No.4 cylinder is low

programs.
Normal
signal
1.Control circuit of fuel injector open to ground 1. Repair harness
EC-59
DTC P0271 Control circuit of fuel injector in No.4 cylinder is high

programs.
Normal
signal
1.Control circuit of fuel injector open to power 1. Repair harness
P0300 Several cylinder misfire occurred

P0301 One cylinder misfire occurred
DTC P0302 Two cylinder misfire occurred
P0303 Three cylinder misfire occurred
P0304 Four cylinder misfire occurred
Set up emergency control light or flash malfunction indicator light Power Limited or
programs. normal
1. Re-install crankshaft and camshaft signal
1. Crankshaft camshaft timing failure or repair
2. Ignition fuel injection system failure 2. Repair ignition fuel injection system
3. EVAP system failure failure
4. Basic mechanical or cylinder pressure abnormal 3. Repair EVAP failure
4. Repair the air intake system failure
DTC P0321 Crankshaft TDC on the gear signal improper

programs.
Normal
signal
Power-supply wire E33 1 5V
Signal wire E15 2 0～-5V
Ground wire E17 3 0V
1. Circuit intermittent open 1.Repair harness
2. Crankshaft signal deviation 2. Repair signal failure
3. Sensor installed aslant 3. Re-install sensor
EC-60
DTC P0322 Speed sensor signal failure

programs.
Normal
signal
Power-supply wire E33 1 5V
Signal wire E15 2 0～-5V
Ground wire E17 3 0V
1. Coil open 1. Replace sensor
2. Signal wire to ECU circuit open 2.Repair harness
3. Signal wire to ECU circuit short 3.Repair harness
DTC P0327 The voltage of KS signal circuit voltage is too low

Close knock closed-loop control, the ignition advance is in the
programs.
default value
Normal
signal
Signal A E19 1 0～-1V
Signal B E20 2 /
1. Coil open 1. Replace sensor
2. Circuit open 2.Repair harness
3. Circuit short to low-voltage 3.Repair harness
DTC P0328 The voltage of KS signal circuit voltage is too high

Close knock closed-loop control, the ignition advance is in the
programs.
default value
Normal
signal
Signal A E19 1 0～-1V
Signal B E20 2 /
Coil short to power or high-voltage 1.Repair harness
2. Internal mechanical loose vibration failure 2 Repair mechanical failures
EC-61
DTC P0340 Phase sensor improperly installed

Light on malfunction indicator light torque limits
programs.
Normal
signal
Power supply E32 1 5V
ground E36 3 0V
Signal E79 2 0-5V square wave
1.Phase sensor improperly installed 1.Correct the installation
2.Poor connection of connector 2.Repair connector
DTC P0341 Phase sensor signal improper

programs.
Normal
signal
ground E36 3 0V
1. Repair OCV valve failure
1.Phase position between crankshaft and camshaft
2. Repair VCP actuator failure
improper
3. Repair mechanical timing failure
DTC P0342 The voltage phase sensor is too low

programs.
Normal
signal
ground E36 3 0V
1. Signal wire short to ground 1.Repair harness and connector
EC-62
DTC P0343 The voltage phase sensor is too high

programs.
Normal
signal
ground E36 3 0V
1. Signal wire short to power 1.Repair harness and connector
2. power-supply wire short to power 2.Repair harness
DTC P0420 TWC oxygen storage capacity deterioration

Light on malfunction indicator light
programs.
Downstream oxygen sensor change frequency and
amplitude exceeds the limits 1. Replace fuel.
1.Please use leaded gasoline 2. Repair oxygen sensor circuit failure,
2.Oxygen sensor failure then replace oxygen Sensor
3.Fuel pressure is too high 3. Remove fuel pressure fault
4.Misfire fault 4. Repair misfire fault
5.Catalytic converter fault 5. Replace catalytic converter
DTC P0444 EVAP Canister solenoid valve fault

programs.
Normal
signal
Power supply Main relay138 2 12V
0-12V square
Control E46 1
wave
1. control circuit open 1.Repair harness and connector
2. Coil open 2. Replace the solenoid valve.
EC-63
DTC P0458 The voltage of EVAP Canister solenoid valve is too low
programs.
Normal
signal
0-12V square
Control E46 1
wave
1.Control circuit short to ground 1.Repair harness
DTC P0459 The voltage of EVAP Canister solenoid valve is too high
programs.
Normal
signal
0-12V square
Control E46 1
wave
1.Control circuit short to power 1.Repair harness
DTC P0506 Idle control speed below target idle speed

programs.
1.Air intake and Exhaust clogged 1.Troubleshoot
2. Engine mechanical failure. 2.Troubleshoot
3. Throttle generator power-supply failure 3. Repair harness fault
4. Throttle seizure 4. Replace throttle
5. Throttle internal fault 5. Replace throttle
6.ECM failure 6. Replace ECM
EC-64
DTC P0507 Idle control speed above target idle speed

programs.
1. The intake pipe leakage 1.Troubleshoot
2. Throttle seizure 2. Replace throttle
3. Throttle internal fault 3. Replace throttle
P0560 System battery voltage signal improper

DTC P0562 System battery voltage too low
P0563 System battery voltage too high
Light on malfunction indicator light being prone to pack up
programs.
1. The battery is dead or poor connected 1.Troubleshoot
2. Excitation circuit open 2. Repair circuit failure
3. Generator does not generate 3. Replace alternator
4. Alternator regulator failure 4. Replace alternator
DTC P0602 Electronic Control Unit encoding failure

programs.
1. ECM data error 1. Replace or refresh ECM
DTC P0604 Electronic Control Unit RAM failure

programs.
1. The battery wire not connected 1. Resume power supply
2. Internal control module error 2. Replace ECM
DTC P0605 Electronic Control Unit ROM failure

programs.
1. Internal Module error 1. Replace ECM
EC-65
DTC P0606 Electronic Throttle security monitoring function failure

Set up emergency control Light on malfunction indicator light, may be accompanied by
programs. throttle pedal and throttle error codes
1. Repair throttle pedal related failure
1. Throttle pedal position sensor fault
2. Repair Electronic Throttle related
Electronic throttle position sensor fault
failure
3. ECM internal fault
3. Replace ECM
DTC P0627 Control circuit of fuel pump relay fault

Light on malfunction indicator light, cannot start
programs.
Normal
signal
Power supply 154 87 12V
Coil Power 153 86 12V
Output 152 30 12V
Control E69 85 1～8V
1. control circuit open 1.Repair harness and connector
2. Coil open 2. Replace the relay
DTC P0628 The voltage of control circuit of fuel pump relay is too low
programs.
Normal
signal
Output 152 30 12V
1.Control circuit short to ground 1.Repair harness and connector
EC-66
The voltage of control circuit power of fuel pump relay is too

DTC P0629
high
programs.
Normal
signal
Output 152 30 12V
1.Control circuit short to power 1.Repair harness and connector
DTC P0650 MIL driving circuit fault

programs.
Normal
signal
Power supply 140 12V
Control E31 1～8V
1.Control circuit open/short to ground/power 1.Repair harness
2.MIL burned out 2. Replace malfunction indicator light
EC-67
Electronic Throttle actual position and target position error

DTC P1545
exceeds the limit
Light on malfunction indicator light,ECM cut throttle actuator
current, and the return valve back to 6 degrees of throttle
position though spring. And then, according to opening of the
accelerator pedal, ECM adjust the engine power output through
programs.
control of fuel injection (intermittent fuel shut off) and ignition
timing, to allow vehicles to continue to maintain a minimum
speed.
Check whether the actual position is
1. Motor driving circuit failure consistent with the theoretical position
2.Throttle position sensor fault 1. Replace throttle
3. Throttle motor failure 2. Repair throttle position sensor circuit
4. Throttle seizure fault
3. Replace throttle
4. Replace throttle
DTC P1558 Too much resistance for opening throttle

programs.
1. Too much carbon cumulated on throttle
1. Clean Throttle
2. Throttle seizure
2. Replace throttle
3. Throttle internal fault
3. Replace throttle
Throttle lower limit position initialization self-learning

DTC P1565
failure
programs.
1. Self learning failures
1. Self-learning throttle again
2.ECM failure
2. Replace ECM
EC-68
DTC P1568 Too much resistance for pulling back throttle

programs.
1. Too much carbon cumulated on throttle
1. Clean Throttle
2. Throttle seizure
2. Replace throttle
3. Throttle internal fault
3. Replace throttle
DTC P1651 SVS light driving circuit fault

programs.
Normal
signal
Power supply 160 12V
Control E11 1～8V
1.Control circuit open/short to ground/power 1.Repair harness
2.SVS light burned out 2. Replace malfunction indicator light
DTC P2088 The voltage of VVT Intake Control Valve Circuit is too low
Light on malfunction indicator light, off VVT control
programs.
Normal
signal
1-12V square
Control 48 2
wave
1. Harness circuit open or short to low-voltage 1.Repair connector and circuit
2. OCV valve coil fault 2. Replace OCV valve
EC-69
DTC P2089 The voltage of VVT Intake Control Valve Circuit is too high
Light on malfunction indicator light, off VVT control
programs.
Normal
signal
1-12V square
Control 48 2
wave
1.Control circuit short to power 1.Repair harness
DTC P2106 Electronic Throttle drive-level failure

Light on malfunction indicator light, torque limits electronic
throttle function disabled with the other error codes coming
programs.
out
1. Electronic throttle harness open or short 1. Repair harness
2.Electronic throttle motor failure 2. Replace throttle
3.Throttle position sensor fault 3. Replace throttle
4, Intake air pressure sensor failure 4. Repair oxygen sensor failure
The voltage of accelerator pedal position sensor1 signal is too

DTC P2122
low
Set up emergency control Light on malfunction indicator light, applying sensor 2 signal, if
programs. both failed, maintain a high idling speed
Normal
signal
Sensor 1 ground E36 3 0V
Sensor 1 power supplied E33 2 5V
1. Circuit open 1. Repair harness

2. Signal wire open to ground 2. Repair harness
3. Sensor internal Open 3. Replace pedal
EC-70

DTC P2123
high
Normal
signal
1. Power-supply wire or Signal wire short to power 1. Repair harness

2. Sensor internal failure 2. Replace pedal

DTC P2127
low
Normal
signal
1. Circuit open 1. Repair harness

2. Signal wire open to ground 2. Repair harness
3. Sensor internal Open 3. Replace pedal
EC-71

DTC P2128
high
Normal
signal
Sensor 2 signal E40 6 0.3～2.3V
1. Power-supply wire or Signal wire short to power 1. Repair harness

2. Sensor internal failure 2. Replace pedal
DTC P2138 Accelerator pedal position sensor signal improper

Set up emergency control Light on malfunction indicator light,maintain a high idling
programs. speed
1. Sensor 1 and 2 circuit couple 1.Repair harness

2. Accelerator pedal fault 2.Replace accelerator pedal
Air-fuel ratio closed loop control self-learning value above

DTC P2177
upper limit (medium load zone)
programs.
Fuel dilute continuously, long-term fuel correction + 1. Repair the air intake and exhaust, fuel
20 % systems failure
1.Fuel and gas mixture too dilute. 2. Repair upstream oxygen sensor signal
2. Upstream oxygen sensor failure error fault
EC-72
Air-fuel ratio closed loop control self-learning value above

DTC P2178
lower limit (medium load zone)
programs.
Fuel dilute continuously, long-term fuel correction + 1. Repair the air intake and exhaust, fuel
-20% systems failure
1.Fuel and gas mixture too thick. 2. Repair upstream oxygen sensor signal
2. Upstream oxygen sensor failure error fault
DTC P2195 Upstream oxygen sensor aging (too dilute)

Normal
signal
Signal positive E18 4 0～-1V
1. Fuel and Gas mixture long-term dilute. 1. Repair the air intake and exhaust, fuel
2. Oxygen sensor aging, oxygen signal long-term systems failure
dilute. 2, Replace Oxygen sensor.
DTC P2196 Upstream oxygen sensor aging (too thick)

Normal
signal
Signal positive E18 4 0～-1V
1. Fuel and Gas mixture long-term thick. 1. Repair the air intake and exhaust, fuel
thick. 2, Replace Oxygen sensor.
EC-73
DTC P2270 Downstream oxygen sensor aging (too dilute)

programs.
Normal
signal
Signal negative 130 1 12V
Signal positive E28 2 Low-voltage
2. Fuel and Gas mixture long-term dilute. 1. Repair the air intake and exhaust, fuel
dilute. 2,Replace Oxygen sensor.
DTC P2271 Downstream oxygen sensor aging (too thick)

programs.
Normal
signal
Signal negative 130 1 12V
Signal positive E28 2 Low-voltage
2. Fuel and Gas mixture long-term thick. 1. Repair the air intake and exhaust, fuel
thick. 2, Replace Oxygen sensor.
EC-74
J4 Service Manual Anti-theft System
Engine anti-theft system

System overview
Engine anti-theft system achieves security feature through two electronic
encryption: Transponder and IMMO, IMMO and ECM, after going though
Transponder's wireless identification, IMMO will go under EC0M's wired
identification, if identified, ECM will ignite and inject fuel normally, and if it is not
identified, the motor will not start, and thus to achieve encryption anti-theft and make
the vehicle more reliable and secure.
Anti-theft system consists of 4 components: Intrusion Indicator light (integrated
on the dashboard) and anti-theft controller, transponders, Anti-Theft coil; details are
as follows:
Part name Quantit Remarks

y
Anti-theft 1 The controller is installed under the frame support
controller.
Transponders. 2 The transponders are installed within the two keys
Anti-Theft coil 1 The coil is installed on the ignition lock
Alarm indicator 1 the intrusion indicator symbol integrated in the
light
instrument cluster: .
Components and their location map
5
2
1 3 4
EC-67
1 - Anti-theft controller 2-Beam support 3 - Ignition lock 4 -Anti-Theft sensor coil 5 -

Transponders.
Illustrative diagram
Anti-theft System Illustrative Diagram
Components inspection
1. Check whether the power supply of Anti-theft system controller works (9 V -
16 V).
2. The terminal definitions of Anti-theft system control model are as follows:
Controller Terminal Definition Table
Pin definition Rem
Anti-theft controller connectors
arks
1 Antenna 1
2 B＋
3 IG1
4 W-wire
5 R-wire
6 Antenna 2
7 GND
8 LED
EC-68
9 NC
10 K-wire(Dia
gnostic
Interface)
The installation and removal of components

The installation and removal of EC014
Anti-theft controller
1) Removal procedures
 Disconnect negative battery
terminal.
 Remove mounting bolts of
controller on the beam support under instrument desk .
 Disconnect the controller port and wire port connector.
2) Install according to the reverse steps of removal.
The removal and installation of

EC015
Anti-theft sensing coil.
1) The removal and installation of
Anti-theft sensing coil.
 Disconnect negative battery
terminal.
 Remove the ignition lock.
 Remove the screw of Anti-theft coil and ignition lock.
 Disconnect the Anti-theft port connector;
2) Install according to the reverse steps of removal.
The transponders are installed in the keys and are supplied together with key
EC-69
assembly.
Diagnose and Match

1) Trouble Diagnosis
When a vehicle fails, the service technician can use diagnostic instruments to get
the digital code which represents failure information from the memory of Anti-theft
controller. Based on the code that corresponds to the specified error message, the
service technicians are able to quickly locate the point of failure, and to troubleshoot
and repair; common types of failures are as follows:
NO Meaning
1 Anti-theft coil short to ground
2 Anti-theft coil open to power source
3 Anti-theft coil short to power source
4 Anti-theft controller does not store any
key information
5 PIN code isn't put into Anti-theft
controller.
6 Anti-theft controller does produce SK.
7 Anti-theft controller failed the ECM
identification.
8 Key Identification failed
9 Base station cannot communicate
2) Off line/After-sales Match Functions

The diagnostic function of Anti-theft controller can be used for the match of the
whole engine anti-theft system (including keys, Anti-theft controller, and engine
control module) when engines are off line from the plant.
The function also supports to replace the keys, Anti-theft controller, and engine
control module within the whole engine anti-theft system.
EC-70
Any of the devices needs to be re-matched, if you need to replace any one of
keys, anti-theft controller and engine control module. As to the matching process,
please reference to operating manual of the diagnostic scanner.
Note: There are 3 flashing mode in IMMO indicator light: When the whole
vehicle battery is powered on and key is in the ignition switch OFF position, the
indicator light's flash cycle is 5 seconds, each cycle indicator lights for 250 MS; When
key is switched onto the ignition switch ON position, if anti-theft system
identification succeeds, the indicator light is off and remains at dim status; if
authentication fails, the LED flashes 0.5 seconds to cycle, each cycle indicator lights
for 250 MS, the vehicle will not start. If identification fails and cannot start, please
contact your service technician to diagnosis the system.
EC-71
J4 Service Manual. Foreword
J4 Service Manual
Foreword General Catalogue
This Manual is helpful for technical
maintenance staff for JAC and provides Overview and Maintenance
effective and correct maintenance and
service for an electric vehicle of JAC RS
series. To ensure the customer Chapter I Overview
satisfaction of the JAC's car products, it
is extremely essential that the Chapter II Maintenance
professional maintenance technicians for
JAC's car have the friendly service and Engine Sub-volume
the capability of proper operation;
therefore, the maintenance technicians
must fully understand the contents in this Chapter I Engine Machine
Manual. This Manual shall be accessible
for reference at any time. Chapter II Engine Electrical Equipment
All contents in this Manual, including Chapter III Engine Electronic Control
pictures, technical parameters are the System
latest. But if product modification affects
maintenance, JAC will provide technical
bulletin or supplementary volume. Chassis Manual
Therefore, please obtain the latest
information about this Manual. JAC Chapter I Transmission System
reserves the right to make change in
design, addition or improvement for the Chapter II Clutch System
product.
This Manual shall not be copied or Chapter III Drive System
modified without written authorization
from JAC in any form including, but not Chapter IV Suspension System
limited to electronic, paper, video and
mechanical form. Chapter V Brake System
During the process of maintaining Chapter VI Steering System

JAC car, if genuine parts that are not
from JAC or disqualified oil, the
vehicle may be damaged.
Sub-volume of Body Electrical
and Body Structure
Chapter I Body Electrical
Chapter II Body Structure
Chapter III Body Data
Circuit Maintenance Manual

Contents of Chassis
J4 Service Manual Sub-volume Workshop
Chassis Sub-volume Workshop

Chassis - Transmission System.......................................................... MT-1
Overview........................................................................................................ MT-1
Precautions................................................................................................................MT-1
Preparation work.......................................................................................................MT-1
Common fault diagnostic..........................................................................................MT-3
System specification................................................................................................. MT-4
Manual transmission gearbox oil..............................................................................MT-5
Oil real...................................................................................................................... MT-6
Control mechanism of selecting gear....................................................................... MT-7
Manual transmission assembly................................................................................. MT-9
Disassembly and assembly..................................................................................... MT-11
Maintenance data and specification........................................................................MT-29
Maintenance............................................................................................................MT-30
Chassis - Clutch System...................................................................... CL-1

Precautions................................................................................................................ CL-1
Preparation work....................................................................................................... CL-1
Common fault diagnostic.......................................................................................... CL-1
Hydraulic oil of clutch...............................................................................................CL-3
Clutch master cylinder.............................................................................................. CL-4
Clutch pedal.............................................................................................................. CL-6
Clutch pressure plate, friction plate of clutch and flywheel......................................CL-8
Hydraulic pipeline................................................................................................... CL-11
Service parameters.................................................................................................. CL-12
Chassis - Drive System.........................................................................DS-1

Precautions................................................................................................................ DS-1
Preparation work....................................................................................................... DS-1
Common fault diagnostic.......................................................................................... DS-2
Front wheel hub and steering knuckle.......................................................................DS-2
Front drive shaft........................................................................................................ DS-8
Contents of Chassis
Service parameters.................................................................................................. DS-17
Chassis - Suspension System.............................................................FSU-1

Front suspension system.............................................................................FSU-1
Precautions.............................................................................................................. FSU-1
Preparation work..................................................................................................... FSU-2
Front suspension assembly..................................................................................... FSU-2
Front shock absorber...............................................................................................FSU-4
Lower swing arm.................................................................................................... FSU-7
Lateral stabilizer bar................................................................................................FSU-8
Front sub-frame assembly.......................................................................................FSU-9
Fault diagnosis...................................................................................................... FSU-10
Maintenance data and specification...................................................................... FSU-11
Rear suspension system............................................................................ FSU-12
Precautions............................................................................................................ FSU-12
Preparation work................................................................................................... FSU-12
Rear suspension assembly.....................................................................................FSU-13
Rear shock absorber.............................................................................................. FSU-14
Rear coil spring..................................................................................................... FSU-15
Rear torsional girder assembly..............................................................................FSU-16
Fault diagnosis...................................................................................................... FSU-17
Maintenance data and specification...................................................................... FSU-18
Chassis - Brake System....................................................................... BR-1

Wheel & Tire................................................................................................. BR-1
Precautions................................................................................................................ BR-1
Tire............................................................................................................................ BR-1
Wheel tire assembly.................................................................................................. BR-3
Tire pressure monitoring........................................................................................... BR-5
Fault diagnosis.......................................................................................................... BR-8
Maintenance data and specification.......................................................................... BR-9
Service braking..............................................................................................BR-9
Precautions................................................................................................................ BR-9
Preparation work..................................................................................................... BR-10
Contents of Chassis
Brake pedal............................................................................................................. BR-10

Brake master pump................................................................................................. BR-12
Brake fluid.............................................................................................................. BR-13
Brake pipeline......................................................................................................... BR-13
Brake vacuum booster assembly component.......................................................... BR-16
Front disc brake caliper...........................................................................................BR-19
Rear parking brake.................................................................................................. BR-24
Fault diagnosis........................................................................................................ BR-29
Maintenance data and specification........................................................................ BR-32
Parking brake control.............................................................................................. BR-33
Anti-lock braking system (ABS)................................................................BR-37
Precautions.............................................................................................................. BR-37
Preparation work..................................................................................................... BR-38
System specification............................................................................................... BR-38
ABS mode............................................................................................................... BR-40
Speed sensor............................................................................................................BR-40
ABS hydraulic assembly .......................................................................................BR-42
ABS control module............................................................................................... BR-43
Exhaust of ABS system...........................................................................................BR-46
Chassis - Steering System.................................................................... PS-1

Precautions.................................................................................................................PS-1
Preparation work........................................................................................................PS-1
Electric power steering system overview.................................................................. PS-1
Steering wheel............................................................................................................PS-3
Steering wheel assembly............................................................................................PS-5
Steering column assembly......................................................................................... PS-7
Power steering gear assembly..................................................................................PS-10
Solutions to common faults..................................................................................... PS-12
Maintenance data and specification......................................................................... PS-13
J4 Service Manual Transmission System
Chassis - Transmission system

Overview
Precautions
■ Do not reuse the discharged gear oil of M/T
■ When inspecting or replacing manual transmission gear oil, keep the vehicle level.
■ When dismantling and installing transmission, keep the interior free from any dust and
foreign matter.
■ Before dismantling or disassembling, check and confirm correct installation position. If
installing mark is needed, the function of the part bearing such a mark after that shall not be
affected adversely.
■ Tighten the middle and then the other bolts and nuts in a diagonal order step by step as
required. If the tightening sequence is defined, please follow it.
■ Do not damage sliding and fitting surfaces.
Preparation work
Special tools to be used are shown in following table:
Special Tool Table
No. Tools Overall Diagram Code Instructions
Installation and dismounting of

1 Bearing remover JAC-T1B001 each gear, bearing and shaft
sleeve
Installation and dismounting of

2 Bearing remover JAC-T1B002 each gear, bearing and shaft
sleeve
Installer should be combined

3 Installer cover JAC-T1B005
with installer joint.
MT‐1
Installer cover should be

4 Installer-100 JAC-T1B006
combined with installer joint.
5
Installer cover should be
Installer-100 JAC-T1B007
combined with installer joint.
JAC-T1B008 When combined with installer,

JAC-T1B009 it is necessary to install
6 Install connector bearings of middle shaft and
JAC-T1B011 input shaft as well as bushing
JAC-T1B012 of gear 1, gear 2 and gear 4.
Mounting bearing used with

7 Mounting handle JAC-T1B016
relevant installer.
Shift gears oil Install transmission shift shaft

8 JAC-T3B001
seal Installer oil seal
Differential oil
9 JAC-T3B002 Install differential oil seal
seal installer
Transmission
Dismantle transmission gear
10 spring pin JAC-T3B003
shift fork spring pin.
remover
Right bearing
installer of Install transmission Housing
11 JAC-T3B005
intermediate intermediate shaft right bearing
shaft
MT‐2
Common fault diagnostic

Table of common failure diagnosis
Failure Mode Cause Countermeasures
Shifting fork shaft worn Replace
Shifting fork or synchronizer sleeve worn Replace
Slipping and
out-of-mesh Shifting fork shaft position spring weaken or damaged Replace
Replace synchronizer gear
Synchronizer sleeve and chamfered teeth damaged
sleeve and gear
Transmission gear oil insufficient Added
Clutch pedal free stroke incorrect Adjust
Clutch friction plate distorted or damaged Replace
Clutch pressure plate damaged Replace the pressure plate
Gear shifted
difficultly Synchronizer gear ring worn Replace
Replace synchronizer gear
Synchronizer gear bushing and gear chamfered teeth worn
sleeve or gear
Shifting fork shaft deformed Replace
The cable isn't installed to proper position. Adjusting cable
Transmission gear oil insufficient Added
Bearing damaged or worn Replace
Noisy
Gear damaged and worn Replace
Synchronizer part damaged and worn Replace
Oil seal of input shaft is worn or damaged. Replace
Oil seal of differential is worn or damaged (bad quality of the Replace
surface of transmission shaft causes the abrasion of oil seal).
Oil leakage
Oil leakage in the oil plug Replace
Sealant of lock bolts of 1st gear and 2nd gear is fail. Replace
th
Sealant of lock bolts of 5 gear and reverse gear is fail. Replace
MT‐3
System specification
1. Structure schematic diagram
Transmission Structure Schematic Diagram
2. Principle of movement:
1st gear: Engine → Clutch → Input shaft spline 1 → Input 1st gear 3 → Output 1st gear 18 → 1/2
gear synchronizer 17 → Output shaft 2 → Differential 19
2nd gear: Engine → Clutch → Input shaft spline 1 → Input 2nd gear 6 → Input 2nd gear 16 →
1/2 gear synchronizer 17 → Output shaft 2 → Differential 19
3rd gear: Engine → Clutch → Input shaft spline 1 → 3/4 gear synchronizer8 → Input 3th gear
7 → Output 3th gear 15 → Output shaft 2 → Differential 19
4th gear: Engine → Clutch → Input shaft spline 1 → 3/4 gear synchronizer8 → Input 4th gear
teeth 9 → Output 4th gear teeth 14 → Output shaft 2 → Differential 19
5th gear: Engine →Clutch →Input shaft spline 1 → 5/R gear synchronizer 11 → Input 5th gear
10 → Output 5th gear 13 → Output shaft 2 → Differential 19
Reverse gear: Engine → Clutch → Input shaft spline 1 → 5/R gear synchronizer10, Reverse gear
synchronizing ring 12 → Reverse gear 5 → Input reverse gear 4 → 1/2 gear synchronizer17 →
Output shaft 2 → Differential 19
MT‐4
3. Shift principle
When the vehicle is going forward, gear shifting of transmission shall be as follows: gear shifting
for speeding shall be made level by level from Gear 1 to 5, and vice versa; Do not use rotating
speeders when the vehicle is going forward. Under the condition that the complete vehicle has
gear shifting operation, to avoid misoperation, the transmission is set with a function that 5th gear
reversing is not allowed. In principle, the reverse shall be turn on a 3s pause later after the clutch
is pressed when the vehicle is stationary; do not switch to the gear when the vehicle is running
forward; do not turn on any forward gear when the vehicle is rotating speedersing.
Caution:
■ It's allowed not to observe the gear shifting principle of transmission in emergency when the
vehicle is working.
Manual transmission gearbox oil
1. Replace manual transmission gear oil
1) Displacement MT001
① Remove oil drain plug, drain gear oil.
■ Tightening torque: 10-17 N•m
② Check if the surface of oil drain plug has iron scraps.
If yes, remove them.
2) Fill MT002
① Remove filling plug. Refill new gear oil until the oil
level reaches to the specified limit near mounting
hole.
② Gear oil model and oil filling capacity:
75W/90 GL-4gear oil.
Oil filling capacity: 2.0 L
③ Check fuel level after filling.
④ Tighten filling plug.
MT‐5
2. Check MT gear oil MT003

■ Make sure that there is no gear oil leakage on or
around manual transmission.
① Remove filling plug.
As shown in figure 1.2.002 and 1.2.003, Check oil
level through mounting hole of filling plug.
② Tighten filling plug
Caution:
■ Do not start the engine during inspection for oil level.
Oil real
1. Removal and installation
1. Removal MT004
① Drain transmission gear oil. Please see “Manual
transmission gear oil".
② Remove the front drive shaft from the axle. Please see
“Front drive shaft".
③ Remove the oil seal on differential side with a slotted
screwdriver.
Caution:
■ Do not breakout transmission housing.
2) Installation
① Use a special tool to install oil seal on differential side onto the clutch housing and
transmission housing.
Caution:
■ Apply proper amount of grease to the lip of new oil seal.
② Install all dismantled parts according to reverse order of dismantling.
③ Fill manual transmission gear oil, and check fluid level. Please see “Check manual
transmission gear oil “.
3) Check if drive shaft is flexible after installed.
MT‐6
Control mechanism of selecting gear

1. Components
2
Control mechanism of selecting gear drawing
1st select gear wire drawing 2ndshift control device 3nd selecting gear handle
2. Removal and installation MT005

1) Removal
① Remove battery. Please see “Battery".
② Remove the air filter assembly. Please see "Air filter
assembly".
③ Select gear handle located at the neutral gear.
④ Remove select gear handle
⑤ Remove rear section of auxiliary fascia console. MT006
Please refer to “Auxiliary Fascia Console".
⑥ Remove the selector & shift gear lock pin and spring
retainer (internals & externals)
Please refer to Fig. MT005 to Fig. MT008.
MT007
MT‐7
MT008
⑦ Unscrew off the fixing bolts of selector gear wire on MT009

front engine compartment plate side.
⑧ Remove fixing bolt of select gear operating device. MT010
⑨ Remove the selector gear mechanism assembly from MT011

the inside vehicle.
MT‐8
2) Installation
Pay attention to the following considerations and
install in the order opposite to dismantling.
■ Properly install the gear selector or shifter pull-wire. MT012
■ Pay attention to mount direction of spring disc.
■ When gear shifting lever is placed to 1st gear – 2nd
gear and 5th gear- reversing side, make sure the lever
can be shifted to neutral position smoothly.
■ When the gear shifting lever is shifted to a gear,
make sure that the gear shifting is smooth.
Manual transmission assembly

Removal and installation:
1) Removal MT013
① Disconnect negative battery cable.
② Remove battery and support of battery. Please see
“Battery".
③ Dismantle old air filter assembly. Please see "Air
filter assembly".
④ Discharge hydraulic oil from the clutch, and
disconnect oil pipe of the clutch from quick coupler
of hydraulic release bearing of the clutch. Please see
“Clutch pipeline".
Caution:
■ Please do not depress the clutch pedal during removal.
⑤ Disconnect speed sensor, reverse light switch and crankshaft position sensor wire harness
connector on the transmission.
⑥ Remove the crankshaft position sensor. Please see “Crankshaft position sensor”.
⑦ Dismantle oil pipe clamp of the clutch from fixing bracket of left suspension of manual
transmission and disconnect oil pipe of clutch master cylinder.
⑧ Disconnect transmission select gear wire drawing. Please see “control mechanism of
selecting gear".
⑨ Install the lifting frame onto the engine hook.
⑩ Remove the starter. Please see “Starter".
⑪ Drain the gear oil. Please see “Replace manual transmission gear oil".
MT‐9
⑫ Remove front drive shaft. Please see "Drive shaft".

Caution:
■ After dismantling of front drive shaft, please insert a suitable plug into side oil seal.
⑬ Remove the engine deflector.
⑭ Remove the engine support beam. Please see "Engine supporting beam".
⑮ Remove the lower support and lower clapboard of transmission.
■ Tightening torque: M6 5-6 N•m M8 12-15 N•m
⑯ Remove left suspension holder of transmission.
⑰ Use a jack to lift transmission assembly, and dismantle fixing bolts between transmission and
engine.
⑱ Remove the transmission assembly from vehicle.
2) Install
Pay attention to the following cautions and install it in the reverse order of removal.
■ When installing transmission assembly onto the engine, first pretighten the fixing bolts and
then tighten fixing bolts according to the following standards.
Screw-in direction: 1: transmission side → engine side (1, 3, 5, 6, 7)
2: Engine side → transmission side (2, 4)
Tightening torque: 1 50-70 N•m MT014

3 1
2 50-70 N•m 5
3 50-70 N•m 7
6
4 50-70 N•m
4
5 50-70 N•m
6 50-70 N•m 2
7 50-70 N•m
■ Fill hydraulic oil of clutch, and exhaust gas in clutch hydraulic pipeline. Please see “Clutch
pipeline".
■ After installation, check gear oil level of manual transmission, and then check if there is any
gear oil of transmission leakage and whether the mechanical installation is loose. Please see
“Check manual transmission gear oil”.
MT‐10
Disassembly and assembly

1. Disassembly of transmission gearbox assembly MT015
(1) Drain oil
Caution:
■ Remove the oil drain screw plug with wrench, and
drain oil from the oil drain screw plug. It is not
allowed to drain oil from other positions.
(2) Disassemble the rear cover screws.
(3) Disassemble the input & output shaft lock nuts.
MT016
(4) Remove the reverse cone shock insulator, reverse MT017

cone and reverse synchronization ring.
(5) Disassemble the 5/R gear fork spring pin. MT018
MT‐11
(6) Disassemble the 5/R gear fork and 5/R gear MT019
synchronizer. Synchronizer gear sleeve and gear hub.
(7) Remove the 5th gear synchronization ring and input MT020
5th gear fitting
(8) Remove the output 5th gear.
(9) Remove the ball plug, reverse gear shaft bolts and MT021
clutch case joint bolts.
MT022
MT‐12
MT023
MT024
(10) Use a magnet to suck steel ball out of lock ball plug MT025
hole.
(11) Remove the casing. MT026
MT‐13
Caution: MT027
■ If the housing adheres to the clutch housing tightly,
knock the edge of the housing gently with rubber
hammer or copper rod to loosen it.
(12) Remove the reverse gear and reverse gear shaft.

MT028
(13) Disassemble the mounting bolt of reverse gear shift MT030

mechanism.
(14) Remove the reverse gear shift mechanism fitting. MT031

(15) Disassemble the fork spring pin of 1/2 gear and
3/4.gear.
MT‐14
(16) Remove the fork shaft fitting and fork. MT032
Caution:
■ Before removing shift shaft components and shift
fork, Rotate the fork block to separate it from
interlock plate.
(17) Disassemble the bearing pressure plate of input shaft.
MT033
(18) Remove the input shaft assembly, output shaft MT034

assembly and differential assembly.
(19) Disassemble the interlock plate screws.

MT035
MT‐15
(20) Disassemble the gear selector shaft fitting.

MT036
Caution:
■ Punch the slot pin of shift shaft from the bolt hole of
interlock plate.
2. Input shaft assembly disassembly MT036
th
(1) Disassemble the input 5 gear lining.
(2) Disassemble the ball bearing (behind the input shaft), MT037
input 4th gear lining, and 3/4 gear synchronizer
assembly.
Caution:
■ Use clip forceps to remove the clip (on the rear of
input shaft) and install special drawing tool on the 3rd
combination gear. Meanwhile dismantle 3/4 gear
synchronizer assembly, input 4th gear lining, ball
bearing (on the rear of input shaft) at the same time.
And then take out 3rd speed synchronizer and input
3rd gear components.
MT‐16
3. Output shaft assembly disassembly MT038

(1) Disassemble the tapered roller bearing (behind the
output shaft) and output 4th gears.
Caution:
■ Install a special puller on the output 4th gear, and
dismantle taper roller bearing (on the rear of output
shaft) and output 4th gear at the same time.
(2) Disassemble the output 3rd gear, output 2nd gear MT039
lining, output 2nd gear assembly, 1/2 gear
synchronizer assembly and output 1st gear assembly.
4. Disassembly of differential assembly MT040

(1) Disassemble the main reduction gear
(2) Disassemble the groove pin. MT041
(3) Remove the planet gear shaft, planet gear, planet gear
thrust pad, half-axle gear and its thrust ring.
MT‐17
5. Inspection of Key Parts

(1) Check input shaft assembly
1) Check if the teeth of input shaft gear are broken, tooth surface has pitting corrosion, serious
abrasion and gluing condition. If any of the above conditions occurs, it is necessary to
replace input shaft.
2) Check if the spline of input shaft has serious abrasion and damage. If yes, it is necessary to
replace input shaft.
3) “Feel” the bearing with hand for flexible rotation and stagnation. If the bearing rotates
inflexibly or has stagnation, the bearing must be replaced.
Caution:
■ Front ball bearing of input shaft can't be dismantled. If replacing output shaft or front bearing
of output shaft, these two parts must be replaced together at the same time.
(2) Check output shaft assembly
Check if the teeth of output shaft gear are broken, tooth surface has pitting corrosion, serious
abrasion and gluing condition. If any of the above conditions occurs, it is necessary to
replace output shaft.
Caution:
■ Inner ring of front bearing of output shaft can't be dismantled. If replacing output shaft or
inner ring of front bearing of output shaft, these two parts must be replaced together at the
same time.
■ “Feel” the bearing with hand for flexible rotation and stagnation. If the bearing rotates
inflexibly or has stagnation, the bearing must be replaced.
(3) Check the differential assembly
1) Check if the teeth of main reduction gear are broken, tooth surface has pitting corrosion,
serious abrasion and gluing condition. If any of the above conditions occurs, it is necessary
to replace main reduction gear.
2) Check if the planetary gear and half gear as well as spline have serious abrasion and damage.
If yes, it is necessary to replace them.
3) Check if the outer ring of taper roller bearing and the roller have serious abrasion. If yes, it is
necessary to replace bearing.
Caution:
■ Inner ring of taper roller bearing can't be dismantled.
■ If the inner ring of taper roller bearing is damaged, it is necessary to replace differential case
and inner ring of taper roller bearing at the same time. After replacement, it requires to
re-select upper adjusting shim of differential. The magnitude of interference is 0.15-0.20
mm.
(4) Inspect the synchronous ring
1) Inspect the surface of the synchronous ring gear for damage or scratch.
MT‐18
2) Inspect the conical part for damage or abrasion, and inspect the threads for damage by
compression.
Synchronous Gear
3) Under the condition of pressing the synchronous ring towards gear, inspect the clearance “A”.
If “A” is less than the limit value, replace it.
Limiting value: 0.5 mm
(5) Inspect the synchronizer gear sleeve and gear hub
1) Assemble the synchronizer gear sleeve together with the gear hub, and inspect if they slide
smoothly with stagnation or not.
2) Inspect the front and rear ends on the inner surface of gear sleeve for damage.
Caution:
■ When it is necessary to replace the synchronizer gear sleeve or gear hub, replace them
together as a set.
6. Input shaft assembly
(1) Install input 3rd speed roller bearing, input 3rd gear MT042
components, synchronizing spring and 3rd gear
synchronizer.
Caution:
■ Install the synchronizing spring on the position of synchronizer as shown in figure.
MT‐19
Synchronizing
(2) Install the 3rd and 4th gears synchronizer assembly. MT043
Caution:
■ Install the 3/4 gear synchronizer gear hub according to the direction shown in figure.
This face is toward 3rd gear. This face is toward 4th gear.
When installing synchronizer hub, confirm whether synchronizing ring clipped.
■ Synchronizer gear sleeve installation
Speed synchronizer
Speed synchronizer
gear hub
MT‐20
When installing synchronizer gear sleeve, make sure that two deep gear groove of synchronizer
gear hub meets two high racks of gear sleeve.
(3) Install the input 2nd gear lining.
MT044
(4) Install the synchronization spring, 4th gear MT045

synchronization ring, input 4th gear needle bearing,
input 4th gear fitting and input 4th gear thrust pad.
(5) Fit in the ball bearing behind the input shaft.

MT046
(6) Fit in the snap ring behind the input shaft.

Caution:
■ Snap ring thickness shall be so selected that axial
clearance of input shaft bearing will be satisfactory.
Standard value: 0-0.09 mm
MT‐21
(7) Fit in input speed V lining. MT047
7. Output shaft assembly

(1) Install output 1st and 2nd gear roller bearing, output 1st MT048
gear components, 1st and 2nd gear synchronizer
components.
Caution:
■ Install the 3/4 synchronizing spring onto the synchronizer according to the direction shown
in figure.
Synchronizing
(2) Install the 1st and 2nd gears synchronizer assembly. MT049
MT‐22
Caution:
■ Install the 1/2 gear synchronizer gear hub in the direction shown in the Figure.
This surface faces to 1st gear. This face is toward 2nd gear
When install synchronizer hub, confirm whether synchronizing ring clipped.
■ When installing synchronizer gear sleeve, make sure that two deep gear groove of
synchronizer gear hub meets two high racks of gear sleeve.
Speed synchronizer
Speed synchronizer
gear hub
■ Install the 1/2 gear synchronizer gear sleeve according to graphical direction.
2nd gear
1st gear
(3) Install the 1/2 gear synchronization ring elements and

MT050
output 2nd gear lining
MT‐23
Caution:
■ Oil hole on the gear sleeve should be aligned with oil
hole on the output shaft.
(4) Fit in output 1st and 2nd gears needle bearings, output MT051
2nd gear fitting and output 3rd gear
(5) Fit in the spacer bush and output 4th gear MT052
(6) Install the tapered roller bearing behind the output MT053
shaft
8. Differential assembly MT054

(1) Install planetary gear, thrust cushion of planetary gear,
half gear, thrust ring of half gear.
Caution:
■ First install the thrush ring of half gear on the back of
half gear, and then install half gear onto the
differential.
After installing a thrust cushion of planetary gear onto the
back of planetary gear, make sure that the two planetary
gears engage with half gear at the same time. And then
rotate planetary gear to install it onto proper position.
MT‐24
(2) Insert the planet gear shaft.

MT054
(3) Install the groove pin. MT055
(4) Fit in the main reduction gear. MT056
9. Transmission assembly MT057

(1) Input gear shift rock arm components, bolts of
interlock plate, reversing lock chip and torsion spring.
Caution:
■ Correct mounting position of torsion spring, as shown
in the below Figure:
MT‐25
MT058
MT059
(2) Fit in the differential assembly, input shaft assembly MT060

and output shaft assembly.
(3) Install the 1/2 gear fork shaft assembly, 3/4 gear fork
shaft assembly, 5/R gear fork shaft assembly, 1/2 gear
fork, and 3/4 gear fork and spring pin.
Caution:
■ Elastic pin must be replaced with a new one.
(4) Install the pressure plate and its screws MT061
MT‐26
(5) Fit in the reverse shift mechanism fitting MT062
(6) Install the reverse gear and reverse shaft MT063
(7) Fit in the magnet and oil chute and then close the box MT064
Caution:
■ Gluing shall be made evenly. Ungluing is prohibited.
(8) Fit in steel ball, ball spring, ball plug, clutch case joint MT065
bolts and reverse shaft bolts.
MT‐27
(9) Install input 5th gear. MT066
(10) Install input 5th gear roller bearing, input 5th gear MT067
components and 5th gear synchronizer.
(11) Fit in 5/R gear synchronizer assembly and 5/R gear MT068
fork
(12) Fit in reverse synchronization ring, cone, cone shock MT069

insulator and input & output shaft lock nut
Caution:
■ It has not to pull out after locking nut was tighter.
MT‐28
(13) Fit in rear cover. MT070
Caution:
■ Gluing shall be made evenly. Ungluing is prohibited.
Maintenance data and specification

Tightening Torque
No. Name N•m
1 Bolt connecting reversing gear shifting mechanism and clutch body 14.7-21.6
2 Oil drain plug 40-60
3 Pressure plate and clutch housing connecting bolt 14.7-21.6
4 Connecting bolt of clutch and housing 34.3-41.2
5 Front cover bolt 6-8
6 Odometer fixing bolt 4-6
7 Reverse axle bolt 42.2-53.9
8 Rear cover bolt 14.7-21.6
9 Lock ball screw plug 29.4-41.2
10 Lock nut 137.2-156.8
11 Oil filler screw 30-40
12 Selecting gear position 40-50
13 Interlock plate guide bolt 19.6-26.5
14 Reversing light switch 29.4-34.3
15 Release fork and separation rocker arm connecting nut 30-42
MT‐29
No. Name N•m
16 Mounting bolt of main reduction gear 75-85
17 Selecting gear support and clutch housing connecting bolt 14.7-21.6

Main Technical Parameters
Type 5th forward gears, 1st reverse gear
Operation method Telecontrol
Rated input torque 180 N•m
Mass of assembly About 36.5Kg
Maintenance
The transmission gearbox shall be used and maintained according to the requirements for use and
maintenance of commercial vehicles, generally classified as technical maintenance of three levels.
Regularly check and replace (or add) lubricant of transmission gearbox.
List of Regular Inspection and Maintenance for Gearbox
Distance and time (in months) are indicated for the items, perform inspection as required,
whichever comes first.
○ Check position, tighten or adjust; ★ Replace lubricant
Interval of Overhaul (by the reading of Odometer and number of months, whichever comes
first)
Item
Months － 3 6 12 18 24 30 36 42 48 54
Odometer reading × 1,000 km 1 5 10 20 30 40 50 60 70 80 90
Internal inspection of gearbox
Inspect the level of gear oil in the gearbox ○ ○ ○ ○ ○
Replace the gear oil General service conditions ★ ★ ★ ★ ★

in the gearbox Severe service conditions ★ ★ ★ ★ ★ ★ ★ ★
Other inspection items
Caution: The “Severe service conditions” include the following items.

 Running in dusty area or always exposed to salty air or salty water.
 Running on uneven road or mountain road with accumulated water.
 Running in cold area.
 In cold seasons, engine kept idling for long or always running in short distance.
 Have to use brake frequently and emergency brake for many times.
 Towing vehicle.
MT‐30
 It is for the vehicle which is used to be a taxi or rent car.

 Under the high temperature above 32°C, the time of driving slowly in jammed urban area
exceeds 50% of total driving time.
MT‐31
 Under the high temperature above 30°C, the time of driving at the high speed above 120km/h
exceeds 50% of total driving time.
 Overloaded driving.
Lubrication and Sealing
Item Lubricant and sealant Quantity
Gear oil for transmission gearbox Gear oil 75W/90 GL-4 2.0L
Transmission spline Lubricating grease Appropriate amount
Transmission gearbox oil seal Lubricating grease Appropriate amount
Adjoining surface between transmission gearbox

KESAIXIN®1596F Appropriate amount
housing and clutch housing
Adjoining surface between transmission gearbox

KESAIXIN®1596F
housing and rear cover
Contents of Quick-wear Parts

No. Code Name Quantity
1 D-1701251-00-00 Lock nut 2
2 D-1701551-00-00 Oil seal (input shaft) 1
3 D-1702201-00-00 Oil seal (shiftgear shaft) 1
4 D-2303011-00-00 Oil seal (differential) 2
5 Q5280525 Elastic pin 3
6 H-1701516-79-00 Gasket (oil drain screw plug) 1
7 Q2580820S Pressure plate screw 3
MT‐32
J4 Service Manual Clutch System
Chassis - Clutch System

Precautions
■ Recommended clutch hydraulic oil is a brake liquid “DOT4”.
■ Do not reuse the drained clutch hydraulic oil.
■ Pay attention not to spray vehicle hydraulic oil of the clutch onto the paint of vehicle body.
■ Please do not use mineral oil such as gasoline or kerosene, to avoid corrosion of rubber part
in hydraulic system.
■ Please do not decompose master pump, hydraulic release bearing.
Warnings:
■ Please use a dust aspirator to clean clutch friction plate. Do not use compressed air to clean
it.
Preparation work
Special tools to be used are as below:
Special Tool Table
1 Flywheel stop dog JAC-T1F011 Fixing fly wheel

The performance diagnosis of clutch assembly and clutch control system should be performed by
experienced driver or skillful repair technician.
The following (fault) diagnosis involves common problems and possible causes. After conducting
proper diagnosis, adjust or replace parts according to corresponding Countermeasures and proper
sections of detailed procedures specified in Manual.
When repairing vehicle, clutch disc and clutch friction plate can't be repaired. If any of them is
damaged, it is necessary to replace the complete assembly.
If the rivet of clutch friction plate is worn or clutch friction plate is stained by engine oil or grease,
this clutch friction plate can't be reused.
If a part is required to be replaced, use a qualified new part to replace it.
This diagnosis table is helpful to diagnose faults of clutch system caused by the following
conditions: clutch can't be released, can't be released completely, can't be engaged completely,
skidding, noise, vibration.
The digit on this diagnosis sheet does refer to the order of inspection. There is no precedence
relationship among potential causes.
CL‐1
Diagnosis Table of Clutch System

Items Potential Cause Countermeasures
If clutch can't be disengaged, it means the clutch
can't operate or cut off the power transmitted from Replace the deformed, worn or cracked
the engine. parts.
Check the following conditions
1. Clutch release rod deformed.
No 2. Diaphragm spring deformation.
disengagement 3. Support ring of diaphragm spring is Adjusted clutch system.
fractured.
4. Clutch pedal control system and clutch cable
are adjusted wrongly.
5. Clutch friction plate sticks to flywheel or
clutch cover.
Incomplete disengagement of clutch may make it Replace the deformed, worn, cracked or
impossible to cut off the power transmitted from over-size parts. If clutch friction plate
the engine and it is difficult to operate the can't cooperate with the spline of the input
gearshift because clutch friction plate and shaft of transmission, replace the plate; if
transmission input shaft continue running. necessary, replace the input shaft.
Check the following conditions: If the friction plate of clutch exceeds the
1. Clutch friction plate is deformed. It may rock size as specified or is damaged, replace it.
when rotated. Replace does not apply clutch thrust
2. Clutch friction plate is damaged. bearing.
Incomplete 3. Clutch friction plate spline doesn't match Adjust clutch system to eliminate
separation transmission input-shaft spline, or spline unnecessary clearance and mechanical
tooth face is damaged. faults.
4. Clutch friction plate sticks partially to Reinstall the parts that were assembled
flywheel or bites clutch cover. incorrectly.
5. The thickness of flywheel/clutch
cover/clutch friction plate exceeds the size as
required.
have mechanical fault or improper
adjustment.
Incomplete engagement of clutch may make it Replace the deformed, worn or cracked
impossible to transmit engine power to parts.
transmission input shaft. Meanwhile, clutch Replace clutch friction plate or defective
friction plate may slip. clutch assembly.
Check the following conditions: Adjust the free stroke of clutch pedal
1. Clutch friction plate is contaminated by correctly.
engine oil or grease. Adjust clutch system to eliminate
Incomplete
2. Clutch friction plate is damaged. unnecessary clearance and mechanical
engagement
3. Clutch pedal has no free travel. faults.
4. Diaphragm spring/ clutch disc/ clutch release Reinstall the parts that were assembled
lever/ spline of clutch friction plate is incorrectly.
deformed or damaged.
have mechanical fault or improper
adjustment.
CL‐2
Items Potential Cause Countermeasures

Clutch friction plate slips, may make it impossible Replace the deformed, worn or cracked
to transfer engine power as normal. parts, those beyond the size or
Check the following conditions: specification.
1. Clutch friction plate is worn. Countermeasures to "incomplete
separation" and "incomplete engagement".
2. Clutch friction plate is contaminated by
engine oil or grease. Stop engine, lower the temperature in the
housing of clutch (if too high), and make
3. Clutch is engaged incompletely.
further diagnosis.
4. Both thickness of flywheel/clutch
Slipping Install the clutch correctly that is
cover/clutch friction plate and frictional
designated.
surface exceed the size as required.
Adjust clutch system and clutch cable, to
5. Over-temperature in clutch housing is caused
remove unnecessary clearance and
by improper driving.
eliminate mechanical fault.
6. Install unsuitable clutch.
Reinstall the parts that were assembled
incorrectly.
Do not leave your foot on the clutch pedal
all the time.
Check the following conditions: Replace the deformed, worn or cracked
1. Improper clutch friction plate. parts.
2. Poor balance. Install clutch friction plate as designated.
3. Clutch thrust bearing fault. If some part is poorly balanced, replace
Noise
the clutch assembly.
4. Clutch friction plate is subjected to torsional
force vibration attenuation, and the spring is Adjusted clutch wiredrawing.
damaged. Reinstall the parts that were assembled
incorrectly.
This situation will occur when clutch friction
plate can't engage with flywheel softly.
Check the following conditions:
1. Damper spring of clutch friction plate fails to
Shaking meet the specification. Replace clutch assembly.
2. Clutch friction plate fails to meet the
specification.
3. Clutch friction plate is contaminated by
engine oil or grease.
Hydraulic oil of clutch

1. Overhaul key points
Caution:
■ Please do not use vacuum pump or any other type of air discharger power device for this
system.
■ Check the height of clutch hydraulic oil level. Ensure the level is right.
■ Do not spray hydraulic oil of the clutch onto the vehicle body paint and other parts. If
hydraulic oil of the clutch sprays onto the paint of vehicle body and other parts, immediately
wipe it with dry cloth.
CL‐3
2. Discharge the air in the pipeline:

Caution: When dismantling clutch pipeline, clutch master cylinder, hydraulic release bearing, if
clutch pedal is soft, it is necessary to discharge air from the system.
1) Loosen the bleed screw of clutch cylinder.
2) Press clutch pedal slowly until air is exhausted.
3) Completely step on the pedal and keep it and then tighten the bleed screw.
4) Supplement hydraulic fluid to the clutch hydraulic system.
Caution:
■ Always keep the reservoir level between the MIN and MAX.
5) Repeat the above steps until the clutch hydraulic oil discharged from the system is clean
without any blister.
6) Ensure clutch works soundly.
① Start the engine, press clutch pedal and switch carefully to Reverse about 2s later. If there is
large noise when choosing a gear, press the clutch pedal to the end 5 times to discharge air
from the system.
② Check the clutch performance about 30s later. If there is large noise still, please discharge air
again.
Clutch master cylinder
1. Components
4
3
6
Exploded View of Clutch Master pump

1-Fluid reservoir 2-Clamp 3-Piston 4-Snap ring 5-Pushing rod 6-Master pump body
7-Locking pin
CL‐4

1) Removal
① Drain hydraulic oil from clutch air exhaust bolt in CL001
front of clutch.
② Disconnect the lock pin of clutch master cylinder push
rod with clutch pedal.
③ Disconnect the hose from clutch master cylinder to CL002

brake master cylinder.
④ Disassemble the clutch master cylinder oil pipe and CL003

unscrew off the fixing bolts of the cylinder.
⑤ Take out master pump of clutch.
2) Inspection after removal

■ Check if clutch pipeline is blocked.
■ Check if clutch hose and pipe are damaged or rusted.
3) Installation
■ Apply the specified hydraulic oil onto the inner wall of pump and the surface of piston
assembly (brake hydraulic oil DOT4).
■ Make system bleed air. Please see “Hydraulic oil of clutch “.
■ Adjust clutch free stroke. Please see “Inspection and adjustment on vehicle".
■ Tightening torque refers to “tightening torque table”.
CL‐5
Clutch pedal
1. Personalized inspection and adjustment CL004
Free stroke inspection:
■ Press clutch pedal by hands until you feel some
resistance, and then use a scale to measure whether
the free stroke is within the specified range.
Pedal free stroke: 6-13 mm

1. Components
Diagram of Clutch Pedal
2. Removal
① Remove clutch pedal lock pin, disconnect pushing rod CL005
connecting with master pump of clutch.
② Remove clutch pedal fixing bolt, take out clutch CL006

pedal.
CL‐6
3) Inspection after removal CL007

Check if clutch pedal is distorted, damaged or there is
a crack welding cut. If any of the above conditions
occurs, please replace clutch pedal assembly.
4) Installation
Install in the order opposite to that of dismantling.
Caution:
■ When adjusted clutch pedal height, do not push pulling rod into the master pump of clutch.
■ After adjustment, check if the stroke and free stroke of clutch pedal are within specified
range.
■ If the free stroke of clutch isn't within the specified range, there must have air in hydraulic
pipe of the clutch and fault in clutch master cylinder. It is necessary to discharge air from the
system, and dismantle and check master cylinder or clutch.
CL‐7
Clutch pressure plate, friction plate of clutch and flywheel

1) Components
Clutch Exploded View

1-Flywheel 2-Clutchfriction plate 3- Clutch pressure plate 4- Fixing bolt
Caution:
■ Do not make the surface of clutch friction plate, disc and flywheel stained with any grease.
2. Dismantle
① Remove manual transmission assembly on the vehicle. Please see “manual transmission
assembly".
② Uniformly release fixing bolts of clutch disc. And then dismantle clutch disc and clutch
friction plate.
Caution:
■ Loosen 1 to 2 cycles of each bolt each time, to avoid damage of flange of clutch housing.
③ Dismantle fixing bolts of flywheel from the rear of cylinder block, and then remove
flywheel.
④ Remove hydraulic release bearing on the transmission housing.
① Friction plate of clutch
■ Check if the surface has degradation and grease stain caused by rivet loosing, single surface
contact and burning. If yes, please replace clutch friction plate.
CL‐8
■ Measure the sinking depth of rivet. If it exceeds limit CL008

value, please replace clutch friction plate.
■ Check if return spring is loosened or damaged; if so,
please replace clutch friction plate.
■ Install clutch friction plate onto the input shaft, and
Check sliding condition and loosening of rotation. If
the sliding operation is bad, clean it. If the fault still
exists after assembly, please replace it. If the
loosening is obvious, please replace clutch friction
plate or input shaft, or replace both of them at the
same time.
② Clutch pressure plate
■ Check if the end of diaphragm spring is worn and if there is any height difference. If there is
obvious abrasion or the height exceeds limit value, replace clutch friction plate.
② Check if pressure plate surface is worn, cracked or discolored.
■ Check if clutch cover rivets are loose. If so, replace the plate.
③ Hydraulic separate bearing
Check if bearing is burnt or damaged, has abnormal sound, or rotates unsmoothly, etc.
■ Check if the diaphragm spring of hydraulic bearing has abrasion. Replace it if any.
④ Flywheel CL009 Dial indicator
■ Use a dial indicator to measure the levelness of the
contact surface between flywheel and clutch friction
plate. If it doesn't meet requirement, please replace
flywheel.
■ If the contact surface between clutch disc and clutch
friction plate has burning or discolor sign, please
grind it with sand paper.
Caution:
■ Please measure the levelness on the exterior surface of flywheel (do not measure it on the
fixing pin).
4) Installation
① Clean clutch friction plate and the spline slot of input shaft, and remove grease and worn
metal scraps.
② Apply grease onto the spline slot of input shaft.
Caution:
■ Recommended grease: SAE J310 or equivalent.
CL‐9
■ Make sure that the grease is applied to the specified position; otherwise, it may cause clutch
producing noise, bad release effect or damage. Excessive grease may also cause sliding or
vibration.
③ Install flywheel and tighten it with specified tightening torque. Use a special tool to install
clutch friction plate and clutch disc.
④ Perform it by steps in the order shown as in the figure CL010
and evenly tighten the fixing screws of clutch in turn.
Caution:
■ Tight 1-2 cycles for each bolt and gradually tighten it
well.
Tightening torque: 15-2 N•m
⑤ Install hydraulic release bearing.
⑥ Install manual transmission on the vehicle. Installing
process, Please see “Manual transmission".
CL‐10
Hydraulic pipeline
1
2
3
4
5
7 8
6
9
Hydraulic Pipeline Diagram
1-Clutch pressure plate and clutch drive plate 2-Rocker arm 3-Pushing rod
4-Clutch work cylinder and hose assembly 5-Spring clip disc 6-Support 7-Hard pipe
8- Clutch master cylinder 9- Clutch pedal
Pay attention to the following precautions when dismantling and installation of hydraulic pipe of
clutch.
Caution:
■ Do not spray hydraulic oil of the clutch onto the vehicle body paint and other parts. If
hydraulic oil of the clutch sprays onto the paint of vehicle body and other parts, immediately
wipe it with dry cloth.
■ When installing clutch pipe on the hydraulic release bearing, three-way valve, clutch pipe,
please insert it completely to the bottom and Check if the clamp is installed to proper
position.
■ Use oil pipe wrench to tighten the pipe joints.
■ After installation, please discharge air from clutch hydraulic system. Please see “Air
exhaust".
CL‐11
Service Parameters
1. Technical parameters
Technical Parameter Table
Clutch free stroke 6-20 mm
2. Grease
Lubricating Grease Table
Master pin of main pump Kunlun no.2 low temperature grease
3. Tightening torque
Fastening Torque Table
Item Torque (N•m)
Master pump of clutch fixing bolt 20-28
Master pump of clutch fixing nut 20-28
Oil pipe fixing support 20-28
Air exhaust bolt 8-12
Clutch pressure plate mounting bolt 20-28
CL‐12
J4 Service Manual Drive System
Chassis - Drive System

Precautions
1. Instruction for maintenance of drive shaft
1) Do not remove the components that need overhaul like steering knuckle.
2) Be sure to operate on a dust-free work platform as much as possible.
3) Please clean the components surface before removal and installation.
4) During working, pay attention not to stain parts, and avoid foreign matters entering into the
parts.
5) Be sure to re-assemble carefully the disassembled parts in the correct order. If the operation
is interrupted, be sure to shield the parts with clean cover.
6) Be sure to use paper type cloth instead of fiber cloth to prevent cloth cuttings from attaching
the parts.
7) The disassembled parts (except for rubber parts) should be cleaned with kerosene, and blown
to dry or dried with paper or cloth.
2. Instruction for inspection, maintenance or replacement of components
1) Check the specified torque of fastener after the assembly.
2) After assembly of system, it is necessary to conduct necessary positioning inspection.
3) Disposable parts can't be reused.
4) Before Repair or Replace component, and completely inspect.
Preparation work
Use appropriate maintenance tools to remove and install.
1. General Tools
Table of Common Repair Tools
No. Tools Overall Diagram Instructions
1 Power tool Install and remove bolt and screw
DS‐1
2. Special tool
Special Tool Table
1 Move drawplate of drive link JAC-T1D003 Remove connected bulb

Table of Common Failure Diagnosis
Fault Symptom Fault Possible Cause Countermeasures
Knuckle of the drive shaft is worn-out Replace
Vehicle deviation Wheel bearings are worn-out, frictional and make abnormal noise Replace
Front suspension and steering are defective Adjust or replace
Drive shaft is worn-out, damaged or bent Replace
Vibration Drive shaft and spline of the hub make abnormal noise Replace
Wheel bearings are worn-out, frictional and make abnormal noise Replace
Wheel unbalance Adjust or replace
Runout
Front axle steering knuckle is defective Adjust or replace
Drive shaft is worn-out, damaged or bent Replace
Spline of the drive axle hub is worn-out Replace
Spline of the drive axle hub is worn-out Replace
Noise is too big
Wheel bearings are worn-out, burnt and make abnormal noise Replace
Nut in the hub is loose Adjust or replace
Front suspension and steering are defective Adjust or replace
Front wheel hub and steering knuckle

1. Inspection in the car
Confirm whether each component is fixed (clearance) and worn properly and normally.
1) Inspection of wheel bearings
■ Push the wheel hub and bearing assembly along axial direction by hand to confirm the
wheel-hub bearing is not loosen. If any, please replace or reinstall bearings.
■ Rotate the wheel hub to confirm that no abnormal noise or any other abnormalities. If any,
please replace bearings.
DS‐2

1) Components
Disassembly diagram of front axle

1-Lower swing arm 2-Ball head 3-Brake caliper Fixing bolt 4-Dustproof cover 5-Hub assembly
6- Lock nut 7, 8, 9-Brake disc 10-Brake caliper 11-Steering knuckle 12-Shock absorber 13-Nut
14-Snap ring 15-Wheel bearing 16-Lower swing arm locking nut
2) Removal DS001
① Lift the vehicle and remove the front tire. Please
refer to "Wheels and Tires".
② Remove the wheel speed sensor from the knuckle.
Please refer to "Wheel Speed Sensor".
Caution:
■ Do not pull the wire harness of wheel speed sensor.
■ While installing, check the gap between the wheel
speed sensor and the hub.
Clearance standard value: 0.5 mm
③ Release the set bolts of the brake hose and remove
the brake hose. Please refer to "Brake Line".
DS‐3
④ Remove the front brake caliper assembly from the DS003

knuckle, and hang and fix it. Please refer to “Front
Brake Caliper “.
Caution:
■ Do not depress the brake pedal after removing the
brake caliper.
⑤ Remove the brake disc stop screw from the hub and
take off the disc.
⑥ Loosen hub locking nut. DS002

⑦ Hit the drive shaft gently with the hammer (or other
appropriate tool) and wooden block to disengage the
wheel hub from the steering knuckle assembly, and
then remove the lock nuts from the wheel hub.
Caution:
■ Support housing (universal joint group), shafts and
other components after putting down the drive shaft.
■ If you still cannot disengage the wheel hub from the
drive shaft after performing these operations, you can
use the puller (or other appropriate tool).
⑧ Remove the bulb of steering tie rod from the DS004
knuckle.
Caution:
■ Special tools or right tools should be used to avoid
damaging the bulb dust cover.
⑨ Remove the shock absorbers from the knuckle and its DS005
set bolts.
DS‐4
⑩ Remove the drive shaft from the wheel hub. DS006
Caution:
■ The angle to place the universal joints of the drive
shaft should not be too wide. Avoid overstretching
and prevent the gate from falling off.
⑪ Remove the lower swing arm bulb from the steering DS007
knuckle. Please refer to "Lower swing arm".
Caution:
■ Special tools should be used to avoid damaging the
bulb dust cover.
⑫ Remove the wheel hub and steering knuckle assembly.

Caution:
■ Check the component for deformation, crack and other damages. Replace if any of the
above.
Check the dust cover of the tie-rod outer ball for damage, oversized axial clearance and
twisting. Please refer to the "Tie Rod".
4) Installation
■ Installation is in the reverse order of removal. Please refer to "Maintenance Parameters" for
information about the tightening torque.
Caution: do not use the damaged components.
■ When installing the tie-rod bulb, be sure to fix the bolt to avoid its rotation and then tighten
its nut.
■ In the case of no load, tighten each part removed when removing the front wheel hub and
steering knuckle to its final torque.
■ Check the wheel alignment. Please refer to "Inspection of front wheel alignment ".
■ Check if the wiring harness of the wheel speed sensor is connected correctly. Please refer to
"Wheel speed sensor".
DS‐5
3. Disassembly and assembly

1) Disassembly
① Use internal snap ring pliers to remove the snap ring. DS008
② Remove the hub and the dust helmet from the

knuckle.
③ Remove the wheel bearing inner ring from the hub.
④ Remove the wheel bearing outer ring from the
knuckle.
Caution:
■ To avoid personal injuries due to bearing slipping
off, be sure to operate as standardized.
■ If you still cannot disengage the steering knuckle
from the wheel bearing after several attempts,
replace the steering knuckle assembly.
① Steering knuckle
■ Check the contact surfaces between the steering knuckle and wheel bearing for scratch, crack
or other damage.
■ If any of these conditions, repair or replace it depending on the actual conditions.
② Brake disc
Check the brake disc surface for cracks and other damages.
③ Snap ring
■ Check the snap ring for crack or other damage.
Caution:
■ Do not use any damaged part.
④ The hub
■ Check if the hub bolts are elongated.
DS‐6
■ Check the contact surfaces between the wheel hub and wheel bearing for scratch, crack or
other damage.
■ Replace or change if any of the above.
3) Assembly
① Apply moderate grease to the contact surface of the knuckle and wheel bearing.
② Press new wheel bearings into the knuckle and install a new snap ring.
Caution:
■ Do not press the wheel bearing inner ring, in case the wheel bearing assembly should be
damaged.
■ Model of left and right wheel bearing must be consistent.
■ Do not reuse the damaged components.
③ Install the dust cover.
④ Press the hub into the knuckle.
Caution:
■ Do not press the wheel bearing outer ring to avoid the wheel bearing assembly.
4) Inspection after assembly
■ Check if the hub and wheel bearing are installed in the right place.
■ Measure the bearing axial clearance.
Limiting value: 0.064-0.088 mm
Caution:
■ If the axial clearance exceeds the limit, please reassemble it.
4. Replacement of the wheel bearing
For information about removal and installation, please refer to the steps of “Front wheel hub
and knuckle”.
Caution:
■ Check the left and right wheel bearing models for consistency.
■ Carry out necessary road test.
DS‐7
Front drive shaft

1. Inspection and maintenance in the car
1) Check the drive shaft and universal joint for looseness and other damage.
2) Check the dust cover for crack and other damage.
Caution:
■ If the drive shaft produces noise or vibration, replace the drive shaft assembly.
2. Replacement of the drive shaft dust cover
1) Lift the vehicle and remove the front tire of vehicle. Please refer to "Wheels and tires".
2) Remove the wheel speed sensor from the steering knuckle. Please refer to "Wheel speed
sensor".
Caution:
3) Remove the front brake caliper assembly from the knuckle, and hang and fix it. Please refer
to “Front brake caliper “.
Caution:
■ Do not depress the brake pedal after removing the brake caliper.
4) Remove the cotter pin and release the hub locknut.
5) Hit the drive shaft gently with the hammer (or other appropriate tool) and wooden block to
disengage the wheel hub from the steering knuckle assembly, and then remove the lock nuts
from the wheel hub.
Caution:
■ Support housing (universal joint group), shafts and other components after putting down the
drive shaft.
■ If you still cannot disengage the wheel hub from the drive shaft after performing these
operations, you can use the puller (or other appropriate tool).
6) Remove the bulb of steering tie rod from the knuckle.
Caution:
■ Special tools should be used to avoid damaging the bulb dust cover.
7) Loosen the set bolts and nuts of the shock absorbers and knuckle.
DS‐8
8) Separate the drive shaft from the hub and bearing assembly.
Caution:
■ The angle to place the universal joints of the drive shaft should not be too wide. Avoid
overstretching and prevent the gate from falling off.
9) Remove the dust cover clamp. DS009
10) Screw the drive shaft puller (or other appropriate
tool) into the screw hole of the universal joint
sub-assembly to pull out the universal joint
sub-assembly from the shaft.
Caution:
■ If you cannot pull out the universal joint
sub-assembly, remove the drive shaft assembly from
the car and then try it again.
11) Remove the snap ring from the drive shaft and the
dust cover.
12) Dry the grease on the universal joint sub-assembly
with paper towels.
13) Apply suitable amount of lubricating grease into the DS010
tooth hole of universal joint until the lubricating
grease flows out of round slot and tooth hole. After
greasing, wipe off the outflow of the used grease
with clean cloth.
14) Wrap around the spline in tape to avoid damaging the Sub-assembly
dust cover. Install the new dust cover and dust cover
clamp in the drive shaft.
Caution:
■ Do not reuse dust cover and dust cover clamp.
15) Remove the tape on the shaft.
16) Place the snap ring on the grooves along the edges of
the shaft. Make sure that the intermediate shaft at the
axis edge is in alignment with the universal joint
sub-assembly. And then, re-install the shaft to the
universal joint sub-assembly with the snap ring.
Caution:
■ Do not reuse the snap ring.
■ Special tools are recommended to install the snap
ring.
DS‐9
17) Use a plastic hammer to mount the universal joint DS011

sub-assembly on the drive shaft. Sub-ass
Caution:
■ Verify that the universal joint sub-assembly has been
properly engaged when rotating the drive shaft.
18) Apply a right amount of grease evenly to the dust DS012 avoid Transformation of
cover inside from its large-diameter side. dirt-proof boot
19) Mount the dust cover in the tank as illustrated in the

figure.
Caution:
■ If any grease sticks to dust cover mounting surface
(indicated by *), the boot can fall off. Wipe all the
grease on the surface of the dust cover. Slotted screwdriver
20) Insert the flat-blade screwdriver into the dust cover DS013
from the large diameter side to make its internal air
bleed out, and adjust its mounting length to avoid
deformation.
Caution:
■ If the mounting length of the dust cover is overlong,
it may damage the dust cover.
■ Use the flat-blade screwdriver with care, do not
touch the inside of the dust cover.
21) Fix the new dust cover clamp with a tool.
Caution:
■ Do not reuse the dust cover clamp.
22) Fix the universal joint sub-assembly and the drive shaft, and then confirm the correct
position in the case of the dust cover rotation.
Caution: if the dust cover has been installed improperly, please use a new boot clamp to reinstall
it.
23) Make sure that the snap ring at the transaxle side has been fully engaged.
24) Insert the drive shaft into the wheel hub and bearing assembly, and then tighten the lock nuts
of wheel hub.
25) Install the set bolts and nuts of the shock absorbers and knuckle.
26) Install the bulb of the steering tie rod and tighten the locknut according to the standard
tighten torque.
DS‐10
Caution:
■ When installing, fix the bolt to prevent rotation before tightening the nut.
27) Install the brake caliper component and fasten the brake hose. Please refer to "Front brake”
and “Brake line".
28) Install the wheel speed sensor to the knuckle. Please refer to "Wheel speed sensor".
29) Tighten the locknut to standard torque.
30) Install the cotter pin.
Caution:
■ Do not reuse the cotter pin.
31) Install the tire and tighten it in accordance with standard torque. Please refer to “Service
Parameter “.
1) Components
Diagram of Drive Shaft Assembly
2) Removal
① Lift the vehicle and remove the front tire. Please refer to "Wheels and Tires".
② Remove the wheel speed sensor from the knuckle. Please refer to "Wheel Speed Sensor".
Caution:
③ Remove the front brake caliper assembly from the knuckle, and hang and fix it. Please refer
to “Front brake caliper “.
Caution:
■ Do not depress the brake pedal after removing the brake caliper.
④ Remove the brake disc.
⑤ Remove the cotter pin and release the hub locknut.
⑥ Hit the drive shaft gently with the hammer (or other appropriate tool) and wooden block to
disengage the wheel hub from the steering knuckle assembly, and then remove the lock nuts
from the wheel hub.
DS‐11
Caution:
■ Support housing (universal joint group), shafts and other components after putting down the
drive shaft.
■ If you still cannot disengage the wheel hub from the drive shaft after performing these
operations, you can use the puller (or other appropriate tool).
⑦ Remove the bulb of steering tie rod from the knuckle.
Caution:
■ Special tools should be used to avoid damaging the bulb dust cover.
⑧ Loosen the set bolts and nuts of the shock absorbers and knuckle.
⑨ Remove drive shaft from the wheel hub and bearing assembly.
⑩ Remove drive shaft from the transmission side.
Caution:
■ When removing the drive shaft do not place the drive shaft universal joints in an excessive
angle. Do not stretching the slip joint excessively.
3. Inspection after disassembly
① Rotate the universal joint to check if it can move smoothly and for any serious loose.
② Check the dust cover for cracks, damage and grease leakage.
③ If any non-compliance occurs, disassemble the drive shaft and replace the faulty parts.
4) Installation
Caution:
■ When installing the drive shaft, replace the transmission side oil seal.
① Front drive shaft
■ Installation is in the reverse order of removal. For tightening torque, please refer to “Service
parameters”.
Caution: do not reuse non-reusable components.
■ Avoid damaging the oil seal when inserting the drive shaft into the transmission side.
Caution:
■ Confirm the snap ring of this side has been fully engaged.
■ Apply gear oil on to the drive shaft splines.
■ The opening of the snap ring should face down before installing the drive shaft.
DS‐12

1) Components
1
2
3
4
5
6
5
2
9
8
Exploded view of drive shaft

1-Snap spring 2-Housing 3-Snap ring 4-Three-fork assembly 5-Anti-dust boot
6- Dust cover clamp. 7- Lock nut 8-Anti-dust cover 9-Wheel speed sensor gear ring
2) Disassembly DS014 Matching mark

① Transmission side
a. Fix the drive shaft in the caliper.
Caution:
■ When fixing the drive axle in a vise, be sure to use
aluminum or copper plates to protect the drive shaft.
b. Remove the dust cover from the housing after removing the dust cover clamp.
c. Mark the housing and the drive shaft with assembly marks, respectively, and then pull the
drive shaft out from the housing.
DS‐13
Caution:
■ Use paint or similar materials to mark. Please do not scratch the surface.
d. Remove the trigeminal assembly from the drive shaft DS015
after removing the snap ring.
Snap ring
e. Remove the dust cover from the drive shaft.

f. Use paper towels to dry the old grease on the housing.
② Wheel side
a. Fix the drive shaft in the caliper.
Caution:
■ When fixing the drive shaft in a vise, be sure to use aluminum or copper plates to protect the
drive shaft.
b. Remove the dust cover clamp, then install the dust cover from the universal joint
sub-assembly.
c. Screw the drive shaft puller (or a suitable tool) into the thread of the universal joint
sub-assembly, and then pull away the universal joint sub-assembly from the drive shaft.
Caution:
■ If you fail to remove the universal joint sub-assembly even if trying several times, replace
the drive shaft assembly.
d. Remove the snap ring from the drive shaft and the dust cover.
e. Remove the dust cover from the drive shaft and the wheel speed sensor.
f. Turn the ball-and-cage, and wipe off the used grease on the universal joint sub-assembly
with paper towel.
① Drive shaft
Check the drive shaft for jumpiness, cracks and other damage. In case of any of the said
conditions, replace the drive shaft assembly.
a. The Universal Joint Sub-assembly (Wheel side)
Check the following item:
■ Check the universal joint sub-assembly for excessive rotation and check the drive shaft for
excessive loose.
■ Check the universal joint sub-assembly inside for entry of foreign matter.
DS‐14
■ Check the universal joint sub-assembly for signs of press, crack and internal damage.
If you find any non-compliance, replace the universal joint sub-assembly.
b. Housing and trigeminal assembly (transmission side)
If you find any scratch or wear on the housing rolling contact surface or tri-yoke rolling
contact surface, be sure to replace the housing and tri-yoke assembly.
Caution:
Housing and trigeminal assembly are used in the same device.
② Dust cover and wheel speed sensor
■ Check for crack and other damage. Replace if any of the above.
4) Assembly
① Transmission side
a. Wrap the splines in the drive shaft with adhesive tapes to avoid damage to the dust cover.
Install the new dust cover and dust cover clamp in the shaft.
Caution: Do not reuse dust cover and dust cover clamp.
b. Remove the tape around the axle shaft spline. DS016
Adhesive
tape
c. When installing the trigeminal assembly, mark the DS017 Cross-shaft componentTo
paint mark. Install the reversed shaft on the trigeminal
assembly
Matching
mark Matching
mark
Spline
Drive shaft
DS‐15
d. Fix the trigeminal assembly to the housing with the DS018

snap ring.
Snap ring
e. Coat the tri-yoke assembly and the sliding surface DS019 To avoid Transformation
with the recommended lubricant. of dirt-proof boot
f. Install the housing to the tri-yoke assembly, and then
apply the recommended grease.
g. Mount clamps to the tank as illustrated in the figure.
Caution:
■ If the grease sticks to the fixed surface of the dust Slotted screwdriver
cover, dust cover may fall off. Dry all grease on the
surface.
h. Hinder the flat-blade screwdriver into the dust cover
from the large diameter side to make its internal air
bleed out, and adjust its mounting length to avoid
deformation.
Caution:
■ If the mounting length of the dust cover is overlong, it
may damage the dust cover.
■ Use the flat-blade screwdriver with care, do not touch
the inside of the dust cover.
i. Use special tools to fix the new dust cover clamp.
Caution:
■ Do not reuse the dust cover clamp.
j. Fix the housing and the drive shaft, and then confirm the correct position when rotating the
dust cover.
Caution: If the dust cover has been installed improperly, please use a new boot clamp to reinstall
it.
k. Install the wheel speed sensor and the dust cover to the housing.
② Wheel side
Assemble in accordance with the Steps 14-23 of "Replacement of drive shaft dust cover".
Caution:
■ When installing, make sure that the universal joint sub-assembly and the drive shaft are
located at the same line.
DS‐16
■ When installing, make sure the wheel speed sensor and the housing have been fully engaged.
■ Press the boot before installing the wheel speed sensor.
DS‐17
Service Parameters
Fastening Torque Fastening Torque
Item Item
(N·m) (N·m)
Connecting nut of rear cantilever
Drive shaft locknut 220-260 130-150
and rear steering knuckle
Connecting nut of steering knuckle
75-90 Bolts of retaining bracket roll bar 17-26
and shock absorber assembly
Bulb of down swing arm and The connect nut of stabilizer rod
60-72 35-45
connect nut of knuckle. and lever
Connecting nut between rear
Wheel nuts 90-110 100-120
cantilever and vehicle body
Rear-wheel hub bearing locknut 180-220 Rear cantilever eccentric nut 80-100
Connecting nut of rear shock
75-90 Limit bolt of brake disc 10-15
absorber and rear steering knuckle
DS‐18
J4 Service Manual Suspension System
Chassis - Suspension system

Front suspension system
Front post assembly
Front stabilizer bar pulling
assembly
Front hub bearing

assembly
Front
steering
knuckle
assembly Front stabilizer bar
assembly
Front lower Front stabilizer bar

swing arm bushing
assembly
Front sub-frame Front stabilizer bar

assembly mounting support
Schematic Diagram of Front Suspension Assembly
Precautions
■ When installing suspension or rubber bushing, it can be tightened finally only when the tires
shall be on the ground, without load.
■ After maintenance of suspension components, be sure to check the wheel alignment.
■ Oil has to shorten service life of rubber bushing. The flowed oil must be wiped away.
■ Idle condition means that fuel, engine coolant and lubricant has been filled, spare tire, jack,
driver's tool and foot pad are at specified position.
■ Do not reuse lock nut. Always use a new nut when installing. When replacing, before
tightening lock nut, do not wipe anti-rusting oil from lock nut.
FSU‐1
Preparation work
Special tools to be used are shown in following table:
Special Tool Table
Move drawplate of
1 JAC-T1D003 Removal of connected bulb
drive link.
Removal machine of Removal and installation of

2 JAC-T1D004
damping spring damping spring
Front suspension assembly

Confirm whether each component is fixed (clearance) and worn properly and normally.
1) Check clearance of track rod
① Park the front wheel straight ahead.
② Place a crowbar (or similar tools) between track rod and knuckle.
③ Lever to check the clearance.
Caution:
■ Do not destroy dust cover of bulb.
■ Do not use excessive force to destroy the assembly part.
2) Inspection of shock absorber
Check if the assembly part is leaking, destroyed or worn-out.
2. Front wheel alignment check
1) Specification
Measure the wheel alignment in idle load.
2) Pre-inspection
Check the following item:
① Check if the tire pressure is normal and tire is worn-out.
② Check if the wheel jumps.
FSU‐2
③ The clearance of wheel bearing.

④ The clearance of track rod.
⑤ Check if the fixed points of axle and suspension are loose or out of shape.
⑥ Check if each suspending part, steering knuckle, shock absorber and tie rod are cracked,
deformed or damaged.
⑦ The height of vehicle body.
3. Check the toe-in of the front wheel
Caution:
■ Locate the wheel in level and idle condition.
■ The toe-in value of the front wheel: 0°±10′
If the above value is not within the standard, please adjust according to the following steps:
1) Check the above value on the four-wheel aligner. FSU001
2) Adjust and fix the steering wheel.
3) Loose the locknut at the end of track rod.

FSU002
4) Rotate the left/right tie rod in clockwise/counter clockwise, and adjust the value of toe-in to
the standard value.
Caution:
■ The amount of rotating the tie rod shall be proper.
5) Lock the locknut at the end of track rod.
4. Check camber angle, rear caster angle and kingpin inclination.
Front-wheel camber: 0°±30′
Rear caster angle: 4°±30′
Kingpin inclination angle: 13°±30′
FSU‐3
Caution:
■ Camber angle, caster angle and toe-in angle of main pin are set before leaving factory, so do
not adjust them.
■ If camber angle, kingpin caster angle and kingpin inclination angle are out of standard range,
please check if front suspension, steering knuckle, shock absorber and tie rod are worn or
damaged. If any, replace any suspected components.
Front shock absorber
1. Components
Diagram of Front Shock Absorber Assembly
2. Removal and installation FSU003

1) Removal
① Remove the front tire.
② Disconnect the connector of wheel speed sensor.
Caution:
③ Remove flexible brake hose card and cut off flexible FSU004
brake hose.
④ Remove self-locking nut of shock absorber and body.
■ Tightening torque: 21 -25 N•m
⑤ Remove set bolts and nuts of absorber and steering
knuckle.
FSU‐4
⑥ Take out shock absorber assembly.

FSU005
2) Installation
Install it in the reverse order of removal
Caution:
■ Under idle condition, completely tighten each part removed at the time of dismantling shock
absorber.
■ Check the wheel alignment.
1) Components
1
7
8
2
5 9
10
Front shock absorber stand column assembly exploded view

1-Self-locking nut 2-Upper support assembly 3-Plane bearing
4- Upper support saddle of the coil spring 5-Coil spring upper vibration isolation cushion
6-Dustproof cover 7-Shock absorber buffer block 8-Front coil spring
9-Coil spring lower vibration isolation cushion 10-Front shock absorber body
FSU‐5
2) Disassembly
Caution:
■ Do not destroy piston push rod of shock absorber when removing components of shock
absorber
① Use spring compressor to compress coil spring until it is loose completely.
Caution:
■ Confirm the compressor is installed in the right position, and then compress coil spring.
■ When tightening spring compressor bolts, do not use pneumatic tools.
③ Fix the end of piston push rod and remove the locknut of piston push rod.
■ Tightening torque: 49-68.6 N•m
Caution:
■ Confirm compressed coil spring is slack.
④ Remove upper support saddle, vibration cushion of the coil spring, dust helmet and buffer
block.
⑤ Remove coil spring with a compressor, and then release the compressor slowly.
⑥ Remove down vibration cushion of the coil spring and remove the shock absorber.
① Shock absorber
Caution:
■ Whether the shock absorber has deformation, crack and damage. Replace it if any.
■ Check the piston push rod for damage, wear and deformation. Replace it if any of the above.
■ Check the piston for oil leakage. Replace it if any.
② Vibration cushion of the coil spring, buffer block and dust helmet.
Check if there is crackle and if the rubber components are worn-out. Replace it if any.
③ Coil spring
Check the coil spring for crack, wear and damage. Replace it if any.
④ Upper support saddle of the coil spring
Check for cracks, wear, deformation and other damage. Replace it if any.
⑤ Plane bearing
⑥ Upper support assembly
FSU‐6
4) Assembly FSU006
Coil spring
Installation is in the reverse order of removal.
Caution:
■ Do not destroy the piston push rod when assembling
the components on shock absorber.
Lower spring seat
■ Adown the larger diameter end and direct down
Place spring onto
support saddle of the spring. proper position.
■ Be sure that compressor has assembled on the coil

spring before pressing coil spring.
■ Before releasing compressor, check if the mounting
position of the coil spring is correct.
■ Check if the auxiliary aiming mark is correct.
Lower swing arm
1) Removal FSU007
① Lift the vehicle and remove the wheel tire.
② Unplug cotter pin, and dismantle slot type nut fixing
lower swing arm ball pin and lower swing arm.
③ Unscrew off the fixing screws of lower swing arm
and sub-frame rear point.
④ Dismantle fixing bolt of rear fixing point of lower
swing arm and auxiliary frame.
Caution: fix the lower swing arm ball joint and then
unscrew the locking nut to avoid rotation during removal.
⑤ Remove the lower swing arm assembly.
① Visual inspection
■ Check the bushing for wear or damage. Replace it if any.
■ Check if rear swing arm is deformed or destroyed. Replace it if any.
■ Check if dust cover of bulb or down swing arm cracks. Replace it if any.
■ Check all the set bolt and nut. Replace it if any damage.
FSU‐7
3) Installation
Caution:
■ Pre-tighten the bolt between front rubber sleeve of lower swing arm and set bracket to avoid
the rubber sleeve from deforming.
■ Under idle condition, tighten each part removed at the time of dismantling lower swing arm.
Lateral stabilizer bar
1) Removal FSU008
① Disassemble the fixing nut of front left & right
stabilizer bar link connecting ball and front pillar
assembly.
② Disassemble the fixing nut on front left & right
stabilizer bar link connecting ball and front stabilizer
bar assembly.
③ Remove the set screw bolt of left and right stabilizer FSU009
rod and dissemble fixed frame and bush.
④ Remove the stabilizer rod assembly.

Check if stabilizer bar, connection ball of stabilizer bar, support structure of stabilizer bar
and stabilizer bar bushing are deformed and worn. Replace it if any.
■ Move the bulb stud manually to see if it is flexible.
■ Check if the dustproof shield of stabilizer rod has crack and grease leakage. Replace it if any.
3) Installation
■ Install it according to the reverse order of dismantling.
■ When tightening lock nut, first fix bolts of horizontal stabilizer rod and avoid rotating it.
Caution:
FSU‐8
■ Do not reuse non-reusable components.

■ When assembling bush and fixed frame of stabilizer rod, note the direction.
■ Under idle condition, tighten each part removed at the time of removing front stabilizer rod.
Front sub-frame assembly
1. Components
Front sub-frame component diagram

1) Removal
① Lift the vehicle and remove the tires.
② Disassemble the steering column assembly and steering shaft U-joint screws.
③ Unscrew off the fixing bolts of engine rear mounting with the front sub-frame.
④ Fixing bolts of sub-frame with front vehicle body point.
⑤ Fixing bolts of sub-frame with rear vehicle body point.
Take down front sub-frame assembly.
■ Check if sub-frame has clack
FSU‐9
Fault diagnosis
Fault Symptoms Fault Possible Cause Countermeasures
Wheel alignment is improper Adjust
Rotation beyond the ball joint of lower arm Replace
Steering heaviness
Tire pressure is too low Inflation
W/O power steering Repair or replace
The absorber is faulty. Repair or replace
Return is poor Wear or damage to stabilizer bar Replace
Coil spring is worn-out or destroyed. Replace
Worn lower swing arm bushing Replace
The air pressure is lower or higher. Adjust the air
The tire is worn out abnormally.
pressure
Lack of resistance for bulb connection of down swing Replace
Vehicle deviation
arm.
Bush of down lower swing arm loose or worn-out. Replace
The vehicle runs biased to a single arm.
side
lower swing arm is bent Replace
arm.
Steered wheel vibration Bush of down lower swing arm loose or worn-out. Replace
Wear or damage to stabilizer bar Replace
Vehicle declines.
FSU‐10

Technical Specification Table
Items Parameter and Specification
Front suspension from Coil spring with independent suspension in Mac Pherson style.
Type Two-way hydraulic drum
Stroke 168 mm
Shock absorber
Damping Stretch 1115 N ± 165 N (0.3 m/s)
force Compression 355 N ± 77 N (0.3 m/s)
Color mark: a white line with a
Coil spring Free height: 329±5 mm
yellow line.
Toe in (Front) 0°±10′
Camber angle of wheel 0°±30′
Wheel
Inner caster angle 13°±30′
alignment
Rear caster angle 4°±30′
Kingpin offset 9.7mm
Fastening torque table

Item Torque (N·m)
Fixing bolt of front lateral stabilizer bar mounting support and sub-frame 45-55
Front lateral stabilizer bar and lateral stabilizer bar pulling rod
55-65
connecting nut
Connecting nut of front lateral stabilizer bar pulling rod and front post
55-65
assembly
Nut of front shock absorber and body assembly 21-25
Front shock absorber upper self-locking nut 49-68.6
Front shock absorber and steering knuckle connecting bolt 100-120
Lower swing arm ball pin and steering knuckle connecting bolt 100-120
Lower swing arm ball pin and lower swing arm connecting nut 100-120
Lower swing arm front bushing and sub-frame connecting bolt 170-190
Lower swing arm rear bushing and sub-frame connecting bolt 100-120
Front sub-frame front fixing nut 170-190
Front sub-frame rear fixing bolt 170-190
FSU‐11
Rear suspension system

Precautions
■ When installing the suspension, it can be tightened finally only when the tires shall be on the
ground, without load.
■ After maintenance of suspension components, be sure to check the wheel alignment.
■ When installing rubber bushing, it can be tightened finally only when the tires shall be on the
ground, without load.
■ Oil has to shorten service life of rubber bushing. The flowed oil must be wiped away.
■ Idle condition means that fuel, engine coolant and lubricant has been filled, spare tire, jack,
driver's tool and foot pad are at specified position.
■ Do not reuse lock nut. Always use a new nut when installing. When replacing, before
tightening lock nut, do not wipe anti-rusting oil from lock nut.
Preparation work
Common and special repair tools are shown in table below:
General Tools Table
1 Power tool Installation and removal of bolt and screw
FSU‐12
Rear suspension assembly

1. Component
Rear absorber
Rear torsional Rear hub unit
assembly girder assembly assembly
Upper rubber
cushion of
Rear coil
Lower rubber
spring
cushion of
Diagram of Rear Suspension Assembly

Confirm whether every component is fixed (clearance and looseness) and its condition (be
worn-out or damaged).
Check if shock absorber and mounting position has oil leakage or damage.
3. Inspection of rear wheel alignment
Caution:
■ Toe-in angle and camber angle are set before leaving factory, so do not adjust them.
■ After the abrasion and loosening of relevant parts of rear suspension, it is necessary to Check
if the rear wheel alignment parameters meet requirement. If no, please replace relevant
deformed and worn parts.
■ Standard value:
Toe-in of rear wheel: 19′±10′
Rear-wheel camber: -1°±30′
1) Specification
Measure the wheel alignment in idle load.
2) Pretest
Check the following contents:
① Check if the tire pressure complies with standards and whether the tire is worn-out.
② Check if the wheel jumps.
FSU‐13
③ The clearance of wheel bearing.

④ Check if all the components as well as fixed points are loose.
⑤ Control the performance of shock absorbers.
⑥ Check if each cantilever is flawed, deformed and damaged.
⑦ Vehicle height.
Rear shock absorber

1. Components
2
7
3
Rear shock absorber assembly component diagram

1-Self-locking nut 2-Upper mounting vibration isolation pressure pad
3-Upper mounting plate of rear reducer 4-Limiting seat 5-Buffer block 6-Dustproof cover
7-Rear shock absorber body

1) Removal FSU009
① Lift the vehicle and remove the wheel tire.
② Remove connecting bolt of shock absorber and body.
③ Remove shock absorber and rear torsional girder.
FSU‐14

① Shock absorber FSU010
■ Check if the shock absorber is leaking. Replace it if
any.
■ Check if the piston push rod is damaged, worn-out or
deformed. Replace it if any.
② buffer block, dust helmet
Check the buffer block and dust cover for abrasions
and damages. Replace it if any.
③ Upper mounting plate of rear reducer
■ Check rear shock absorber upper mounting plate for
abrasions or damages. Replace it if any.
④ Limiting seat, upper mounting vibration isolation
pressure pad
■ Check if limit seat, upper mounting shock absorption
cushion have abrasion or damage. Replace it if any.
3) Installation
Caution:
■ Under idle condition, completely tighten each part removed at the time of dismantling shock
absorber.
Rear coil spring

1) Removal
① Remove the connecting screw of rear shock absorber FSU011
with rear torsion beam.
Tightening torque: 100-120 N•m
② Remove upper rubber soft cushion of rear spring, rear
spiral spring and lower rubber soft cushion of rear
spring.
FSU‐15
Caution:
FSU012
During dismantling, pay attention to sudden falling of
spring, and avoid personnel injuries!
① Upper rubber cushion of rear spring, Lower rubber
cushion of rear spring
■ Check if the upper support cushion of rear spring and
lower support cushion of rear spring have abrasion or
damage. Replace it if any.
② Coil spring
■ Check if spiral spring has abrasion or damage.
Replace it if any.
3) Installation
Caution:
■ When installing lower support cushion of spring, it is necessary to align rubber round
cylinder of lower support cushion with corresponding support plate hole of spring on the rear
torsion beam, and install them on proper positions.
■ Adown the larger diameter end and direct down support plate of the spring.
■ Check if the auxiliary aiming mark is correct.
■ On no-load condition, conduct final tightening to each part.
Rear torsional girder assembly

1. Components
Diagram of Rear Torsional Girder Component
FSU‐16

1) Removal
① Remove connecting bolt of rear torsional girder and shock absorber.
② Use a jack to support rear torsion beam assembly.
Caution:
■ During dismantling, it is not allowed to let the jack slide.
③ Remove fixing bolt between rear torsional girder and body.
2) Installation
Caution:
Fault diagnosis
Fault Symptom Fault Possible Cause Countermeasures
Loose assembly Fasten
Abnormal sound Fatigued or damaged wheel bearing Replace
Damaged shock absorber assembly Replace damaged component
Defective tire quality Replace
Excessive tire pressure Adjust the pressure
Damaged shock absorber assembly Replace damaged component
Vibration
Loosen tire nut Tighten
Shortened or broken coil spring Replace
Defective tire quality Replace
Body inclination Shortened or broken coil spring Replace
FSU‐17

Item Parameter and Specification
Rear suspension form Torsion beam type
Type Two-way hydraulic drum
Stroke 223mm
Shock absorber
Stretch 635N±102.5N (0.3m/s)
Damping force
Compression 265N±62.5N (0.3m/s)
Type Spiral straight spring
Coil spring Free height 335±5mm
Color mark One write or one yellow
Toe in (Rear) 19′±10′
Wheel alignment
Camber angle of wheel -1°±30＇

Item Tightening torque (N·m)
Bolt of rear shock absorber and body assembly 45-55
Upper self-locking nut of rear shock absorber 24.5-34.3
Connecting bolt of rear shock absorber and rear torsional girder 100-110
Bolt of rear torsional girder and body assembly 100-110
FSU‐18
J4 Service Manual Brake System
Chassis - Brake system

Wheel & Tire
Precautions
■ Please use the original wheel.
■ During the period of new tires, a sudden starting, turning and braking shall be avoided to
prevent new tires from early damage under severe working conditions.
■ A new tire shall be subject to wheel balancing before use.
Tire
1) Inspection
1. Check air pressure.
① Check the tire inflation pressure. Adjust if not within BR001
the standard range.
Standard value: 240±10 KPa
Caution:
■ Use a tire pressure gage of excellent quality to check
tire pressure.
■ Check if wheels are worn, aerated incorrectly, cracked
or otherwise damaged.
■ When ambient temperature varies largely, check tire
pressure frequently.
② Incorrect tire pressure may cause: BR002
a. Insufficient pressure will cause quick wear to tire
shoulder, tire deflection and increase rolling
resistance.
b. Excessive pressure will cause quick wear to tire crown
and decreased tire buffer capability.
BR‐1
2) Check incorrect positioning.

If the front wheel toe-in or the rear wheel toe-in is too large BR003
or too small, it will affect the feather-like wear of tires.
Inner side
Toe-in is too badly worn
BR004
Inner side
Toe-in is too slightly worn
3. Tire tread check. BR005

① Check the tire tread depth.
Caution: Tire specification 185/65R15 88H
■ When the tire tread depth reaches the limit or less, the
wear indicator will appear on the tire tread pattern.
When the wear indicator appears, please replace the
tire.
② Check the tire tread pattern for foreign matters. Please BR006
clear away if any.
4) Check the wheel for cracks and other damages. If
deformed, please check the wheel run-out.
① Remove the tire from the wheel, and install on the tire
balancer. Transverse run
out Radial
② Set the micrometer in the position as shown in the runout
mount
figure.
For wheel runout, please refer to the "Maintenance data
and specification". If the total runout exceeds limit value
(see "repair data and specification" in wheel and tire),
please replace it.
BR‐2
2) Rotation
■ The tire rotation shall be carried out when the vehicle BR007
travels every 8,000 km. Perform tire rotation when
replacement a new tire.
Caution: Please refer to the table for tire rotation
recommended.
3. Replacement
① When the vehicle travels 50,000 km, the tires shall be replaced.
② If there is one of the following conditions, the tire shall be replaced as well:
■ The wear indicator appears at 3 or more positions on the tire tread pattern.
■ The cord or cord line appears in the tire rubber.
■ The tire tread or shoulder is cracked, and the cord ply appears.
■ The tire is bulged, swelled or layered.
■ The tire has punctures, scratches or other damages, and its damage degree is difficult to
repair.
Wheel tire assembly

1. Removal and installation BR008
1) Dismantle
① Remove wheel nuts.
② Remove wheel tire assembly.
2) Install BR009
Install wheel tire assembly and tire nuts.
Caution:
■ Pre-tighten orderly and tighten evenly in a diagonal
order for manual installation.
■ In case of automatic tightening, adjust the tightening
torque and tighten once.
■ Tighten all wheel nuts faithfully in the order shown in
the drawing.
BR‐3
2. Wheel Balance
1) Dismantle
① Remove the wheel tire needed to be adjusted.
② Remove the old balance weights of the wheel at both side, and remove foreign matters from
the tire tread pattern.
Caution:
■ Be careful not to scratch the wheel during disassembly and installation.
■ Remove the tape from the tires if they are new.
2) Adjustment of wheel balance
① Install the wheel onto a balancing machine oriented to the central hole and then start the tire
balancing machine.
② When the imbalance value on both sides is displayed on display screen of wheel balancer,
select balance weight with weight of near displayed value to install on both sides of the
specified wheel.
Caution:
■ Install the outside balance weight first, and then the inside balance weight.
■ Clear the fitting surface of wheel before installing balance weight.
a. Install balance weights in the positions as shown in the BR010
figure.
40g Adhesive
weight Center of gravity
Align with
groove
Indicator position of wheel
balance weights (angle)
b. When installing balance weight to wheels as shown on BR011

the right figure, it shall be put in the slot area on the
inner wall so that the center of balance weight is
aligned to the position (or angle) shown on wheel
balancer.
Indicator position of vehicle

balancing machine (angle)
c. If the calculated weight of balance weights exceeds 50g, install two balance weights on a
straight line.
Caution:
■ Balance weight can't be used repeatedly. It shall be replaced every time.
BR‐4
■ Number of installed balance weights is no more than three.

■ Always use the original balance weights.
■ Do not put one balance weight on another.
③ Start the wheel balancer again.
④ Hammer balance weight in the inside of wheel according to the position (or angle) indicated
by wheel balancer.
⑤ Start the balancer, and make sure that the rest imbalance value on both sides is only 5g or
less. If the rest imbalance value on any side exceeds 5g, repeat the installation procedures of
balance block.
Tire pressure monitoring

System warning mode
High voltage alarm mode
If tire pressure value is higher than 125% of standard value, system will send high pressure
warning information. Warning mark lamp on the instrument will light up constantly, while
TPMS warning light will go out constantly. If no operation is conducted, the system will keep
warning. If recovering normal pressure value, after the controller receives normal data meeting
required package, warning mark lamp on the instrument goes out, while TPMS warning light
lights up constantly.
Low voltage alarm mode
If tire pressure value is lower than 75% of standard value, system will send high pressure warning
information. Warning mark lamp on the instrument will light up constantly, while TPMS
warning light will go out constantly. If no operation is conducted, the system will keep warning. If
recovering normal pressure value, after the controller receives normal data meeting required
package, warning mark lamp on the instrument goes out, while TPMS warning light lights up
constantly.
High temperature alarm mode
If tire temperature value is higher than high-temp standard value 85°C, system will send high
temperature warning information. Warning mark lamp on the instrument will light up
constantly, while TPMS warning light will go out constantly. If no operation is conducted, the
system will keep warning. If recovering normal tire temperature value, after the controller
receives normal data meeting required package, warning mark lamp on the instrument goes
out, while TPMS warning light lights up constantly.
For quick air leakage warning mode, when pressure of some tire lowers to more than 30KPa
within 1min, the system will treat quick air leakage warning information. Warning mark lamp on
the instrument will periodically light up or go out, while TPMS warning light goes out
constantly. If no operation is conducted, the system will keep warning. If at this moment, the tire
pressure doesn't change or pressure rises up, after the controller receives normal data meeting
specified package, warning mark lamp on the instrument goes out, while TPMS warning light
goes out constantly. For low electricity warning mode, when sensor battery has low amount of
electricity, the system will treat the low electricity warning information, and warning mark lamp
BR‐5
on the instrument goes out constantly; while TPMS warning light lights up constantly. If no
operation is conducted, the system will keep warning. If at this moment, after pressure sensor of
tire sends normal data frame to the controller and the controller receives normal data meeting
specified package, warning mark lamp on the instrument goes out constantly; while TPMS
warning light goes out.
For sensor losing mode, under normal traveling condition, if the information is not received
from one or more sensors (within two) of the system within 5min while other sensors are normal,
the system will judge the sensor which doesn't send information is losing or damaged, and the
system will treat the sensor losing warning information. Warning mark lamp on the instrument
goes out constantly; while TPMS warning light lights up constantly. If no operation is conducted,
the system will keep warning. If at this moment, the controller receives normal data frame from
the pressure sensor of relevant losing tire, after the controller receives normal data meeting
specified package, warning mark lamp on the instrument goes out constantly, while TPMS
warning light goes out. Alarm indicator light
After the vehicle is switched on and started and under the condition that tire pressure is normal,
the warning indicator lamp of tire pressure monitoring system and TPMS will go out
constantly. When there is any fault or specified operation is conducted, indicator lamp will light
up to indicate current condition and indication of detailed warning indicator lamp.
Significance as following table:
Alarm
TPMS Condition Condition Status of ω and PMS Remarks
Level
The system has no TPMS warning light goes out,
During driving /
fault currently. ω warning light goes out.
TPMS warning light goes out,
Quick leakage Vehicle during
Primary ω warning light is flashing
alarm driving
rapidly (frequency of 2Hz).
High pressure
alarm, Low TPMS warning light goes
Vehicle during
pressure alarm,
driving
Secondary out, ωwarning light lights
High temperature up constantly.
alarm
Sensor failure,
alarm of low Vehicle during TPMS warning light goes out,
Three-level
electric quantity driving ω warning light goes out.
for sensor
Tire pressure
controller and
When is energized TPMS warning light goes out,
instrument Three-level
to start ω warning light goes out.
communication are
switched off.
TPMS do not TPMS and ω light up for 2 s
When is energized
complete sensor / at the same time and then go
to start
study out.
TPMS warning light goes out,
TPMS complete When is energized
/ ω warning light goes out after
sensor study to start
2s.
BR‐6
Alarm
TPMS Condition Condition Status of ω and PMS Remarks
Level
TPMS goes into After the switching Go into sensor study
Ω and TPMS lights light up
the sensor study on of vehicle's / mode handed with tool
constantly.
mode ACC uniformly
TPMS completes After the switching Complete study
TPMS and ω warning lights
sensor study and on of vehicle's / uniformly handed with
go out at the same time.
exits study mode ACC tool
BR‐7
Operating instructions
Learning TPMS sensor
This function is used when sensor and controller equipment are required to be combined, such as
offline study, replacement of new sensor, loss of communication between sensor and display
screen, etc.
Operation steps
Step 1: park the combined vehicle to the specified position, and power up vehicle ACC.
Step 2: use a hand tool to select "uniform combination" under "sensor combination" mode, and
then press "confirm" key to send it. The controller receives command and enters into combination
mode. warning light and TPMS light up constantly.
Step 3: Under the condition the hand tool is in "TPMS offline distribution" mode, In sequence
activate them and read tire sensor ID on relevant vehicle position according to the sequence of
(left front → right front → right rear → left rear) shown in screen.
Step 4: operator enters into the vehicle and close the door.
Step 5: hand tool points at tire pressure controller (Caution: different tire pressure controller has
different installation positions on actual vehicle. When combining or deleting sensor ID, it is
necessary to point at different position of the controller on the vehicle), and press "confirm" key
to combine them. the system will finish combination within 10s. After successful combination,
warning light and TPMS will go out.
Step 6: switch off vehicle's ACC and then power up it again. At this moment, after successful
combination, vehicle warning light will light up for 2 s and go out, and TPMS will go out
constantly.
Caution: if the study doesn't finish within 10s after pressing "confirm" key in step 5 and warning
light doesn't go out, please repeat step 4 and 5 to finish combination.
Precautions
■ The operator must finish deleting and combination operation inside vehicle, and the door
must be closed (use the shield of vehicle body to reduce outer radiation).
■ Hand tool should point at tire pressure controller, and keep 1m away from controller.
■ Make sure that all vehicles except for current vehicle stop (ACC stop), or keep other vehicle
at least 2m away from current vehicle (distance of two window glass).
■ It is forbidden to use hand tool except for combination of tire pressure, to avoid misoperation
(such as misoperation of deleting some sensor). Emission distance of hand tool is easy to be
affected by battery power and barrier shield. Please timely charge power. During
combination, make sure that there is no other object between hand tool and tire pressure
controller.
BR‐8
Fault diagnosis
Fault Symptom Fault Possible Cause Countermeasure
Over-deflection of tire and rim Replace
Wheel nuts loosened Locking
Tire unbalance Adjust
Tires worn unevenly Adjust or replace
Circular vibration of steering wheel
Short tire pressure Adjust
Front wheel bearing damaged or worn Adjust or replace
Fault of steering system Adjust or replace
Fault of suspension system Adjust or replace
Early wear to tires Incorrect tire pressure Adjust
Incorrect tire pressure Adjust
Tire noise
Tire deterioration Replace
Tire unbalance Adjust
Road noise or body vibration
Rim or tire deformation Repair or replace
Tires worn unevenly Adjust or replace
Over-deflection of tire and rim Replace
Wheel nuts loosened Locking
Vertical vibration of steering wheel Tire unbalance Adjust
Engine foot rubber worn or fractured Replace
Rubber of transmission bracket is fractured or worn. Replace
Incorrect tire pressure Adjust
Tire worn excessively or unevenly Adjust or replace
Steering wheel biased to one side Fault of steering system Adjust or replace
Fault of braking system Adjust or replace
The tire pressure on both sides is uneven. Adjust
Rim or tire deformation Repair or replace
Instable service of vehicle Wheel nuts loosened Locking
Fault of steering system Adjust or replace
The tire pressure on both sides is uneven. Adjust
Braking biased to a side
Fault of braking system Adjust or replace
Steering wheel feels heavy Fault of steering system Adjust or replace
Steering wheel returning incorrectly Fault of steering system Adjust or replace
BR‐9

Item Parameters
The steel wheel 0.6 mm
Radial
The aluminum wheel 0.3 mm
Wheel pulsation The steel wheel 1.0 mm
Axial
The aluminum wheel 0.3 mm
Tire pressure (cold state) 240±10 KPa
Tire specification 185/65R15 88H

Item Tightening torque
Wheel nuts 90-110 N•m
Service braking
Precautions
■ It is recommended to use “DOT4” brake fluid.
■ Do not reuse the brake fluid discharged.
■ Do not spray brake fluid on the paint surface, so as to protect paint. If it is splashed on the
paint surface, wash with clean water immediately.
■ Wash all brake cylinder components with clean brake liquid.
■ Please do not use mineral oil such as gasoline or kerosene, to avoid damage of rubber part in
hydraulic system.
■ When removing and installing oil pipe, please use special oil pipe wrench.
■ When installing the brake oil pipe, make sure to check the tightening torque.
■ If the brake is soft after repairing or replacing the brake disc and brake shoe, or when
traveling for a short distance, it is necessary to grind brake combination surface.
■ Make sure that there is no brake fluid on the brake disc. Please do not spray brake fluid onto
the brake disc; otherwise, it may cause brake failure.
BR‐10
Preparation work
Use special service tools to remove and install if necessary.
Maintenance tool list
1 Oil pipe wrench Remove and install the brake oil pipe
2 Power tool Remove and install the bolts and nuts
Brake pedal
1. Inspection and adjustment BR012 Lock nut
Adjustment of clearance between brake pedal and brake
limit switch bolt:
1) Remove driver side lower guard board assembly.
2) Disconnect brake lamp switch connector and loosen
nut of brake limit switch and release brake pedal, and
rotate switch bolt to keep the clearance between
switch bolt and brake pedal 0.5mm-1mm. Brake pedal gear

2. Brake pedal free stroke BR013
1) Under the condition that the engine stops, step brake
pedal for 2-3 times.
2) Confirm that the vacuum of the brake vacuum booster
is eliminated, and press the pedal with hand.
3) Confirm that the free travel of the pedal is within the
standard range before the resistance appears.
■ Standard value: 3mm-8mm
4) If the free travel exceeds the standard range, adjust.
Caution:
■ If the free travel cannot be adjusted within the range, replace the damage parts.
BR‐11

1) Removal
① Remove driver side lower guard board assembly.
② Disconnect the brake light switch connector.
③ Remove the lock pin connected with the brake
vacuum booster, and disconnect from the brake
vacuum booster.
④ Remove the set bolts of the brake pedal and body, and
BR015
the set screw nuts of the brake pedal and brake
vacuum booster.
⑤ Take the brake pedal out.

① Brake pedal
■ Check the movable pin of the brake pedal for wear or deformation.
■ Check the brake pedal for cracks, twisting or other damages.
② Lock pin and bush
■ Check the lock pin and bush is damaged or deformed, and replace it if any.
③ Brake light switch
a. Use the multimeter to measure whether 2 terminals of the brake light switch are on while
pressing and releasing the brake light column.
b. As shown in figure, the terminals are off when the BR016
column is pressed more than 4 mm and they are on
when releasing, so that the brake light switch is in
working order. Non-conducting Conducted
BR‐12
3) Installation
Install it according to the reverse order of removal.
Caution:
■ Check if the brake pedal works smoothly.
■ Check brake pedal free stroke.
■ Check the clearance between the brake pedal and
brake light switch.
Brake master pump

1. Inspection in the car BR017
Check if master pump installing face, oiler installing face
and brake pipe joint leak.

BR01
1) Dismantle
① Drain the brake fluid.
② Remove brake fluid level switching connector.
③ Disconnect the master cylinder brake pipe with an oil
pipe wrench.
④ Remove the brake master cylinder to clutch master
BR019
cylinder connecting pipe and the master cylinder set
screw nut, and then remove the master cylinder
assembly.
Caution:
■ Do not bend or damaged brake pipeline.
2) Installation
Caution:
■ Before installation, apply grease on the master cylinder: -SAE J31 0, NLGI No2 or
equivalent.
BR‐13
① Install the master cylinder assembly on the brake vacuum booster, and tighten the nut.
Caution:
■ Do not damage the sliding surface of the piston push rod. Do not make foreign matters fall
on the surface.
② Install the brake pipe on the master cylinder assembly, and pre-tighten.
③ Tighten the brake pipe nut with oil pipe wrench or equivalent.
④ Install the brake fluid level switch connector.
⑤ Add Fresh brake fluid and emit air.
Brake fluid
1. Check the height of brake fluid level
BR020
Check if brake fluid level in the oiler is between MIN and
MAX. If the level is too low, check if the oiler and brake
system leak.
2) Start the vehicle, release parking handle and see if brake warning light goes out. If it doesn't
go out, check if parking brake switch or brake fluid level switch is faulty.
Brake pipeline
Hydraulic pipeline diagram
Schematic Diagram of Hydraulic Pipe

1- Brake master pump 2- ABS module assembly
Caution:
■ All braking oil pipes must not be excessively bent, twisted and tensioned.
■ Make sure that all brake pipes will not clash with other parts when the vehicle is stationary
or turning.
■ The brake oil pipes are the most important safety parts. If there is brake fluid leakage, always
BR‐14
tighten the retaining device. If any damaged parts found, please replace it with new
appropriate parts.
■ When disconnecting brake pipe, please seal the joint end to avoid dust entering.
Front brake pipe and hose
1) Removal
BR023
① Remove the tire.
② Remove the bolts from brake hose.
Caution:
■ Pay attention to the falling of copper washer.
③ Remove the brake hose and brake pipe joint with oil
pipe wrench, and take down the clamping plate.
④ Remove from the front shock absorber the fixing bolts BR024
in the middle of brake hose.
⑤ Take the brake hose and brake pipe down.
2) Installation
Install it in the reverse order of removal.
Caution:
■ Do not reuse the gasket and oil pipe washer.
■ Note the installation direction of the brake hose joint.
■ Refill the braking liquid and release air.
BR‐15
Rear brake pipeline and brake hose

1) Removal BR025
① Disassemble the joint of rear braking hose with
both-end braking tube, and take the pad off.
② Remove the braking tube joint on rear brake end.
③ Remove brake hose and brake pipe.
2) Installation
Brake pipe of master brake cylinder and ABS module assembly
1) Dismantle BR026
① Remove two oil pipe connector of master brake
cylinder end.
② Remove two oil pipe connector of ABS module
assembly end.
③ Unscrew off two fixing nuts in the middle of braking
tube.
■ Tightening torque BR027

Oil pipe connector 16-18 N•m;
Fixing nut 10-15 N•m
④ Disconnect ABS module assembly and oil pipe

BR028
connector again.
BR‐16
Caution:
■ Drain brake fluid from ABS module assembly or dismantle ABS module assembly.
2) Install
Caution:
■ First install fixing bracket of ABS module assembly. And then tighten bolt. Clip ABS module
assembly to ABS fixing bracket. Installation sequence of ABS module assembly is shown in
figure BR028:
■ Do not make the brake pipe bend due to installation difficulty. When installing pipe assembly,
make sure that fixing pipe clips and sleeve are installed to proper position.
① Connect left front brake hose assembly and left front brake caliper, and then let the complete
pipe smoothly pass through shock absorber bracket and body bracket, and install it with left
front brake pipe and install clamp. At last, fix it on the steering knuckle with bolts. The
installation in right side is the same as that of in right side.
② Fix the rear brake pipe assembly under the body with bolts or nuts.
③ Refill the braking liquid and release air.
Caution:
■ Retighten the adapter between the brake pipe and the brake hose if it leaks, or replace the
parts if any damaged.
① Check if the brake hose, the brake pipe and the adapter leak fluid, contact with the other
parts and loose or they are damaged, twisted and deformed.
② When the engine runs, exert some brake force and keep for several seconds, and then Check
if each part has liquid leakage.
Brake vacuum booster assembly component
Diagram of Brake Vacuum Booster Assembly

1- Vacuum booster 2- Main brake cylinder 3- Oil brake can
BR‐17

1) Operation inspection BR029
Start the engine and press the brake pedal a few times, so
that the vacuum inside brake vacuum booster is equal to
the atmosphere. Press brake pedal to the end and start
engine. When vacuity is up to standard, ensure if the
clearance between brake pedal and floor is shortened.
Caution: BR030 Good Badly

■ The interval of pressing the brake pedal is 5s.
2) Inspect air tightness
■ Start engine, let it idle 1min, and stop when brake
vacuum booster turns vacuum. Eliminate vacuum by 3rd
pressing the brake pedal as normal. Check if the 2nd
clearance between the brake pedal and the floor 1st
increases gradually.
■ When the engine is working, press and hold brake
pedal to shut it down. Ensure no change occurs to
pedal travel 30 s after the pedal is pressed.
Caution:
■ Do not bend the brake pipe when removing the brake
vacuum booster.
■ Please replace the damage lock pin.
■ Do not damage the thread of fixing bolts on the
vacuum booster.
1) Removal BR032
① Dismantle old air filter assembly
② Remove clamp from vacuum hose, and then dismantle
vacuum hose from brake vacuum booster.
③ Dismantle lock pins and washers from brake pedal.
④ Remove the connecting nut of the brake pedal and
brake vacuum booster.
⑤ Remove connecting bolt of brake pedal and body.
⑥ Remove the brake vacuum booster from the engine compartment.
BR‐18
2) Inspection after removal BR033

Output rod length
① Inspection of the length of the push rod
a. Apply a vacuum pressure of -66.7KPa to the brake
vacuum booster with a manual vacuum pump.
Pre-load
b. Check the length of the push rod
■ Pulling rod length: 116.7-117.3 mm
② Vacuum hose
Check if it damaged or cracked. Replace it if any.
3) Installation
① Install brake master cylinder and vacuum booster assembly onto relevant positions of vehicle
body, make the brake pedal assembly pass through the middle of push rod of vacuum booster
and install it on the vacuum booster bolts, and then tighten four mounting nuts.
② Install brake pedal and pin shaft of push rod of vacuum booster; meanwhile, apply -SAE J31
0, NLGI No2 lubricating grease on the surface of pin shaft. When the pin shaft isn't installed
normally, adjust the length of adjusting bolt of the pedal to ensure that the pin shaft can be
installed naturally. But it is not allowed to adjust the length of push rod of vacuum booster or
let the push rod of vacuum booster on compression condition.
③ Fix the brake pedal upper-support with combined screw.
④ Fix the vacuum hose assembly onto proper position of vacuum booster.
Caution:
■ When installing, insert vacuum hose into proper position.
■ Do not use lubricant during installation.
⑤ Adjust the free travel of the brake pedal.
⑥ Tighten the push rod locking nut to the specified torque.
⑦ Install air filter assembly.
⑧ Refill brake fluid and brake fluid, and then air exhaust.
BR‐19
Front disc brake caliper

BR034
1) Check brake shoe breaking-in
Caution:
■ Standard thickness: 11 mm
■ Wear limit thickness: 2 mm
2. Components
Exploded View of Brake Caliper Assembly

1- Dustproof cover of bleed screw 2- Bleed screw 3- Hex bolt with flange surface
4- Caliper body 5-Position 6-Rectangular sealing ring 7-Dustproof cover pin of pin
8-Inner brake block with sound absorbing disc assembly 9-Leaf spring
10-Outer brake block with silent blade assembly 11-Guide pin 12-Piston
13-Piston dust proof cover 14-Rubber sleeve 15-Support
Caution:
■ It is necessary to completely clean brake wheel cylinder and brake shoe, to minimize damage
caused by particles and other matters in the air.
■ When removing the brake wheel cylinder, please do not press the brake pedal, so as to avoid
ejecting the piston.
■ Please do not damage piston dust cover.
■ Unless dismantling or replacing brake wheel cylinder, do not dismantle fixing brake of brake
wheel cylinder and bolts on the brake hose. Here, lift the brake wheel cylinder by rope, and
avoid pulling the brake hose.
■ If the brake shoe shim is corroded seriously, please replace with a new one.
■ Replace the shim whenever replacing the brake shoe.
BR‐20
■ Confirm no brake fluid on brake disc.

3. Remove and install brake show BR035
1) Removal
② Remove fixing bolt of brake caliper assembly
position.
③ Lift up the brake caliper assembly with a rope and
then remove internal & external brake shoes and etc.
BR036
2) Installation
① Install shoe spring onto the brake shoe.
Caution:
■ Install according to shim retaining direction.
② Press the piston when installing the brake shoe, and
install the brake wheel cylinder on the brake wheel
cylinder retaining bracket.
③ Install the brake shoe on the brake wheel cylinder
retaining bracket.
Caution:
■ Pay attention to brake fluid level in the brake oil can.
④ Install the fixing screw of cylinder position pin and
tighten it.
⑤ Fix brake disc, step brake shoe straightly until the
brake has reaction.
⑥ Check the rotation resistance of brake.
⑦ Install the tire of vehicle.
BR‐21
Remove and install brake caliper component

1) Dismantle
② Remove the brake hose bolt, and then disconnect the
brake hose.
Caution:
■ Pay attention to the falling of copper washer.
③ Remove retaining bracket bolt of brake caplier
assembly, and remove brake caplier assembly.
2) Install BR038

1) Disassembly
① Dismantle fixing bolts of positioning pins of brake BR039
wheel cylinder, and dismantle brake wheel cylinder
from fixing bracket of brake wheel cylinder. If
necessary, remove the brake shoe and brake shoe
shim from the brake wheel cylinder retaining bracket.
Caution:
■ Do not fall the brake shoe and brake shoe shim.
② Dismantle positioning pin of wheel cylinder and
dustproof cover of positioning pin from fixing
bracket of brake wheel cylinder.
③ Shown as figure. Place a proper wood block, blow air
into the set bolt hole of the brake hose evenly, and
remove the piston and piston dust cover.
Caution:
■ Be careful that finger couldn't be clamped by piston.
BR‐22
④ Remove the piston seal ring from the brake wheel BR040
cylinder with slotted screwdriver. Piston seal ring
Caution:
■ Do not damage the inner wall of brake wheel
cylinder.

① Brake wheel cylinder
Caution:
■ Clean up cylinder with new brake fluid. Please do not use gasoline or paraffin.
■ Check if the inner wall of cylinder is damaged or worn. If any, please replace brake wheel
cylinder.
② Brake wheel holder
■ Check if retaining bracket is worn, cracked or damaged. Replace it if any.
③ Piston
■ Check if piston surface is corrodent, worn or damaged. Replace it if any.
■ Do not sand the piston surface with abrasive paper.
④ Sliding pin, pin bolt and pin dust cover BR041
Piston seal ring
■ Check the sliding pin, pin bolt and pin dust cover for
wear and cracks. Replace it if any.
3) Assembly
Caution:
■ Use the specified rubber grease during assembly.
■ Do not reuse the piston sealing ring and dust cover.
① Apply rubber grease on the piston seal ring, and install it into the cylinder block.
BR‐23
② Apply brake fluid on the piston, and apply rubber

grease on the piston dust cover. Cover the piston end BR042
Piston dustproof cover
port with the piston boot and then fix the cylinder Piston
body side on the piston dust cover into the groove on
the cylinder body slowly.
③ Extend the hand into the cylinder block, and insert
the piston side edge of the piston dust cover into the
piston groove.
Caution:
■ Evenly press the piston, and avoid friction with the
inner wall of the cylinder block.
④ Install the sliding pin and sliding pin dust cover on
BR043
the brake wheel cylinder retaining bracket.
⑤ Install the brake shoe shim on the brake shoe.
Caution:
■ Install according to shim retaining direction.
⑥ Install the brake shoe assembly on the brake wheel BR044

cylinder retaining bracket.
⑦ Press the piston while installing the brake shoe and
then install the brake cylinder on the brake cylinder
mount.
⑧ Tighten pin bolt.
Inspection of brake disc

1) Visual inspection
■ Check the brake disc surface for uneven ear, cracks and serious damage. Replace it if any.
2) Runout check
① Fix the brake disc to wheel hub.
Caution:
Ensure the axial clearance of wheel bearing is not too large before measurement.
② Check the jerk value with micrometer. (Measure it about 10mm of brake disc edge).
■ Runout limit value: 0.05 mm
③ If the runout exceeds the specified value, please replace or perform necessary machining.
BR‐24
3) Thickness inspection BR045

■ Check the thickness of the brake disc with a
micrometer. If the thickness is less than the wear
limit, please replace the brake disc.
Standard thickness: 26 mm
Wear limit: 24.4 mm
Brake breaking-in steps :

Repair or replace brake disc. Soft braking occurs after replacing brake shoe or after a short
distance. Please observe the following procedures to run in contact surface between brake disc
and brake shoe.
■ Before running-in, pay attention to control the vehicle speed if the brake effect is poor.
■ Only execute the step on the safe road surface and in safe traffic condition, pay attention to
safety.
1) Drive the vehicle on the straight road.
2) Push the brake pedal down without proper efforts to brake the vehicle within 3-5s.
3) After driving vehicle a distance, park the vehicle for 3min to cool brake system.
4) Repeat steps 1 to 3 until the brake shoe and the brake disc are run in completely.
Rear parking brake

1) Check brake shoe breaking-in
■ Check the thickness of the brake shoe from the
inspection hole of the brake bottom plate.

BR046
1) Removal
② Remove the rear brake drum stop bolt, and take down
the brake disc.
BR‐25
③ Release parking brake and dismantle clamp spring on BR047

the parking brake cable and the head of parking brake
cable.
④ Remove rear brake pipe connector. BR048

⑤ Remove head fixing bolt of wheel speed sensor.

Caution:
⑥ Remove four fixing bolts of rear hub assembly, take BR049
down rear hub assembly and cushion block.
⑦ Take down rear brake assembly

① Brake drum Inner diameter (ID)
BR050
■ Check if the inside diameter and circular runout of
the brake drum are within the standard value. Process
and Replacement should be carried out if
non-conformance.
Standard value: 204 mm
Circumferential runout: < 0.05 mm
BR‐26
② Brake shoe BR051
■ Check the thickness of the brake shoe and the contact

condition with the brake drum. If non-conformance,
please replace it.
Standard thickness of brake shoe (A): 4mm
Allowable limit thickness(A): 1mm
③ Brake bottom plate

Check if the brake bottom plate is worn or damaged.
Installation
■ Install it according to the reverse order of dismantling.
■ Four fixing bolts on the rear wheel hub assembly should be tightened according to diagonal
sequence.
■ Before installing, the diameter of the brake shoe shall be adjusted in Φ203.35±0.15 mm so as
to install the brake drum.
■ Clean the inner surface of the brake drum during installation, and prevent the contact surface
of the brake shoe and brake drum from touching grease. Wash by acetone if contacting and
replace the same type of brake shoe assembly if it is serious.
■ After installing the brake drum, press the brake pedal several times to seat the brake shoe.
Caution:
■ The brake is equipped with a self-regulation mechanism for clearance. The shoe clearance
shall be automatically adjusted to the normal use value in the above braking process.
■ Adjust parking brake cable. Please refer to "Parking Brake System".
■ Bleed the air of brake system. Please refer to "Brake Fluid".
BR‐27

1) Components
Exploded View of Rear Brake Assembly

1-Observe blocked 1 2-Observe blocked 2 3-Pick tension spring
4-Self-adjustment mechanism assembly 5-Brake cylinder assembly 6. Hexagon flange bolt
7- Bleed screw 8-Air drain screw dustproof cover 9-Upper tension spring
10-Pick with axis pin assembly 11-Brake shoe assembly 12-Lower tension spring
13-Base plate assembly 14-Brake shoe pressure spring 15-Limiting pin
16-Brake shoe with parking pull rod assembly
2) Removal
① Dismantle pick drag spring. BR052
BR‐28
② Remove shoe pressure spring and handle of pressure BR053

spring.
③ Open the shoes, remove the upper & lower springs BR054
and self-regulating mechanism assembly.
④ Remove the parking wire from the brake shoe with BR05
parking lever assembly and take off the shoes.
⑤ Remove the set bolt of the brake wheel cylinder, and
take down the brake wheel cylinder from the brake
bottom plate.

① Brake wheel cylinder BR056
Check if the outside of the brake cylinder is worn or
damaged by others, whether the piston is flexible, whether
the contact surface of the piston and the shoe is worn and
whether there is oil leaked. Please replace brake wheel
cylinder if the above situation occurs.
② For pick dray spring, upper drag spring, lower drag spring, self-adjusting mechanism
assembly and brake shoe with parking pull rod assembly, Check the elasticity of springs and
Check if self-adjusting mechanism assembly and brake shoe with parking pull rod assembly
have deformation or other damage.
BR‐29
4) Assembly
■ First install the upper tension spring, and then lower BR057
tension spring.
■ Pay attention to mounting direction of self-adjustment
mechanism assembly.
Tighten
forward
Fault diagnosis
Common Troubleshooting Table for Rear Brake System
Fault Possible Cause Countermeasures
1 Fluid leakage at pipe joint or rear brake 1. Tighten up or replace after rub-up.
wheel cylinder cup
2. Residual air in pipeline 2. Bleed air
Brake 3. Too big clearance between brake shoe and 3. Readjust
insufficiently brake drum
4. Greasy or hardened shoe surface 4. Rub or replace
5. Overheated brake drum, air resistance in 5. Replace, cooling and bleed air
pipeline
1. Blocked rear brake wheel cylinder oil 1. Clean up or replace
return hole or swelled cup
2. Clearance of shoe drum is to small 2. Readjust
Difficult
release of brake 3. The power of shoe pull-off spring weaken 3. Replacement
or breakage
4. Shoe or bottom plate deform, return is 4. Revise or replace
blocked
1. Rear brake shoe severely worn 1. Replacement
2. Brake drum is out of round 2. Cut and need to balance performance
check
3. Frictional noise may be caused during the 3. Remove foreign matters, and sand the
slipping of the smooth surface when the rear brake shoe with coarse abrasive
Noisy surface of the rear brake shoe is too paper.
smooth, the friction coefficient is low but
the brake pressure is high, or when the
foreign matter is plugged between the
friction pair to squeeze the friction
surface.
BR‐30

1. The brake clearance is too little and the 1. Readjust brake clearance in accordance
free stroke of the brake is too short; the with specification in this situation
braking force is not released completely
when releasing the brake pedal, so that the
friction pair is in the friction condition for
a long time; thus, it is difficult to drive off,
it is weak to drive, and you will feel hot if
you touch the surface of the wheel hub by
hands.
2. The brake handle is not released 2. Adjust in accordance with specification
Brake drum
completely. It may be caused by if necessary
fever caused by
misalignment or operational negligence.
brake drag
As a result, the friction pair is in the
friction condition for a long time to heat
up.
3. The heat caused by braking makes the 3. Repair or replace pull-off spring to
return spring heated and deformed and troubleshoot
little elastic or even inelastic, so that the
brake shoe assembly shall not be returned
timely after braking; thus, the braking
cannot be released thoroughly in time to
heat the brake drum.
The parking brake control wire drawing or the Check if the surface of the brake control wire
brake drawing is not drawn flexibly in their drawing (drawbench) and the brake system
coat due to common wire drawing or coat rust, component is damaged, whether the handle is
Parking brake as well as broken, dropped or inelastic drag operated flexibly without clamping
fail spring; therefore, the parking brake could not stagnation, and whether the drawing
be released to be ineffective. connector and the fixed part are loosened and
damaged, and repair or replace them if
necessary.
Common Troubleshooting Table for Brake Master Cylinder

Insufficient air pressure for left and right
Adjust
tires
Adjust front wheel improperly Adjust
Brake shoe is in poor contact Adjust
Vehicle deviation when braking
Grease or oil on brake shoe surface Replace
Eccentric or unevenly worn brake drum Replace
Brake cylinder assemblies incorrectly Adjust
Faulty self-adjusting mechanism Adjust
BR‐31

Low or polluted brake fluid Supply or replace
There is air in brake system System exhaust
Brake booster is faulty Adjust
Brake shoe is in poor contact Adjust
Brake insufficiently Grease or oil on brake shoe surface Replace
Overheated rotating parts due to drag of the
Adjust
brake shoe
Brake line limitation Adjust
There is air in brake system System exhaust
Brake fluid is leaking Adjust
Increase pedal travel (decrease
distance between pedal and floor) Faulty self-adjusting mechanism Adjust
There is an excessive clearance between the
Adjust
push rod to the brake master cylinder.
Parking brake do not open enough Open
Parking brake adjust improperly Adjust
Pull-off spring of brake system is worn Replace
Return opening of brake master cylinder
Adjust
limits
Brake lag Rear drum brake pull-off spring is damaged Replace
Sliding part lubricate insufficiently Grease
One-way valve of brake master cylinder or
Replace
pull-off spring of piston is faulty
Too small clearance between the push rod
Adjust
and brake master cylinder
Rear brake shoe is damaged Adjust
There is lubricating grease or oil in rear
Replace
brake shoe surface
Insufficient parking brake function Parking brake cable is stuck Adjust
The travel of parking brake handle is too
Adjust
large
BR‐32

Item Specifications
Type In series
Brake master pump
Cylinder bore 22.22mm
Type Vacuum
Brake booster Specification (dimension) 10 inch
Boost ratio 7.3: 1
Type Caliper/ ventilated disc
Brake disc diameter 256mm
Front brake Brake disc thickness 11mm
Thickness of clutch block 10.8mm
Cylinder bore 54mm
Type Drum brake
Rear parking brake
Diameter of wheel cylinder 17.46mm
Brake hub diameter 204mm
Thickness of clutch block 4mm

Item Torque (N·m)
Front brake caliper and steering knuckle connecting
65-75
bolt
Connecting bolt of rear brake and rear hub 65-85
Front/rear brake caliper air exhaust bolt 7-13
Brake pedal upper support fixing bolt 20-25
Brake pedal fixing nut 20-25
Brake hose and brake caliper connecting bolt 25-30
Brake pipe connector 16-18
BR‐33
Parking brake control

1) Stroke of parking brake handle
■ Pull up parking brake handle with a force of 200N,
and make sure that the pawl is in specified groove
(there is a click sound when passing through a tooth.
Check it by listening to and counting the sound of
pawl).
■ Standard value: 7 - 9 gear
2) Inspection of elements:
① Verify whether the fixing of each element is normal.
② Whether parking brake handle assembly is bent, damaged, cracked.
Replace if any of the above.
③ Check the parking brake cable for wear and damage. Replace it if any.
④ Is parking brake warning light switch work normal. If it doesn't work normally, please Check
or replace it.
⑤ Disassemble the parking brake switch connectors and check the continuity between the
positive terminal and vehicle body.
■ When parking brake pedal is upward, it should be conducted.
■ When parking brake pedal is downward, it should not be conducted.
3) Adjustment
① When parking brake operation handle is on release condition, insert left and right parking
brake cable joints into the mounting hole of balance plate of parking operation handle. As
shown in figure After the installation of cable, tighten adjusting nut and make sure that the
distance L between adjusting nut and the end of cable is 31-34 mm.
Adjusting nut
Adjusting screw rod
Parking handle assembly
BR‐34
② After the commissioning, pull up parking hand along the vertical direction of handle with a
force of about 200 N at a distance of 25 mm from handle button. And then adjust adjusting
nut to let the handle locked at teeth No.7-9. Or, adjust the adjusting nut to adjust the L value.
Detailed adjusting method: if the number of pulling up teeth is less than 7, the distance L
should be reduced. If it is more than 9, the distance L should be increased.
Caution:
■ After adjusting completely, check if the rear wheels are dragged under the condition that the
parking brake handle is released.
2. Components
Parking brake cable system drawing

1- Parking handle assembly 2. Left parking brake wire drawing assembly
3. Right parking brake wire drawing assembly 4- Snap spring
1) Removal and installation

BR059
① Removal
a. Remove auxiliary fascia console rear section BR059
assemblies.
BR‐35
b. Unscrew adjusting nut and dismantle the head of left BR060

and right parking brake cable assembly from cable
buckles.
c. Disconnect wire harness of parking brake switch, BR061

dismantle four fixing bolts of parking brake handle,
and take out parking brake handle assembly.
d. Release clamp spring, and then dismantle the head of BR06

parking brake cable assembly from brake shoe with
parking brake pull rod assembly.
e. Dismantle fixing bolts from fixing brackets on the

BR063
parking brake cable.
BR‐36
f. Take parking brake cable from the mounting pipe BR064

hole at the bottom of the vehicle body.
② Inspection after dismantling

■ Check if button mechanism work flexibly. If it can't return normally, please replace it.
■ Check parking brake handle pawl is worn.
■ Check the parking brake cable for deformation, wear, bending and looseness. Replace it if
any.
③ Installation
Fault diagnosis
Indicator lamp steadily burns or not burn at all;
① Check if the performance of indicator lamp is damaged.
② Check if the screw between indicator lamp and teeth plate seat is loose.
Maintenance
If any of the above conditions occurs, please replace or reinstall indicator lamp.
Brake force is not enough and or lose efficacy:
① Check if connecting plate of cable is connected with brake cable.
② Check if locking nut loosed
③ Check if parking brake shoe was worn.
Maintenance
① First condition: please connect connecting plate of cable and brake cable.
② Second condition: please replace lock nut.
③ Third condition: please adjust the distance of lock nut.
④ 4th condition: please adjust parking brake shoe clearance
BR‐37
Anti-lock braking system (ABS)

Precautions
When maintaining anti-lock braking system (ABS), please observe the following items.
Otherwise, anti-lock brake system may be damaged.
1. Disconnect the connector from the ABS control module before electric welding operation.
2. The ABS parts are particularly sensitive to EMI (Electro-Magnetic Interference), pay care
attention to the routing, position, installation and position of all ABS parts as well as whether
the wiring, adapter, the clamp and the support are intervened.
3. Do not charge the battery that is still connected during engine starting by the rapid charger
because it may make the battery invalid or damage the ABS parts.
4. Make sure to turn off the ignition switch, then disconnect the battery negative, and
disconnect the connector of the ABS control module assembly.
5. Do not attempt to repair any ABS parts; all ABS parts can be serviced by replacement.
6. Do not hang suspension parts on the wheel sensor harness, to prevent damage to the sensor
harness.
7. The ABS control module shall not be placed in the environment at above 105°C.
8. Brake loop should neither contain inorganic substances such as chlorine and sulphur, nor
mineral oil or ester group plasticizer/ softener (including parts possibly producing these
substances dissolving).
9. In ABS operation, the brake pedal will vibrate slightly, and mechanical noise may be heard;
this is normal.
10. Start up the vehicle after the ignition switch is turned to ON, the brake pedal may be shocked,
or there is working noise heard from the motor of the ABS hydraulic assembly. This is the
normal condition during operation inspection.
11. The braking distance for vehicles equipped with the ABS may be longer than for those
without it on uneven, gravel, rough or snow-covered (deeper fresh snow) roads.
12. When the brake system is broken down, first, differentiate it is due to either the ABS or the
common brake system, for example, differentiating whether the vacuum booster, the brake
hydraulic system, the brake and other parts are broken down.
13. If the size and the type of the tire are not used as per the correct compound, or the brake shoe
is not JAC’s original part, the braking distance or the steering stability may be deteriorated.
BR‐38
Preparation work
General maintenance tools and specified tools maybe used in service.
Special tool table
ABS system fault

1 Diagnostic unit
diagnostic
System specification
1. Brake system diagram
1. Front left brake assembly 2. Vacuum booster with brake master cylinder and oil can assembly 3. Brake pedal assembly 4
ABS module assembly 5. Front right brake assembly 6. Brake pipelines 7. Rear left brake assembly 8. Rear left wheel speed
sensor 9. Rear right brake assembly 10. Rear right wheel speed sensor 11. Front left wheel speed sensor 12. Front right wheel
speed sensor 13. Parking handle assembly 14. Left and right parking cable assembly
2. ABS function
The ABS controls the hydraulic brake pressure of the four wheels during emergency brake or the
brake on the dangerous road surface to prevent the wheels from locking. The advantages in using
ABS are as follows.
(1) Allowing the vehicle to steer reliably when meeting obstacles in emergency braking.
(2) Keeping the vehicle stopping stably and controllably on a curve in emergency braking.
Caution:
BR‐39
■ If the electrical system is interrupted, the failure protection mode starts, ABS enters into the
disabled state, and the ABS warning light comes on.
■ The special can tool provided by JAC can be used for diagnosis of the ABS electrical system.
■ During braking, the brake pedal will vibrate slightly, and some mechanical noise may be
heard. This is normal working of ABS.
3. EBD function
Electronic brake distribution (EBD) can accurately control the brake force of each wheel and
ensure the stability of the vehicle during braking. It can effectively balance the equal wheel speed
required for braking under normal braking conditions. EBD can distribute brake pressure
necessary for each wheel by using oil inlet valve and outlet valve in ABS hydraulic adjusting
module, to provide effective brake and stability of vehicle.
4. Failure protection function
ABS system electric failure, ABS warning light will come on. If EBD has an electrical fault, the
brake warning light and ABS warning light will come on.
Meanwhile, ABS enters into one condition of the following failure protection functions.
1) For ABS failure, only EBD is activated, and the vehicle state is the same as the vehicle
without ABS.
2) For EBD failure, EBD and ABS are disabled, and the vehicle state is the same as the vehicle
without ABS or EBD.
5. Principle diagram of ABS system fluid pressure
Motor
RFP2damper 2 RP damper1
Energy accumulator 2
FREV PR Air RLEV RL Air RREV RR Air Energy FKEV PL Air
(volume is 3 ml)
inlet valve inlet valve inlet valve accumulator inlet valve
(volume is 3
ml)
FRAV Oil return RLAV RL Oil RRAV RR Oil FLAV FL Oil

valve return valve return valve return valve
BR‐40
ABS mode
ABS will enter into the anti-lock brake mode if wheel slip happens in the brake period. During
antilock braking, the pressure of the hydraulic circuit of each wheel will be under control to
prevent wheel slippage. Each wheel is provided with an independent hydraulic pipe and valve.
ABS can decrease, hold and increase the braking hydraulic pressure of each wheel. But ABS
cannot increase the hydraulic pressure beyond the pressure value transferred by the master
cylinder during braking. When ABS is operating, the brake pedal feels a series of quick vibration.
Each valve position changes rapidly along with the required wheel speed to cause vibration. The
pedal vibration occurs when ABS is operating, and stops during normal braking or when the
vehicle stops fully. Due to rapid cyclic use of the solenoid valve, the motion noise can be heard. If
the ABS is used on the dry road surface, the tires will make intermittent sharp sound when it is
adjacent to slide. The noise and pedal vibration are normal when ABS is operating. The operation
of the brake pedal shall be identical with that of the system without during normal braking. The
equal force of pressing the pedal can keep the vehicle stability, and can ensure the shortest
stopping distance.
1. Pressure maintenance
When the ABS control module detects wheel slip, it will close the oil inlet valve, and also close
the oil outlet valve in the hydraulic assembly, so as to isolate the system. This can maintain the
stability of the pressure on the brakes so that the hydraulic pressure will not increase or decrease.
2. Pressure decrease
If the ABS control module still detects wheel slip in the pressure holding mode, it will decrease
the pressure of the affected wheel. The oil inlet valve keeps closed, and the oil outlet valve opens.
Excessive fluid/pressure is stored temporarily in the accumulator in the hydraulic assembly, until
the pump motor can transfer brake fluid to the reservoir of the master cylinder.
3. Pressure increase
If the ABS control module detects that the wheel slippage has been reduced under the mode of
keeping the pressure or reducing the pressure, it will increase the pressure of the wheel affected
by the master cylinder pressure. The oil inlet valve opens, and the oil outlet valve closes. Partial
or all pressure from the brake master cylinder will be applied to the wheel.
4. Working process of ABS
When the vehicle is traveling, each wheel speed sensor will generate a voltage signal proportional
to the wheel rotation speed. ABS controller receives the wheel speed data and judges whether
there is 1 or more wheels slowing down more thickly than the reference speed as slippage. It will
activate the module as required to control the brake pressure of each wheel to make it optimized.
Speed sensor
It consists of the sensor itself and ring gear, one group provided for each wheel. This vehicle
model uses the active wheel speed sensor, which needs an external power supply (12V) to work.
It can provide a constant amplitude signal regardless of speed value.
1. Components
It consists of the body and gear ring. A group contains one wheel.
BR‐41
2. Removal BR065
1) Front wheel
① Disconnect power supply of vehicle
② Lift the vehicle.
③ Disconnect the sensor connector.
④ Loosen the fixing bolt at the head of sensor and
slowly take out the sensor.
Caution:
■ Do not use hard force to draw the wire harness of
wheel speed sensor.
■ Pay attention to the clearance between the wheel
speed sensor and signal gear during installation.
Standard value: 0.2-1.1 mm
2) Rear wheel BR067
① Disconnect power supply of vehicle
② Lift the vehicle and remove the rear wheel tire.
Caution:
■ Unscrew the set nut of the tire before lifting up the
vehicle.
③ Disconnect the sensor connector.
④ Unscrew the set bolt of the wheel speed sensor, and
take out the wheel speed sensor slowly.
Caution:
■ Do not use hard force to draw the wire harness of
wheel speed sensor.
■ Pay attention to the clearance between the wheel
speed sensor and signal gear during installation.
Standard value: 0.2-1.1 mm
1) Check if there is any foreign matter in sensor mounting hole and metal particles on brake
disc surface.
2) Check if the teeth number of teeth gear of wheel speed sensor is correct, whether there are no
foreign matters and rustiness.
BR‐42
3) Clean the sensor mounting hole and brake disc surface before installation.
4. Install
Install it in the reverse order of removal, and tighten the bolt to the specified torque.
Caution:
■ The wire harness shall not be twisted after installation.
ABS hydraulic assembly

1) Dismantle BR068
① Turn off all ignition switches and disconnect the
negative cable of battery.
② Remove ABS control module connector.
③ Press the pedal above 60mm and fix by the pedal
rack.
■ Close the center valve of the hydraulic assembly, so
brake fluid will not flow out from the outlet when
opening the system.
④ First, dismount the brake pipe on the hydraulic assembly to the master cylinder and mark,
and then block the outlet by the plug at once.
⑤ Dismount the brake pipes to various wheels and mark, and then block the outlet by the plug
at once.
⑥ Remove the bolt on the ABS hydraulic assembly retaining bracket.
⑦ Remove the whole ABS hydraulic assembly from the bracket.
2) Install
Install the ABS hydraulic assembly in the reverse order or removal.
Caution:
■ Tighten the brake pipe joint connected with the hydraulic assembly to the specified torque.
■ The plug of the hydraulic opening on the ABS hydraulic assembly can only be dismounted
when the brake pipe is to be installed in order to avoid the foreign matters from entering into
the brake system. Please refer to “Brake Pipeline” for the following steps.
① Install the ABS hydraulic assembly on the bracket and tighten to the specified torque.
② Remove the plug on the hydraulic port, install the brake pipe and confirm that the pipe is
connected correctly.
③ Connect the hydraulic assembly to the brake pipe of the master cylinder.
BR‐43
④ Install the brake pipe and tighten to the specified torque.

⑤ Add new brake fluid into the fluid reservoir until the level is up to the MAX position and
exhaust according to the specified method.
⑥ When turning the ignition switch to ON position, the ABS warning light comes on and then
goes out.
⑦ Clear the stored DTCs, and read again whether there are DTCs.
⑧ Finally perform road test and confirm that the ABS function is normal.
Caution:
If the ABS hydraulic assembly has a fault, replace the assembly.
ABS control module

1. Components
The vehicle adopts BOSCH ABS 9 ABS. ABS control module and hydraulic assembly is
integrated.
2. ABS control module pin description
Definition table of ABS Control Module Pin
Pin No. Definition Pin No. Definition
1 The power terminal of motor (positive) 20 N.C.
Output of wheel speed sensor (FRT/RH
2 21 N.C.
wheel)
3 Active EBD warning lamp 22 N.C.
Signal terminal of wheel speed sensor
4 23 N.C.
(FRT/RH)
5 N.C. 24 N.C.
6 Diagnostic K Line 25 Power terminal of valve relay
7 N.C. 26 CAN-HI
8 27 Active ABS warning light
(FRT/LH)
The power terminal of ECU (Ignition
9 N.C. 28
power wiring)
10 N.C. 29
(RR/RH)
11 N.C. 30 Brake Lamp Switch Input
The power terminal of wheel speed sensor
12 N.C. 31
(RR/LH)
13 The ground terminal motor 32 N.C.
14 CAN-Low 33 Vehicle speed signal output
15 N.C. 34 N.C.
BR‐44
Pin No. Definition Pin No. Definition

16 35 N.C.
(FRT/RH)
17 36 N.C.
(RR/RH)
18 37 N.C.
(RR/LH)
19 38 ECU cable
(FRT/LH)
ABS control module pin location diagram
3. Check of ABS control module

Caution:
■ Please execute the basic check of brake system.
1) Basic check of brake system
① Check brake fluid level. If the level is low, fill brake fluid.
② Check the area near the brake pipeline and ABS hydraulic assembly for leakage. In case of
leakage, check the following:
a. If the ABS hydraulic assembly connecting part loosens, tighten the oil pipe nut of the
pipeline to the appointed torque (16-30 N•m). Check leakage again, and confirm no brake
fluid leakage.
b. If the oil pipe nut of the joint and the thread part of the actuator are damaged, replace the
damaged parts. Check leakage again, and confirm no brake fluid leakage.
c. If it leaks out of the actuator connecting part, wipe by the clean cloth and then re-check. If
there is leakage still, replace the damaged parts.
d. If there is leakage in the hydraulic assembly, wipe with clean cloth and check again. If there
is leakage still, replace the hydraulic assembly.
Caution:
■ If no special needs, do not disassemble the ABS hydraulic assembly (including control
module).
③ Check if brake shoe is worn.
BR‐45
④ Looseness of power circuit port and battery check.

■ Check for loose battery positive/negative terminal. At the same time, confirm that the battery
voltage is normal.
2) ABS warning lamp and brake warning lamp check
① Confirm that the ABS warning light is on for about 3s and the brake warning light comes on
when turning the ignition switch to “ON” position. If they are not on, please refer to
“Common Symptoms and Analysis Procedure of ABS”.
② Check if the ABS warning light goes out after the ignition switch is turned to “ON” about 3s
and whether the brake warning light goes out after the engine starts up. If they are not off,
please refer to “Common Symptoms and Analysis Procedure of ABS”.
③ If the ABS warning light does not go out after 10s since the engine starts, please refer to
“Common Symptoms and Analysis Procedure of ABS”.
Caution:
■ The brake warning light comes during the parking brake operation (when the switch is in
position ON) and when the brake fluid level sensor is working (the brake fluid is
insufficient).
3) Check ABS control module by using diagnosis device.
Detect the control module control data and stored DTCs by the scan tool. If abnormal,
service according to the fault prompt. Please refer to "Failure diagnosis".
4) ABS failure code table
Fault Code Description
C190004 ECU too high voltage
C190104 ECU too low voltage
C100004 ECU hardware fault
C101008 ECU software fault
C006B06
C003108 Front left wheel speed sensor signal fault
C003200 Open circuit of left front wheel speed sensor
C00A000 Front left wheel speed sensor short ground circuit fault
C00A100 Front left wheel speed sensor short circuit fault to power supply
C00A900 Left front wheel speed sensor has fault, but the cause isn't found.
C003408 Front right wheel speed sensor signal fault
C003500 Open circuit of right front wheel speed sensor
C00A200 Front right wheel speed sensor short circuit fault to ground
C00A300 Front right wheel speed sensor short circuit fault to power supply
C00AA00 Right front wheel speed sensor has fault, but the cause isn't found.
C003708 Left rear wheel speed sensor signal is fault.
C003800 Open circuit of left rear wheel speed sensor
BR‐46
Fault Code Description

C00A400 Rear left wheel speed sensor short to ground
C00A500 Rear left wheel speed sensor short to power supply
C00AB00 Left rear wheel speed sensor is fault, but the cause isn't found.
C003A08 Rear right wheel speed sensor signal fault
C003B00 Open circuit of right rear wheel speed sensor
C00A600 Rear right wheel speed sensor short circuit fault to ground
C00A700 Rear right wheel speed sensor short circuit fault to power supply
C00AC00 Right rear wheel speed sensor fails but its reason does not detected
Wheel speed sensor has other faults (such as: fault in left and right sequence, multiple
C109904
sensor error).
C001004 Front left oil inlet solenoid valve fault
C001104 Front left rear fluid outlet solenoid valve fault
C001404 Front right oil inlet solenoid valve fault
C001504 Front right fluid outlet solenoid valve fault
C001804 Left rear oil inlet solenoid valve fault
C001904 Left rear fluid outlet solenoid valve fault
C001C04 Rear right oil inlet solenoid valve fault
C001D04 Rear right fluid outlet solenoid valve fault
C109504 Valve relay fault
C002004 Motor faults
C007208 Other faults of valve (Overheat protection, signal failure or hardware fault)
Exhaust of ABS system

1. Exhaust condition of ABS system
It is necessary to perform the ABS bleeding procedure when one of the following conditions
occurs:
1) The braking line cannot realize the pedal height or feeling required according to the
traditional exhaust method.
2) Replace ABS hydraulic assembly.
3) Excessive fluid loss.
4) Possible air suction.
■ This procedure uses the scan tool to driver the system valve and operate the pump motor, so
as to remove air from the secondary circuit. These secondary loops are normally closed and
can only be opened during the initializing period and the ABS operating period while starting
the vehicle. Open these secondary loops by the automatic exhaust procedure, make all airs
flowed out and collect them in the hydraulic assembly to remove them out of the system.
2. Exhaust of ABS system
BR‐47
1) Items required
① Diagnosis device with correct software
② Brake fluid
③ Lifter
④ Bleeding bottle with hose for receiving fluid from the vehicle
⑤ Suitable safety equipment, include safety goggles.
⑥ Two servicemen are needed: one pushes the brake pedal down and control the diagnostic unit
and the other keeps the hydraulic fluid of the main cavity of the brake master cylinder level
and switch on and off the exhaust screw according to the process of the diagnostic unit.
2) Initial inspection
① Check the charging state of the battery, and service the battery and charging system as
required.
② Connect the scan tool, and select current or past DTCs. Before carrying out ABS gas
exhausting, clear all failure diagnosis codes. Remove the fault first if DTCs cannot be
cleared.
③ Check the appearance for damage and leakage. Service as required.
3) Steps before exhaust
① Start the engine.
② Connect the scan tool, and establish communication with ABS.
③ Lift and support the vehicle properly.
4) Bleed on the vehicle.
Caution:
Press down the EXIT key on the diagnostic unit to stop the automatic exhaust procedure at any
time.
■ Select “Automatic Bleeding Procedure” from the scan tool and follow the instructions.
(Please refer to the actual scan tool procedure)
■ In the basic bleeding and automatic bleeding process, it is necessary to press the brake pedal
and hole the brake fluid level of the brake master cylinder.
■ When bleeding one wheel, ensure that the hose is connected with the bleed screw and empty
to the chamber containing brake fluid. This chamber must be 30mm higher than the bolt with
the hose filled with brake fluid. This is to prevent air from entering the brake pipeline again.
■ The first step is basic bleeding. This step must be performed before automatically exhausting
to obtain good pedal height and feeling as well as ensure the best performance of the ABS.
■ The first step of the automatic exhaust procedure is to rotate the pump and the reducing valve
for about 30 s. It is unnecessary to open and close the bleed screw in this step. The brake
pedal pressurizes or depressurizes continuously in the whole process.
BR‐48
■ In the next step, the serviceman will be demanded to open one of the exhaust bolts for the
diagnostic unit. The scan tool then circularly checks the pressurizing valve and pump motor
for about 30s. The brake pedal needs to pressurize or depressurize continuously in the whole
process.
■ For the rest exhaust bolts, the step 6 will be repeated by the diagnostic unit to exhaust.
■ When the automatic bleeding procedure ends, the scan tool will display the corresponding
information.
■ Press the brake pedal to measure the pedal height and feeling. Repeat Steps 1 to 8, until the
pedal is acceptable.
Caution:
■ The automatic exhaust procedure may be stopped temporarily to access to the mode of “cool
down waiting” during repetitive operation.
5) Automatic exhaust
Do not proceed until the timer exceeds the time, and this process cannot be crossed.
Diagnosis steps in the vehicle
① Enter into the Special Fault Diagnosis System for JAC Car.
Special fault diagnosis
system for JAC car
Developed by LAUNCH Co. Ltd
Please login in time
Start
Exit Original Info Help

Start
② Select the Special V10.01 Full System for JAC Car. Diagnostic software version selection
Special V10.01 system for JAC car
This program can diagnose all

electrically-controlled systems produced by JAC in
and before 2007.
PgUp PgDn Enter
Back Help
Start
BR‐49
③ Enter into the automatic bleeding procedure. Follow the Air bleeding mode
prompts.
1st step
Please tighten all bleed bolts,
step brake pedal, and then click
"YES" to continue
Yes No
Start
④ The first step of system exhaust. Air bleeding mode
Start air bleeding mode

Please strictly follow the instructions
of system to operate
Yes No
Start
⑤ Exhaust is ongoing. Air bleeding mode
The bleeding mode is processing,

pump is started and this process will
last for 20 s
Diagnosis front page
Start
BR‐50
⑥ The first step is finished. Air bleeding mode
1st step completed
Enter
Start
⑦ The second step of exhaust. Air bleeding mode
2nd step
The bleeding of right rear wheel is
processing. Please connect oil outlet
pipe, screw off right rear bleed bolt,
and then step brake pedal.
Enter
Start
⑧ Exhaust is ongoing. Air bleeding mode

last for 20s.
Start
BR‐51
⑨ The third step. Air bleeding mode
3rd step:
Deflate the rear left wheel tire,
connect the oil drain pipe, open
left and right bleed bolts, and
then depress the brake pedal
Enter
Start
⑩ Exhaust is ongoing. Air bleeding mode

last for 20s
Start
⑪ The third step is finished. Air bleeding mode
3rd step completed
Enter
Start
BR‐52
⑫ The fourth step Air bleeding mode
4th step:
First front right wheel blow off,
please connect with oil drain pipe,
open front left bleed bolt, and depress
in brake pedal
Enter
Start
⑬ Exhaust is ongoing. Air bleeding mode

last for 20s.
Start
⑭ The fourth step is finished. Air bleeding mode
5th step:
open front right bleed bolt, and
depress in brake pedal
Enter
Start
BR‐53
⑮ The fifth step. Air bleeding mode
第五步：
open front right bleed bolt, and
depress in brake pedal
Enter
Start
⑯ Exhaust is ongoing. Air bleeding mode

last for 20s.
Start
⑰ The process of exhaust is finished. Air bleeding mode
Bleed processing is completed.
Enter
Start
BR‐54
Fault diagnosis
1. Brief introduction of failure diagnosis
1) Do failure diagnosis to get a thorough understanding of various system (control and
mechanism) of the vehicle.
2) Know the customer’s complaints before check. After understanding the symptoms, carefully
ask to the client about the complaint.
3) The symptom check must start from the initial stage, so as to completely correct the fault. It
is very important to playback the symptom for intermittent fault according to the meeting
with the customer and the past cases. Do not check according to some special conditions.
Most of intermittent faults are caused by poor contact. It is effective to sway the suspicious
wire harness or the plug-in with hands under such circumstances.
4) After completing diagnosis, make sure to perform “Clear DTC”.
BR‐55
2. Diagram of diagnosis process

Diagnosis process is as follows:
Determine
确定故障内容fault contents
Familiar
了解”注意事项”with “Caution items” and the
method to find faults soonest
速诊断以最快找出故障
Do primary inspection
进行初步检查
IsABS
ABS故障灯是否亮
trouble light on?
Y
N 检查
Check ABS执行器和电气
ABS actuator and the harness
If diagnostic unit display DTCs N
诊断仪是否显示故障码单元与数据连接口线束
of electrical unit and data connector
Y
Do self-diagnosis
进行自我诊断 again
Abnormal Implement symptom diagnosis process
进行症状诊断程序
Check and repair faulty parts

检查与修理故障零件 Confirm the symptoms
确认症状
Abnormal
Clear self-diagnosis result, and drive the
car at the speed of 30 km/h30km/h或更
清除自诊断结果，以 or higher for
高的车速驾驶一分钟以上
more than 1 min Normal
Normal
正常
Do self-diagnosis
再次进行自诊断 again
Check the result

检查结果
3. Diagnosis information and process

1) Self-diagnosis
The Abs control module performs self-diagnosis on the system, which can detect the system
fault. Once it is in trouble, set up the diagnostic trouble code (DTC), turn on the ABS
warning light, and shut down the ABS system at the same time.
2) Display of failure diagnosis
The special scan tool can display DTCs.
3) Clearing failure diagnosis
The DTCs in the ABS control module memory can be cleared by the scan tool.
Caution:
■ Check if the system operation is normal and DTC appears after the clearing step.
BR‐56
■ The DTC shall not be cleared away by dismantling the ABS control module plug-in,
disconnecting the battery wire or going out.
4) Intermittent faults or intermittent faults due to poor contact are mostly caused by the
following conditions:
① Incorrect electric wiring.
② Fault electric connecting.
③ Stuck relay or solenoid valve.
5) Initialization Order
The ABS control module performs initialization test at the beginning of the each ignition
cycle.
The initialization order is: solenoid valve and pump motor, to check if the part operation is
normal. If a fault is detected, the ABS control module will set the corresponding DTCs. You
can hear or feel some actions during initializing order and this is one part of the normal
operation of the system. If the ABS control module discovers no signal is input in the brake
switch (the foot releases the brake pedal), initialize immediately. If the signal is input into the
brake switch (the foot pushes down on the brake pedal), stop initializing until no signal is
input in the brake switch (the foot releases the brake pedal) or the speed is up to 16Km/h.
4. Diagnostic circuit inspection
1) System specification
The diagnostic circuit can detect the problems caused by faulty ABS/EBD system. The
diagnostic circuit check will guide the service technician to perform the next step of
diagnosing fault.
2) Diagnosis procedure
Maintenance steps of ABS/EBD system as follows:
① Check if the vehicle has mechanical faults related to the brake system.
■ The level of the brake fluid reservoir is correct.
■ Check the brake fluid of the master cylinder for pollution.
■ Check the brake master cylinder/ABS hydraulic assembly for leakage.
■ Check the brake parts of all wheels.
■ Verify whether brake drag exists.
■ Verify whether braking is stable (drag or rush-out).
■ Check the brake shoe for wear/damage.
■ Check the wheel bearing for damage.
■ Check the wheel (speed) sensor and harness.
■ Check the wheel speed sensor connector/ring gear for damage/check the tire tread
depth/wear degree.
■ Carry out road test, verify the condition and correct.
BR‐57
② The check of diagnostic circuit must follow the applicable diagnostic fault procedure. All
system faults are removed, clear ABS DTCs.
Fault Diagnosis Table
Step Diagnostic
Yes No
s
1. If possible, connect or install all parts disconnected or removed
previously.
1 2. Turn the ignition switch to ON position, and the engine stops. To steps 2 To steps 4
3. Install the applicable scan tool on DLC, and make it communicate with
the ABS control module.
2 Are there current or past DTCs? To steps 3 To steps 7
1. Record current DTCs
2. Record the past DTCs.
3. Record the historical data, for example, the time set by various DTCs,
3 the time firstly set from various DTCs, the time previously set from
various DTCs, the speed when setting the DTC, and other enhanced
data that are helpful to diagnosis.
4. Do not clear DTCs before recording the information from the scan tool.
4 Can the scan tool communicate with other modules on the same data line? To steps 5 To steps 6
To "no communication with ABS control module" in ABS control module
5
fault procedures.
6 Go to the data link connector unit of the electrical end part.
1. Flameout.
2. Wait for 10 seconds.
7 To steps 8 To steps 9
3. Start the engine.
4. Observe the ABS warning light after starting.
8 Is any light always on? To steps 9 To steps 10
9 Go to the “ON” fault procedure of the corresponding light.
10 Go to the “INOPERATIVE” fault procedure of the corresponding light.
5. Common Symptoms and Analysis Procedure of ABS

1) Lost communication with ABS control module
The typical causes of lost communication with ABS control module are:
■ Poor contact of diagnostic port.
■ ABS control module not grounded.
■ No voltage provided by battery to ABS control module
■ No voltage provided by ignition switch to ABS control module
■ Data line open/short circuit.
■ Data line resistance is too high.
BR‐58
2) ABS warning light NOT ON/no DTCs

The typical causes of ABS warning light failed and no DTCs set are:
■ Fault-ABS warning light / loose socket.
■ Instrument panel fuse disconnecting.
■ Fault-instrument warning light drive module.
■ Fault-ABS control module.
■ Open or short line between ABS control module and instrument.
3) ABS warning light on/no DTCs
The typical causes of ABS warning light on with no DTCs set are:
■ Open circuit between instrument and ABS control module.
■ ABS control module is not grounded.
■ Short circuit between instrument and ABS control module.
■ Fault-instrument warning light drive module.
■ Fault-ABS control module.
4) Brake warning light ON
The typical causes of the brake warning light on with no DTCs set are:
■ Fault-parking brake switch.
■ Too low brake fluid level or faulty brake fluid switch.
■ EBD failure due to the following faults in ABS.
a. Failed two concentric wheel speed sensors.
b. Open circuit to battery or short circuit to ground.
c. Motor grounded or short circuit to battery.
e. ABS control module is open to ground wire or short to battery.
f. Open circuit to ignition switch or short circuit to ground.
■ Instrument and ABS control module open circuit.
■ Fault warning lamp circuit.
■ Instrument fault
■ Faulty ABS control module
5) Brake warning light not on/no DTCs set
The typical causes of brake warning light not on and no DTCs set are:
■ Fault-bulb/loose socket.
■ Instrument panel fuse disconnecting.
■ Instrument fault
BR‐59
■ Faulty ABS control module

■ The circuit between ABS control module and instrument is grounded.
BR‐60
J4 Service Manual Steering System
Chassis - Steering system

Precautions
■ When inspecting steering system, place the vehicle on level and dry ground.
■ The bolts of the components in the steering system must be tightened to the specified torque.
■ After overhauling the steering column assembly, steering gear and other steering mechanism,
it is necessary to check wheel alignment.
■ Maximum voltage of system should not exceed 18V, and minimum voltage should not be
less than 9V.
■ Check frequently and keep the tire pressure at the specified value.
■ Once there is abnormal clearance, sticking, head swinging symptoms, it is necessary to find
out where is the fault position, steering drive transmission unit, power steering system or
steering pull rod system, and eliminate the fault.
■ Check with care the parts of the steering system for abnormal impact frequently. For
damaged parts or fault parts, it is necessary to timely replace it.
■ Do not weld the part of steering gear and system rods in any manner.
■ Regularly check if there is interference or abrasion of EPS wire harness, whether connector
is loose. If any abnormality is found, timely replace it.
Preparation work
General Tools Table
Removal and Installation of Bolts

1 Power tool
Nut
Electric Power Steering System Overview

Power steering system is designed to reduce driver's working intensity. As passenger cars need to
run fast and the load to steering wheel increases, power steering gear becomes indispensable and
is used very widely. Power steering system has such advantages:
It can reduce steering force on the steering wheel. It's especially obvious when taking a turning in
the original place or at a low speed but a large turn angle.
■ Steering sensitivity is improved.
■ The kickback of ground against the steering wheel is reduced.
■ This can protating speedent wheels from turning suddenly if a tire explodes, thus ensuring
service safety.
■ If the allowed load of steering wheel is larger, it may increase freedom of the entire setup.
PS‐1
■ They are relatively more energy saving and environmental protection.

Composition of power steering system:
Power steering system consists of steering wheel assembly, steering pipe with intermediate shaft
assembly, mechanical steering gear assembly, etc. Of which, mechanical steering gear is the
actuating part of electric booster of steering system. Steering column motor is linked with the
complete vehicle power supply system, which provides power source for the system.
The structure of power steering system is diagrammed as follows:
Structure diagram of power steering system

1-Steering wheel assembly 2-Steering column with intermediate shaft assembly
3-Mechanical steering gear assembly
Steering process:
When rotating steering wheel, torque sensor detects the change of torque exerted on the steering
wheel, and instructs boosting motor to rotate through ECU control unit, so as to drive steering tie
rod assembly to move and achieve boosting steering function.
Returning process:
After steering, the force exerted on the steering wheel disappears. Torque sensor detects the
change of torque exerted on the steering wheel and instructs boosting motor stop rotates through
ECU control unit. Under the effect of self-aligning torque of front wheel, the vehicle will travel
straightly forward until the vehicle returns to straight traveling position.
Road feel effect:
Road feel effect refers to the ability of causing the steering feeling. When driver exerts force to
the steering wheel, it also acts on the torsion bar of steering gear simultaneously, so that it's
deformed torsionally. This deformation depends on wheel turning resistance; the deformation
increases as the resistance increases. So the driver can feel the change of steering resistance based
on the force he exerts to the steering wheel.
PS‐2
Steer wheel
Inspection in the car:
1) Check installation conditions
① Check if steering device assembly, front suspension, axles and steering column are installed
correctly.
② Check if there is any moving clearance when steering wheel moves vertically, transversely
and axially.
③ Check if set nuts and bolts of steering device assembly are loose.
2) Check the free travel of the steering wheel
① Turn the steering wheel to keep the front wheels straight forward. Start engine and rotate
steering wheel leftwards or rightwards gently until front wheels begin to move. Measure the
movement of the steering wheel on the excircle.
■ Free stroke of the steering wheel: 30 mm
② When the measured value exceeds the standard value, check installation of each joint of
steering column and the steering mechanism. Correct or replace relevant parts as necessary.
③ If the idled travel exceeds 30mm still, shut off engine, make front wheels run in a line, exert
5 N along periphery of steering wheel and check the idled travel, which shall not exceed 10
mm. If it exceeds 10mm, check if the steering gear assembly is eligible.
④ If the travel is still at a limit, leave steering wheel in the middle when the engine is shut
down, exert 4±0.6 N to the periphery of steering wheel and check the free travel.
■ Standard value: < 15 mm
⑤ If it exceeds the standard value, remove the steering gear and check the total torque of the
pinion.
3) Check the middle.
① Ensure steering device assembly, steering column and steering wheel are installed correctly.
② After wheel alignment, perform the middle position inspection. Please refer to "Inspection of
front wheel alignment".
③ Stop the vehicle straight forward, and confirm that the steering wheel in the middle.
④ Release the tie rod lock nut and rotate the adjustment level left and right for fine tuning to
affirm whether the steering wheel is in the middle.
4) Check the static steering force of the steering wheel
① Stop the vehicle on a flat dry ground, and pull up the parking brake lever.
② Start the engine.
Caution:
■ The tire pressure value shall be within the standard value.
PS‐3
③ Rotate the steering at wheel 360° from the middle position to check the steering effort of the
steering wheel and to check if there is obvious fluctuation.
■ Steering force of steering wheel: < 34 N Allowable fluctuation: < 5.9 N
④ If the steering force of the steering wheel exceeds the specified value, check or adjust the
following items:
a. The lower swing arm and steering tie rod end for damage.
b. The gear preload of steering gear and the rotating torque of steering tie rod end.
c. The rotating torque of lower swing arm ball joint.
5) Check self-return of steering wheel
Caution:
■ Turn slowly and sharply to confirm whether its acting force and the returning performance
have no difference along the left direction and the right direction by feeling.
■ Be sure to execute the step on the safe road surface and in safe traffic condition, pay
attention to safety.
Rotate the steering wheel at 90° and run at the speed of 35 PS001
km/h to hold for few seconds, and then release the steering
wheel to return at least more than 70%.
6) Inspection of front wheel steering angle

① Check the toe-in of the front wheel and then its PS002
steering angle. Place the front wheel in the steering
angle measures (front wheel positioning steering
wheel) to check the maximum inner and outer wheel
steering angle of the left and right wheels.
■ Inner wheel: 36°±1.5°
Outer wheel : 30°±1.5°
② When engine idles, measure steering angle by rotating steering wheel left and right to the
end.
■ If the measured value is not within the standard range, adjust the tie rod.
The adjustment method of steering angle is as follows:
When the steering angle exceeds the standard value, release the lock nut of the left and right
steering tie rods, rotate the left and right tie rods with the wrench respectively to adjust the
steering angle to the standard value, and then lock the lock nut with the tightening torque of 50-55
PS‐4
N•m. When adjusting the exposed length of the thread of left and right tie rod, pay attention to
make the length of left and right tie rods uniform.
Caution:
■ When the inner wheel steering angle exceeds standard, adjust the tie rod at this side to rotate
outward to increase the inner wheel steering angle; and when the outer wheel steering angle
exceeds standard, adjust the tie rod at this side to rotate outward to reduce the outer wheel
steering angle.
Caution:
■ The toe-in is related to other wheel alignment parameters and steering wheel adjustment.
7) Inspection of the tie rod end dust cover
① Press with finger, and check the dust cover for cracks or damage.
② If there are cracks or damage on the dust cover, replace the steering tie rod end.
Caution:
■ When the dust cover has cracks or damage, the tie rod end may be damaged jointly.
8) Check the rotating torque of the steering tie rod end PS003
① Swing the tie rod 10 times quickly.
② Measure the swing resistance of the tie rod with a
spring scale.
■ Standard value: 0.5-3 N•m
■ If the measured value is not within the standard
value, replace.
Steering wheel assembly

1) Dismantle PS004
① Disconnect the battery negative terminal, and wait for
above 3 minutes.
② Remove the driver’s airbag module from the steering
wheel.
③ Lock steering and remove the set screw nut of the
steering wheel.
④ Lift up the steering wheel from the steering shaft.
Caution: If it’s not easy to pull it out, please use the steering wheel puller.
2) Install
Install it according to the reverse order of dismantling.
PS‐5
Horn cover assembly dismounting as following steps:

1. Connection area between steering wheel and DAB clamp (red circle)
2. Assembly drawing of steering wheel and DA

9H dismounting
hole
3H dismounting
hole
6H dismounting
hole
Schematic Diagram of DAB Dismantling on Complete Vehicle (total 3 steps). Use the flathead
screwdriver (15cm) as a special tool.
1. Dismantle 3H dismantling hole: rotate steering wheel for 90° counterclockwise, and use
screwdriver to pry the groove of 3H dismantling hole (for detailed structure, refer to right
above figure) to separate DAB claw from steering wheel bracket.
② Dismantle 6H dismantling hole: rotate steering wheel for 90° counterclockwise again, and
use screwdriver to pry the groove of 6H dismantling hole (for detailed structure, refer to right
above figure) to separate DAB claw from steering wheel bracket.
③ Dismantle 9H dismantling hole: turn steering wheel to middle position and rotate steering
wheel for 90° clockwise again, and use screwdriver to pry the groove of 9H dismantling hole
(for detailed structure, refer to right above figure) to separate DAB claw from steering wheel
bracket.
3. Horn cover assembly
Align the steering wheel with connection area of DAB and press them; meanwhile Check if the
clearance is uniform.
PS‐6
Caution:
■ The installation can be performed only when wheels are in straight driving state and the
steering wheel is in the middle. Or, make marks on the steering wheel and set bolt in advance
before removal, and ensure that the marks are aligned during installation.
■ The steering column must rotate smoothly and do not make click sound or shall not be stuck
in the installing condition.
■ After installing the other parts on the steering wheel, adjust the gradient of the steering wheel
and the steering column 5-6 times; the maximum force applied for operating the locking
position of the steering column shall not exceed 60-100 N. When the locking position of the
steering column is in the free position, the maximum force applied for the gradient of the
steering wheel and the steering column shall not exceed 100 N.
■ Mounting position of clock spring (hair spring).
■ Do not distort timer spring after tightening it.
Steering column assembly

Diagram of Steering Column Assembly:
2 1
Schematic diagram of Steering Column Assembly:

1- Steering column assembly 2- Countershaft assembly
Caution:
■ Do not apply excessive axial force to the steering column assembly during removal and
installation.
■ Do not move the steering gear when removing the steering column.
1) Dismantle
① Park the vehicle straight.
② Disconnect the battery negative terminal, and wait for above 3 minutes.
PS‐7
③ Remove the driver airbag module.

④ Remove the steering wheel.
⑤ Remove the steering column upper and lower covers and driver’s instrument panel lower.
⑥ Remove the combined switch assembly and clock spring from the steering column.
⑦ Disconnect all wire harness connectors on the steering column, and move away the wire
harness from the steering column assembly.
⑧ Unscrew off the connecting bolts of steering PS005
column with lower shaft and separate the column
from the steering gear.
⑩ Unscrew off the fixing nut on the steering column PS006

assembly, turn down the column and take out the
column assembly.

① Check if steering column is cracked, deformed or otherwise damaged. If so, replace it.
② Check the spline of the steering column shaft for wear or broken tooth, and replace if any.
3) Disassemble
① Disassembly
a. Unscrew connecting bolts of steering column and universal joint of connecting shaft, and
then dismantle universal joint.
b. Remove the steering lock if necessary.
Caution:
■ Make sure to replace the special bolts when re-installing the steering lock.
PS‐8
c. Remove the adjustable steering column and bracket if PS007 Cross bite screw tap
necessary.
Special bolt
② Key point of disassembly Steering lock support
Removal of special bolts:

a. Use an electric drill to make a hole on the special bolt,
which is big enough to receive the screw tap.
b. Use a negative screw tap to remove the special bolt. Steering lock body
4) Check after dismantling

① Check the adjusting bracket and spring for cracks and damage.
② Check if the steering lock mechanism is operated normally.
5) Assembly
Assemble steering lock assembly, bracket assembly and special bolt.
Caution: PS008
■ When installing on the steering column assembly,
align the steering lock assembly and the steering lock
bracket with the lock notch of the steering column to
temporarily lock the steering lock.
■ After confirming the steering lock correctly operates,
lock the special bolt until the bolt head is locked off.
Gap
6) Installation
Caution:
■ Do not reuse the unavailable part.
■ Keep the steering wheel in the middle and install the steering column assembly.
■ When installing the connecting shaft on the steering column, note the installation position.
When the vehicle stops straight, turn the steering wheel to the end several times, and confirm
that the steering wheel is operated flexibly.
PS‐9
Power steering gear assembly

Component
Component Diagram of Steering Gear
Caution:
■ If rotating the steering wheel when separating the steering column from the steering gear
assembly, it may injure the clock spring. So you must fix the steering wheel first.
Caution:
PS009
① Stop the vehicle straight forward.
② Disconnect connecting bolts of intermediate shaft
assembly and mechanical steering gear from driver's
cab, and then separate steering column and steering
gear.
③ Remove the locking nut of the tie rod end.
④ As shown in the figure, remove the steering tie rod
PS010
end from the steering knuckle with special tool.
Lock nut
Rope
Ball joint
⑤ Remove the front sub-frame assembly and engine PS011

mount.
Caution:
■ Please use jack to support.
PS‐10
⑥ Remove fixing bolt of mechanical steering gear on PS012

the sub-frame.
⑦ Take down power steering gear assembly on the
frame.
Caution:
■ Take out slowly with care, and do not damage the tie rod dust cover.
① Mechanical steering
■ Check the gear rack for smooth operation and wear.
■ Check the gear preload.
a. Rotate the gear at the speed of 4-6 s per turn and measure the pre-load of the gear within the
full range of the rack.
■ Standard value: 0.6-1.3 N•m
b. If the measured value exceeds the specified value, adjust the plug, and then re-check the gear
preload.
c. If it is still incapable of obtaining the specified pre-load of the gear by adjusting the blockage,
check or replace the blocking component.
② Steering tie rod
■ Check the rotating torque of steering tie rod.
a. Rotate the tie rod rapidly for 10 times.
b. Measure the swing resistance of the tie rod with a spring scale.
■ Standard value: 0.5-3 N•m
If the measured value is not within the standard value, replace.
Caution:
■ When the tie rod slowly swings without excessive clearance, it can be still used even if the
measuring value is lower than standard value. If the measured value is high than 4.3 N•m,
the tie rod must be replaced.
③ Tie rod dust cover
■ Check the dust cover for damage, and replace if any.
■ Check the dust cover for correct installation position.
3) Installation
PS‐11
Caution: Do not reuse non-reusable components.

Caution:
■ When machinery the power steering gear with the steering column, pay attention to the
installation position.
■ When machinery the power steering gear assembly, keep the tires on the level ground in an
idle condition to finally tighten the nut and the bolt.
■ Turn the steering wheel to the end left and right several times, and confirm that the steering
wheel is operated flexibly.
EPS ECU DTC
Fault code Description
C1111 Sensor main signal fault
C1115 Sensor sub-signal fault
C1114 Sensor power supply fault
C1113 Main and sub-fault of sensor
C1141 Motor and current open circuit
C1142 Motor and current is abnormal 1
C1145 Motor and current is abnormal 2
C1153 Power supply voltage is too low
C1112 Power supply voltage is too high
C1154 Abnormal relay
C1121 Speed signal fault 1
C1122 Engine revolving speed signal fault
C1155 Temperature is abnormal or ROM is error.
Countermeasures to common faults

Deviation (test the vehicle on a flat road from two directions);
Failure causes
1) Steered-wheel ball joint or front wheels are positioned incorrectly.
2) The steering lever system is twisted, deformed and over-worn.
3) Pretightening of rack inside steering gear is misadjusted.
4) Steering wheel vibrates, returns poorly or strikes driver's hand when .
Elimination of faults:
PS‐12
1) Adjust front-wheel alignment and ball joint of steered wheel.

2) Adjust or repair pretension of steering gear rack.
3) Check and adjust each joint of steering system as required.

Specification Table
Item Specifications
Diameter of steering wheel φ375mm
Steering column and lower shaft Three-class crumple
Operation torque of steering wheel 4.5±0.5 N•m
Power steering gear rack travel 130±2 mm
Wire drive ratio 45.3
Circle number of steering wheel 2.87±0.1
Mechanical steering gear type Pinion and rack

Item Quantity Fastening torque (N•m)
Fixing nut of steering wheel 1 42-52
Steering column mounting nut 2 20-25
Steering column mounting bolt 1 20-30
Steering column assembly and intermediate shaft assembly
1 30-35
connecting bolt
Connecting bolt between intermediate shaft assembly and
1 30-35
mechanical steering gear
Main fixing bolt of mechanical steering gear 2 100-110
Fixing bolt of mechanical steering gear 2 110-120
Steering tie rod tie-in adjusting nut 2 50-55
Steering gear ball head slotted nut 2 50-55
PS‐13
J4 Service Manual
J4 Service Manual
Foreword Master Table of Contents
This manual is intended to help the Overview and maintenance

professional maintenance technicians
Chapter 1 Overview
authorized by JAC Passenger Car Sales
Company provide effective and correct Chapter 2 Maintenance
maintenance and service for JAC B-Class

Engine
series models. The warm service and proper
operation from the professional maintenance Chapter 1 Engine mechanical
technicians of JAC passenger cars are essential Chapter 2 Engine electronics

for ensuring customer satisfaction to JAC
Chapter 3 Engine Electronic
passenger car products. Thus, maintenance
technicians should fully understand this Chassis
manual. This manual should be placed in a
Chapter 1 Transmission system
handy place for your convenient reference.
All the contents in this manual have been Chapter 2 Clutch system
updated including pictures and technical Chapter 3 Drive system

parameters .In case maintenance works are
Chapter 4 Suspension system
affected due to product improvement, JAC
Chapter 5 Brake system
Passenger Car Sales Company will provide
technical bulletins or supplementary volumes. Chapter 6 Steering system
Therefore, you should use this manual and pay

Body Electrical &
close attention to obtaining latest update
relevant information. JAC Passenger Car Sales Chapter 1 Body Electrical
Company reserves the rights to change, add or Chapter 2 Body Structure

improve designs of its products. Chapter 3 Body data
No part of this manual is allowed to be
reproduced or modified in any form, including Circuit Troubleshooting
but not limited to electronic media, paper,
sound and image, and mechanical media,
without written authorization from JAC
Passenger Car Sales Company.
J4 Service Manual body electrical and structural
directory
Body Electrical & Structure
Body Electrical SRS - 1

Safety Auxiliary
SRS - 1
System ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Precautions SRS - 1
Preparations SRS - 1
Summary of Safety Airbag System SRS - 2
Fundamental principle of safety airbag system SRS - 3
Driver Side Airbag SRS - 5
Front Passenger Side Airbag SRS - 6
SRS - 8
Safety belt
SRS - 11
Safety belt pretensioner in the front row
SRS - 11
Safety airbag Timer-spring
SRS - 15
Safety airbag control module (SDM)
SRS - 17
Fault diagnosis
SRS - 24
Safety airbag System Servicing
Disposal method of abandoned safety airbag system

SRS -26
component
AC Air Conditioning System AC - 1
Precautions AC - 1
Service tools AC - 3
directory
Inspection of Air Conditioning System and Filling of AC - 5
Refrigerant AC - 8
System Control AC - 13
Functions, Positions, and Inspection of System Components AC - 21
System Removal and Installation AC - 25
AC - 26
Failure analysis and troubleshooting summary table
ETACS Information and time Electronic Control System ETACS -
Precautions ETACS -
Layout of Components ETACS -
Function Description ETACS -
Replacement of ETACS control module and alarm speaker ETACS -
14
Definition of ETACS control module terminal ETACS -
15
Operation instruction of ETACS remote control key code ETACS -
selection 16
ETACS common failure analysis ETACS -

directory
17
Technical parameters ETACS -
20
Combination
CSW - 1
Switch………………………………………………………
Descriptions CSW - 1
Component check CSW - 3
Replacement of combination switch CSW - 4
Check after installation CSW - 4
Lighting System LT - 1
Precautions: LT - 1
The front combination Light Replacement LT - 1
Front fog lamp LT - 5
Taillight LT - 7
High-mounted stop LT - 10
lamp ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... LT - 10
License plate light LT - 11
Rear fog lamp LT - 12
The dome
light ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... LT - 13
Combination meter CM - 1
directory
Summary CM - 1
Instrumentation CM - 3
features ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Operating instructions CM - 5
Combination meter connector and pin CM - 7
definition ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
The driver information CM - 8
display ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
installation and disassembly of Combination meter CM - 10
Wiper and Washer WW-1
Wiper WW - 1
System ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... WW - 5
Washing system WW - 7
Rear window defroster

WW - 9
Trouble inspection and repair
HORN HORN-1
Component position HORN-1
Schematic HORN-1
Horn check HORN-1
Trouble inspection and repair HORN-2
Removal and Replacement of horn HORN-3
Replacement of horn button HORN-4

directory
Cigar Lighter CTGAR
-1
CTGAR -
Component position
1
CTGAR -
Schematic
1
CTGAR -
Trouble inspection and repair
2
AV Audio System AV-1
Layout of Components AV - 1
AV - 1
Horn system Schematic
AV - 2
Audio unit
AV - 2
Audio unit and antenna replacement
AV - 4
Sedan Rear Speaker
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... AV - 4
Replacement of Front and Rear Loudspeakers
PTS – Parking Aid System PTS-1
Layout of Components PTS - 1
System Block Diagram and PTS - 2
Schematic ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... PTS - 2
System Interface Definition PTS - 3

directory
description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Sensor
Replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Mirror ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... PM - 1
Descriptions PM - 1
Layout of Components PM - 1
Schematic PM - 2
Component check PM - 3
Replacement of inside rear view mirror PM - 4
Replacement of outside rear view mirror PM - 6
Mirror adjustment
PM - 7
switch ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Electric windows and doors PW - 1
Summary PW - 1
Component description PW - 1
Function Description PW - 2
Schematic PW - 3
Element PW - 4
Replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. PW - 15
. ...
Fault diagnosis
Body Structure BODY-1

directory
Engine Cover and Doors BODY-1
Precautions: BODY-1
Engine Hood Assembly BODY-1
Fenders BODY-4
The replacement of front door assembly : BODY-4
The replacement of rear door assembly : BODY-8
Trunk lid BODY-1
Oil filler of fuel tank 2
Locking system BODY-1
BODY-1
Interior & Exterior Trims EI -1
Precautions: EI - 1
Front bumper replacement EI-1
Front bumper beam replacement EI-3
Rear bumper replacement EI-4
Sun visor replacement EI-5
A column upper guard plate replacement EI-6
Replacements of front door sill protect board assembly. EI-7
A column lower guard plate replacement EI-7
Replacements of rear door sill protect plate assembly. EI-8

directory
B-pillar Garnish EI-9
C-pillar upper guard plate replacement EI-10
Top armrest EI-11
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... EI-11
Ceiling EI-13
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... EI-15
... EI-16
Carpet EI-18
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... EI-19
... EI-20
coat rack assembly
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Luggage assembly
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Seat
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
...
Signage
replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
...
Front windshield
directory
Console IP-1
Precautions: IP-1
Driver Side Airbag replacement IP-1
Steering wheel replacement IP-3
Tube post Shield

IP-4
Replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Safety airbag Timer-spring IP-5
Driver side instrument panel replacement IP-7
Ignition switch replacement IP-9
Glove box replacement IP-11
Console replacement IP - 12
Steering column replacement IP-13
Combination instrument replacement IP-15
A/C control panel replacement IP-16
Dashboard replacement IP-17
Dashboard Support
IP-20
Replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Body Dimension Data Data - 1
Body data: Data - 1
Engine compartment data: Data - 2
Side member data: Data - 3

directory
J4 Workshop Manual safety assistant System
Electric device
Fundamental principle of safety airbag system
Precautions
Warning:
■Airbags can explode accidently and cause severe damage, if you don’t operate
as correct procedures while maintaining.
■Airbags may not be exploded and cause severe damage while maintaining
■Before maintenance (including remove, install, exam and replace parts),
following tips must be obeyed, and operate according to Maintenance Manual
1. Do not decompose airbag component, including driving and passenger side
airbag.
2. Do not manitain the following parts, only replace
1) Driving side airbag
2) Passenger side airbag
3) Safety belt tenser
4) Safety airbag control module;
5) Clock spring
3. Do not expose airbag under high temperature or near flame
4. If airbags are stained by liquid such as grease/detergent/engine oil/water, they
should be wiped by dry cloth immediately
5. Do not let airbags fall down Do not use airbags that has fallen down
6. Use original parts from authorized distributor,only.
7. If decompose airbags, put them on even place, Do not load any goods on its
top.
8. Verify if the replacement ID no. is correct. Do not use the component of other
cars as the substitute.
9. Remember to dispose airbags before discarding cars or safety airbags.
10. After the detonation of safety airbag, the charging device would become very
hot, and won't be handled until it naturally cools down. Do not lower the temperature
SRS-1
with water.
11.It is prohibited to measure the electric resistance of safety airbag module as
this may detonate the safety airbag.
Preparations
Common and special tools necessary for the maintenance
Tool Diagram Purpose
Simulator-joint of
Simulator for check of harness
resistance
Summary of Safety Airbag System

The safety airbag system is composed of the main safety airbag, passenger safety
airbag, clock spring, safety airbag module, explosive released pretensioner of
driver-sided safety belt and passenger-sided safety belt, side airbag switch of
passenger side. The passenger airbag can be turned off temporally by the switch off
passenger airbag button, which will turn on the PAB (passenger Safety airbag)
warning light on the dashboard. If driver doesn't fasten safety belt, ETACS will
receive signal and alarm light on dashboard will turn on. If the driver fastens the
safety belt, the alarm light of safety belt will turn off.
When the ignition switch turns to 2nd gear, safety airbag system activates, ECU
will check as fixed procedure automatically. If the alarm light is off after 4 seconds, it
means the system is normal after self-check, then ECU will start monitoring. if the
alarm light flash or keeps on, it means self-check fails and system is abnormal. During
the normal process of driving (incl. all road condition and interferences), ECU does
not give the ignition order, the airbag plays no roll；In case of severe forward collision,
ECU will issue in time the incentive ignition, stimulating the airbag component to
open the airbag and absorbing the partial impact energy from the driver and front row
SRS-2
passenger, alleviating the possible damage of passenger. driving and passenger side
safety belt precaution device will be activated,safety belt will be tightened, pulling
passenger who are away from seats because of inertia back to seats to protect them.

Condition of safety airbag opening
Impact Angle Diagram Enabling the Opening of Safety Airbag
The frontal impact in sufficient power occurred within the range at 30ºdeviation
from the centerline of car may open the airbag.
Layout of Safety Airbag System Components
SRS-3
Layout of Safety Airbag Components
1-driving airbag 2-passenger airbag 3-Safety airbag control module position
3. Principle of restraint system

Collision of car will cause abrupt change in the speed. Due to the inertia effect,
the passenger in the car continues to move forward, causing the impact between the
inboard passenger and interior panels. The Passenger Restraint System (SRS) is
designated to use the restraint system (incl. the seats, safety belt and safety airbag etc.)
to prevent or decrease the injury caused by the impact between the passenger and
interior panels.
1) Schematic Diagram of Restraint System
Impact
Sign Control/diag Explosion Airbag
Sensor nose system
Restr
Precaution S Restr
Driver/passe
e
nger
at
Loading
b
Safety belt pretension system SRS-4
Schematic diagram of Control system
2) Principle of safety airbag

Prior to the impact occurred between the inside passenger and hardware, an
air-charged airbag is rapidly inserted between the passenger and the hardware,
absorbing the dynamic energy of passenger
SRS001
with the air bag inherent permeability and the
exhaust throttling of deflating hole, retarding
the violent impact and isolating the passenger
from the interior hardware to protect
passenger .
3) Principle of safety belt

At first, retract instantly, at the first time of the accident occurrence, the
passenger will be “pressed” down on the seats by the impact acceleration, inclination
angle of car and acceleration of webbing straining;
Then appropriately relaxe, the safety belt properly loosened until the impact peak
elapsed, or passenger subject of the airbag protection.
Driver Side Airbag
1. Components
Driver side airbag is located on the steering wheel.
SRS001
2. Specification
■Airbag capacity: 50L
Note:
■The front face of pad shall face upwards, when old driver side airbag is
SRS-5
demounted or new airbag is mounted.

■It is not allowed to measure the electric resistance of airbag, which may
possibly give rise to accidental ignition of airbag.
■The driver side airbag shall be stored in a place with ambient temperature lower
than 80℃ and far away from electrical noise.
■During the welding operation, the negative (-) of battery should be turned off
and the connector of airbag disconnected.
■When discarding car or safety airbag, the special tool should be used to
detonate the airbag.
3. Removal
1) Disconnect the negative pole (-) of battery for more than 3 minutes.
Disconnect DAB
9H disassembly hole
3H disassembly hole
6H disassembly hole
2) Schematic diagram of disconnecting DAB(3 steps), disconnecting tool is a

straight screwdriver with length of 15cm.
Disconnect 3H hole
Rotate handwheel 90°anticlockwise, disconnect 3H hole's Groove with
screwdriver (for detailed structure showed in diagram)
Disconnect 6H hole
Rotate handwheel 90°anticlockwise, disconnect 6H hole's Groove with
screwdriver (for detailed structure showed in diagram)
Disconnect 9H hole
Put the driving wheel back to middle, rotate it 90°clockwise, disconnect 6H
hole's Groove with screwdriver(for detailed structure showed in diagram)
SRS-6
3) Disassemble the connector and take out the
safety airbag module. SRS003
4) Place the safety airbag module

SRS004
properly as required, shown as in figure.
4. Installation
Installation is in the opposite order of removal.
Front Passenger Side Airbag

1. Component schematic
SRS005
Front passenger side airbag is embedded
on the passenger side instrument panel.
Driver side instrument panel
Note:
■Please don't put or paste anything on the surface of airbag.
2. Specification
■Airbag capacity: 90L
SRS-7
Note:
■Please refer to the “Driver Side Airbag” for notices.
3. Removal:
1) Disconnect the negative pole(-) of SRS006
battery for more than 3 minutes.
2) Remove the glove box. SRS007
3) Remove the lamp of glove box.
4) Remove 2 screws fixing Passenger-sided safety airbag; disconnect wiring

connector, bring down passenger side airbag
SRS008
4. Installation
Safety belt
Note:
■Make sure Retractor won't be damaged when remove safety airbag.
SRS-8
■Replace the damaged buckle on fender apron

■Adjust hight
1. Safety belt in the front row
1) Removal
B pillar top hood panel
Front door panel
B pillar below hood panel
below door panel
Back door panel
①First, remove shield both in front door and back door

②Remove lower cover, twist off lower SRS009
Upper fixing bolt
fixing screw
Guide bracket screw
■Stipulated torque: 45N.m-55N.m

ALR
③ Remove lower trim pane on B pillar
lower fixing bolt
④ Remove uper trim panel on B pillar
⑤ Twist off upper fixing screw
■Stipulated torque: 45N.m-55N.m.
SRS010
⑥ Twist off screws, remove Retractor.
⑦ Twist off screw and bolt on guide bracket.
■Stipulated torque: 6N.m-8N.m
2) Installation.
SRS-9
2. Mortise lock of front safety belt

1) Removal
① Remove front seats (refer to seat)
② Bottom seat up, separate wiring plug (driver seat).
③ Twist off fixing screws, remove gasket and mortise lock of front safety belt.
The seat belt latch
nut gasket wiring
2) Installation
3. Safety belt in the rear row
1) Removal
① Remove rear seats (Refer to Rear seat)
② Remove the coat rack.
③ Twist off fixing screw, remove lower fixing screws on rear safety belt.
SRS-10
hallstand
Lower fixing bolt
④ Twist off assembling bolt, remove rear safety belt, can refer to front safety
belt.
SRS011
2) Installation
4. Mortise lock on rear safety belt SRS012
1) Removal
① Remove rear seats (refer to Rear seat)
② Twist off fixing screw, remove buckle on safety belt.
■stipulated torque: 45N.m-55N.m.
2) Installation
SRS-11
Safety belt pretensioner in the front row

1. Specification
■Ambient temperature of using gas Generator:-35℃～+105℃
Note:
■Aux. restraint system (e.g. “safety airbag” and “safety belt pretensioner”) and
the safety belt used together, helping mitigating impact and injury risk of driver and
the front-row passenger.
■To prevent and decrease the risk of being injured and death due to invalidation
of safety airbag system, all maintenance operations should be made in the service
center of JAC authorized shop.
■Improper maintenance, incl. incorrect removal and installation of safety belt
pretensioner will cause the mis-action of the system, and result in the accidental
personnel injury and death.
■Except the operations stated in the Manual, electrical test equipment is not
allowed to use to test any of the circuits of safety airbag system.
2. Removal and installation of the safety belt pretensioner in the front row
Please refer to the “Removal and Installation of Front-Row Safety Belt”.
Note:
■Prior to the removal or installation, be sure that the ignition switch is off and
the negative (-) of battery disconnected, then wait for more than 3 minutes.
■Do not use the electrical test equipment to test the pretensioner of safety belt
Safety airbag Timer-spring

SRS013
1. 1.Component schematic
SRS-12
2. Safety airbag Timer-spring

1) Removal
① Disconnect the negative pole (-) of SRS014
battery for more than 3 minutes.
② Remove the driver safety airbag

SRS015
module, take off Connector.
SRS016
③ Remove screws and take off steering

wheel.
Steering wheel
Note:
■The fixing nuts can be fully taken out until the steering wheel is loosened,
otherwise the steering wheel may cause personnel injury.
SRS-13
④ Disconnect the connector of horn.

SRS017
⑤ Poke the three bayonets embedded in combination switch of the clock spring
Note:
■Be sure 3 bayonets completely loose, and then take off timer-spring, which
needs to be careful because it is easily to get damaged.
SRS018
⑥ Take out the timer-spring of safety airbag.
SRS019
2) Installation
Note:
SRS-14
■ Take out the safety airbag timer-spring from the package and check if it is in
intact state and the dowel pin inserted on the part.
■Open the connector cover, and insert the wiring connector of safety airbag into
the connector hole, then close the cover.
■Prior to the installation of safety airbag timer-spring, be sure that the front
wheel is located in the center (orientation).
■Prior to the installation of safety airbag timer-spring, be sure that the
timer-spring is located in center (twist clockwise to the end, then turn back
anticlockwise, for 2.5 cycles)
Definition of connector of timer-spring
SRS-15
Safety airbag control module (SDM)

1. Specification and function of the safety airbag control module (SDM)
1) Induction of car collision.
2) Detonation of driver- and passenger-sided safety airbags.
3) Detonation of driver and passenger-sided pretensioning safety belts.
SRS-16
4) Monitoring safety airbag system.

5) Inform driver state of safety airbag system via the warning indicator: ready or
malfunction.
6) Run the diagnosis and maintenance through the serial diagnosis
communication port.
7) Record the impact related data and operating state of airbag system
components after collision.
8）Transmit impact signal to the ETACS module after collision and enable the
ETACS module to open the locked door to ease passenger to escape.
2. Safety airbag control module (SDM) pins
SDM Terminal Diagram
Description of SDM terminals
3. Circuit diagram of safety airbag
SRS-17
Safety airbag
安全气囊-1 L-1
FS21保险
A-7
046
Driver Safety airbag passenger Safety airbag

驾驶员气囊助手席气囊
M83
1 2
M82
149 诊断
Diagnostic
0.75R
M-1
4 3
0.5 OW
0.5 OB
0.5 OG
0.5 OL
0.5 OR
\
5 10 11 18 19 9
DAB+
DAB-
PAB-
PAB+
K_LINE
安全气囊模块
Safety airbag module
M84
6 46 7 17 16 13 14
0.35 O
0.5 OR
0.5 OW
0.5 O
0.5 0V
0.35 BR
0.75B
2 1 2 1
驾驶员侧
Driver safety belt 副驾驶员侧
passenger safety
安全带预紧
pretensioner belt安全带预紧
pretensioner
M89 M92
057 093 150
H-4 D-10 P-3
BCM_B21 ECU_72 安全气囊
Safety airbag
indicator
警示灯
M86 G_SRS
Fault diagnosis
1. Safety airbag system diagnosis
SRS-18
After the ignition switch is turned to the position “ON”, the safety airbag
indicator on the dashboard flashes for several seconds and goes out, it indicates the
safety airbag system operates in normal condition. Provided the ignition switch is
turned to the position “ON” and the safety airbag indicator doesn't flash or always
flashes, it means there is failure in the airbag system. To further confirm the failure
cause, special diagnostic scanner should be applied for diagnosis.
1) Fault code read by diagnostic scanner.
2) Maintenance implemented according to the prompt of fault code
3) Fault code elimination by diagnostic scanner.
Note:
■After the failure elimination, the diagnostic scanner has to be used to clean out
the fault code left in the system.
2. Table of Trouble Codes

Trouble code Trouble description
B1000 ECU internal fault
B1001 Configuration error
B0026 Too high resistance value of driver’s safety airbag
B0022 Too low resistance value of driver’s safety airbag
B0024 Line-to-ground short-circuit or line contact of driver’s
safety airbag
B0025 Power short-circuit of driver’s safety airbag
B0017 Too high resistance value of co-pilot’s safety airbag
B0016 Too low resistance value of co-pilot’s safety airbag
B0018 Line-to-ground short-circuit or line contact of co-pilot’s
safety airbag
B0019 Power short-circuit of co-pilot’s safety airbag
B0065 Too high resistance value of driver’s safety belt
pretensioner.
SRS-19
B0064 Too low resistance value of driver’s safety belt
pretensioner.
B0066 Line-to-ground short-circuit or line contact of driver’s
safety belt pretensioner.
B0067 Power short-circuit of driver’s safety belt pretensioner.
B0058 Too high resistance value of co-pilot’s safety belt
pretensioner.
B0057 Too low resistance value of co-pilot’s safety belt
pretensioner.
B0059 Line-to-ground short-circuit or line contact of co-pilot’s
safety belt pretensioner.
B0060 Power short-circuit of co-pilot’s safety belt pretensioner.
B1328 Power voltage too high.
B1327 Power voltage too low.
B0671 Line-to-ground short/open-circuit or line contact of system
fault.
B0673 Power short-circuit of system fault.
B0051 Front airbag detonated .
B0052 Max. operation limit reached by the safety airbag controller
and no further use allowed.
B0049 Output line to power short-circuit by impact.
B0048 Output line to ground short/open-circuit by impact.
B1000 ECU internal faults

steps Measures Yes No
Visually observe if the ground wiring
1 connection of safety airbag ECU power is To step 3 To step 2
normal.
2 To step 3
3 Replace the ECU of safety airbag.
SRS-20
B1001 Configuration error

B0026 Too high resistance value of driver’s safety airbag

Visually observe if the ECU of safety airbag is
1 in normal connection with the safety airbag To step 3 To step 2
wiring.
Whether the failure is eliminated after the To step 3
2
safety airbag harness replaced.
3
Timer-spring replaced.
4
driver’s safety airbag replaced.
B0022 Too low resistance value of driver’s safety airbag

wiring.
Whether the failure is eliminated after the
2 To step 3
3 To step 4
4
B0024 Ground short-circuit or line contact of driver’s safety airbag

wiring.
2 To step 3
3 To step 4
4 Whether the failure is eliminated after the To step 5
SRS-21

B0025 Power short-circuit of driver’s safety airbag

Steps Measures Yes No
wiring.
2 To step 3
3 To step 4
4
B0017 Too high resistance value of co-pilot’s safety airbag

1 in normal connection with the co-pilot’s safety To step 3 To step 2
airbag harness.
2 To step 3
3
co-pilot safety airbag replaced.
B0016 Too low resistance value of co-pilot’s safety airbag

1 in normal connection with the co-pilot’s safety To step 3 To step 2
airbag harness.
2 To step 3
3 To step 4
B0018 Ground short-circuit or line contact of co-pilot safety airbag
1 To step 3 To step 2
in normal connection with the co-pilot’s safety
SRS-22
airbag harness.
2
3
B0019 Power circuit of co-pilot safety airbag

Visually observe if the ECU of safety airbag is To step 3 To step 2
1 in normal connection with the co-pilot’s safety
airbag harness.
2
3
B0065 Too high resistance value of driver’s safety belt pretensioner
1 in normal connection with the pretensioner To step 3 To step 2
harness of driver’s safety belt.
2 To step 3
3
driver’s safety belt pretensioner replaced.
B0064 Too low resistance value of driver’s safety belt pretensioner

2
3
B0066 Ground short-circuit or line contact of driver’s safety belt pretensioner

SRS-23

2
3
B0067 Power short-circuit of driver’s safety belt pretensioner

2 To step 3
3
B0058 Too high resistance value of co-pilot’s safety belt pretensioner

harness of co-pilot’s safety belt.
2
3
co-pilot’s safety belt pretensioner replaced.
B0057 Too low resistance value of co-pilot’s safety belt pretensioner

2
3
SRS-24
B0059 Ground short-circuit or line contact of co-pilot’s safety belt pretensioner

2
3
B0060 Power short-circuit of co-pilot’s safety belt pretensioner

2
3
B1328 Too high power voltage

Check if the battery is in normal voltage
1 Ignition switch ON :12.56V To step 3 To step 2
Engine run:14V
2
battery replaced.
Visually observe if the power harness of To step 5 To step 4
3
safety airbag ECU is in normal condition.
4
B1327 Too low power voltage

SRS-25
Check if the battery is in normal voltage

1 Ignition switch ON :12.56V To step 3 To step 2
Engine run:14V
2
battery replaced.
3
4
B0673 Power short-circuit of system failure lamp

Check if the connection line of the terminal 1
1 of safety airbag ECU is conductive with the To step 3 To step 2
failure lamp of airbag on instrument.
2 To step 3
connection line replaced.
Check if the power and contact line of safety To step 5 To step 4
3
airbag is normal.
4
fault harness replaced.
B0051 Front airbag already detonated

1 Verify if the front airbag has been detonated To step 2 To step 3
2 To step 3
front safety airbag replaced.
3 front airbag and connection harness of safety To step 4
airbag replaced.
B0052 safety airbag controller reaching Max. operation limit and no further use
allowed
SRS-26
B0049 impact output line short-circuit to power

Check if the connection line between the
connector terminal 5 of safety airbag ECU
and the terminal 21 of ETACS plug M37 is in
normal condition
Replace the ECU of safety airbag and ETACS
2 To step 3
connection harness
3
4
B0048 Ground short/open-circuit of impact output line

Check if the connection line between the
connector terminal 5 of safety airbag ECU
and the terminal 21 of ETACS plug M37 is in
normal condition
Replace the ECU of safety airbag and ETACS
2 To step 3
connection harness
Visually observe if the power harness of
4
Other than the operations stated in the Manual, it is not allowed to use electric
equipment for testing any of the SRS system circuits. The SRS line harnesses may be
identified through Yellow and/or Orange harnesses or harness connectors. Do not try
to repair, connect or modify the SRS harnesses. If harness is damage, it should be
replaced by new one. The grounding place should be kept clean. The diagnosis
performance may read out SRS self-diagnostic result through the X431 diagnosis
scanner. The diagnosis mode may help the service technician position and check the
fault parts and components.
SRS-27
Safety airbag System Servicing

1. Precautions to be taken after the collision occurrence
Note:
■After occurrence of any impacts, the safety belt assemblies of all seats incl. the
retractors and other metal parts and components should be checked.
■We suggest replacing all safety belt assemblies used during the collision,
otherwise they may cause serious personal injury in the accident. In case of the frontal
impact detonating the airbag, even if the safety belt has not been used, the safety belt
pretensioner should be replaced.
In following cases, please replace the safety belt assembly (incl. fixing bolts):
■The safety belt is in use upon the occurrence of impact (except the impact is
very soft and the safety belt, retractor and clip ring show no damage and in normal
performance)
■The safety belt has been fully damaged in the accident (i.e. safety belt damaged,
retractor distorted or slide slots).
■The fixing point of safety belt has been fully damaged in the accident. Check
the fixed area of safety belt for damage or deformation before installing new safety
belt assembly. If necessary, service.
■Deformation or wear of fixing bolts.
2. In case of accidents, where the middle and side impact occurred during the
low-speed collision, rollover and rear-end collision etc., and the airbag not detonated,
the following items should be checked:
■Check the SDM housing and installation bracket for any dents, cracks or deformation.
■ Check the connectors for any damage and the terminals for any deformation.
Check if the installation bolts and earth line are intact.
3. Maintenance and check of safety airbag system
1) Safety airbag module
① Check the liner cowl for any dents, cracks or deformation.
② Check if the connector is damaged, the terminals deformed and wires
clipped.
SRS-28
③ Check the gas generator housing of safety airbag for any dents, cracks or
deformation.
④ Install the safety airbag components on the steering wheel and check the
match-up or alignment with the steering wheel.
2) Timer-spring
① Check the connectors of timer-spring and sheath for any damage and the
terminals for any deformation.
②Visually check the housing for any damages.
3) Steering wheel and steering column
① Check the electric wiring (fit inside the steering wheel) and the connectors
for any damage and the terminals for any deformation.
② Install the safety airbag components on the steering wheel and check the
match-up or alignment with the steering wheel.
③ Check the steering wheel for any noise, the steering for flexible control and
excessive clearance.
Note:
■Align first the timer-spring on bottom of the steering wheel, then install the
steering wheel on the column.
■Method of timer-spring alignment:
Turn the timer-spring to the end clockwise, then return it more than 2.5 cycles to
make the arrow on the timer-spring in alignment.
4）Other parts and components
■ Check the wiring for any jamming, the connectors for any damage and poor
connection and the terminals for any deformation.
■All safety airbag components after detection of faults have to be replaced
instead of use after reparation.
■If the parts and components of safety airbag system are required to be removed
or replaced due to maintenance and troubleshooting etc. the operation sequences
should be followed respectively.
5) Warning/Notice labels
SRS-29
There are many SRS Warning/Notice labels on the car, which are attached on:
■Steering wheel framework
■Driver-sided safety airbag components
■Timer-spring
■Passenger-sided safety airbag components
■Safety airbag control module (SDM)
■Sun visor above the front windshield
■The instructions on the labels should be followed when servicing SRS. If
contaminated or damaged, they should be replaced.
6) Safety airbag control module (SDM)
Note:
■After the occurrence of SDM faults, the replacement has to be made instead of
reparation.
Disposal method of abandoned safety airbag system component

Prior to discarding the safety airbag or the car fitted with the safety airbag, the
following process measures should be taken for detonation.
1.
1) If the car is going to be discarded, the safety airbag needs to detonate inside
the car. If the car continues to be used and only the safety airbag module discarded,
the detonation of safety airbag should be made outside the car.
2) Because of great amount of smoke produced from the safety airbag explosion,
cares should be taken to prevent from breathing it in, for it is irritating and possibly
choking to your throat. The residence area should be kept off as much as possible.
3) As the explosion noise of safety airbag is extremely loud, thus the residence
areas should be kept off far away as much as possible. In case of human approaching,
the warning of imminent noise should be given.
4) Only one airbag module can be trigged per time.
5) When the airbag module and the safety belt pretensioner are ready for
detonation, personnel should stay at least 10m away from the component to be
SRS-30
detonated.
6) After the explosion, the airbag module should be set aside at least more than
30 minutes due to the high temperature.
7) The personnel assigned to perform this task or the field staff should be
protected with the suitable ear protective equipment.
2. Disposal method of detonation inside the car (when discarded)
1) Remove the car to an isolated site.
2) Disconnect both positive (+)/negative (-) cables from the battery terminals,
then remove the battery from the car.
Note:
■After the negative (-) detached from the battery, you should wait at least for 3 minutes,
then continues the next procedure.
3) Detonation of safety airbag module (driver-sided):

① Remove the lower cowl of steering column.
② Disconnect the connection between the connector of safety airbag
timer-spring and that of safety airbag harness.
Note:
■After the connector of safety airbag timer-spring disconnected from the body
harness of safety airbag, the positive (+) of timer-spring connector will be
automatically short-circuited, to prevent the safety airbag from unexpected detonation
due to the electrostatic.
4) Connect two wires in length of more than 10meters to two leads of safety
airbag adapter wiring and wrap up the joint with the insulation tape. The other ends of
those two wires should link to each other (short-circuit) to prevent the safety airbag
from unexpected explosion.
5) Connect the pin access plug of safety airbag with the safety airbag adaptor
wiring and extend the detonating cord to the outside.
6) In order to minimize the detonation noise, all doors and windows of car should
be closed and the car should be protected with cover.
Note:
SRS-31
■If the window glass has any damage trace, they may be broken down during the
detonation. Thus ensure that the car is protected with cover.
7) At a site as far as possible away from the car, detach two wires each from
other, and connect them respectively with two terminals of battery (this battery has
been already removed from the car) so as to detonate the safety airbag.
Note:
■Prior to the detonation of safety airbag with above method, you should check
and be sure no persons in or nearby the car.
■Please wear the safety goggles.
■The gas charger is still hot after detonation, thus you should wait for at least 30
minutes until it cools down and move it. Though the gas released from the detonated
safety airbag is non-toxic, it is irrespirable. For the moving rules of the detonated
safety airbag, please refer to the Discard Method of Safety Airbag already Detonated.
■If the safety airbag component cannot be detonated by the above-stated method,
do not approach them. Please get into contact with the local dealer.
8) After detonation or operation, please discard the safety airbag component
according to the Discard Method of Safety Airbag Already Detonated.
3. Disposal method of detonation outside the car
1) This should be performed on a free plane terrain at distance of more than 10m
away from the obstacles and other persons.
2) Even if in breeze weather, the safety airbag module should be detonated at
the downwind of the battery.
① Disconnect both positive (+)/negative (-) cables from battery terminals, then
remove the battery from the car.
Note:
■After the battery cables detached, you should wait for at least 3 minutes before
the next procedure.
② Remove safety airbag module from the car
Note:
SRS-32
■ Place the safety airbag component on a flat ground and keep the liner upward.
Do not place any objects on its top.
3) When detonating the driver-sided safety airbag module:
Connect two wires in length of more than 10m to two leads of safety airbag
adaptor wiring and wrap the joint up with insulation tapes. The other ends of those
two wires should link to each other (short-circuit) to prevent the safety airbag from
unexpected explosion.
4) Set up the safety airbag module as follows:
① Hold the safety airbag adaptor connected to the above wires, pass it through
underneath of prepared used tire assembly, and further connect to the safety airbag
module.
② Pass the thick wire through the mount hole of safety airbag component, then
fix the safety airbag component on the used tire of wheel, keeping the liner on the
airbag component upward.
Note:
■ Save space for the adaptor wiring below the wheel. If such space not is
available, the reaction force from the safety airbag detonation may damage the wiring
of adaptor
③ Stack three used tires without rims on the top fixing the tire of safety airbag
component.
④ At the site as far as possible away from the safety airbag module and
screened places, disconnect two connected wires from each other and connect them
respectively to two terminals of battery (the battery already removed from the car)so
as to detonate the safety airbag.
Note:
■Prior to detonation, carefully check and be sure that nobody nearby.
■As the detonated gas generator is very hot, you should wait for at least 30
minutes and move it until it cools down. Though the gas released from the detonated
safety airbag is non-toxic, it is irrespirable. For the moving rules of the detonated
safety airbag, please refer to the Discard Method of Safety Airbag already Detonated.
SRS-33
■If the safety airbag component cannot be detonated by the above-stated method,
do not approach them.
■After detonation or operation, please discard the safety airbag component
according to the Discard Method of Safety Airbag Already Detonated.
4. Disposal method of the safety airbag already detonated
Discard the detonated safety airbag in accordance with the enforced local laws
and (or) regulations as other parts and components. In case of discard, special cares
should be taken for the following points:
1) As the detonated gas generator is very hot, you should wait for at least 30
minutes and move it until it cools down.
2) Do not spray water or oil on the safety airbag detonated.
3) Possible substances irritating to the eyes and skin may be attached on the
detonated safety airbag components, thus, wear the gloves and goggles while handling
the detonated safety airbag components.
Note:
■ If substances still entered into eyes or attached on skin after following those
precautions, you should rinse those parts by great amount of clean water. If the skin
becomes inflamed, handle it by medical treatment immediately.
4) Tightly seal up the vigorous PVS bag containing the discarded safety airbag
component.
5) Wash your hands after completion of this work.
5. Removal of safety airbag control module.
1) Turn off the ignition switch, disconnect the negative (-) of battery and wait for
at least more than 3 minutes until the energy storage capacitor of inbuilt SDM
Complete the discharge.
2) Remove auxiliary dashboard (see Removal and Installation of Auxiliary
Dashboard) SRS020
of Auxiliary Dashboard)
3) Remove 2 screws fixing SDM
Loosen and pull out wiring connector of SDM
SRS-34
Take out SDM.
Note:
■ Do not let the SDM drop or bump.
SRS021
6.Install as the opposite order of

removal of safety airbag control module
(SDM)
Note:
■When installing, pay attention to the
SDM direction, and align the arrow on SDM to the same direction of car driving.
SRS-35
J4 Service Manual Air Conditioning System
AC Air Conditioning System

Precautions:
It is required to observe the following notices when air conditioning system is
inspected and maintained, or otherwise it may cause vehicle damage and personal
injury.
■ It is required to use gloves and goggles so as to avoid chilblain, blindness, and other
effects on skin during skin contact, as the freezing point of refrigerant is low but the volatility is
strong.
■ It is required to flush the contact place immediately with clear water, and
required to go to ophthalmology and dermatology for diagnosis and treatment, in case
when refrigerant splashes into the eye or gets in touch with the skin. It is not allowed
to rub the eye with hand or handkerchief.
■ The site must be ventilated, during refrigerant related operations. Discharge of
refrigerant in large quantities at enclosed site may lead to oxygen deficiency.
■ Refrigerant Discharge Allowance: 1000ppm (4184mg/m2)
It may give rise to anomaly or susceptibility of heart and cardiovascular system,
as well as immune system, and anomaly of respiratory system or skin diseases, if the
quantity of discharge is excessive.
■ It is not allowed for moisture, dust, and other extraneous substances to be
present in the surrounding environment, during refrigerant related operations, and
these extraneous substances may be harmful to the air conditioning system when they
flow inside.
■ Gas leak detector shall be prepared when operations related to refrigerant are
conducted. R-134a refrigerant may generate harmful gas when it gets into contact
with high-temperature objects, and therefore attention shall be paid to leak prevention.
■ R-134a refrigerant must be used for the air conditioning system of this vehicle
type. It may cause adverse impact on the system parts if other refrigerants are used.
■ R-134a refrigerant and R-12 refrigerant are incompatible, and so blending is
not allowed even in a very little quantity.
AC-1
■ It is not allowed for pyrophorus or ignitable materials to be present around the

vehicle, during operations related to refrigerant, and special attention shall be paid, as
explosion may be aroused in the case when refrigerant tank is exposed into heat
source.
■ R134a container is in the high-pressure state, and it is absolutely not allowed to
be placed under high-temperature environment. Moreover it is required to check
whether or not the temperature of storage environment is below 52℃.
■ Dust covers are generally used for air conditioning parts in order to prevent the
inflow of sewage, dust, and water content. Dust covers shall be removed before
operation and sealed after operation.
■ The refrigeration oil synthetic oil (PAG) applicable to R-134a is easier to
absorb moisture than R-12, and the absorptivity is higher by 10 times than the
refrigeration oil of mineral oil. It will affect the compressor, the lubricating function,
and the durability when moisture is excessive.
■ Humidity produces extremely bad impact on air conditioning system, and
therefore it is advisable to avoid operation on rainy days.
Refrigeration oil must be coated on “O”-ring, when air conditioning system is
re-assembled after removal, and especially, the bolt connected parts shall be manual
installed before they are installed by two wrenches. AC001 Bolt locating pin
■ When flange connecting parts are assembled,

the nuts and bolts shall be connected at the same time Positive connecting part Negative connecting part
Nut
while the pipeline is gently pushed
■ When the air-conditioner is installed, applying
push
torque above the standard to assemble or clamping “O”-ring with excessive force
will lead to the leak of refrigerant, and therefore
operations should be in accordance with the provisions.
■ It is not allowed for hose to be twisted.
■ It is absolutely not allowed to separate the air conditioning system before
refrigerant is fully recovered. Refrigerant and refrigeration oil will discharge under
the impact of system pressure, which will pollute the surrounding environment, if the
AC-2
system is separated before recovery.

■ Refrigeration oil (Model: PAG) must be added when refrigerant is refilled,
during replacement of air conditioning parts.
Table for Filling Capacity of Refrigeration Oil
Replacement of
refrigerant pipe 10 cc 30 cc
Evaporator
Replacement of
30 cc Replacement of Pipeline 30 cc
Condenser
Replacement of Drying
30 cc - -
Bottle
When replacing the compressor, the required amount 120ML shall reduce the amount
of discharged refrigeration oil from the old compressor, and the result is the amount of
refrigeration oil needed to be discharged from the new compressor.
Specified amount - the amount of refrigeration oil discharged from the old compressor
= the amount of refrigeration oil discharged from the new compressor.
Note: Even if there is no discharged oil from the removed compressor, it is not
allowed to discharge the oil from the new compressor more than 50ML.
Service tools:
Common and special tools necessary for the maintenance
Table of Special Tools for Inspection and Maintenance of Air Conditioning System
Name of
Name of Tool Picture of Tool Picture of Tool
Tool
High-Streng
Digital th Lamp of
Multimeter Invisible
Light
AC-3
R-134A
Manifold
Ripping Pincers
Measuring
Apparatus
Halogen Tracing
Leakage Color
Detector Injector
R134A Tracing Microtherm

Paint ometer
Shaft Seal
Positive Flow
Protection
Control Valve
Device
Pressure
50lb Refillable
Test
Recovery Tank
Adapter
Name of Name of
Picture of Tool Picture of Tool
Tool Tool
Air
Conditioni
“O”-Ring
ng System
Detaching
Lip Seal
Tool
Detaching
Tool
AC-4
Valve
Core
“O”-Ring
Removal
Installation
and
Tool
Installation
Tool
Spring Spring
Caliper Caliper
refrigerant
Recovery/
passive
Regenerati
Test
on, and
Light
Refilling
System
AC-5
Inspection of Air Conditioning System and Filling of Refrigerant

1. Installation of refrigerant filling instrument AC002
low
high
1) Close the manual valves on both ends of low
refrigerant filling instrument.

off
2) Install the filling pipe of refrigerant filling on
instrument in the connecting place. Connect the LP

pipe at LP pipe nozzle and the HP pipe at HP pipe
nozzle, and then tighten the nuts with hand.
2. Operation of Refrigerant Discharge
1) Connect the refrigerant filling instrument to the system.
2) Put the cleanly cleaning cloth in the open place of central hose.
3) Gradually open the HP manual valve and discharge the refrigerant.
Caution:
The compressor refrigeration oil will discharge from the system, if the exhaust
velocity is too fast.
4) Check whether or not the trace of refrigeration oil is present on the cleaning
cloth, and slightly close the manual valve when trace is present.
5) Slowly open the LP manual valve, after the measuring scale of filling instrument is
dropped to 3.5kg/cm2.
6) It is required to slowly open the HP and LP manual valves, in order to reduce

system pressure, until the measuring scale displays 0 kg/ cm2.
3. Evacuation Operation of Refrigeration System
Caution:
■ The system must be evacuated after refrigerant discharge. It is to remove the
air and moisture through this operation, for 15 minutes after respective parts have
been assembled.
1) Confirm whether or not engine is under “Close” status.
2) Connect the filling instrument to the joint place of compressor, and close the
two ends.
3) Confirm whether or not refrigerant is discharge from the system.
AC-6
4) Connect the central pipeline to the air suction place of vacuum pump.
5) Open the HP and LP valves of filling instrument after vacuum pump is
operated.
6) The measuring scale of LP detector is larger than 0.96kg/ cm2 vacuum after
10 minutes, otherwise air leak exists with the system, repair as follows.
Make use of the filling system for the refrigerant container.
Inspect the leak place with leak detector, and repair it if any.
Discharge the refrigerant and evacuate the system.
Continue evacuation, if no leak evidence is found.
low high
7) Re-operate vacuum pump. AC003
8）The measuring scales of filling
instrument on both ends shall maintain
air close close
0.96kg/cm2 vacuum
8) Continue evacuation until measuring Vacuum pump
scale displays 0.96kg/cm2.
Stop evacuation after 15 minutes of evacuation and close the pressure valve of
filling instrument, then disconnect pipes from the pump. This allows refrigerant to be
filled.
4. Use of Refrigerant Control Valve
Fully turn the Handle in counterclockwise
AC004
direction, before valve and refrigerant
container are connected.
2) Place the disc to the top position in
counterclockwise direction.
3) Turn the disc with hand in clockwise
direction, after central pipeline is connected to
valve device.
4) Turn the handle in clockwise direction and drill in the upper part of the seal.
5) Loosen the nut of connecting pipeline for connecting joint of filling
AC-7
instrument.
6) Tighten the nut after exhaust for several seconds.
5. Filling of Refrigerant (in Gaseous
AC005
State) low
on off
Refrigerant
Caution:
■ It is to fill the gas refrigerant to the system through LP end device, and the
refrigerant in gaseous state will flow into the system, when the refrigerant
container is placed in a straight way.
1) Install the refrigerant container to the regulating valve.
2) Open the LP valve, and adjust the valve for the LP measuring scale to be
controlled below 4.2kg/cm2.
3) Start the engine and turn on the air conditioning system.
Caution:
■ Place the container in a straight way, in order to prevent the liquid refrigerant
from being filled into compressor through air suction port.
4) Close the LP valve after specified quantity is filled.
■ Specified Refrigerant Filling Capacity:480±20g
5) The container may be put into a water
AC006
tank of about 40℃, if refrigerant filling speed
is too slow.
Immerging in water, and heat the
Refrigerant water to approximate 40℃
Caution:
AC-8
■ It is not allowed to heat water up to higher than 52℃, under whatever

circumstances.
■ It is not allowed for high-temperature light to get in touch with the container.
6. Filling of Refrigerant (in Liquid State)
AC007
Refrigerant
Caution:
■ This operation is to be used for filling through HP end. Upend the refrigerant
container, and the refrigerant will then be able to enter into the system.
1) Close the two ends of HP and LP valves completely, after system is
evacuated.
2) Install the regulating valve for refrigerant container.
3) Fully open the HP valve and then upend the container.
4) Excessive system filling will increase discharge pressure,
and therefore, it is required to fill refrigerant and close the HP valve with correct
capacity at the same time while the weight of refrigerant is measured.
■ Specified Refrigerant Filling Capacity:480±20g
5) Close the valve of filling instrument after specified refrigerant is filled.
6) Check whether or not air leak exists by leak detector.
Caution:
■ Don’t start the engine when HP end is used for filling.
■ It is not allowed to open the LP valve when liquid refrigerant is used for
filling.
■ Performance test must be made before separation of filling detector.
System Control
1. System Overview
AC-9
Electric controlled air conditioning system is applied to this vehicle type.

Supercooling type is used for air conditioning condenser, and therefore the refrigeration
performance is enhanced. In order to contribute to defrosting performance, automatic
switch to external circulation mode is selected during the mixed and defrosting pattern.
Control of condenser fan is divided into low and high two phases according to vehicle
speed, temperature of cooling water, and difference in pressures of air conditioning
refrigerant. Increase in air delivery and air mixing capacity of blower may improve the
refrigerating and heating performances.
Drawing for Control Panel of Electric Air Conditioning System
2. Schematic Drawing for Refrigeration

low-temperature and
High low-pressure liquid
AC-10
High low-temperature and

low-pressure gas
Condenser
Installed in the front of Evaporator
vehicle, it is supposed to During the process of vaporific refrigerant
convert refrigerant of gas changing into gas, heat will be absorbed from the
state into liquid refrigerant air passing through the evaporator by making use
of high temperature and of blower.
high pressure. (the drop of surrounding temperature)
Blower
Send the air into the evaporator and
Drying Bottle Compressor send the cooled air into the vehicle.
Absorb the moisture in Driven by the engine pulley, it
refrigerant, and store can convert the
refrigerant. low-temperature low-pressure
Expansion Valve
gas refrigerant into high
It allows refrigerant to expand rapidly
pressure and temperature gas
and convert it into low-temperature
and send to compressor,
low-pressure liquid.
controlled by the clutch.
AC-11
3. Schematic Drawing of Components
1 2 3 4
11
6 5
10 9 8
Schematic Drawing for Components of Air Conditioning System

1- lower air passage II 2 - Air conditioner assembly 3 - Warm Air water pipe assembly 4 -
condenser and guide plate assembly
5 - exhaust pipe assembly 6-pipeline and expansion valve bracket 7-Compressor bracket
8-Compressor Assembly
9-lower air passage I 10-lower air passage III 11 - AC controller assembly
4. Control Form of Air Conditioning Control Panel and Description about

Functions
Fully electric control method is applied to air conditioning control, and the rear
defrosting/reversing/rearview mirror heating switch is integrated on the panel, while
servo motor control is applied to the internal and external air circulation patterns as
well as air blowing pattern. Backlight/LED is used for panel illumination, and the key
symbols are spray painted and radium carved. The functions of keys and knobs on air
conditioning panel are indicated as in the following figure.
AC-12
Connector type of air blow

Connector type
controller
Schematic Drawing for Air Conditioning Control Panel

1 - internal and external air circulation patterns switch 2 - air-conditioning Mode Knob 3 - A/C
air conditioning switch
4 - air blower knob 5 - Temperature Control knob 6 - Rear defrosting heating switch
Schematic Drawing of Control Circuit and Description about Connecting Pins
Diagram of Control Module Terminals
I/NO USE Connector type NO . Remark
1
2 AC output signal
3 Evaporation sensor (5V)
4 Blower switch on signal
Temperature motor positive
5 pole
Motor temperature feedback
6 voltage
Temperature motor negative
7 pole
Rear defrosting open/close
A/C control KET 050 23M
A 8 signal
panel MG 642,179
Rear defrosting switch
9 indicator
10
11
12 Backlight negative pole
13 Backlight positive pole
New Air Blow Motor negative
14 pole
New Air Blow Motor positive
15 pole
16 Sensor bottom wire
AC-13
Mode Motor Reference

17 Voltage (5V)
18 Mode Motor feedback voltage
19 Mode motor negative pole
20 Mode motor positive pole
21 ground wire
22 Battery positive pole
23 Ignition switch
1 Medium and high speed
2 Public end
Airflow
KET 250 6MKET 3 Ground
B switch
250 6M 4 High Speed
plug-in
5 Medium and low speed
6 Low speed
Schematic Diagram of Control Circuit
Blower motor
Speed regulation
resistance
Mode motor
Three-way-
pressure
switch Temperature
motor
Circulation air door

motor
Evaporation sensor
Rear defrosting switch
AC-14
Functions, Positions, and Inspection of System Components

1. Air conditioner assembly
Air conditioner assembly consists of the blower, expansion valve and evaporator,
heater, and housing, and so forth. The air from the outside sucked by blower, passes
through evaporator, heater, etc, entering the vehicle, in order to achieve
air-conditioning normal performance.
1 2 3 4
21 5
7
20
8
19
9
10
18
11
17 16 15 14 13 12
Explosive view air conditioner
1- defrosting outlet sponge 2 - heater water inlet/oulet hose bracket 3-air-cycle inlet left housing
4-air-cycle inlet sponge 5-air-cycle inlet right-shell 6 - circulation air door 7 - Filter Element 8
AC-15
-circulation air door motor 9 - blower upper housing 10 - Blower Assembly 11 - speed resistor 12
- blower lower housing
13 - weep pipe 14-lower air passage throttle 15 - evaporator core 16 - Temperature throttle 17 -
heater core 18 - Temperature throttle motor 19 - distribution box 20 - Mode Motor 21 - mode
damper
2. Blower
The blower comprises motor and fan, and the air door motor at air suction port is
used to transit internal/external air mode, and to suck in the internal air or the external
air.
The function of air door motor at air suction port is achieved through the button
for internal/external air of controller. The air enters through the two side intakes,
when it is in the internal circulation mode, and the air enters through the filter on the
front-end shield of vehicle while it is in the external circulation mode. The blower is
used to suck in the air at this point, and for heat exchange through evaporator, for the
refrigerated air to enter into the vehicle.
3. Speed Regulation Resistor
1) Function
To randomly regulate the blower motor speed according to the change in output
current
2) Installation Position
The installation position of speed regulation resistor is indicated as in the figure
AC008
AC008
AC009
3) Appearance
The appearance of the speed regulation
resistor is indicated as in the figure AC009
AC-16
4. Internal/External Circulation Air Door Motor

1) Function
To be installed on blower assembly, and controlled by the internal/external
circulation selection button on automatic air conditioner, to actuate the
internal/external circulation air door, and to achieve the transition of air inlet mode.
The installation position is indicated as in the figure AC010.
AC010
5. Blower Motor
1) Function
Rotate the fan to form the air delivery required by air conditioning system by
making use of the vehicle power supply.
2) Drawing of Component
3) Test Method:
Add random voltage to “+” terminal, and inspect it after “-” terminal is earthed.
It is namely normal when the rotating speed of blower is faster if higher voltage is
applied.
6. Evaporator Temperature Sensor
1) Function
AC-17
AC011
Sense the temperature of evaporator core and transmit it to FATC to prevent

freezing of evaporator
It is assembled inside the evaporator core as im the figure. The sensor is
internally provided with thermosensitive resistor for negative temperature coefficient,
and therefore the resistance increases when temperature drops, while the resistance
drops when temperature rises.
3) Table of Parameters (Temperature – Resistance – Output Voltage)
The compressor will disconnect when the temperature stays at 0 degrees C (6.9
K Ω) compressor, and will actuate when the temperature reaches 3.5 °C (5.9 K Ω).
Table of Parameters for Evaporator Temperature Sensor AC012.
AC012
AC-18
7. Evaporator & Heater

AC013
The air delivered by blower will firstly be
cooled down through evaporator.
According to the different open & close degree of
temperature control air door, part of the air through
the evaporator will be sent to heater core, and the
rest air will be sent to the upper housing. In order to
control indoor temperature and air mixing, the rear part of heater housing is the place
for the mixture of the air through the heater core and the air into the upper housing.
Thus mixed air through the effect of mode air door motor is sent to the required air
outlet, to achieve the performance of indoor temperature adjustment amd
defrosting/demisting. Namely the heater assembly adjusts air mixing, temperature
control, and air outlet direction.
8. Mode Air Door Motor

1) Function
To be assembled in the left part of heater shell, controlled by the signal of mode
switch for air conditioning panel (FATC), to start the position of air door with
small-sized motor in regulation mode inside the air door motor - The changing
differences in voltage when motor is started are reflected to FATC, and FATC judges
the feedback signal. When air door reaches required position, the work of motor will
stop.
AC014
3）Schematic Diagram of Control Circuit

AC-19
Diagram for Circuit of Mode Air Door Motor
9. Temperature Control Air Door Motor

1) Function
To be installed on the right side of heater shell, controlled by the operating signal
of temperature control knob on AC controller, to start the small-sized motor to
regulate the position of temperature control air door - The changing differences in
motor voltage when motor is started are reflected to AC Controller, which will judge
the reflected signal. When air door reaches required position, the work of motor will
stop.
2) Installation Position AC015
Schematic Diagram of Control Circuit
AC-20
Feedback voltage
Diagram for Circuit of Temperature Control Air Door Motor
10. Condenser and Drying Bottle

1) Function
The HTHP gas refrigerant from compressor cools down at normal temperature.
Cooling of condenser depends on the forced air delivery of running air and fan. The
condenser for this vehicle type is in the parallel flow type, combined together with
drying bottle. The refrigerating performance is enhanced, the quantity of refrigerant
required by the system is reduced, through cooling, and the number of parts is reduced
through combination with drying bottle. It used to replace drying bottle in the past,
when contamination arises with system, but it is only required to replace the drying
agent after the cover of drying bottle in the lower-end part is detached for this vehicle
type.
2) Installation Position AC016
11. Engine Cooling System

1） Concept of Cooling Fan Control
The engine cooling unit (ECU) controls the rotating speed of cooling fan by two
phases (High/Low) after the input vehicle speed, air conditioner load, and temperature
AC-21
value of cooling water are compared.

When vehicle speed sensor and cooling water temperature sensor are confronted
with failure, it drives the cooling fan, and as high-speed operation at the same time.
2) Cooling Fan picture
Cooling fan is integrated into the front-end module, and it switches high/low
speed operation by acquiring cooling water temperature, speed, and related
information.
The power of cooing fan at high speed is 180 to 220 W, and at low speeds is 120 to
150 W.
3） Cooling Fan Control circuit
POWER
LOW SPEED
POWER
Cooling Fan Control circuit
AC-22
Cooling Fan Pin Definition

NO. PART NO. PART NAME CONNECTOR TYPE
WIRING HARNESS END PART END
1 1308113U8510 FAN JACKET: FCI 60402501 JACKET: FCI 60500901
ASSEMBLY INSERTING SLICE: FCI 60040441 INSERTING SLICE: LEAR
26691.330.710
SEALING PLUG: LEAR
16697.627.626
2 FAN JACKET: DJ70328-6.3-21 JACKET: DJ70328-6.3-11
ASSEMBLY INSERTING SLICE: DJ6218-E6.3B INSERTING SLICE:
SEALING PLUG: DJ6116 6.3B
SEALING PLUG: DJ9011
THE SHAPE OF THE CONNECTOR DEFINITION OF THE CONNECTOR (PART END)
1 HIGH SPEED POSITIVE
GEAR
2 LOW SPEED POSITIVE
GEAR
3 NEGATIVE NEGATIVE
12. Three-Way Pressure Switch
AC-23
1) Function
Medium-pressure switch is added in the past air conditioning two-way pressures
for the three-way pressure switch, and the medium-pressure switch is started and
sends signal to the engine control unit, when system pressure rises. At this point the
water tank fan and the condenser fan are under the high-speed status, thereby to
prevent the performance drop arising when pressure rises, and to be able to protect the
air conditioning system when pressure (HP/LP) is under anomalous condition.
The installation position is indicated as in the figure.
AC017
3） Circuit Diagram
Diagram for Circuits of Three-Phase Pressure Switch
4） Specifications and Parameters

Table of Specifications and Parameters for Three-Phase Pressure Switch
HFC - 134 a
High-pressure OFF 3.14 Mpa
medium-pressure ON 1.77 Mpa
Low-pressure OFF 0.196 Mpa
AC018
System Removal and Installation
1. Removal and installation of air
conditioner assembly
1) Removal
AC-24
① Recover the refrigerant in the system with special refrigerant recovery

equipment.
② Disconnect the batter negative connection.
③ Open the engine compartment, and disconnect the warm air water pipe joint.
④ Remove the fastening bolts for expansion valve.
⑤ Remove the instrument panel assembly.
⑥ Loosen the bolts for bracket of instrument panel, and carry off the bracket of
instrument panel.
⑦ Remove the fastening bolts and nuts for the air conditioner assembly.
⑧ Disconnect the circuit plug-in connector, and take out the air conditioner
assembly.
2) Installation.
Assembly is the reversed order of removal.
2. Removal and installation of Temperature Control Motor

1) Removal AC019
① Disconnect the battery negative connection.

② Remove the instrument panel.
③ Disconnect the plug-in connector, and remove
the fastening screws for temperature control motor.
④ Take off the temperature control motor.
2) Installation. AC020
3. Removal and installation of mode damper motor

1）Removal:
③ Disconnect the plug-in connector, and remove the fastening screws for mode
damper motor.
AC-25
④ Take out the mode damper motor.

AC021
2) Installation.
4. Removal and installation of internal/external
circulation air door motor.
1) Removal
③ Disconnect the plug-in connector, and remove the fastening screws for
internal/external circulation air door motor.
④ Take out the internal/external air door motor.
2) Installation.
AC022
5. Removal and installation of Heater

1) Removal
① Remove air conditioner assembly
② Remove the fastening bolts for heater.
③ Take off the stationary baffle, and pull out the heater outwards.
2) Installation
Assembly is the reversed order of AC023
removal.
6. Removal and installation of

Evaporator
1) Removal
① Remove air conditioner assembly
② Remove the screw and buckle in AC024
the middle of the distribution box assembly

(Not all included in the picture).
AC-26
③ Remove the fastening screws around the evaporator.

④ Pull apart the evaporator and the heater assembly from the middle, and take
out the evaporator.
2) Installation
7. Removal and installation of Air

AC025
Conditioning Panel
1) Removal
① Unclench the edge frame of air
conditioning panel by slotted screwdriver.
② Pull out the controller (all the buckles
in connection).
③ Pull out the air conditioning control panel outwards and disconnect the two
plug-in connectors behind.
2) Installation.
Assembly is in the reversed order of removal.
8. Removal and installation of Condenser
1) Removal
① Recover the refrigerant in the system with special refrigerant recovery
equipment.
② Disconnect the batter negative connection.
③ Remove the front bumper.
④ Remove the framework of front bumper.
⑤ Discharge the refrigerant and disconnect the connection with respective
pipelines.
⑥ Remove the front-end module assembly.
⑦ Remove the mounting bolts for condenser.
AC-27
⑧ Take out the condenser assembly.

2) Assembly is the reversed order of removal.
9. Removal and installation of Air Conditioning Filter
1) Function
Foreign matters outside the car will be prevented entering inside so as to keep a
comfortable inner environment by the use of the air-conditioning filters.
2）Replacement Cycle
It may cause blockage with extraneous matters, increase in noise of blower,
reduction of air outlet delivery, and other failures, if the filter is not replaced for a
long time.
The replacement cycle is 5000~12000 km, and it shall be frequently inspected
and replaced in the areas where atmospheric pollution is severe or road conditions are
not good. Frequent wash and change is recommended.
3) Replacement Steps
① Hold down the two sides of storage box and remove it downwards.
AC026
② Press down and Pull out the buckle of the air conditioning filter cover, and
remove the cover.
③ Take our the air conditioning filter from air conditioning filter cover.
④ The air conditioning filter installation is the reversed order of the above
mentioned.
Caution:
AC-28
■ To replace the filter, put the concave side upwards, and cannot be reversed.
Maintenance cycle
E
v
E
e
v
r E
Ev er
Eve y ve
Maintenance item Content ery y
ry q ry
we M
day u ye
ek o
a ar
nt
rt
h
e
r
Refrigerant to observe whether or not the flowing liquid has
Refrigeration System Compressor
★
amount bubbles through the observation glass.
Whether or not hoses have cracks or damage ★
Whether or not there is leak in each joint place ★
Pipeline
Whether or not each fixed clamp has loose or
★
damage.
Refrigeration Oil Refrigeration Oil Replacement ★
Belt Check the belt tension and whether there is wear ★
Compressor Check whether there is any loose bolts and
★
Bracket damaged brackets
Check whether there is dirt clogged, and clean if
Condenser
Condenser Core ★
necessary
Whether it functions well and whether it has
Fan Motor ★
strange sound.
Water
Evaporator
Check whether the clamp has loose. ★

Inlet/Outlet Hose
Whether it functions well and whether it has
Fan Motor ★
strange sound.
Check whether the electrical apparatus
Control box ★
Electrical apparatus components
components are intact

plug-in Check whether the wire head and the plug-in ★
connector connector have loose or got off.
Check whether the high and low pressure is ★
Pressure Switch
normal
Temperature Check whether the wind speed is normal in ★
Control Position 3.
Electromagnetic Check whether it can properly close or
★
Clutch disconnect
AC-29
Notice: ★ indicates the checking, adjustment, repair and replace if necessary.

To replace refrigeration oil, the compressor shall replace the new oil according to the
regulations.
Failure analysis and troubleshooting summary table
Symptom Possible fault Cause Solution

1. Check with eyes:
1 To observe whether there is oil stain in
the connection place of each part, once
there is oil stain, which means the
system has leakage. Soap water can be
applied to the suspicious area, and
then observe whether there are
AC System without Leakage exists in the bubbles..
refrigerant system 2 Observe each part to detect the
abnormal fault. For instance, there are
scratches, squash and impact damage
on the surface of the condenser and
evaporator core.
2. Through the vacuum method, listen
carefully near the parts to catch sizzle
sound; if any, there is leakage here.
3. Inspect with equipment:
1 Apply electronic Leak detector of high
sensitivity.
2 Dye tracing for leakage.
1. First confirm refrigeration oil specifications
and should not be blended; specifications of
common use: PAG;
2. After recovering refrigerant: add
approximately 30 g refrigeration oil.
3. To replace the compressor, pour out all the
Replacement of the system refrigeration oil in the compressor, and add the
Improper amount of
parts, increase or reduce in oil same as that in the changed compressor.
refrigeration oil in
accordance with the 4. Replacement of pipeline: add approximately
system.
regulations. 30g refrigeration oil.
5. Replacement of condenser: add
approximately 60g refrigeration oil.
6. Replacement of evaporator: add
7. Replacement of drying agent: add
1. Circuit Fault.
1 Check whether the motor circuit or
Air conditioning without plug-in connector has loose or got off.
Airflow is abnormal 2 If fuse gets off or damaged, replace it.
wind.
If relay breaks down, replace it..
AC-30
2. Mechanical Failure
1 IF motor breaks down, replace it.
2 If temperature air door mechanism
gets damaged, unable to adjust throttle
to the cooling state, replace it;
3 If controller breaks down, replace it.
If the speed regulation module is damaged,
replace it.
1. Low voltage, check the Power Supply
Battery.
2. Whether the air duct is congested, and
whether all the grilles are opened.
3. Whether the blow surface has leakage, check.
Airflow of air conditioning 4. The speed regulation module fails and needs
is slightly small. to be replaced
5. Whether the wind resistance of the air filter is
excessive, resulting in the block of dust and
extraneous matters.
6. Reversed direction of motor rotation , switch
the positive and negative pole of the plug-in
connector.
System without refrigerant Pressure gage test, please refer to check of
refrigerant leak.
No air blow Please refer to Check of abnormal airflow.
1. Electromagnetic Clutch does not work
1 Fuse blown, replace it;
2 If the plug-in connector in the circuit
gets off and damaged, check the
Air Conditioning
circuit and replace it.
without Cooling
3 Replace the burnt relay.
Compressor does not work 4 Remove the damaged clutch assembly,
repair or replace.
2. If drive belt is broken, replace it.

3. Signal is not clear.
1 Pressure switch is damaged, no
pressure signal; by short circuit signal
detection, if damaged, replace it.;
2 ECU failure, inspection and
maintenance.
4. If the compressor has an internal damage,
replace it.
1. Test the pressure to see whether it is in the
normal range of values; refill the refrigerant if it
Insufficient refrigerant is insufficient.
2. Check whether the system has a
Air conditioning microleakage.
cooling is not very 1. Discharge superfluous refrigeration oil and
Excessive refrigeration Oil fill the required amount of refrigeration oil.
good
Compressor is not in 1. The slip of compressor belt or clutch.
normal state
Airflow of air conditioning Please refer to Check of abnormal airflow.
is slightly small.
AC-31
1. High pressure is lower than normal value,

and low pressure is lower than normal
value
1 If there is blockage in the expansion
valve, clear obstructions.
2 If expansion valve is not fully opened,
adjust the valve or replace it.
3 Add the refrigerant if it is insufficient.
2. High pressure is higher than normal value,
and low pressure is higher than normal
value
1 If the condenser cooling is poor, check
the condenser fan airflow and replace
Pressure is not normal the defective parts;
2 If refrigerant is excessive, discharge
some.
3. High pressure is lower than normal value,
and low pressure is higher than normal
value
1 compressor failure, lack of capacity
and necessary to be replaced.
2 Insufficient refrigerant, and refill.
4. High pressure is higher than normal value,
and low pressure is lower than normal
value
1 The impurity exists in the system,
leading to congestion.
There is blockage in the warm air water pipe.
Clear the blockage.
Water valve is damaged, resulting in the
blockage for water to enter into the core for
circulation; inspection and maintenance is
no hot water in the core
needed.
No heating The wrong outlet position of water from the
performance in AC engine prevents water entering into the core for
System circulation; inspection and maintenance is
needed.
No air blow in AC system Please refer to Check of abnormal airflow.
Temperature control of controller is damaged so
Failure control as not to adjust the temperature damper to the
maximum heating. Replace the controller.
insufficient hot water Check whether the water supply to the engine is
circulation sufficient, or the engine failure.
Poor heating The internal flow of hot Clear the internal blockage or a replace heat
performance in AC core is not smooth. exchanger.
System Small airflow. Please refer to Check of abnormal airflow.
Mode damper is not correct The rotation of temperature damper is not in
place, with the mixture of heat and coldness.
Turn on the air conditioner and start the
Compressor with abnormal compressor to see if the clutch has grinding
sound noise. If there is abnormal sound, replace the
AC System with
compressor.
abnormal sound
Whether there is flowing chirps sound in the
Pipeline expansion valve
expansion valve after the air conditioner is
with abnormal sound
started; adjust expansion valve and replace.
AC-32
Whether there is resistance when adjusting the

damper mechanism, and whether there is "tick"
Damper mechanism with
or "chuckling" sound; in such a situation, the
abnormal sound
damper mechanism shall be coated with
lubricating oil or some parts shall be replaced;
Abnormal sound in the blower volute:
1 There is a booming sound, check the
motor has no reversed rotation; adjust
plug-in circuit.
2 "Creak" or "sizzle" sound comes,
Blower with abnormal indicating motor damage. Replace the
sound motor.
3 A "bang-bang" sound indicates the
extraneous matters in the volute.
Remove and check.
The blower is not installed firmly, resulting in
vibration sounds.
Remove the filter and check whether there is
Filter with mildew serious contamination on the surface. Replace
in time.
Whether there is oil stain on the surface of
AC System with Radiator surface
evaporator and heater in production. Replace
peculiar smell contamination
and clean if necessary;
Condensate water is not fully discharged,
Discharge of condensate
resulting in water deteriorating in the housing.
water is not smooth
Replace drain port location.
AC-33
J4 Workshop Manual ETACS control system
ETACS information and Electronic Time Alarm Control System

Precautions
■Prior to removal of electric connector, the battery negative has to be removed
and wait for at least more than 1 minute, otherwise it will cause vehicle damage.
■When removing and installing component, protect the parts from being
detached with cloth so as to prevent damage.
■ Be careful not to damage the body components.
■In case where the removal/installation of some components cannot be achieved
by one person, then two should be available for operation so as to prevent drop-down.
■Do not use excessive force when removing and installing some trim parts, for it
may cause the part deformation.
Layout of Components
2
1
ETACS-1
Layout of ETACS
1-tweeter（anti-theft） 2-ETACS module
Function Description
1. Front washer-linked wiper control
ON
Ignition switch
IGN.S/W OFF
> 0.6s T3
ON
Front washer switch
OFF
T1 T2 T3
O
N
Front wiper
OFF
T1：0.6±0.1s T2：2.5—3.8s T3：0.2—0.6s （MAX） T4：one period of wiper.
If the washer switch turns on for more than 0.6s with the ignition switch on the
position “ON”, the wiper will act at T1 (0.6±0.1s) after the activation of washer
switch until the washer switch turns off with the wiper continuously brushing for 3 T2
circles ( 3times);wiper wipe once if the washer switch is at T3(0.2～0.6s).
2.Speed induction type intermittent control
Turn front wiper to intermittent position, adjust time of intermittence by
receiving Real-time speed signal and front wiper intermittent adjustment signal.
ON
Ignition switch
IGN.S/W OFF
ON
Front intermittent switch
OFF
ON
Front wiper
OFF
T1 T2 T3
ETACS-2
T1：0.3s T2：4/3s T3: Intermittent time
Intermittent Value of Intermittence Intermittence

grade resistance time(speed≤100km/h) time(speed>100km/h)
of
pisition
’’Level 1’’ 0 4s 4s
’’Level 2’’ 12.5K 6s 5s
’’Level 3’’ 25.2K 8s 6s
’’Level 4’’ 37.9K 10s 7s
’’Level 5’’ 50K 12s 8s
3. Locked rotor protection of front wiper

If there is no return signal from wiper in 18 seconds, close relay output of front
wiper.
4. Time control of rear windshield defrost
ON
Generator
Terminal “L” OFF
ON
Defrost switch
OFF
ON
Defrost relay
OFF
T1 T1 T1
T1：20±2ms
Generator is working, charging indicator is off, turn on defrost switch, defrost

relay starts to work, lasting T1（20±2min）, If the interval between two times of press
down the defrost switch is shorter than T1, then the defrost performance will be
ETACS-3
deleted by pressing down the defrost switch for the second time.
5. Ignition keyhole lighting control
When the ignition switch is on the position “OFF“, any of the front doors LH/RL
is opened, the ignition lock lamp lights up and goes out in T1 (10±1s) after the door
closed up;if front door is open, ignition switch turns to "ON", lamp goes off.
O
N
Ignition switch
IGN.S/W OFF
ON
Front door switch
DR S/W OFF
ON
Ignition keyhole
lighting
OFF
T1 T1 T2
T1：10±1s T2：0—10s
Left/right door open time lasts > 15min, Ignition keyhole lighting goes off.
6. Lighting control of driver’s front dome light
Turn front dome light on DOOR,open front door, front dome light goes on; after closing
door,if ignition switch is on ACC/OFF,front dome light will go off after T1 （ 30±2s ） ,T2
（5.5±0.5s). if ignition switch is on,front dome light goes off.
ETACS-4
T1：30±2s T2 5.5±0.5s T3 15min

If door keeps open more than 15mins, innner dome light goes off for 5.5s;
7. Power window time control
When the ignition switch is on the position of ON, front door closes, power
window can be operated. When the ignition switch is on the position LOCK or ACC,
the power window is operable within T1 (30±3s); if the front door opens within T1
(30±3s), the power window is inoperable.
ON
Ignition switch
OFF
ON
Front door switch DR
S/W
OFF
ON
Power window
generator
OFF
T1 T1
T1：30±3s
8. Taillight auto-off control
Under any situation where the lighting switch (combination switch LH) shifts
from “OFF” to “ON”, the taillight lights up.
The taillight will go out under some of the following controls, when:
1) The lighting switch (combination switch, LH) shifts from “ON” to “OFF”;
ETACS-5
2) The key is taken out coinciding with the driver-sided door opened, the taillight
will go out; if the key is inserted again, the taillight lights up.
Notes: Here the taillight refers to the small light system.
Insert
Ignition key
Pull up
ON
Small light switch
OFF
ON
Driver-sided door
switch
OFF
ON
Taillight relay
OFF
9. Front fog lamp control

Ognition on, small lamp opens, open front door switch, front fog lamp lights up, small lamp
switch to OFF or front fog lamp switch off, front fog lamp goes off.
10. Rear fog lamp control

When the ignition switch is on the position “OFF” with the light switch
(combination switch LH) and the front fog lamp switch turned on, turn on the rear fog
lamp switch on the A/C control panel, it will not light up; when the ignition switch is
on the position “ON”, with the light switch shifted to small light (combination switch
LH) and the front fog lamp switch turned on, the rear fog lamp will light up by
turning on the rear fog lamp switch, where if the front fog lamp turned off, the rear
fog lamp will be also put out; when the light switch shits to other light positions, the
rear fog lamp will be not subject the control of front fog lamp, i.e. the front fog lamp
switch is turned off, and the rear fog lamp switch may freely control the rear fog
lamp.
ON
Taillight relay
OFF
ETACS-6
ON
Ignition switch
OFF
ON
Front fog lamp switch
OFF
ON
Rear fog lamp switch
OFF
ON
Rear fog lamp
OFF
11. Electric door lock control

Remote Control Central Lock can be controlled in driver side, when it is closed,
fastener outputs signal of locking, doors will be locked; when it is opened, fastener
outputs signal of unlocking, doors will be opened.
Pull
out
Driver-sided door switch
Press down
Pull
out
Passenger-sided door
switch
Press down
ON
Door locking output
OFF
ON
Door unlocking output
OFF
ETACS-7
12. Key management control

With key inserted to car and driver-side door open, fastener output unlocking
signal, so doors can't be locked; if keep pressing fastener switch, fastener will output
unlocking signal after T2, and output unlocking signal 3 times afterwards; within T3
(0s<T3<0.5s) pressing fastener switch, driver-side door closes, loosen fastener in the
meantime, outputting unlocking signal, doors will not be locked.
Insert
Ignition key
Pull up
Turn on
T3
Driver-sided door switch
Turn off
Locking
Door locking switch
The
unlocking
ON
Front door unlocking
Output OFF
T1 T2 T1 T1
T1：0.5±0.1s T2：1±0.1s T3：0 s<T3<0.5s
13. unlock automatically while impact.

Airbag explodes after impact, and airbag control module outputs signal of 240ms
to ETACS, 200ms is low level, 40ms is high level,BCM will outputs T3(5sec)
unlocking motion after T2(40msec), then doors will be open. Now, indoor dome light
opens, alert warning light glitters (period is 0.72s,duty cycle 50%). When hazard
warning lamp is glittering, ignition switch OFF or doors open will relieve hazard
alerting.
ETACS-8
“ON”
ON
Impact
OFF
Unlocking ON
signal output OFF
14. Automatic locking

If the ignition switch is on the position “ON” with the door unlocked, the door
will be automatically locked when the speed is over 40Km after T1 (1±0.3s); if
fastener unlocks while driving, door will be locked automatically again after T1
(1±0.3s).
ON
Ignition switch
OFF
40km/h higher than
Vehicle Speed Sensor
40km/h lower than
The unlocking
All doors locking switch
Locking T1 T1
ON
Locking relay
OFF
T1：1±3s
15. Auto-unlocking with the key pulled up

When the doors are in the locking state, the locking relay will give a T1
(0.5±0.1s) unlocking signal after the key is pulled up, afterward the doors will stay in
unlocking state.
Insert
Ignition key
Pull up
The unlocking
ETACS-9
All doors locking switch
Locking
ON
Locking relay
OFF T1
T1：0.5±0.1s
16. Alert function

All doors and engine cover closed, lock door with remote controller or
mechanical key,hazard warning light glitter once T1(1.0±0.2s), warning light rings
once（100ms）, alert state starts; with doors and back trunk closed, door locks if use
remote control to lock, but hazard warning light doesn't glitter, it is not in the state of
alert. With all doors closed, hazard warning light glitters once T1(1.0±0.2s), warning
horn rings once（100ms）, state of alerting starts.
Open
All doors front cover
Close
ON
Remote controller locking
OFF
ON
Locking relay
OFF
Alert
Alert state
Non-alert
ON
Hazard warning light T1
OFF
T1：1.0±0.2s
17. Alert relieve function

Relieve alerting state with remote controller or mechanical key, door unlocks,
hazard warning light glitters T1 (0.5±0.2s), another glitter occurs after T2（0.5±0.1s）,
indoor dome light opens if it stay on“DOOR”, Unlock with remote controller and
mechanical key, no doors will be locked within 30s after the door unlocked by the
ETACS-10
remote controller, and enter automatically into alert state, indoor lamp (“DOOR”)
goes off.
This function is set to prevent the doors from triggering by misconduct.
ON
Remote controller unlocking
OFF
ON
Unlocking relay
OFF
Alert
Alert state
Non-alert
ON
Hazard warning light T1 T2 T3
OFF
ON T4 T4
Driver dome lighting
OFF
ON
Door switch DR S/W
OFF
ON
Locking relay
OFF
T1：0.5±0.1s T2：0.5±0.1s T3：1±0.1s T4：30±1s
18. Alarm function

When car stays in alerting state, open doors and engine cover, warning siren
rings T1(27±2s), then rings(T1) again after T2(10±1s), after 3 times, hazard warning
light glitter at T3（0.5±0.1s）,duty cycle 50%, time is the same as warning siren.
Alert
Alert state
Non-alert
Open
Rear trunk door closed
ON
ETACS-11
Warning siren T1 T2
OFF
ON
OFF
T1：27±2s T2：10±1s T3：0.5±0.1s

19. New abnormal conditions occurred in alert state
While in alerting state, if doors and engine cover open, warning siren rings,
Hazard warning lights flashes; It will finish 3 alarms and enter into alarm state if there
are doors activated within the time of 3 alarms.
Open
ON
Start relay
OFF
ON
Warning siren
OFF
ON
Hazard warning light
OFF
20. While warning, relieve alarm with remote controller or mechanic key.
In alarm state, use the remote controller or mechanic key to relieve the alarm.
The unlocking relay outputs an unlocking signal, the doors stay in unlocking state;
Relieve the alarm state, the warning siren stops buzzing and the hazard warning stops
after flashing two times. Stay in alarm-relieved state.
ON
Remote controller unlocking
OFF
ON
Unlocking relay
OFF
Alert
Alert state
ETACS-12
Non-alert
ON
Start relay
OFF
ON
Warning siren
OFF
ON
OFF
T1 T2
T1：0.5±0.1s T2：0.5±0.1s
21. In alarm state, use the remote controller locking with the door closed.
In alarm state, while door closed, use remote controller or mechanical key to lock.
Activate relay to cut off the power, the hazard warning light will go out after flashing
for T1 (1±0.2s). Stay in alarm set state.
Open
ON
OFF
ON
Locking relay T1
OFF
ON
Start relay
OFF
ON
OFF
T1：1±0.2s
22.In alarm state, use the remote controller locking with the door opened
In alarm state, use remote controller or mechanical key to lock with the door
opened, the locking relay will output an locking signal to start relay for power cut-off;
if all doors are closed at this time, the hazard warning light will flash once T1
(1±0.2s), horn rings once, then alarm state starts.
ETACS-13
Open
ON
OFF
ON
Locking relay
OFF
ON
Start relay
OFF
ON
OFF
T1：1±0.2s
23. In alarm state, relieve the alert in absence of the remote control key
In alarm state, the alarm may be relieved in 30s with the ignition switch on the
position “ON”.
Insert
Ignition key
Pull up
ON
Ignition switch
OFF 30 s
ON
Warning siren
OFF
Alert
Alert state
Non-alert
24. Doors abnormally opened after the alarm is relieved

After the alarm relieves, the alarm buzzs continuously and restores its initial state
when the doors abnormally opened.
ETACS-14
Open
ON
Start relay
OFF
ON
Warning siren
OFF
ON
OFF
25. Remove/install the battery in both alert and alarm states

After the battery removed in alert and alarm states, the warning siren buzzs by
refitting the battery, as it stays in alert state at this moment.
Alert
Alert state
Non-alert
Open
Remove
Battery
Installation
ON
Start relay
OFF
ON
Warning siren
OFF
26. Remove/install the battery in the process of alarm relief

After the battery removed during the alarm relief, refit up it again, the alarm state
will be set.
Remove
Battery
ETACS-15
Installation
Alert
Alert state
Non-alert
27. Lock Protection Function
If it keeps lock and unlock for 8 times within 10s, close door lock output (now
it is unlocked), restores after 15s.
28. Searching car function
Warning horn rings for 3 times(500ms rings, 500ms stops) if receiving wireless remote control
signal>0.5s, duty cycle 50%, and warning alert lamp glitters for 3 times, same frenquency with
alarming horn.
Replacement of ETACS control module and alarm speaker

1. Remove the battery negative pole (-).
2. Open and remove glove box with hands
ETACS001
3. Remove Parking restrictions on both sides of glove box with hands

ETACS002
4. Remove ETACS MODULE fixing bolt.

ETACS003
ETACS-16
5. Disconnect the ETACS module connector and remove the ETACS module.
6. Removal of alarm speaker assembly. ETACS004
1) Remove the front bumper.
2) Remove the bolts on the tweeters, disconnect the connector and remove the
tweeter assembly
7. Installation in the reverse order of removal.
Definition of ETACS control module terminal
B
A
Diagram of ETACS Control Module Terminals
Definition Table of ETACS Control Module Terminals

Definition of connector A (white) Definition of connector A (white)
1 Interior lights 13 Small light relay
2 Alarm relay 14 Anti-theft alarm
3 Front wiper relay 15 Power window relay
4 Rear defrost relay 16 front fog lamp relay
high spped relay of front
5 17 Co-pilot’s seat door switch
wiper
6 Rear fog lamp relay 18 hazard warning relay
7 return signal of front wiper 19 Ground
8 Door locking relay 20 Keyhole light
Buzzer power
9 21 NC
supply(reserved)
ETACS-17
10 B+ 22 NC
11 Door unlocking relay 23 NC
12 Trunk switch 24 Speed signal
Definition of connector B (grey) Definition of connector B (grey)

1 Driver seat door switch 13 Small light switch
Driver seat door lock
2 Rear fog lamp switch 14
switch
High speed switch of front
3 Low speed of front wiper 15
wiper
Inching switch of front
4 Front sprinkler switch 16
wiper
Mechanical key unlock
5 17 Storage code
switch
Mechanical key lock
6 18 IG1
switch
Front wiper intermittent
7 Defrost signal 19
switch
8 Front fog lamp switch 20 Engine hood switch
9 IG2 21 Safety airbag signal
Front wiper intermittent
10 Four-door Switch 22
adjustment
11 Key insert switch signal 23 Generator L
12 Headlight switch 24 Outside antenna
Operation instruction of ETACS remote control key code selection

1. Connect the code selector to the diagnosis interface. ETACS005
2. Press down the training button.
The indicator (green) on the code selector lights up
While the body turning indicator lights up. The remote controller code selection gets
ready.
3. Press down any button on the remote controller (key).

Hold down 1s until the turn light dies out, which means the remote controller
code selection is achieved.
ETACS-18
Next, press down any button on the second remote controller for the training of
second one.
4. Pull up the connector plug of code selector after waiting for 5s, exit from the
code selection state (The process of code selection will be effective by completion
within 5s, otherwise ineffective).
Then, the two remote controllers of successful code selection may be applied.
Note:
■For each code selection operation, only the training of two remote controllers is
allowed. If the third button is pressed down, the first trained remote controller will be
automatically ineffective. If the fourth is pressed down, the second trained
auto-lapsed.
■The time for each code selection operation is limited to 5s. Please complete two
code selections within 5s. It will exit automatically from the code selection mode after
5s.
■If the owner lose the remote controller, he/she can renew the training for two
new remote controllers. The previously trained two will be automatically lapsed.
Fault diagnosis
1. If the training button pressed down, the turning light does not light up, which
means the connection failed.
1) Please check if the connector of code selector is in proper contact.
2) Repress the training button until the turning light turns on.
2. If the turn light shines but does not go out after the remote controller pressed
down, please change another remote controller. If it continues shining, please check
if the body controller (ETACS) is damaged.
ETACS common failure analysis

1. Controller ineffective (lock/unlock and flash)
A. Is it controllable with another controller?

Yes, it means there is a failure in this remote controller or it has not been set in
this Intrusion Alarms System (it is possible that the new duplicated remote controller
ETACS-19
has deleted this remote controller).

No, then refer to the next step as follows.
Notes: It is rather rare that two remote controllers fail at the same time.
B. If both remote controllers are inoperable, please check: door warning
switch(key inserting switch)
① Check the pin of “door warning”with the multi-meter. If this pin is under
high voltage power, the controller will be not effective.
② The controller is ineffective with the key in the ignition lock.
2. The controller can only unlock instead of locking.
A. Check if the center lock system can perform the locking. If yes, there is a
failure in ETACS. If not, a failure is in the locking relay.
B. Check if the central lock system can perform the locking. If it is relocked,
there might be a failure in the lock device. Under such circumstance, the central lock
switch in the lock device is functional.
3. After the door is locked by the remote controller, no flashing and horn prompt
will be given.
This case occurs generally due to a certain door switch not closed (the door
unclosed). See input of “Locking by the remote controller with the doors not closed”:
switch of 4 doors/ engine hood switch/trunk switch
4. Alarm rings period after locking doors remotely
Please check engine hood indicator/door indicator/indoor light/courtesy
lamp/courtesy lamp on dash board, if one of them is on, it means door switch or trunk
switch is not well conductive. Please close all doors/ hood or replace switch or adjust
door/trunk.
5. Remote controller unable to set into ETACS
While the remote controller is set up, all remote controllers should be reset again,
Because the previous setting of remote controller will be deleted with the first remote
controller successfully set.
6. Close distance of remote control
A. try another remote controller, if the remote control distance is too far away,
ETACS-20
then change the battery of remote controller.

B. If the second one is still close, please check if the position of Intrusion Alarms
antenna is proper. If still in such case, it is necessary to change ETACS.
C. Note: The remote control distance is set commonly beyond 5m. If the remote
control distance is too far, it is easy to press wrong button of remote controller and
cause, in consequence, inside goods lost. Besides, the battery lifecycle of remote
controller will be shortened.
7. Interior lights constantly shining
A. It is generally due to the doors, engine hood and tailgate not closed
completely, or the switch damaged. Please check all doors or replace the switch. At
this moment, there will be no light flashing or horning if locking by remote control.
B. Interior lights switch stay in permanent ON, or the interior lights switch
grounds.
8. Horn doesn't ring
Both terminals of the alarm speaker present the polarity. Horn will not ring in
case of reverse connection.
9. No fast locking function
A. If the remote control locking is in normal function, but no fast locking
performance available, then the speed signal has not accessed into the ETACS
MODULE.
B. The failure of lock devices in the front doors LH/RH causes signal delivered
by the lock device on the locking position, thus the “Fast Auto-Lock” won’t operate.
10. When the car is driving at more than 40km/h, the lock device repeats the
cycles of locking for several times:
A. When the car starts driving, the “Speed Auto-Lock Function” will take effect
for auto-lock (lock-up). The car stays in locking state. If, in this moment, the doors are
unlocked, the interlock function of “ignition switch and door locks (prevent key from
locking in the car)” takes effect and automatically unlocks. In such way, the lock
device repeatedly performs unlocking/locking And it seems that car repeats locking,
unlocking and relocking.... and so on.
ETACS-21
B. When the car starts driving, the “Speed Auto-Lock Function” will take effect
and lock automatically (lock-up). At this moment, if the lock device is not in position,
the lock device switch remains on the unlocking position, the “Speed Auto-Lock
Function” remains functional and relocks. At this moment, it seems that the car
always performs locking.
C. When car starts driving, the “Speed Auto-Lock Function” will take effect and
automatically locks (lock-up). At this moment, if the lock device rebound after
locking and shifts the lock device back on the unlocking position, the “Remote
Control Central Lock Function” will take effect and automatically unlock. In such
way, the lock device repeatedly performs unlocking/locking And it seems that car
repeats locking, unlocking and relocking.... and so on.
Note: Uncompleted tapping or rebound of lock device is probably caused by
mechanical fault: lock is frozen or can not move fluently, increasing resistance.
11."Coo-coo" noise inside the door
It is commonly the skidding sound from the lock device made during locking.
Please replace the lock device.
12. Auto-lock-up by the central remote control
A. After unlocking by the remote control, the door is not opened, then the
auto-lock will enter into alert state in 30s. At this time, the alarm will rings if
manually opening the door.
B. Possibly a central control signal of locking given by the lock device.
C. In some cases, the vehicle speed signal has failure while idle and give a speed
signal, which causes speed automatically lock up.
13. The alarm buzzer horn alarms automatically within a period of time after the
locking
It might be a failure in the 4 D switch, engine hood switch or tailgate switch
which automatically locks up, triggering the alarm.
16. The failure of window up-down, wiper blockage, central remote control
ineffective and intrusion alarms out of run.
A. Take out the ETACS, and reinsert it to see if the failure disappears.
ETACS-22
Sometime, the poor contact of connector will cause the system out of power supply
and operation.
B. If the system stays inoperable, the ETACS has a failure and should be
replaced.
17. Angle difference in the remote controller
It is normal that the remote controller has the angle difference because the radio
transmission is subject of obstruction effect and reflection point stack. But anyway,
the “No blind area within 6m in any directions” should be guaranteed.
18. Failure of window up-down
Short-circuit of relay burns out the driving components which drive the power
window relay.
19. Other cases causing the ETACS output damage
• Relay short-circuits and connects directly with the power supply, resulting in
damage on some driver components.
• Harness short-circuits and causes damage on some driver components.
• Harness short-circuits and causes some outputs out of control.
Technical parameters
Table of Technical Specification
ETACS-23
Items Specification
Voltage DC12V
Voltage range DC9V ～DC16V
Static current MAX 6Ma (at 12.8V)
Insulation resistance 100MΩ (DC500V tramegger)
Operation temperature -40ºC～85ºC
Storage temperature -40ºC～85ºC
Front wiper relay DC 12V, 200mA (relay load)
Front wiper relay(high spped) DC 12V, 200mA (relay load)
Rear windshield defrost relay DC 12V, 200mA (relay load)
Ignition keyhole lighting DC 12V, 1.4W (bulb load)
Driver dome lighting DC 12V, 10W×2 (bulb load)
Power window relay DC 12V, 200mA (relay load)
Taillight relay DC 12V, 200mA (relay load)
Rear fog lamp relay DC 12V, 200mA (relay load)
Electic door locker relay DC 12V, 200mA (relay load)
Alarm speaker DC 12V, 200mA (relay load)
Front fog lamp relay DC 12V, 200mA (relay load)
ETACS-24
J4 Service Manual Combination Switch
Combination Switch
Descriptions
1 2
Combination Switch Assembly Diagram
1. Lighting control switch 2. Wiper control switch
2. Lighting control switch

It controls the signals from the turn lights LH/RH, headlight, front fog lamp, side
turn light and overtaking light.
It controls the signals from the side turn light and overtaking light. The headlights
work in operation mode of headlight, it can also implement the conversion of two
functions from the high beam to low beam, from the low beam to high beam.
CSW001
1) Turn light
There are two Up-positions (Right turn)
and two Down-positions (Left turn) on the
turn signal lever, which are used to deliver
the turn signal.
To deliver a change lane signal, push the operating lever up or down till the end.
When the turn is finished, the operating lever will automatically retract. There are two
flashing arrows on the combination instrument, which display the turn direction
signals.
It is still required to push the operating rod upward or downward thoroughly and
CSW-1
loosen the operating rod, to send out the lane-changing signal. The operating rod will
automatically reset, when vehicle lane-changing operation is completed. When driver
sends out turning or lane-changing signal, if turn arrow flashes too fast, the signal
light may possibly have burned out, and other drivers will not be able to see the sent
turning signal. If certain bulb is burned out, it shall be replaced, to avoid traffic
accident. The bulb shall be checked as to whether or not it is burned out, and then the
fuse is to be inspected, if turn arrow on the instrument fails to flash when driver sends
out turning or lane-changing signal.
2) Headlight/low beam converter
If you wish to convert the headlight from the low beam to high beam, push the
turn signal/multi-function operating lever deviated from the driver. With the high
beam connected, the combination instrument will display the high beam signal if the
ignition switch is communicated.
If you wish to convert the headlight from the high beam to low beam, push the
turn signal/multi-function operating lever toward the driver.
3) Overtaking flash
This function enables the driver to deliver the overtaking signal to the headed
driver by using the high beam headlight. In use of this function, pull the turn signal
/multi-function operating lever toward the driver until the headlight high beam starts
shining, and then release the operating lever to turn off the headlight.
4) Front fog lamp
Front and rear fog light switch is located on the turn signal lever. When
the end of the bucket switch is in the position, you can rotate the lever
central knob to turn the front fog lights, position open the rear fog lights on, at
this point in the instrument cluster * (front and rear fog light indicator light goes on as
a reminder . Turn to the position "OFF" to shut down the fog lights.
2. Wiper control switch
CSW002
1）Wiper operating control modes
(wash, intermittent, low-speed and
high-speed.
CSW-2
Clearance, low-speed, high-speed). Wiper in clearance document

When the wiper is located on the space gear, there are three mode options as high,
mid and low.
Use the operating lever on right side of steering column to operate the front
windshield wiper.
Windshield wiper is only with the ignition switch communicated that the front
windshield wiper can be operated.
Front windshield
Turn the operating lever to this position, allowing the high-speed wiping.
Turn the operating lever to this position, allowing the low-speed wiping.
Turn the operating lever to this position, allowing the option for a circle of
delayed wiping.
Move the mid-section of wiper operating lever to the LO, allowing the increased
delay, and to the HI, allowing the decreased delay. It is only with the operating lever
on the INT position that the wiper speed can be regulated.
2) Front windshield washing liquid
To wipe the front windshield, pull the washing liquid operating lever of front
windshield wiper toward the driver with the ignition switch already communicated.
Caution:
■In freezing weather, the wiper will not be operated without preheating the front
windshield. Otherwise the washing liquid will freeze on the front windshield and
obstruct the driver’s view.
■When the operating lever is released, the scrubber will stop working, but the
wiper will continues to run about three circles, then stop wiping or restore the initial
wiping speed previously used by the driver
Component check
According to the table below, check the conductivity between the terminals of
CSW-3
wire connectors. If the conductivity between the wiring connectors and all terminals is
non-conform to that as stated in the diagram, change the switch.
Passing
Steering switch Light switch switch fog switch
Alarm lamp switch

Internal link
Light lever switch continuity figure
Wiper switch Washing switch
Wiper lever switch continuity figure
Replacement of combination switch

Caution:
■Before removing the electrical connectors, the battery negative pole has to be
removed and wait for at least more than 3m, otherwise it will damage the car.
■When removing and installing component, protect the parts to be detached with
cloth so as to prevent damage.
CSW-4
■When removing the metal clamps from the trim parts, wrap the flat screwdriver
edge with cloth.
■ Be careful not to damage the body components.
■ When installing the body trim parts, first confirm clamps securely fitted in the
plate orifice on the body, then carefully press them in.
■ In case where the removal/installation of some larger components cannot be
achieved by one person, then two should be available for operation so as to prevent
the drop-down.
■ Do not use excessive force when removing and installing some trim parts, for it
may cause the part deformation.
1. Removal
1) Disconnect the battery negative pole and wait for at least 3m.
2) Remove the steering wheel air bag module
3) Remove the steering wheel.
4) Remove the top/lower covers of steering column.
5) Remove air bag clock spring, and the clock spring is easy to be damaged,
make sure 3 pins have been completely parted from the clock spring before removing
it.
6) Disconnect the combination switch connector.
7) Remove three fixing screws of combination switch.
8) Take out the combination switch assembly.

2. Installation.
Installation is the reverse order of removal.
■Tightening torque of fixing screw: 4 N·m
Check after installation

1. Operate the lighting handle of combination switch and check all lights and
switches for proper working condition:
2. When the lighting handle on the position “OFF”, all exterior lights and the
night guide lamp of interior electric equipment should go out.
CSW-5
3. When the lighting handle on the small light, the marker lamps, F/R position
lamps, license plate lamp, instrument lighting and the night guide lamp of interior
electric equipment should light up.
4. When the lighting handle on the small light, press down the front (rear) fog
lamp switch, all front (rear) fog lamps should light up.
5. When the lighting handle on the position large light, the low beam of headlight
should light up, and all clearance lights remain in shining state.At this time, push
down the handle, the high beam of headlight will light up; return the handle to the
original position, then pull it up , the high beam lights up, and it will reset
automatically when is released.
6. When the lighting handle turned forward (backward) about 12°, all right (left)
turn lights start flashing, and the right (left) turn indicators on the instrument starts
flashing, it will stop flashing when the handle reset on the original position. When the
handle turned forward (backward) about 9°, the right (left) turn light flashes, and reset
automatically when the handle released.
7. When the alarm switch is pressed, all turn lights should flash together while
the L/R turn indicator lights on the instrument should do the same.
8. Operate the wiper/wash of combination switch and check the wiper, scrubber
for proper operation:
1) When the handle on the position OFF, the wiper and scrubber are motionless.
2) When the handle on the position INT, the wiper bar moves intermittently
according to a fixed interval.
3) When the interval regulating button turned to enables the time to vary between
FAST and SLOW, the interval of wiper bar movement changes.
4) When the handle on the position LO, the wiper bar keeps moving at lower
speed.
5) When the handle on the position HI, the wiper bar keeps moving at higher
speed.
6) Press down the wash button at the end of handle during the wiper operation,
toggle the operating handle RH of combination switch about 6° toward your body, the
CSW-6
scrubber nozzle will sprinkle the wash liquid on the front windshield.
CSW-7
J4 Workshop Manual power windows
Power windows
Summary
1. By operating the PW system on each trim panel, the PW system can rise or
lower the corresponding window glass.
2. The main switch on the driver-sided trim panel enables the driver to lift or
lower each occupant-sided window glass and lock up all independent switches on the
doors.
3. The PW system can accept the battery voltage through the circuit breaker in
the junction box only when the ignition switch is on the position “ON”.
4. The PW system includes the PW switch and ETACS control module on every
trim panel and PW motor inside each door.
5. The PW motor and window glass regulator is an assembly. If necessary to
renew the PW motor, then the window glass regulator should be replaced.
Component description
1. PW switch
The PW are controlled by the PW switches on each front trim panel. The
driver-sided PW switch enables the driver to control all PWs. All occupant-sided
windows are powered and grounded by the battery through the PW switch circuit.
When the lock-up switch of driver-sided PW switch is on the position “Lock Up”, the
battery power supply on other door PW switches are interrupted except the
driver-sided PW switch.
2. PW motor
The reversible permanent magnet motor drives the window glass regulator
through the incorporated gear box mechanism. Both battery positive and negative are
connected to two terminals of the motor, which orientate the motor rotation in the
same direction. The motor may rotate in reverse driven by the reverse current from
two of the same junctions. In addition, all PW motors are equipped with the
incorporated self-reset circuit breaker so as to prevent the excessive motor load.
Function Description
PW-1
1. PW rise and drop

Operation of PW: Manual Up and Down, Auto-Down (only applicable to the
driver-sided PW switch).
2
电动门窗 by pressing the button Window-Up, the corresponding window will
Manual up,
4
继电器
automatically
3 rise and will stop rising by button release.
1 3735907U1010
至BCM Manual down: By pressing the button Window-Down, the corresponding window
will automatically lower and will stop lowering by button release.
FS(I)04Automatic
FS（I）01 drop: By pressing the driver-sided Window-Down button till the end,
the 25Adriver-sided
25A window will lower down to the end or until the Window-Down button
is repressed.
11 10
After the ignition switch turned off, the PW stay operable, but it becomes
02inoperable when the following cases occur:
左后门窗开关 switch is over右前门窗开关
1) The OFF time of ignition 30s. 右后门窗开关
DOWN UP
自动升A random door
2) 玻璃升降 is opened.
降控制 DOWN UP DOWN UP DOWN UP
锁止开关 from outside.
3) Door locked-up 闭锁开锁
单元
2. PW lock-up
12 can 9 restrain the
5 The 6PW lock-up switch 03 PW buttons
01 on 8the front 13 RH,
7 door 4
14 rear
2.0 LH2.0 and rear door RH.
door 自动门锁自动门锁
继电器继电器 Tail
1 ILL+ ILL+ ILL+ 5
DOWN 2 UP 5 6 8 4 5 8 6 4 8 6 4
M 左后电动右前电动门
门窗开关窗开关 DOWN UP 右后电动门
DOWN UP DOWN UP
左前电动门窗电机 3 1 窗开关
3 1 3 1
7 7 7 2.0 2.0
ILL- 2.0 2.0
ILL-
2.0 2.0 ILL-
1 2 1 2 1 2
M M M
左后电动门窗电机右前电动门窗电机右后电动门窗电机
Schematic diagram
PW-2
Component replacement
1. Outside water splitting of front window replacement
1) Removal
① Lower window glass to the bottom
② Remove fixing bolt of outside water splitting.
③ Remove rear mirror.
PW001
④ Remove outside water splitting of front door.
Note:
■Please do not apply excessive force during removal, otherwise it may result in
parts deformation.
■ After removal, check gib with eyes. If it is found deformed, please replace.
2) Installation.
① Array outside water splitting of front door with door frame of B pillar, install
it from one end to the other end slowly.
PW002
② Fix bolt of outside water splitting of front door.

■Tightening torque: 3~5 N.m
③ Install rear mirror, refer to "Replacement of rear view mirror".
2. Replacement of front window glass
1) Removal
PW-3
① Remove door trim panel. Refer to "Front door trim replacement"

② Remove waterproof membrane. Refer to "Front door waterproof membrane
replacement"
③ Take off inside rubber strip of front door. Refer to "The replacement of inside
rubber strip of front door"
④ Refit the window glass regulator switch.
Regulate the window glass on the appropriate position so as to ease the
removal/installation of front window glass fixing bolts.
PW003
⑤ Remove bolts securing front window glass.

PW004
⑥ Take off window glass.

2) Installation.
① Reinstall window regulator switch, and lift glass to an appropriate position to
facilitate installation of bolts securing window glass.
② Put window glass onto door, right to installation hole.
③ Install bolts securing window glass.
■Tightening torque: (7~11) N.m
④ Install inside rubber strip of front door refer to "The replacement of inside rubber strip
of front door"
⑤ Install waterproof membrane refer to "Front door waterproof membrane

replacement"
PW-4
⑥ Install door trim panel. Refer to "Front door trim replacement"

3. Replacement of the front window glass regulator
1) Removal
replacement"
④ Remove window glass. Refer to “Front window glass replacement”.
⑤ Remove the 4 fixing nut of glass PW005
support.
PW006
⑥ Remove 3 nuts securing window
regulator motor.
PW007
⑦ Disconnect window regulator motor connector.

⑧ Take out window regulator.
PW-5
2) Installation.
① Install glass hatchway, connect connector of front glass regulator, put into glass
assembly.
② Install the fixing nut of front window glass support.

③ Install the fixing nuts on the glass regulator motor.
④ Install bolts securing window glass. Refer to “Front window glass
replacement”.
⑤ Install inside rubber strip of front door refer to "The replacement of inside rubber strip
of front door".
⑥ Install waterproof membrane refer to "Front door waterproof membrane

replacement"
⑦ Install door trim panel. Refer to "Front door trim replacement"
4. Replacement of front window glass slot
1) Removal
replacement"
④ Remove rear view mirror, refer to "Replacement of rear view mirror".
⑤ Remove outside water splitting of front window. Refer to "outside water
splitting of front window replacement:
⑥ Remove window glass. Refer to “Front window glass replacement”.
⑦ Remove the front window glass regulator Refer to “Front window regulator
replacement”.
PW008
PW-6
⑧ Remove the front window glass slot.

2) Installation.
① Install front window glass slot, install 2 foot part first.
② Install outside water splitting of front window Refer to "outside water splitting of
front window"
■ Tightening torque: 3~5 N.m
③ Front door window regulator Refer to “Front window regulator replacement”.
④ Install bolts securing window glass. Refer to “Front window glass
replacement”.
⑤ Install outside rear view mirror. Refer to "Replacement of outside rear view
mirror".
⑥ Install inside rubber strip of front door Refer to "The replacement of inside rubber strip
of front door".
⑦ Install waterproof membrane Refer to "Front door waterproof membrane
replacement"
⑧ install door trim panel. Refer to "Front door trim replacement"
5. Replacement of male drawer guide of front window glass
1) Removal
replacement"
④ Remove outside water splitting of front window. refer to "outside water
splitting of front window replacement:
⑤ Remove window glass. Refer to “Front window glass replacement”.
⑥ Remove the front window glass regulator Refer to “Front window regulator
replacement”.
PW-7
⑧ Remove the front window glass slot. Refer to "Replacement of front window
glass slot".
Loosen fixing bolt of male drawer guide, remove the guide.
2) Installation.
① Install guide, tighten fixing bolt of guide.
② Install front window glass slot, install 2 foot part first.
③ Install outside water splitting of front window, refer to "water splitting of
front window".
④ Install Front window regulator,refer to “Front window regulator
replacement”.
⑤ Install window glass. Refer to “Front window glass replacement”.
⑥ Install inside rubber strip of front door Refer to "The replacement of inside rubber strip
of front door".
⑦ Install waterproof membrane Refer to "Front door waterproof membrane
replacement"
⑧ Install door trim panel. Refer to "Front door trim replacement"
6. Outside water splitting of rear window replacement

1) Removal
PW-8
① Lower window glass to the bottom

② Remove 2 fixing bolts of outside water splitting.
③ Remove outside water splitting of rear door.
PW009
PW010
Note:
■Please do not apply excessive force during removal, otherwise it may result in
parts deformation.
2) Installation.
① Array outside water splitting of front door with door frame of B pillar, install it
from one end to the other end slowly. PW011
② Fix bolt of outside water splitting of rear door.
7. Replacement of the rear window glass

1) Removal
1. Remove door trim panel. Refer to The replacement of the interior trimming
PW-9
panel of rear door.

② Remove waterproof membrane. Refer to "rear door waterproof membrane
replacement"
③ take off inside rubber strip of rear door. Refer to "The replacement of inside
rubber strip of rear door".
④ Refit the window glass regulator switch.
Regulate the window glass on the appropriate position so as to ease the
PW012
removal/installation of rear window glass fixing bolts.
removal of fixing bolts
⑤ Remove bolts securing rear window glass.

PW013
⑥ Remove fixing bolt of male drawer guide of rear window glass.
PW014
⑦ Take off window glass.
2) Installation.
PW-10
① Reinstall window regulator switch, and lift glass to an appropriate position to

facilitate installation of bolts securing window glass.
② put window glass in the door, right to installation hole.
③ Install bolts securing window glass.
Install fixing bolt of rear guide
⑤ Install inside rubber strip of rear door Refer to "The replacement of inside rubber strip of
rear door".
⑥ Install waterproof membrane Refer to "rear door waterproof membrane

replacement"
⑦ Install door trim panel. Refer to The replacement of the interior trimming panel of
rear door.
8. Replacement of the rear window glass regulator

1) Removal
① Remove door trim panel. Refer to The replacement of the interior trimming
panel of rear door.
replacement"
③ Take off inside rubber strip of rear door. Refer to "The replacement of inside
④ Remove window glass. Refer to “rear window glass replacement”.
⑤ Disconnect window regulator motor connector.
⑥ Remove the fixing nut of glass support.
PW015
PW-11
⑦ Remove nuts securing window regulator motor.
PW016
⑧ Take out window regulator.
PW017
2) Installation.
① Put in window regulator, install the fixing nut of rear window glass support.
② install the fixing nuts on the rear glass regulator motor.
③ Install rear window glass. Refer to “rear window glass replacement”.
④ Connect connector of rear glass regulator.
⑤ Install waterproof membrane Refer to "rear door waterproof membrane
replacement"
⑥ Install inside rubber strip of rear door refer to "The replacement of inside rubber strip of
rear door".
⑦ Install door trim panel. Refer to The replacement of the interior trimming panel of
rear door.
9. Replacement of the rear window glass slot.

1) Removal
PW-12
panel of rear door.
replacement"
⑤ Remove outside water splitting of rear window. refer to "outside water
splitting of rear window replacement"
⑥ Remove the rear window glass slot. PW018
2) Installation.
① Install rear window glass slot, install 2 foot part first.
② Install window glass. Refer to “rear window glass replacement”.
③ Install inside rubber strip of rear door refer to "The replacement of inside rubber strip of
rear door".
④ Install outside water splitting of window glass. Refer to "outside water

⑤ Install waterproof membrane refer to "rear door waterproof membrane
replacement"
⑥ Install door trim panel. Refer to The replacement of the interior trimming panel of rear
door.
10. Replacement of male drawer guide of rear window glass

1) Removal
PW-13
panel of rear door.
replacement"
⑤ Remove outside water splitting of rear window. Refer to "outside water
⑥ Remove the rear window glass slot.
⑦ Loosen fixing bolt of male drawer guide, remove the guide.
2) Installation.
① Install male drawer guide, tighten upper fixing bolt, not lower one.
② Install rear window glass slot, install 2 foot part first.
③ Install rear window glass. Refer to “rear window glass replacement”.
④ Tighten fixing bolt of the guide
⑤ Install inside rubber strip of rear door refer to "The replacement of inside rubber strip of
rear door".
⑥ Install outside water splitting of window glass. Refer to "outside water splitting of
PW-14
rear window replacement"

⑦ Install waterproof membrane Refer to "rear door waterproof membrane
replacement"
⑧ Install door trim panel. Refer to The replacement of the interior trimming panel of
rear door.
Fault diagnosis
1. All door PW inoperable
Check if the 30A fuse No. F31of engine compartment fuse
1 box, the 15A fuse No. F29, 10A fuse No. F12 and 10A fuse To step 8 To step 2
No. F7 of instrument fuse box are Disconnected.
Check if the power supply of ETACS is normal.
(1) Turn down the ignition switch, The voltage between the
terminal No.10 of ETACS plug M36 and the grounding
2 should be equal to the battery voltage. To step 3 To step 9
(2) Turn on ignition switch, The voltage between the
terminals No.18 & 9 of ETACS plug M37 and the
grounding should be equal to the battery voltage.
Check if the ETACS grounding is normal.
Turn down the ignition switch, disconnect ETACS
plug,The terminal No.19 of plug M36 should be
conductive with the grounding.
Check if the PW relay operates normally.
（1）The terminals No. 2 & 4 of relay are of the city power
To step
4 supply. To step 5
7
（ 2 ） Turn ignition switch to on. The terminal No. 1 of
relay should be equal to the battery voltage.
Turn on the ignition switch and check if the terminal No.3 To step
5 To step 6
of PW relay is grounding. 11
Check if the ETACS is conductive with the PW relay
harness. To step
6 To step 14
The terminal No.15 of ETACS plug M36 should be 13
conductive with the terminal No. 3 of relay.
Check if the power supply and ground line of PW switch
on the front door LH are normal.
(1)Turn on ignition switch, The battery voltage should To step
7 To step 15
exist between the terminal No.11 of plug D04 on the PW 12
switch of front door LH and the grounding
(2)The terminal No. 10 of Plug D04 on the PW switch of
PW-15
front door LH should be conductive with the grounding.
After the failure due to the circuit reason checked, change
8 To step 2
the fuse to see if the failure has been eliminated.
Repair the open/short-circuit of ETACS power line to see
9 To step 3
if the failure has been eliminated.
10 Check if the ETACS grounding circuit is open-circuited. To step 4
Repair the circuit failure and change the PW relay to see if
11 To step 7
failure has been eliminated.
12 Replace the PW switch of front door LH.
13 Replace ETACS. To step 7
Repair the connection line between the ETACS and PW to
14 To step 13
see if the failure has been eliminated.
Repair the PW switch harness of front door LH to see if the
15 To step 12
failure has been eliminated.
2. PW of front door LH inoperable

Check if the signal output of PW main switch of front door
LH is normal.
Disconnect the motor plug of PW of LH door, when the
PW main switch of front door LH is shifted up, the voltage
between the terminal No. 2 of PW motor plug D08 of front
door LH and the grounding should be equal to the battery
voltage, 0V between the terminal No.1 and the grounding,
and vice versa when shifted down.
2 Change the PW motor of front door LH

Check if the harness connection between the PW switch of
front door LH and motor is normal.
Repair the harness connector between the PW switch of
4 front door LH and the motor to see if the failure has been To step 2
eliminated.
3. PW of front door RH inoperable
LH is normal.
Disconnect the motor plug of PW of RH door, when the
1 PW main switch of front door RH is shifted up, the voltage To step 2 To step 3
between the terminal No. 1 of PW motor plug D15 of front
door LH and the grounding should be equal to the battery
voltage, 0V between the terminal No.2 and the grounding,
PW-16
and vice versa when shifted down.
2 Change the PW motor of front door RH
Check if the conductivity of the PW switch on the front
door RH is normal.
Disconnect the PW switch plug 12 of front door RH and
3 check the conductivity between the terminals 4, 6, 8 and 1, To step 5 To step 4
3. Going up, terminal 1 & 6 are conductive, 2 & 8 also;
going down, terminal 3& 6 are conductive, 1&4 also; when
stable, terminal 3 & 8 are conductive, 1 & 4 also.
4 Change the PW switch of front door RH.
front door RH and PW motor of front door RH is normal.
The terminals No.3 & 1 of PW switch plug D12 on the
5 To step 7 to step 6
front door RH should be conductive respectively with the
terminals No.2 &1 of PW motor plug D15 on the front
door RH.
Repair or replace the PW switch of front door RH and PW
6 motor harness of front door RH To see if the fault has been To step 7
eliminated.
Check the power supply of the PW switch on the front
door RH is normal
7 turn on ignition switch, the voltage between the terminal To step 4 To step 8
No. 6 of PW switch plug D12 on the front door RH and the
grounding should be equal to the battery voltage,
Check if the terminal No.1 of PW switch plug D04 on the
To step
8 front door LH is conductive with the terminal No.6 of PW To step 9
10
switch plug D12 on the front door RH.
Repair or replace the PW switch plug on the front door LH
9 And PW switch plug connecting cable on the front door To step 10
RH to see if the fault has been eliminated.
10 Change the PW switch on the front door LH.
4. PW of rear door RH inoperable

LH is normal.
Disconnect the motor plug of PW of rear RH door, turn
on ignition switch, when the PW main switch of front door
1 RH is shifted up, the voltage between the terminal No. 2 of To step 2 To step 3
PW motor plug D21-2 of front door LH and the grounding
should be equal to the battery voltage, 0V between the
terminal No.1 and the grounding, and vice versa when
shifted down.
PW-17
2 Change the PW motor of rear door RH
Check if the conductivity of the PW switch on the rear
door RH is normal.
Disconnect the PW switch plug 18-2 of rear door RH and
4 Change the PW switch of rear door RH.
rear door RH and PW motor of rear door RH is normal.
The terminals No.1 & 3 of PW switch plug D18-2 on the To step 6
5 To step 7
rear door RH should be conductive respectively with the
terminals No.1 &2 of PW motor plug D21-2 on the rear
door RH.
Repair or replace the PW switch of rear door RH and
6 PW motor harness of rear door RH To see if the fault has To step 7
been eliminated.
Check the power supply of the PW switch on the rear door
RH is normal.
7 Turn on ignition switch, the voltage between the terminal To step 4 To step 8
No. 6 of PW switch plug D18-2 on the rear door RH and
the grounding should be equal to the battery voltage,
Check if the terminal No. 1 of PW switch plug D04 on the
To step
10
switch plug D18-2 on the rear door RH.
9 And PW switch plug connecting cable on the rear door RH to step 10
To see if the fault has been eliminated.
5. PW of rear door LH inoperable

Check if the signal output of PW main switch of rear LH
door is normal.
Disconnect the motor plug of PW of rear LH door, turn on
ignition switch, when the PW main switch of front door
1 LH is shifted up, the voltage between the terminal No. 1 of To step 2 To step 3
PW motor plug D21-1 of front door LH and the grounding
should be equal to the battery voltage, 0V between the
terminal No.2 and the grounding, and vice versa when
shifted down.
PW-18
2 Change the PW motor of rear door LH
Check if the conductivity of the PW switch on the rear
door LH is normal.
Disconnect the PW switch plug D12 of rear door LH and
4 Change the PW switch of rear door LH.
rear door LH and PW motor of rear door LH is normal.
The terminals No.1 & 3 of PW switch plug D18-1 on the
rear door LH should be conductive respectively with the
terminals No.1 &2 of PW motor plug D21-1 on the rear
door LH.
Repair or replace the PW switch of rear door LH and PW
6 motor harness of rear t door LH To see if the fault has been To step 7
eliminated.
Check the power supply of the PW switch on the rear door
LH is normal
7 Turn on ignition switch, the voltage between the terminal To step 4 To step 8
No. 6 of PW switch plug D18-1 on the front door RH and
the grounding should be equal to the battery voltage,
Check if the terminal No.1 of PW switch plug D04 on the
To step
10
switch plug D18-1 on the front door RH.
9 And PW switch plug connecting cable on the rear door RH To step 10
To see if the fault has been eliminated.
6. PW lock-up switch ineffective

Replace the PW switch on the front door LH and check its
normal operation. If the PW lockup is operable?
3 Check the harness and connectors.
7. PW Auto-Down on the front door LH ineffective

1 Replace the PW switch on the front door LH and check its To step 2
PW-19
normal operation. If the Auto-Down is operable?
PW-20
J4 Repair Manual Engine Cover and Doors
Body Structure
Engine Cover and Doors
Precautions:
■When removing and installing a component, avoid damage or scratch.
■When removing a clip from a trim part, wrap head of flat screwdriver with cloth.
■When installing body trims, firstly make sure their clips have been installed in plate holes
on body firmly, and then press them in carefully.
■When removing and installing large parts and components, have two persons work
together so as to avoid dropping.
■When removing and installing some rubber trims, please do not use excessive force.
Engine Hood Assembly

1. The Replacement of Engine Compartment Hood
1) Removal
① Open and support the engine compartment hood by a serviceman
② Mark the relative position of the hinge to the engine compartment, in order to
locate when installing.
③ The second serviceman uses 10 and 12 of socket or wrench to remove the
fixed bolt, connecting one side of the Engine Compartment hood and Hinge, and lift
engine compartment hood by hands to avoid the surrounding parts.
④ The third serviceman uses No. 10 and No. 12 socket or wrench to remove the
fixed bolt, connecting the other side of the Engine Compartment hood and Hinge
By the cooperation of these three persons, the engine compartment hood is
removed from the hinge.
BODY-1
Tightening torque: 9~11 N.m, 16.7~25.5N.m

2) Installation.
Installing shall accord with the reversed order of removal.
2. The replacement of engine hood rod
Caution:
■ When removing or installing an engine hood rod, additional support must be
used to avoid vehicle damage or personal injury.
1) Removal
① Open and support engine hood.
② Remove the two bolts in rod with 10 of socket or wrench.
BODY001
③ Remove the ball pin of support rod, and take off the rod.
BODY002
2) Installation.
Installing shall accord with the reversed order of
removal.
3. The Replacement of the Hinge of Engine
Compartment Hood
BODY-2
1) Removal
① Removing engine compartment cover,
please refer to The Replacement of Engine Compartment Hood
② Use No. 10 socket or wrench to remove and assembly the two fixed bolts on
fender.
③ Use No. 10 and 12 socket or wrench to remove the fixed bolts, bolting the
hinge and the body.
2) Installation
Installation is the reversed order of removal.
■ Tightening torque: 16.7~25.5 N.m
4. The Replacement of weather strip:
1) Removal
① Use hand or tool to lever up one end of weather strip.
② Remove weather strips.
BODY003
Caution:
■ To remove it, do not pull hard.
2) Installation.
① Firstly, install two ends of the strip, sticking to the ventilation cap through the
diagonal cut
BODY004
② Install it in the card slot on the ventilation cap
from two ends to the middle.
③ Use a rubber hammer to knock on the weather
strip to fix it well.
Caution:
BODY-3
■ To install, do not apply to much strength to knock on the weather7 strip with
the rubber hammer in case of damaging it.
5. The Replacement of weather strip on the front engine hood:
1) Removal
① Use the tool to remove buckles and weather strip in sequence.
2) Installation.
① Connect the buckles of weather strip to mounting holes on the inner board to
fix it well.
Note: When installing, the buckle shall align to the hole to prevent damaging the
buckle.
Fenders
1. Removal:
BODY005
① Remove front wheel cover.
② Remove front bumper.
Front
③ Interior triangular cover board
Anterior
④ Use No. 10. socket of 6 angles to remove 8 combination bolts in the fender.
Caution:
■ Follow the same way to remove and install door assemblies.
■ When remove and install a door assembly, protective measures should be taken
to avoid door and body scratches.
■ After a door assembly is installed, be sure to perform fitting adjustment to
make sure it can be opened/closed normally, at the same time, heads of hinge
BODY-4
assembly bolts shall be repainted (body color).

■ Check rotating parts of hinges for poor lubrication. If necessary, apply
“grease”.
■ Door components are heavy, so have several persons work together during
removal.
2) Installation
The replacement of front door assembly:

1. The replacement of front door limiting stopper
1) Removal
① Use No. 12 socket to remove the fixing bolts, connecting the body and the
limiting stopper. .
② Use No. 10 socket or wrench to remove the two fixing bolts, connecting the
door and the limiting stopper. .
BODY006
2) Installation
2. The replacement of front door assembly
1) Removal
① The replacement of door limiting stopper, please refer to The replacement of
front door limiting stopper
② Use No. 12 wrench to remove the fixed bolts, connecting the hinge and the
door.
BODY-5
BODY007

Caution:
■ Remove in steps, never loosen at a time.
■ Remove from bottom to top.
③ Unplug door harness rubber sleeve and disconnect door electrical connector.
④ With a helper’s aid, lift off door and put it at an appropriate place.
2) Installation.
Caution:
■ Tighten in steps when installing, never tighten at a time.
3. The replacement of the interior trimming panel of front door:

1) Removal
① Open the front door, first use a slotted screwdriver to
pry a buckle of four metal claws and a plastic buckle on the triangular window with
rear-view mirror remove the buckle connecting BODY008 Buckle of four
the bottom and the door trim assembly and disconnect the metal claws
wire harness
Plastic
plug of the rear-view mirror.
buckle
② Loosen the fixed bolts in the rear Buck
door internal handle, and remove internal

handle, please refer to “The replacement of BODY009
BODY-6
Screw
front door inner handle”.

③ Use a slotted screwdriver to pry up the bolt cover on the armrest panel and
then use a Phillips screwdriver to unscrew the captive bolt; use a slotted screwdriver
to pry up the buckle claw between front armrest panel and door trim assembly,
remove the armrest panel, and disconnect the connector of the switch assembly
BODY010
④ Use a Phillips screwdriver to unscrew The grommet screws
two fixed bolts in front door interior trim panel

and a grommet screw. Screw
⑤ Use a slotted screwdriver to pry up the 8 buckles on the front door interior trim panel,
and take off the front door interior trim panel BODY011
from the inside rubber strip.
⑥ Remove the dragline of the front door inner handle, please refer to The
replacement of front door inner handle.
⑦ Disconnect the front door light harness plug, please refer to "The replacement
of front door light.
⑧ Remove front door inner trim panel
2) Installation
First, connect door light wire harness and inner handle dragline, then align the
door trim panel fixed clip to the holes in the metal plate of the door, and press down
firmly in sequence. Tighten three screws.
4. The replacement of front door hinge
1) Removal
BODY-7
① The removal of front door assembly, please refer to The replacement of front
door assembly
② Use No.10 wrench to remove the fixed bolts, connecting the hinge and the
body.
BODY012
2) Installation
5. The replacement of waterproof film of front door:
1) Removal
① Remove door trim panel.
② Disconnect clip securing harness.
③ Separate waterproof film and take it off.
2) Installation. BODY013
Caution:
■ Do not touch adhesive surface so as to avoid
impairing re-bonding effect.
■ When taking waterproof film, take care to avoid
damage to it.
6. The replacement of inside rubber strip of front door
1) Removal
① Remove door trim panel. Refer to "Front door trim panel replacement:
② Use hand to take one end, and then both hands slowly take off inside rubber
strip of front door
BODY-8
Caution:
■ Please do not apply excessive force during removal, otherwise it may result in
parts deformation.
2) Installation.
① Align the inside rubber strip of front door to B pillar card slot, maintaining
clearance 1 ~2 MM; first install the rear end, and then slowly place the inside rubber
strip of front door into position.
The replacement of rear door assembly:

1. The replacement of rear door limiting stopper
1) Removal
① Use No. 12 socket to remove the fixing bolts, connecting the body and the
limiting stopper. .
② Use No. 10 socket or wrench to remove the two fixing bolts, connecting the
door and the limiting stopper. .
BODY014
2) Installation.
Installation is in the reversed order of removal.
2. The replacement of rear door assembly
1) Removal
① The removal of door limiting stopper, please refer to The replacement of
front door limiting stopper
② Use No. 12 wrench to remove the
BODY015
fixed bolts, connecting the hinge and the door.
BODY-9

Caution:
■ Remove in steps, never loosen at a time.
■ Remove from bottom to top.
③ Unplug door harness rubber sleeve and disconnect door electrical connector.
④ With a helper’s aid, lift off door and put it at an appropriate place.
2) Installation.
Caution:
Tighten in steps when installing, never tighten at a time.
3. The replacement of the interior trimming panel of rear door:
1) Removal
① Open the front door, first use a slotted BODY016
screwdriver to pry three buckles on the triangular

window with rear-view mirror and then pull out the
triangular board with strength.
② Unscrew the fixed bolts in the rear door inner
handle, and remove inner handle, please refer to “The
replacement of front door inner handle”.
③ Use a slotted screwdriver to pry up the bolt cover on the armrest panel
and then use a Phillips screwdriver to unscrew the captive bolt; use a slotted
screwdriver to pry up the buckle claw between front armrest panel and door trim
assembly, remove the armrest panel, and disconnect the connector of the switch
assembly
BODY-10
④ Use a Phillips screwdriver to unscrew a grommet screw and a bolt in the

bottom in sequence.
BODY017
The grommet screw
Screw
⑤ Use a slotted screwdriver to pry up the rear door interior trim panel, and take
off the rear door interior trim panel from the inside rubber strip.
⑥ Remove the dragline of the rear door inner handle, please refer to The
replacement of rear door inner handle.
⑦ Disconnect glass elevator switch harness connector, please refer to The
replacement of rear door glass elevator switch.
⑧ Remove rear door inner trim panel
2) Installation
First, connect door light wire harness and inner handle dragline, then align the
door trim panel fixed clip to the holes in the metal plate of the door, and press down
firmly in sequence. Tighten two screws.
4. The replacement of rear door hinge
1) Removal
① The removal of rear door assembly, please refer to The replacement of rear
door assembly
② Use No. 12 wrench to remove the fixed bolts, connecting the hinge and the
body.
■ Tightening torque: 16.7~25.5 N.m.

BODY018
BODY-11
2) Installation
5. The replacement of rear door waterproof film:

1) Removal
① Remove rear door interior trim panel.
② Disconnect clip securing harness.
③ Separate waterproof film and take it off.
2) Installation.
Caution:
■ When assembling the waterproof film, do not allow it to cover clip pilot holes
on door trim.
■ Do not touch adhesive surface so as to avoid impairing re-bonding effect.
6. The replacement of inside rubber strip of rear door

BODY019
1) Removal
1. Remove door trim panel.
① Refer to The replacement of the interior trimming
panel of rear door:
② Use hand to take one end, and then both hands
slowly, take off inside rubber strip of rear door.
Caution:
■ Please do not apply excessive force during removal, otherwise it may result in
parts deformation.
2) Installation.
BODY-12
① Align the inside rubber strip of rear door to B pillar card slot, maintaining clearance 1 ~2
MM; first install the front end, and then slowly place the inside rubber strip of rear door into
position. BODY020
Trunk lid
1. The replacement of trunk lid
1) Removal
① Open the trunk lid.
② Remove trunk interior trim.
③ Remove the connecting wire harness in the trunk lid.
④ Use No. 10 socket or wrench to remove the trunk lid fixed bolts.
⑤ Lift off trunk lid.
BODY021
2) Installation.
Caution:
■ After finishing trunk lid assembly, you should adjust trunk lid to ensure
satisfactory clearances to the left and right and surface difference and free open-close
without interference.
2. The replacement of trunk lid hinge

1) Removal
① Remove the trunk lid., please refer to The replacement of trunk lid
② Use No. 10 socket or wrench to remove the trunk lid fixed bolts.
■ Tightening torque: 6.9~10.8 N.m BODY021
BODY-13
2）Installation
3. The Replacement of trunk lid weather strip:
1) Removal
① Remove the tail lamp. Refer to "Automobile tail lamp replacement.
② Use the tool to pry up weather strip.
③ Remove weather strips slowly.
BODY022
Caution:
■ To remove it, do not pull hard.
2) Installation.
① Align the weather strip butt seam to the trunk lid button
② Use hand to fix the weather strip guide slot to the body, and pay attention to
the clamping of the round corner.
③ Use a rubber hammer to knock on the weather strip to fix it well.
④ The installation of the taillight. Refer to "Automobile tail lamp replacement.
Caution:
■ To install, do not apply to much strength to knock on the weather7 strip with
the rubber hammer in case of damaging it.
Oil filler of fuel tank

1. Filler cover plate replacement
1) Removal
BODY-14
① Open filler cover plate.

② Disconnect the drawstring connecting filler cap with filler cover plate.
③ Remove screws securing filler cover plate.
■ The bolt tightening torque of 7.8 ~11.8 N • M
BODY023
④ Remove filler cover plate.

2) Installation.
2. Filler cap replacement
① Open filler cover plate.
② Remove the drawstring connecting filler cap with filler cover plate.
BODY024
BODY025
③ Remove filler cap.
2) Installation.
Locking system
1. The replacement of engine hood lock
BODY-15 BODY026
1) Removal
① Open engine hood.
② Remove front bumper.
③ Remove bolts securing lock.
④ Disconnect lock cable and take off
engine hood lock.
2) Installation.
2. The replacement of engine hood open-close handle
1) Removal
① Remove the fixed bolts securing open handle base seat of engine hood.
② Disconnect engine hood handle cable.
③ Take off engine hood open-close handle.
2）Installation
BODY-16
J4 Service Manual Interiors and Exteriors
EI Interior & Exterior Trims

Precautions:
■ When removing and installing parts and components, take protective measures
to avoid scratching and damaging parts and components.
■ When removing a trim clip, wrap blade of flat screwdriver with cloth to avoid
scratching body and trim panels.
■ When installing body trims, make sure their clips have been installed in plate holes on
body correctly, and then press them in carefully.
■ When removing and installing large parts and components, have several persons work
together to avoid dropping which could cause components damage and personal injury.
■ When removing and installing trims, please do not apply excessive force so as to avoid
part deformation and damage.
Front bumper replacement
1
9
2
8
3
7
4
Front bumper assembly diagram

1 - Front bumper body 2 -Up grille 3 -Up grille decoration strip,
4 - Down grille decoration strip, 5 - Down grille 6 - Left fog lamp cover
7 - Left hand bracket of front bumper assembly 8 - Buffer beam assembly of Front
EI - 1
Bumper 9 -Front bumper energy absorbing pad
1. Removal
1) Lift vehicle to an appropriate height, and remove screws securing front
bumper and front-end module.
2) Remove the rubber and plastic snaps connecting the front bumper and the
side mudguards.
3) Remove the fixed screws securing the front bumper and the side mudguards.
EI001
4) Remove the snaps connecting the front bumper to the front-end module.
EI002
5) Move away front bumper and disconnect front fog light connector.
EI003
EI004
6) Take off the front bumper.
EI - 2
2. Installation.
Caution:
■ Check after installation for surface difference and clearance at matching place
of bumper and body.
Front bumper beam replacement

1. Removal
1) Remove screws securing the front bumper beam.
EI005
2) Remove the front bumper beam.

2. Installation
Caution:
■ The front bumper beam is fixed to the body by 8 bolts through the location of
the location pin on the front-end module.
■ Tightening torque: 9～11 N.m, 15～20 N.m
EI - 3
Rear bumper replacement
1 6
2 5
4
Rear bumper assembly diagram
1 - Rear Bumper body 2 - Right hand bracket of rear bumper assembly
3 - Rear bumper beam assembly
4 - Left hand bracket of rear bumper assembly 5 - Left energy absorbing pad 6-Right
energy absorbing pad
Caution:
■ The bumper trim panel is made from resin material.Please do not apply strong
force to it, and avoid contact with oils
■ During removal and installation, do not scratch outer surface of bumper.
1. Removal
1) Place your vehicle on a lift and lift it to an appropriate height, and then remove
fixed screws from lower part of rear bumper.

EI006
EI - 4
2) Remove taillight.
3) Remove screws connecting rear bumper with body from under left and right
taillights.
EI007
4) Remove fixed screws of rear bumper at both left and right sides in sequence.
EI008
5) Remove the fixed screws and rubber plastic snaps of the rear bumper.
6) Disconnect parking assist system sensor electronic connector.
7) Take off rear bumper.
2. Installation
Sun visor replacement

1. Removal:
1) Remove screws securing sun visor.
EI009
EI - 5
2) Disconnect connecting wire inside sun visor.

EI010
3) Take off sun visor.

2. Installation
Install in the reversed order of removal of sun visor.
Caution:
■ Follow same steps to replace left and right sun visors.
A column upper guard plate replacement

1. Removal
1) Remove front door sill protect board assembly.
2) Remove the front doorframe rubber strip, please refer to "The replacement of
front doorframe rubber strip".
3) Use a slotted screwdriver to pry up the top of A column upper guard plate,
remove a special plastic buckle and a iron clip in sequence, and take off A column
upper guard plate from the matching place of dashboard.
Special plastic
Iron clip
EI - 6
2. Installation
Snap the bottom of A column upper guard plate into the dashboard, align and
insert the buckle into body holes, and press firmly.
Replacement of front door sill protect board assembly.

1. Removal
Use a slotted screwdriver to pry up the matching structure between the front end
of the front door sill protecting plate and A column lower protect plate, and then, in
turn, remove three door sill buckles. Use a slotted screwdriver to pry up the matching
structure between the rear end of the front door sill protecting plate and B column
lower protect plate, and then take off the front door sill protecting plate.
Door sill
Buckle
B column A column
2. Installation
After the installation of doorframe rubber strip, align the buckle structure of front
door sill protect plate front/rear end to the lower protect plate of A/B column, and
align and press the door sill buckle to the door sill buckle holes with force.
EI - 7
A column lower guard plate replacement

1. Removal
1) Remove front door sill protect board assembly.
2) Remove the front doorframe rubber strip, please refer to "The replacement of
front doorframe rubber strip".
3) Remove the open handle of engine hood, use a slotted screwdriver to pry up
two fixed buckles in the vehicle body, and pull out A column lower protect plate from
the vehicle.
2. Installation
Align A column lower protect plate to the holes in the body and press down the
buckles of A column lower protect plate into the holes with force.
Replacement of rear door sill protect plate assembly.

1. Removal
1) Remove back-row seats, please refer to "Back-row seats replacement".
2) use a Phillips screwdriver to remove three screws, and when it is finished, use
a slotted screwdriver to pry up the matching place between the rear end of rear door
sill protect plate and the B column lower protect plate. Then, remove the buckling of
door sill buckle, and take off the rear door sill protect plate.
EI - 8
B column
Screw
Buckle joint
2. Installation
After the installation of the rear door frame rubber strip, align and insert the
buckling structure of the front/rear end of rear door sill protect plate into the holes of
B column lower protect plate and door sill buckle. Press down firmly. And also align
it to the plastic expansion buckle of the body and tighten the screws with a Phillips
screwdriver.
B-pillar trim panel replacement

1. The replacement of B pillar lower trim panel assembly
1) Removal
① Adjust the front seat position, and remove the front seat belts, please refer to
"Front seat belt replacement.
② Remove front door sill protect board assembly.
③ Remove the front doorframe rubber strip; please refer to "The replacement
of front doorframe rubber strip".
④ Remove rear door sill protect plate assembly.
⑤ Remove the rear doorframe rubber strip, please refer to "The replacement of
rear doorframe rubber strip".
⑥ Adjust the front seat to the front position and remove the lower fixed points
EI - 9
of front seat belts; use a slotted screwdriver to pry up the matching structure of the
upper end of B pillar lower protect plate and B pillar upper protect plate. Remove 5
buckles fixed in the body and take off B pillar lower protect plate finally.
2) Installation.
Align and press down firmly the fixed buckles of B pillar lower protect plate to
the body holes; and then press it tightly with B pillar upper protect plate matching
structure.
2. B pillar upper protect plate replacement
1) Removal
① Remove B pillar lower protect plate, please refer to "B pillar lower protect
plate replacement.
② Use a slotted screwdriver to pry up 3 buckles fixing B pillar upper protect
plate to the body, and then remove B pillar upper protect plate.
EI - 10
2) Installation.
Align and press down firmly the fixed buckles of B pillar upper protect plate to
the body holes; and then press it tightly.
C pillar upper guard plate replacement

1. Removal:
1) Remove C pillar lower protect plate assembly , please refer to "C pillar lower
protect plate replacement".
② Use a slotted screwdriver to pry up 1 iron clamp and 3 buckles fixing C
pillar upper protect plate to the body, and then remove C pillar upper protect plate.
Iron clip
2. Installation
Insert the lower end of C pillar protect plate into the holes of hall stand assembly
firstly; align and press down firmly the fixed buckles to the body holes; and then press
it tightly.
EI - 11
Top handle replacement
1. Removal
1）Open the bolt decoration cap of top handle
EI011 EI012
2) Remove fixed screws of top handle.

3) Remove the top handle.
2. Installation
Installation is in the reversed order of removal steps.
Ceiling body replacement
1. Removal
1) Remove the fixed screws of sun visor main bracket and auxiliary bracket, and
take off the visor. EI013
2) Remove screws securing middle ceiling light and disconnect connectors, and
then take off middle ceiling Light. EI014
EI - 12
3) Remove all auxiliary handle in the vehicle.

EI015
4) Remove door sealing strip.

EI016
5) Remove A-pillar upper trim panel

EI017
6) Remove B-pillar upper trim panel
EI018
7) Remove C-pillar upper trim panel

8) Remove clips securing ceiling body.
EI - 13
9) Remove ceiling assembly gently and move it out of rear door.

2. Installation
Caution:
■ When installing, do not bend ceiling assembly excessively.
■ When installing ceiling assembly, align sun visor holes on ceiling assembly
and the last 2 clip fixing holes with their respective holes on body first and then
install.
Carpet replacement
1. Removal
1) Remove fixing bolt of front seat and disconnect seat connector, and then
move out the seat.
EI019
Front headrest
Left front seat assembly
Installation screw
2) Remove rear seat and their brackets.

EI020
Rear seat back
Back fixing bolts
Cushion fixing buckle
3) Remove front and rear door threshold trim plate.

EI021
EI - 14
4) Remove A, B, C pillar lower trim

EI022
plate.
5) Remove auxiliary dashboard

EI023
6) Remove carpet buckles.

7) Remove the carpet. EI024
2. Installation
1) Place the rear carpet into the vehicle, align it to the
holes and fix it with buckles.
2) Place the front carpet into the vehicle, set it

into place and expose the corresponding holes for
seat installation.
3) Fish out the seat connect wiring harness below the carpet, compact the carpet beside
middle gangway and fix the carpet with buckles.
EI - 15
Hall stand assembly replacement
1. Removal
Use special tools to remove 6 buckles in the front of hall stand assembly, push
the hall stand assembly vertically upward until the front part totally gets off the body,
and take off the hall stand assembly by moving it in front direction.
Caution:
■ The high brake lamp connector must be pulled put before removal.
Buckle
2. Installation
Luggage trunk assembly replacement

1. Replacement of trunk door sill protect plate assembly.
1) Removal
Take out the spare tire cover and remove the threshold sealing strip; use special
tools to remove 3 buckles of the protect plate and pull out the protect plate assembly
vertically upward.
EI - 16
Buckle
2) Installation.
2. Luggage trunk front trim panel replacement
1) Removal
Use a special tool to remove 4 buckles of front trim panel and pull it out.
Buckle
2) Installation.
3. Luggage trunk side trim panel replacement
1) Removal
Use a special tool to remove 8 buckles of left/right trim panel, remove 2
self-tapping screws in the bottom part with a Phillips screwdriver, and pull the
left/right trim panel out.
EI - 17
buckle
buckle
2) Installation.
4. Replacement of trunk lid protect plate
1) Removal
Use a special tool to remove the 15 buckles, and then remove the cover.
2) Installation.
EI025
Seat replacement
Front headrest
1. Front seat replacement
1) Removal
Left front seat assembly
Installation bolt
EI - 18
① Unscrew the seat assembly mounting bolts, and remove the seat assembly
and the headrest.
② Separate safety belt-lock wire.
③ Adjust seat back to an appropriate position so that the seat can be moved out
easily.
④ Move out the seat and reinstall bolts.
2) Installation.
Installation is in the reversed order of removal steps.
2. Rear seat replacement
1) Removal
① Remove the seat cushion and the seat cushion snaps.
② Unscrew the back mounting bolts, lift up the back to get off the hook, and
then take out the back.
■ Stipulated torque: 45N.m-60N.m.
Rear seat back
Back fixing bolt
Cushion fixing bolt
2) Installation
EI - 19
Label replacement
1. Removal
1) Before removal, heat label (name plate) at a distance of approx. 152mm
from it surface in a circular motion for approx. 30 seconds.
2) Use tape to protect mounting surface.
3) Use a flat edge tool, lift or remove label from surface of panel board.
Caution:
■ Do not damage body paintwork.
2. Installation
1) Clear mounting area of label and dry it thoroughly.
2) Heat mounting surface to approx. 27~41℃.
3) Tear off tape protecting layer from back of label and press label into correct
position.
Caution:
■ Stick label in a dustless environment as far as possible. Dust or other foreign
materials may cause unfavorable adhesion.
Front windshield replacement
1 - front
windshield
assembly 2- left ventilating cover plate assembly 3 -right ventilating cover plate assembly 4-
EI - 20
lower ventilating cover plate assembly

5-Front wall sealing strip assembly
1. Removal
1) Open engine hood. EI026
2) Mask surrounding area of front windshield to protect paintwork and roof

interior.
3) Remove front windshield wiper arms and blades.
EI027
4) Remove A-pillar upper trim panel

EI028
5) Remove front windshield garnish strip.

Caution:
■ During removal of windshield, the only suitable lubricant is fresh water.
EI - 21
6) Use glass sealant remover or windshield stationary window glass remover to

EI029
remove the windshield.
7) With a helper’s aid, remove front

EI035
windshield from the vehicle.
8) Check the following components that may result in a broken windshield:

① Windshield sash edge
② Windshield garnish strip
③ Windshield
9) Check windshield sash and adhesive flanging.
10) Clear front shroud, seats, floor, and defroster ducts of all cullets. Clear inner
surface edge of windshield with a lint-free cleaning cloth wetted in a mixture of
isopropyl alcohol and water of 50/50 in volume.
2. Installation
Perform the following operations after windshield sash is handled as required:
1) Stir pressed welding primer for at least 1 minute.
EI031
2) Use a new dauber, apply pressed welding primer
to surface (1) of bonding area.
EI - 22
3) Wait about 10 minutes for primer to dry. Make sure all scratches and abrasions
have been covered.
4) Install washer and VIN plate filler strip.
EI032
5) Install garnish strip to edge of windshield.

If original window garnish is damaged, be sure to replace it.
EI033
6) With the help of an assistant, adapt windshield to sash to determine correct

location mode of front windshield in its sash. EI034
EI035
7) Use tape (1) to mark position of
windshield in its sash
EI - 23
8) Cut off tape from top edge of windshield.

9) With a helper’s aid, remove windshield from its sash using suction cup.
10) Put windshield on a clean and safe surface with its inner face up.
11) If the original windshield is to be reused, clear its surface of almost all
polyurethane adhesive with a multi-purpose knife or razor blade, but retain a film.
12) Clear inner surface edge of windshield with a lint-free cleaning cloth wetted
in a mixture of isopropyl alcohol and water of 50/50 in volume.
Caution:
■ Never clear all traces of adhesive. Clear all accumulated or scattered
polyurethane adhesive debris.
13) If long-term method is used, clear blank welding flanging of almost all
adhesive while retaining approx. 2mm.
14) Stir pressed welding primer for at least 1 minute.
15) Use a new dauber, apply primer to surface of blank welding flanging.
16) Allow clamping welding primer to dry for approx. 10 minutes.
Caution:
■ When applying glass protectant (transparent) to windshield, please be cautious
and careful. Such primer almost dries immediately, so visual area of windshield may
be contaminated in the case of uneven application.
17) Apply approx. 10~16mm glass protectant along outer edge of whole window
inner surface with a new dauber.
18) Apply the second layer of glass protectant to corresponding area on the glass.
19) Wipe up the area coated with primer with a lint-free clean rag immediately.
EI036
20) Stir glass protectant for at least 1 minute.
EI - 24
21) Use a new dauber, apply glass primer to EI037

the same area of glass protectant application. Glass
primer can be used after 8 hours since it has been
applied to the glass. The glass surface for primer
application must be kept clean.
22) Wait about 10 minutes for glass primer to dry.

23) Cut off nozzle of applicator to form EI038
a 6.0mm flanging.
24) Use barrel caulking gun, EI039
coat glass cement flanging evenly and

continuously.
25) Smear glass cement on existing

glass cement on body.
26) With the help of an assistant, EI040
use suction cup to install windshield

into its sash
27) Align tape lines (1) on windshield

EI041
and body.
EI - 25
28) Press windshield into place.

29) Stick windshield to body using tape to reduce movement until glass cement
cures.
30) Clear body of all redundant glass cement.
Caution:
■ Do not spay high pressure water stream on glass cement just applied directly.
31）Perform watertight test to windshield with soft warm water.
32）Check windshield for leakage.
33）If leakage is found, smear more glass cement on the leaky point with a plastic
scraper.
34) Wait until glass cement cures and then recheck front windshield for leakage.
Warning:
■ Approx. 24 hours are required for service materials to cure completely. Before
this, never interfere in the repaired area. In the case of inadequate curing of glass
cement, occupants who do not take protective measures may be thrown out of the
vehicle resulting in personal injury.
Remove protective tape and mask from windshield zone.
Caution:
■ After finishing windshield installation, be sure to wait more than 1 hour for
sealant to cure.
■ After windshield is installed, park your vehicle on a flat ground for more than 4
hours. ■ If you need to run your car at this time, you must drive it slowly within 8
hours.
■ It is not allowed to slam a door with all door windows closed.
■ After windshield installation, do not subject your vehicle to large load within
2-3 days (e.g. driving on irregular and rugged roads).
EI - 26
J4 Service Manual Dashboard
Dashboard
Precautions:
■ Strictly observe precautions for operation of air bag system, otherwise vehicle
damage and personal injury may result.
■ Before removal of an electrical connector, be sure to remove battery negative (-)
and wait at least 1 minute; otherwise, vehicle damage may result.
■ When removing and installing a component, prevent damage or scratches to the
components removed.
■ When removing the metal clamps from the trim parts, wrap the flat screwdriver
edge with cloth.
■ When installing the body trim parts, first confirm clamps securely fitted in the
plate orifice on the body, then carefully press them in.
■ When removing and installing a large component, be sure to have 2 persons
work together so as to avoid dropping.
■ When removing and installing a garnish, please do not use excessive force.
Driver side airbag module replacement

1. Removal
IP001
2) Remove airbag module (DAB).
IP-1
9H remove hole
3H remove hole
6H remove hole
Schematic diagram of removing DAB (3 steps), disconnecting tool is a slotted screwdriver
with length of 15cm.
① Disconnect 3H hole
Rotate steering wheel 90°anticlockwise, pry up 3H hole's groove with
screwdriver (for detailed structure showed in diagram) and separate the DAB buckle
with steering wheel framework.
② Disconnect 6H hole
Rotate steering 90°anticlockwise, pry up 6H hole's groove with screwdriver(for
detailed structure showed in diagram) and separate the DAB buckle with steering
wheel framework.
③ Disconnect 9H hole
Put the steering wheel back to middle, rotate it 90°clockwise, pry up 6H hole's
groove with screwdriver(for detailed structure showed in diagram) and separate the
DAB buckle with steering wheel framework.
3) Disassemble the connector and take out the safety airbag module.
IP002
4) Place the safety airbag module properly as required. As shown in figure.
IP-2
IP003
2. Installation
Steering wheel replacement

IP004
1. Removal
1) Place the ignition switch on the position “OFF”.
2) Remove negative (-) of battery.
3) Remove driver side air bag module, and disconnect driver side airbag module connector.
IP005
4) Disconnect horn button connector.
IP006
5) Draw a position mark on steering wheel hub and align this mark with the score on steering
shaft spline. IP006
IP-3
6) Loosen steering wheel nut.

IP007
Caution:
■Do not loosen nuts completely until steering wheel is loosened so as to avoid
personal injury caused by excessive forced applied during steering wheel removal.
7) Take off steering wheel.
2. Installation.
Installation is in the reversed order of removal. Note: When install DAB, just align
the DAB to the steering wheel corresponding buckling place and press down. Meanwhile, check
whether the matching gap is even.
■ Tightening torque of steering wheel nut:42～52 N•m

Caution:
■ After finishing installation, make sure horn switch works normally and no
interference and abnormal sound exist when you turn steering wheel.
■ After installation is completed, test air bag system using JAC special
diagnostic tester to ensure the system works normally.
■ Steering wheel must be right in the middle with wheels in straight-ahead
position.
Steering column protect cover replacement

1. Removal
IP008
1) Disconnect the battery negative.
IP-4
2) Remove steering wheel assembly, please refer to "Steering wheel

replacement"
3) Remove 3 fixing bolts on the IP009
steering column lower housing.
IP010
4) Remove steering column upper and lower housing.
IP011
2. Installation.
Safety airbag Timer-spring replacement

IP-5
IP012
1. Removal:
IP013
2) Remove the driver safety airbag module, and take off Connector.
Refer to "Driver side airbag module replacement"

IP014
3) Remove screws securing the steering wheel and take off steering wheel.
IP015
IP-6
Caution:
■The fixing nuts can be fully taken out until the steering wheel is loosened,
otherwise the steering wheel may cause personnel injury.
4) Disconnect the connector of horn.
IP016
5) Poke the three bayonets embedded in combination switch of the clock spring
Caution:
■ Be sure 3 bayonets completely loose, and then take off timer-spring, which
needs to be careful because it is easily to get damaged.
IP017
6) Take out the timer-spring of safety airbag.
IP018
IP-7
2) Installation
Caution:
■ Take out the safety airbag timer-spring from the package and check if it is in
intact state and the dowel pin inserted on the part.
■ Open the connector cover, and insert the wiring connector of safety airbag into
the connector hole, then close the cover.
■ Prior to the installation of safety airbag timer-spring, be sure that the front
wheel is located in the center (orientation).
■ Prior to the installation of safety airbag timer-spring, be sure that the
timer-spring is located in center (twist clockwise to the end, then turn back
anticlockwise, for 2.5 cycles)
Driver side instrument panel lower protect panel replacement

1. Removal
1) Remove dashboard left end cover.
IP019
2) Remove 4 screws on the driver side lower cover
IP020
IP-8
3）Remove driver side lower guard board assembly.
IP021
4) Disconnect various plug-in connectors on the driver side lower guard board .
2. Installation
Ignition switch replacement

1. Brief principle
As shown in the figure, the combined steering wheel lock/ignition switch has the
following 4 key positions (LOCK---ACC---ON---START) as well as reminder
switch and night illumination features:
1) “LOCK” (lock)
Ignition switch is turned OFF and steering wheel is locked. In this position, you
can insert or take out your car key. When the key is turned back to “LOCK” position,
the engine will stop running. When the key is pulled out of ignition switch, the
steering wheel lock will be activated to lock the steering wheel.
IP-9
2) “ACC” (accessory)
Steering system is unlocked; electrical accessory circuits are switched on;
small electrical appliances such as interior lights are operable; but both ignition
switch and main electrical circuits are deenergized. The ignition switch key should
not overstay in this position so as to avoid battery exhaust.
3) “ON” (turn on)
Ignition circuit is turned ON and all electrical circuits can work. Alarming
lights and indicator lights should come on. This is the normal position of the key
during driving.
4) “START” (start)
Turn starting motor on to start engine. When the lockhole is in this position, both
headlights and electrical equipment of large power consumption are cut off. After start,
let go of the key and it will rebound to “ON” position automatically.
Caution:
■ After the engine is started, be sure to release the key immediately. Do not let the key
overstay in “START” position.
5) Reminder switch
This light will come on as soon as the key is inserted. After your vehicle is
stopped, it will remind you to pull out the key.
6) Night light
The night light is installed around the ignition key hole. If either front door is
opened, this light will light up to assist the driver to insert the ignition key into the
key hole.
2. Electrical system schematic and connectors information:
IP-10
No.
Function
load switch
Insert the key

Power switch
Remove the key
Night sight
Schematic Diagram of Ignition Switch
3. Removal

IP022
2) Remove the driver-side safety airbag module

3) Remove steering wheel IP023
4) Remove upper and lower decoration cover
5) Remove the safety airbag timer spring
6) Remove connector from ignition switch assembly
7) Remove assembly bolts from ignition switch assembly and key alarm switch
assembly. IP024
IP-11
4. Installation.
Installation is in the reversed order of removal. When installing, ensure correct
and secure wiring.
IP025
Glove box replacement
1. Removal
1) Remove the glove box buckling part.
2)Pull out glove box from opening of instrument panel.

2. Installation. IP026
Installation is in the reversed order of

removal.
Sub dashboard replacement

1. Removal IP027
1) Remove joystick cover.
IP028
2) Remove joystick jacket.
IP-12
3) Remove 2 fixing bolts in the front of sub dashboard.
IP029
5) Remove a bolt securing instrument panel and body.
IP030
2. Installation.
Steering Column replacement
1. Diagram of Steering Column Assembly:
2
1
IP-13
Diagram of Steering Column Assembly

1 - steering column assembly 2 - Intermediate Shaft Assembly
Caution:
■ Never apply excessive axial force to the steering column assembly during the
removal and installation.
■ Never move the steering gear when removing the steering column.
2. Removal
1) Straightly park the vehicle.
2) Disconnect the cathode terminal of battery and wait for more than 3min.
3) Remove the driver-side safety airbag module
4) Remove steering wheel
5) Remove the upper and lower guards of steering column and the lower portion
of driver instrument panel.
6) Remove the combined switch assembly and clock spring from the steering
column.
7) Disconnect every harness connector from the steering column and remove the
harness from the steering column assembly.
8) Remove bolts connecting steering column and lower shaft separate the steering
column and steering gear.
IP031
■ Tightening torque: 30～35 N.m
9) Remove the fixing nuts of steering column assembly, lower the steering
column, and remove the steering column assembly. IP032
■ Tightening torque: 20～30N·m
IP-14
1) Check the steering column for crack, deformation and other damage and
replace in event of any above defect.
2) Check the spline of steering column shaft for wear and tooth breakage and
replace in event of any above defect.
4. Disassembly
1) Disassembly
① Loosen the connecting bolts between steering column and connecting shaft
universal joint and remove the universal joint.
② When necessary, remove the steering lock.
Caution:
■ When reinstalling the steering lock, make sure to replace the special bolts.
③ When necessary, remove the adjustable steering column and support.
2) Disassembly key points
IP033 Screw tap
Removal of special bolts: Special bolt
① Drill with the electric drill on the special bolts Steering lock
bracket
one hole
enough to accommodate the screw tap.
② Remove the special bolts with the left-handed
Steering lock
screw tap.
① Check the adjusting support and spring for crack and damage.
② Check the steering lock mechanism for normal functioning.
4) Assembly
Assemble the steering lock assembly, steering lock
IP034
support and the special bolts.
Caution:
■ When install the steering lock assembly and
steering lock support
IP-15
onto the steering column assembly, align them to the locking

gap in the steering column to lock the steering lock temporarily.
■ After confirming the correct action of the steering lock, lock the special bolts,
till the bolt heads are broken.
lock the special bolts, till the bolt heads are broken.
5. Installation.
Installation is in the reversed order removal.
Caution:
■ Never re-use the components not intended for re-use.
■ Install the steering column assembly when maintaining the steering wheel at
neutral position.
■ When installing the connecting shaft onto the steering column, pay attention to
the installing location.
6. Inspection after installation:

Under the condition that the vehicle is straightly parked, rotate the steering wheel
leftward and rightward to limit point for several times to confirm the smooth
operation of the steering wheel. IP035
Combination instrument replacement

1. Removal
1) Remove negative (-) of battery.
2) Remove the combination instrument panel decoration board

IP036
IP-16
3) Remove screws securing combination instrument.

IP037
4) Unplug connectors of combination instrument remove instrument assembly.
IP038
2. Installation
A/C control panel replacement

IP039
1. Removal:
2) Remove A/C central control panel group shroud.
IP040
IP-17
3) Pull out the air conditioning control panel outwards and disconnect
related connectors, and take off the AC control panel.
IP041
2. Installation.
Dashboard replacement
1. Removal
IP042
2) Remove A/C control panel assembly.

IP043
3) Remove central A/C air outlet assembly.

IP048
IP0044
IP-18
4) Remove audio deck.

IP045
5) Remove left and right moldings of front door.

IP046
6) Remove left and right threshold trim plate of front door.

IP047
7) Remove upper and lower garnishes plate at left and right of A-pillar.
8) Remove left and right fixing bolts from upper part of dashboard.
9) Remove driver side instrument panel.

IP-19
10) Remove engine hood handle.

11) Remove passenger side glove box.
12) Remove bolts and screws securing fixing bracket of glove box, and dismantle
the bracket fixing the glove box.
IP049
13) Remove steering wheel assembly.

14) Remove combination switch.
15) Remove instrument assembly. IP050
16) Remove fixing nut of locating hole on
instrument behind the dashboard.
17) Remove left and right fixing nuts of dashboard.
IP051
18) Remove bolts securing passenger side air bag, dashboard and its bracket.
IP052
IP-20
19) With a helper's aid, lift off ithe dashboard.
2. Installation.
IP053
Instrument Panel Support Replacement

1. Removal
1) Disconnect all electrical equipment

connected with instrument panel support.
2) Disconnect instrument panel harness.
3) Remove fixing bolt from left side of instrument panel support.
4) Remove fixing bolt from right side of instrument panel support.
5) With a helper’s aid, lift off instrument panel support.
2. Installation.
IP-21
J4 Service Manual Body Size Data
Body Size Data

Body data:
During maintenance and service, in order to guarantee various working
performance of vehicle and for better service, please check the body size according to
the data listed below:
Measurement
Location information Value (mm)
data point
The distance between the middle of overhead cover and the
A 791.6
middle of ventilator cover upper plate
Space of R angular between left/right side panel and
B 1278.2
windshield seam allowance.
C A pillar front door frame seam allowance length . 610.7
D The front threshold upper seam allowance width. 685
Space between front door frame seam allowance upper R
E 978.8
angular of A/B pillar
Space between front door frame seam allowance upper R
F 656.3
angular of B/C pillar
G The rear threshold upper seam allowance width. 414.3
H Rear door frame height 924.5
The length of the diagonal between the front-lower part and
I 1295.7
rear-upper part of front door frame
The length of the diagonal between the front-upper part and
J 937.8
rear-lower part of front door frame
Data -1
The length of the diagonal between the front-lower part and

K 1133.6
rear-upper part of rear door frame
The length of the diagonal between the front-upper part and
L 1015.4
rear-lower part of rear door frame
The distance between the middle of overhead cover and front
M 958.8
windshield lower seam allowance
The distance between the middle of ventilator cover upper
N 964.3
plate and front windshield upper seam allowance
Data -2
Engine compartment data

During maintenance and service, in order to guarantee various working
performance of vehicle and for better service, please check the body size according to
the data listed below:
Measurement
data point
The maximum width between the left/right side panel and
A 1474.6
engine compartment
B Space of left/ right front absorber mounting plate holes 1104
The maximum length of the connecting part between front wall
C 737.5
crossbeam and engine compartment
Space of left/right engine compartment longitudinal beam
D 930
front end mounting plate holes
E Right front suspension strengthen girder length 527.2
F Left front suspension strengthen girder length 527.4

Across corner length of right engine compartment
G 1162.5
longitudinal beam and front wall crossbeam
Across corner length of left engine compartment longitudinal
H 1162.5
beam and front wall crossbeam
I Left/right front suspension strengthen girder length 1332.2
Data -3
Right suspension installed back mounting bracket to the engine

J 968.4
compartment width
Side member data:
Measurement
data point
Space between left/right front longitudinal beam and inner
A 888.3
wall
B Space of left/right front sub-frame mounting holes 953
C Space of left/right rear sub-frame mounting holes 1071
Space of the leaking holes in right engine compartment rear
D 465.1
longitudinal beam front/ rear end
Data -4
Space of the leaking holes in left/right engine compartment

E 760
rear longitudinal beam rear end
The distance between front floor girders leaking hole and
F 660
left engine compartment rear longitudinal beam leaking hole
The distance between rear floor left and right girders leaking
G 980
hole
Data -5
Contents of Sub-volume
J4 Service Manual Workshop for Circuit Service
Sub-volume Workshop for Circuit Service

How to use this Manual............................................................................. 1
Instructions............................................................................................................................. 1
Notation.................................................................................................................................. 7
Failure checking guide......................................................................................................... 14
Circuit Diagram…………………………………………………………21
Power distribution system…………………………………………………………............ 21
Start system………………………………………………………………………….......... 33
Charging system……………………………………………………………………........... 35
Engine ECU system…………………………………………………………………..........37
Reversing system……………………………………………………………………..........48
ACC system - CD player……………………………………………………………..........50
ACC system - cigarette lighter………………………………………………………......... 52
Lighting – headlamp……………………………………………………………….............53
Lighting - small light………………………………………………………………............54
Lighting - front and rear fog light…………………………………………………............ 56
Lighting - combination light switch…………………………………………………......... 57
Lighting - turning light, hazard warning light………………………………………..........58
Lighting……………………………………………………………………………............ 59
BCM system………………………………………………………………………............. 61
Electric rearview mirror……………………………………………………………........... 70
Wiper and washer system………………………………………………………….............72
Combination switch - wiper ………………………………………………………............ 73
Air bag………………………………………………………………………………..........74
Diagnosis system……………………………………………………………………..........76
ABS/Brake system…………………………………………………………………........... 77
Auto A/C system…………………………………………………………………….......... 79
A/C system - Mode, Temp actuator…………………………………………………......... 80
A/C system – Compressor…………………………………………………………............81
A/C system - Mode, Temp actuator…………………………………………………......... 82
Manual A/C system - Blower………………………………………………………...........84
Manual A/C system - Mode, Temp actuator………………………………………............ 85
Manual A/C system - Compressor…………………………………………………........... 86
Instrument cluster……………………………………………………………………......... 88
Contents of Sub-volume
J4 Service Manual Workshop for Circuit Service
IMMO………………………………………………………………………………...........91
Electric glass lifting…………………………………………………………………..........92
Door lock……………………………………………………………………………..........97
Door switch…………………………………………………………………………........ 100
TPMS ……………………………………………………………………………….........105
Component Location..............................................................................106
ABS wire harness............................................................................................................... 106
CD audio.............................................................................................................................107
Rearview mirror door wire harness.................................................................................... 108
A/C wire hareness.............................................................................................................. 112
Airbag wire harness............................................................................................................114
Front wall wire harness...................................................................................................... 115
Tail door wire harness and sensor wire harness................................................................. 116
Wire harness of instrument desk........................................................................................ 118
Seat room wire harness.......................................................................................................121
Engine cabin wire harness..................................................................................................123
Ground point.......................................................................................................................128
Wire hareness layout..............................................................................130
Main wire harness.............................................................................................................. 130
Engine wire hareness..........................................................................................................132
Indoor junction box............................................................................................................ 134
Body wire harness.............................................................................................................. 136
Airbag wire harness............................................................................................................138
Ceiling wire harness........................................................................................................... 140
Left/right front door wire harness...................................................................................... 142
Rear door wire hareness..................................................................................................... 144
J4 Service Manual. Foreword
J4 Workshop Manual
Foreword General Catalogue
This Manual is helpful for technical
maintenance staff for JAC and provides Overview and Maintenance
effective and correct maintenance and
service for an electric vehicle of JAC RS
series. To ensure the customer satisfaction Chapter I Overview
of the JAC's car products, it is extremely
essential that the professional maintenance Chapter II Maintenance
technicians for JAC's car have the friendly
service and the capability of proper Engine Sub-volume
operation; therefore, the maintenance
technicians must fully understand the
contents in this Manual. This Manual shall Chapter I Engine Machine
be accessible for reference at any time.
Chapter II Engine Electrical Equipment
All contents in this Manual, including
pictures, technical parameters are the latest. Chapter III Engine Electronic Control
But if product modification affects System
maintenance, JAC will provide technical
bulletin or supplementary volume.
Therefore, please obtain the latest Chassis Manual
information about this Manual. JAC
reserves the right to make change in design, Chapter I Transmission System
addition or improvement for the product.
This Manual shall not be copied or modified Chapter II Clutch System
without written authorization from JAC in
any form including, but not limited to Chapter III Drive System
electronic, paper, video and mechanical
form. Chapter IV Suspension System
During the process of maintaining JAC Chapter V Brake System

car, if genuine parts that are not from
JAC or disqualified oil, the vehicle may Chapter VI Steering System
be damaged.
Sub-volume of Body Electrical
and Body Structure
Chapter I Body Electrical
Chapter II Body Structure
Chapter III Body Data
Circuit Maintenance Manual

J4 Service Manual How to use this Manual
How to use this Manual

Instructions
This Manual contains four major tools for circuit failure inspection and removal.
 Circuit diagram
 Component location index
 Component position drawing
 Wire harness layout
Of which, wire connector shape is attached to the circuit diagram.
1. Circuit diagram
Every system starts from its circuit diagram. The circuit diagrams illustrate all working paths for
each component. For example, power supply of start system and negative grounding connection,
position of wire connector and relevant fuse consisting circuit, switch, etc.
1
To diagnose and remove the faults, it shall firstly know the circuit diagram sufficiently.
B-1
起动系统-1
Start system -1 F42 20A
A-14
008
F13 F13
2.0 R
10A 10A
B+
蓄电池B+
0.5LW
0.85W/R
C-1
007
0.5V
0.5V
2.0 R
1 3
0.5V
ON
OFF
2 M39 4
20.0R
13
I/P-D
0.5P
0.5V
R/L11
1 4
ON
OFF
2 3 091
H-5
2.0 P
EE01
0.5 B
5
2.0 P
E26
1 E28
1
起动 006
Starter
机
A-8
启动机电源输入
E26 Starter power supply E28 Starter
启动机线圈 coil safeguard relay M39 Immobilizer
启动保护继电器
R/L11Start 防盗继电器 relay EE01
input
3 3 1 2 3
1 1 2 1 2 4 5 6
1 4 4
2
2. Component location index

Refer to the component location index in the back of every schematic diagram to locate the
components in the vehicle. Main parts, grounding connection and connectors are listed in the index
of part positions.
B-2
起动系统-2
Start system -2
元件位置索引
Component location index
元件编码code
Component 元件名称
Component name
E26 启动机电源输入
Starter power supply input
E28 Starter
启动机线圈 coil
接头
Connector
I/P-D
EE01
3
3. Component position drawing

It is easy to find out the installation position of components and guide wire connectors illustrated in
the component location index statement in the component location.
M01 Inner
temperature
sensor
M10 M09 radio-cassette

radio-cassette player A (DVD,
player B (CD) CD for public use)
4. Guide wire connector shape

This part shows the shape of every wire connector in circuit diagram and the specific location
diagram of each piece of guide wire according to its color and terminal in the guide wire connector.
Guide wire connector shape diagram will help you to find out the position needed inspection.
Interpretation of shape diagram: When the wire connectors are not separated, the direction is from
wire harness of female wire to that of male wire; when separated, it is the component side or front
plan of male wire connector. When the wiring of guide wire connector is for public use, it means
this guide wire connector is the common wire connector.
Power supply input of Generator S&L

generator
4
5. Guide wire connector shape diagram and terminal number arrangement

1. Wire connector shape diagram
Socket Plug Description

Locking point Locking point
Socket and plug are distinguished by
Actual illustration terminals, not by sheath openings.
Please refer to table below when

Sheath Terminal Terminal Sheath check connector codes.
In case of some connectors can’t be

coded by this method, please refer to
Section “Connector Configuration”.
Figures in this
manual
2) Terminal No. sequence
Number Sequence Description
Socket Numbering from up right to low left
Plug Numbering from up left to low right
5
6. Wire harness lay out

Wire harness layout shows the installation position of major wire harness and guide wire connector,
as well as the path of major wiring harness. The wire harness layout makes circuit maintenance
easier and more convenient.
D18-1
D21-1 FD04
D19-1
左后门线束说明
Description of left rear door wire harness
D18-1 左后玻璃升降开关
Switch for left rear glass lifting
D19-1 左后门闭锁执行器
Actuator for left rear door lock
D21-1 左后玻璃升降电机
Motor for left rear glass lifting
FD04 地板线束接口
Floor wire harness connector
6
Notation
This Manual uses the following electrical notations, electrical symbols and abbreviated names.
1. Notation in circuit diagram
Component Diode
The solid line means that the whole
component is visible. Diode represents that the current can
only flow in the direction of arrow.
Fuse and fusible link

The dotted line means that only part
of the component is visible.
Energized in “ON” position
Fuse box
Brake light The name is marked at the upper The short end is connected
switch (the
switch is
right corner of the component. with other fuses.
closed
when the
brake
Fuse code
pedal is
depressed). Allowable current in protective loop
The function description of the
component follows the name.
City power supply

Connector Engine compartment relay box
Plug
Connector number
Fusible link
Socket
Terminal number in connector
The connector is directly

connected with the component.
Cutout
The connector is connected with

the component via a wire.
The cutout can be reused. It will be
disconnected by heating in case of
current overload. Some cutouts can
automatically reset after cooling while
some shall be reset manually.
The screw terminal of the part
7
The wave line means that the circuit HOT AT ON

is disconnected, however it is Fuse box
connected actually.
The wire is yellow with a red line on it.
Refer to power supply

distribution in page SD-15
The circuit is connecting in the two

pages. The arrow shows the current
direction. You can find “A” in the The branch circuit only shows
location with the symbol. the connection point. Refer to the
identified circuits for detailed
contents of the additional wires.
One wire connecting with an arrow Connection point

directing another circuit.
Name of circuit Connection point code
The disconnected line shows part of

the circuit, referring to the circuit listed The connection point is
in the component diagram. shown by round dot, and the
accurate positions of these
connection points are varying
Refer to Ground Distribution on page on different vehicle models
SD-23
Ground “G”
Different choices of paths are shown by the This symbol shows the tail
selection bracket in the figure below. end of the wire is connected
to body metal.
Auto-gear Manual gear
This ground symbol (one dot

and three lines) shows the
component enclosure is
connected to the body metal.
The dotted line indicates both the red Shielded wire

line and the yellow-blue line are in
E35 connector.
The wire is wrapped with a
shield to prevent from radio
interference. The shield is
always grounded.
8
Connector
Switch
These switches move together. The

dotted lines show they are connected Multiple power lines are
by mechanical devices. connected.
Relay Indicator
The seat belt warning light

The relay shows the status of the is connected with other
coil without current. Once current indicator lights inside the
passes the contact, it will switch. instrument cluster.
Indicator
light
Seat belt The indicator light is shown by
warning light
the lighted icon.
Normally open contact
Normally closed contact
9
2. Electrical symbols on the circuit diagram
电气符号
Electric Symbol 符号Description
Symbol 说明 Electric Symbol 符号Description
Symbol 说明
通过化学作用产生电流
Generate current by chemical action
+ - 通过电流产生热量
Generate heat by current
向电路直接补充电流
Directly supplement current to the circuit
Battery 电加热
Electric heating
蓄电池
Connect to the earth point of the vehicle The heat generated by current can be used
通过线束连接车身接地点，使电流接蓄电通过电流产生热量，也可做车载电源使用
body by wire harness so that the current will as vehicle power supply as well
池负极，形成回路
connect to battery negative terminal to form
loop.
03
Earth point of 点烟器lighter

Cigarette
线束接地点
wire harness
Distribute power to external electrical
可给符合额定电压的外接用电器配电
appliances conforming to rated current.
If the current exceeds the rated current, the
如果电流超过额定电流，易熔丝则熔断，电
fusible link will be fused and the current will
流随即被切断
be cut off immediately.
WARNING: DO NOT EXCEED THE
警惕：更换熔断器的时候不可超过额定电流
Slow-blow RATED CURRENT WHEN REPLACING
缓熔器 Vehicle
车载电源 power
THE FUSE.
supply
The horn sounds when the current passes.

通过电流发出声音
片式保险片
Plate type fuse 片式保险片
Plate type fuse
缓熔器
Slow-blow
Horn
喇叭
Current passes the filament to generate

当电流通过灯丝，产生光，并散发热量
light and radiate heat.
Lighting
灯光照明
Loudspeaker
扬声器
It is mainly used in series circuit to protect

主要用于串联电路，保护限定额定电压的电 Permit or prevent the current passing by
通过打开或闭合回路，来允许或阻止当前电
electrical appliances with limited nominal opening or closing the loop.
器件
voltage. 流通过。
Resistor
电阻
Switch
开关
Convert into mechanical energy by electric

通过电能转化成机械能 It only permits the current to pass the
二极管，只允许电流在一个方向通过。
energy.
M diode along one direction.
Motor
电机二极管
Diode
Absorb or discharge gas or fluid by motor.

通过电机的作用，吸放气体或液体当电流通过时发光。
It is lightened when current passes.
P The diode is different from common bulb that
二极管发光时不产生热量，与普通灯泡不同。
it does not generate heat when lightened.
Pump
泵发光二极管
Light-emitting
diode
10
电气符号
Electrical Symbol 符号
Symbol 说明
Description 电气符号
Electrical Symbol 符号
Symbol 说明
Description
电阻值随温度变化而改变。
The resistance value is various with It is used for heat dissipation of the
用于给发动机散热。
传感器
Sensor
temperature change. engine.
（热敏电阻型）
(Thermistor) 风扇
Fan
Sensor
传感器 The resistance value changes with the
电阻值随部件位置改变而改变。 D
component location. A B
The above diagram shows Loop C-D

上图式代表回路C-D内连于回路A-B。
Loop
回路内连 intra-connects with Loop A-B.
（滑动电阻型）
(Slide resistor) intra-connection
Generate magnetic force via coil to actuate relay contact and make the current pass.
通过线圈产生磁力，吸合继电器触点，使电流通过。
For线圈无电流通过时
coil without current For线圈有电流通过时
coil with current
ON
OFF
Without
无电流有电流
With current
Normally open current
常开继电器 OFF
ON
relay
Generate magnetic force via coil to actuate relay contact and make the current pass.
通过线圈产生磁力，吸合继电器触点，使电流通过。
For线圈无电流通过时
coil without current For coil with current
线圈有电流通过时
ON
OFF
有电流
With current 无电流
Without
Normally
常闭继电器 closed OFF current ON
relay
11
3. Guide wire color description

Wire color Code Wire color Code
Black B Orange O
Blue L Pink P
Brown Br Red R
Green G Purple V
Gray Gr Yellow Y
Light green Lg White W
4. Wire harness identifying marking and system function paging code

Divide the guide wire into the following types according to different positions of the wire:
Wire Harness Name Connector Code
Main wire harness M
Engine cabin wire harness, power supply wire harness E
Control wire harness C
Frame wire harness F
Door wire harness D
Tail door wire harness, ceiling wire harness R
Reverse radar sensor wire harness F
Air bag wire harness A
Grounding G
5. Identification of wire connector code

The guide wire connector identification code comprises of wire harness position identification code
and wire connector identification code. Refer to wire harness layout for the guide wire connector
positions
For instance:
E 10
Shows the major number of guide wire connector (serial number)
Shows the location number of wire harness (engine wiring harness)
12
Caution
 The guide wire connector between wire harness is shown by the following code
For instance:
M R 01
Shows the major number of guide wire connector (serial number)
Rear wire harness
Main wire harness
6. Relay identification
Relay identification code comprises of abbreviation of relay and major number (serial number)
For instance:
R/L 18
Shows the major number (serial number) of relay
Shows the abbreviation of relay
13
Failure detection guide

Voltmeter and test light
Failure detection procedures It can use test light or voltmeter to check circuit
status and use test light to check if there is
Check according to the following 5 steps. voltage or not. The test light is composed of a
1. Verify the dissatisfaction of the user pair of guide wire and 12V bulb. In inspection,
one piece of guide wire connects to the
It shall check the faulty circuit components
electrical ground while the other connects to
complained by the user and make record for the
certain measuring point. If the light turns on,
correct repair and maintenance. It is forbidden
this point is supplied with power.
to dismantle the vehicle before confirming the
reasons. Notice
2. Circuit diagram interpretation and When checking the voltage of electronic
analysis control module, such as the engine control
module (ECM) of the electronic fuel
Analyze and judge the whole circuit of the
injection engine, it shall (necessarily) use
faulty component from power supply to
digital voltmeter with 10M or higher
electrical ground according to the system
resistance to check. Checking the module
circuit diagram, and confirm the operating
circuit by test light may be damage the
method. If fails to judge the operating method,
internal circuit. Therefore, never use test
you shall refer to the circuit working reference.
light to check the Circuit Diagrams.
And inspect other public circuits of the faulty
circuit. Such as the public system circuits of The application methods of voltmeter and test
fuse, electrical ground and breaker on the light are basically the same. The difference lies
circuit diagram. Inspect the public circuits in the test light can only check if there is
failed to be checked in the first step. If the voltage while the voltmeter can display the
public circuits work normally, the problem lies value of voltage.
in the circuit itself. If several circuits are
problematic in the same time, it may be the
problem of fuse or electrical ground.
3. Inspection of circuit and component
Test light
Check it for the second step by testers.
Effective failure diagnosis shall be logical and
simple operating process. It shall confirm the
failure causes by failure diagnosis procedures
or table. Start from the most possible reason
and easiest checking component.
4. Fault maintenance Test light and resistance meter with
Repair necessarily in case of any failure. self-contained power
5. Confirm circuit operation Check if the circuit is accessible by the test
light and resistance meter with self-contained
After finished repairing, it shall recheck to power. The test light with self-contained power
confirm the failure has been removed. In case supply is composed of bulb, battery and two
of fuse burnout, it shall inspect all circuits pieces of guide wire. The bulb turns on if the
publicly using this fuse. two pieces of guide wire connect. Before
inspection, it shall dismantle battery negative
guide wire and pull out the fuse of this circuit.
Failure diagnosis devices
14
City power supply
polarity. If the two values are different, the
Instrument
fuse box
semiconductor components impact the
measuring value.
Test light with

Switch
self-contained power
supply
Test light or
voltmeter
Coil
Short circuit tester

Short circuit tester can find out the position of
short circuit. It will generate impulsive
Caution magnetic force when using the short circuit
tester to check the short-circuited circuit so as
Checking the module circuit by test light
to find out the short position.
with self-contained power supply may be
damage the internal circuit. Therefore,
never test the circuit by test light with Failure detection
self-contained power supply.
1. Voltage detection
It is to check if there is voltage in certain point.
When check the terminal of guide wire
connector, you can test from the backside of the
connector, no need to disconnect the wire.
① When check the voltage with a test light or
a voltmeter, you shall connect the negative
terminal of gauge with that of battery
firstly.
Application of ohmmeter is almost the same as ② Connect the other wire of the test light or
self-power test lamp. But the ohmmeter can voltmeter to the position to be tested.
display resistance reading. The low resistance ③ If the test light turns on, it is powered on.
shows the favorable accessibility. For checking by voltmeter, if the value displayed
on the voltmeter is above 1V less than the rated
The semiconductor elements must be inspected
value, the circuit is faulted.
by digital multi-meter with 10M or higher
resistance. When measuring the resistance by
digital multi-meter, it shall cut off the battery Jumper wire with fuse wire
negative guide wire; otherwise it will get fault
resistance value. When measuring the Use the jumper wire to check open loop circuit.
resistance by the resistance meter, the diode or The jumper wire is the test tool using in series
semiconductor components in the circuit may with the tested guide wire
affect the value. To check if the components
affect the measuring value, it shall measure one The jumper wire can use together with most of
value and measure another after replacing the the guide wire connectors without damaging
them.
15
Warning Disconnect the battery
Fuse box (take out

To protect the tested circuit, do not use the fuse link)
jumper with fuse wire larger than the rated

capacity. Neither can it use jumper wire
instead of input or output signal when Short circuit
connecting to the control modules such as

ECM and TCM.
Switch
Test light or
resistant meter with
2. Short-circuit test self-contained
power supply
① Dismantle the negative terminal of the
battery
Disconnect the
② Connect a leading wire of the test light or load
resistant meter with self-contained power Coil

supply to one terminal of the fuse.
③ Connect the other lead of the test light or
resistant meter with self-contained power
supply to the electrical ground.
④ Look over the wire harness from the one
approaching the fuse box. Repeat this
process till it is approximately 15 cm from Test light or The brake
the test light or resistant meter with resistant meter light
with switch
self-contained power supply. self-contained
power supply
⑤ When the test light turns on or resistance
displays, the circuit from this part to the
electrical ground is short-circuited.
3. Power-on test 4. Check the short circuit by short-circuit

detector
① Dismantle the negative terminal of the
battery. ① Pull out the fused fuse wire, and dismantle
the battery negative terminal.
② Connect one lead of the test light or
resistant meter with self-contained power ② Connect the short-circuit detector to the
supply to the position to be tested. When terminal of fuse wire.
using the resistance meter, it shall short
③ Switch on to check the circuit.
circuit the two pieces of lead and zero the
meter by zero setter. ④ When the short-circuit detector moves to
③ Connect the other lead of the meter to the the short-circuited position, it will generate
other terminal of the load to be tested. impulsive magnetic force between the fuse
wire and the short-circuited position.
④ The light with self-contained power sully
⑤ Move short-circuit detector from the fuse
turns on, the circuit is accessible; when
using the resistance meter, when the box along the lead gradually. As long as
resistance value is very small and the short-circuit detector is between the
approaches to 0, it means the accessibility fuse wire and short circuit, the pointer will
is favorable. move with the size of the pulse current.
Once the detector passed the position of
16
short circuit, the pointer will stop. Disconnect power supply

Fuse box (take out the
fuse link)
Short circuit
indicator short
circuit
Pulsed magnetic field
Instrument Switch
Move the Pulsed magnetic field

instrument along
the circuit
Short circuit
Coil
Pointer stop
sliding point
17
Inspection precautions Battery negative

Battery guide wire cable
Before disconnecting connectors or dismantling

electric parts, first disconnect negative cable of
battery.
Wire harness
If removing wire harness from the wire clamp of
the frame or body, please use a flat-blade
screwdriver to pry up the lock position of wire
clamp.
Do not remove protective adhesive tape wrapped
on the surface of wire harness; otherwise, cable
may rub with parts which may cause water
leakage and short-circuit.
Wrong
Disconnecting connecter
When disconnecting connectors, please hold the Right Wrong
plug and socket, do not hold cable.
18
Disconnect connector by pressing or unplugging

lock handle, and do not forcibly disconnect
connector.
Locking connecter
When locking connector, if a click sound is
produced, it indicates that the connector is Click
locked.
Checking circuit
When using a detector to Check circuit Right Wrong
continuity or measuring circuit voltage, insert
the probe of detector from the side of connector
wire harness.
For waterproof connector, because it is Right Wrong

impossible to insert the probe of detector from
the side of connector wire harness, the
inspection can be performed from connector
side. Meanwhile, to prevent damage of
connecting terminal, use a fine wire to wrap
around the probe before inserting into the
connecting terminal.
19
Sensor, switch and relay

Carefully operate sensor, switch and relay, and
Wrong
do not throw away or impact them with other
objects.
20
J4 Service Manual Circuit Diagram
Circuit Diagram
配电系统-1
Power distribution system-1 A-1
EPD 发动机仓保险盒
Engine compartment fuse box
16B
F11 F10
125A 60A
Battery
蓄电池
+
-
004
A-4
16B
005
15W
T-1
EPS电机
EPS motor
16B
003
A-2
001 002
蓄电池负极搭铁
Battery
negative B-1 C-1
grounding
起动机电源
Starter 发电机电源
Engine
power power
21
配电系distribution
Power 统-2 system-2 A-2
E07 发动机仓保险盒
B+
A-1
003
SF06 SF07 SF08 SF09 SF10 SF11 SF12

30A 30A 30A 50A 30A 30A 25A
2.5R
2.5R
2.5R
2.5R
1.5RY
2.5R
4W
2.5R
2.5R
2.5R
2.5R
F09
10A ME2 1
ME2 27
2R
2R
0.35Br
006 007 008 010 011 012 013 014 015 016
D-10 A-6 A-6 B-1 G-2 G-1 A-9 A-3 D-8 N-1
电喇叭
Electric IGN
点火lock
锁 IGN
点火lock
锁启Start
动系统 Small
小灯前大灯室内
Headlamp 保险盒
Indoor Radiator
散热风扇 ABS
horn system light fuse box fan
22
配电系统-3
SF10
A-2
014
F08 F02
15A 10A
2.5R
Main
主继电器
4.0 R
0.5R
relay
86 30
85 87
2.5R
F03 F04
15A 15A
017 018 019
D-5 D-5 D-5
燃油泵
Fuel pump ECU常电
ECU city ECU
power
0.5RB
024 025 026
D-8 D-7 C-1
020 021 022 023 冷凝风扇继电器

Cooling fan 空调继电器发电机励磁
A/C Generator
散热风扇继电器点火线圈 excitation
D-4
relay relay
D-5 D-6 P-1
Radiator fan IGN coil
前氧传感器
Front oxygen 油泵继电器
Oil pump 喷油嘴
Injector 组合仪表
Instrume relay
后氧传感器碳罐阀、OCV阀
sensor relay nt cluster
Rear oxygen Canister
sensor valve, OCA
valve
23
A-4
配电系统-4
Power distribution system-4
A-1
004
SF01 SF03 SF04 F06

40A 30A 40A 10A
4R
0.5W
2.5W
4RL
3R
3R
F05
10A
0.5R
027 028 029 030 031
N-1 R-1 O-4 O-1 D-7
ABS 电动门窗
Electric 鼓风机
Blower 空调控制面板
A/C 空调压缩机
A/C
Door and control compressor
Window panel
24
配电系统-13
A-5 发动机仓保险盒
A-5 Engine compartment fuse box
R/L1 R/L2 10A

F05 MINI
R/L3 R/L4 R/L5 50A
10A SF09 JCASE
F06 MINI
SF05 30A SF12 25A
SF08 JCASE 10A
JCASE F01 MINI
R/L6 R/L7 40A 30A 30A
SF04 JCASE SF07 JCASE SF11 JCASE
15A
F08 MINI
R/L8 R/L9 R/L10 30A 30A
SF06 30A
SF03 JCASE JCASE SF10 JCASE F09 10A
MINI
FUSE CLAMP
SPACE
F04 15A F11 125A MIDI

EC2 mounting position
MINI
40A
15A SF01 JCASE
EC1 mounting position
EC2
安装位置
F03 MINI F10 60A MIDI
EC1
安装位置 F02 10A
MINI
3 2 1
R/L1-启动继电器
R/L1-Starter relay F01-空位
F01-Vacancy SF01-ABS1
SF01-ABS1
R/L2-鼓风机继电器
R/L2-Blower relay F02-电控单元
F02-Electric control unit SF02-空位
SF02-Vacancy
R/L3-Front wiper relay
R/L3-前雨刮继电器 F03-喷油器
F03-Injector SF03-电动窗
SF03-Electric window
R/L4-Front wiper high speed
R/L4-前雨刮高速继电器 F04-点火线圈
F04-IGN coil SF04-鼓风机
SF04-Blower
relay F05-空调面板
F05-A/C panel SF05-Vacancy
R/L5-空调继电器 SF05-空位
R/L5-A/C relay
R/L6-喇叭继电器 F06-空调压缩机
F06-A/C compressor SF06-IGN switch 1
SF06-点火开关1
R/L6-Horn relay F07-Vacancy SF07-IGN switch 2
F07-空位 SF07-点火开关2
R/L7-主继电器
R/L7-Main relay F08-Oil pump SF08-Power supply for indoor
F08-油泵 SF08-室内电器盒电源2
R/L8-油泵继电器
R/L8-Oil pump relay F09-Horn electrical box 2
F09-喇叭 SF09-室内电器盒电源1
R/L9-散热器风扇继电器
R/L9-Radiator fan relay F010-EPS SF09-Power supply for indoor
SF10-电控系统
electrical box 1
R/L10-Cooling fan relay
R/L10-冷凝风扇继电器 F10-电子助力转向
F011-Generator
SF11-风扇
SF10-Electric control system
F11-发电机
SF12-ABS2
SF11-Fan
SF09-ABS2
25
配电系统-6
A-2 A-2
007 008
2.5R
2.5R
M36
5 1
IGN switch
点火开关引脚
Pin
B1 ACC IG1 B2 IG2 ST
5 6 4 1 2 3
档位
Gear
position
LOCK
ACC
ON
START
6 4 2 3
2.5Lg
PMG 10
仪表保险盒
Instrument fuse box
FS05 FS06
2R
10A 25A
PMG PMM
9 11
PMG
2.0 O
2.5 O
PMK PMK PFA

2.5P
5 13 6 8
1.5R
0.35R
0.5R
034 035 036 037

032 033
I-1 F-3 A-7 A-8 B-1

F-2
Electric
电动后视镜 Reserved
预留点烟器
Cigarette Start
启动系统
CD_A04
rearview lighter system
mirror
009
G-1
大灯继电器
Headlamp
relay
26
配电系统-7
IG1
A-6
035
仪表保险盒
Instrument fuse box
FS34 FS24 FS30 FS29 FS39 FS21 FS35 FS25 FS37

10A 10A 10A 10A 10A 15A 15A 10A 10A
PMN
18
PMK PEE PMN PMJ PEE PMJ PEF PEE PFB PEF PMH
15 8 2 1 17 7 18 18 12 22 5
0.75R
0.5R
0.5R
0.35R
039 041 043 Reserved

预留 046 Reserved
预留 047
TCU
TCU
H-4 S-6 D-5 L-1 N-1
BCM 制动开关
Brake switch ECU ACU ABS
038 040 042 044 045 预留

Reserved 预留
Reserved 预留
Reserved
P-3 Q-1 G-6 T-1 E-1
组合仪表
Instrument IMMO_IG1 警示灯开关
Warning EPS_4 倒车灯开关
Reversing
cluster light switch light
switch
27
Power
配电系统-8distribution system-8 A-8
IG2
A-6
036
仪表保险盒
Instrument fuse box
FS15 FS11 FS13 FS09 FS14 FS03

10A 25A 10A 10A 20A 15A
86 R/L14 30
Rear
后雾灯
fog
继电器
light
relay
85 87
PMN
12
PMM PEE PMN PEF PMN PMM PFA PFA PFA PFA PMM
8 13 6 17 14 13 4 15 16 14 12
0.5L
0.5L
0.5R
Reserved
预留
0.5R
Reserved
预留 052
P-1
ICM indicator
ICM指示
048 049 050 175 051 053 预留预留预留预留

Reserved
Reserved
Reserved
Reserved
H-2 O-4 J-1 U-1 H-5 G-4

BCM 风机继电器
Blower relay 前雨刮
Front TPMS BCM_A6 后雾灯
Rear
空调控制面板
A/C control wiper fog
panel light
28

配电系统-9 A-9
B+
A-2 A-10
013 065
PED
1 仪表保险盒
Instrument fuse box
FS38 FS36 FS27 FS31

15A 10A 15A 20A
PMG PFB PTC PMG PMG PEF PMH PMG

3 7 10 4 12 21 4 7
0.5G
0.35G
0.5G
0.35G
0.5G
0.5R
0.5R
0.5G
1.0R
1R
054 055 056 057 058 059 060 061 062 063 064
F-1 S-4 H-7 H-5 H-2 Q-1 H-6 P-2 S-6 M-1 S-1
CD记忆电源
CD 门灯
Door 行李箱灯
Trunk 顶灯
Ceiling 钥匙插
Key IMMO_B+ ETACS Instrument
仪表B+ 制动灯开关
Brake 诊断接口
Diagnostic 中控门锁
Center
入开关 B+
memory light light light insert light interface control
power switch switch door lock
29
配电系统-10
A-9
065
仪表保险盒
Instrument fuse box
FS17 FS23 FS26 FS22

30A 20A 10A 10A
85 30 85 R/L15 30
PCBPCB
R/LR/L Front
前雾灯
fog
后除霜继电器
Rear defroster relay 继电器
light
relay
86 87 86 87
FS08
10A
PMG PFA PFA PMM PTC PMG PMK PMN PEF

6 12 5 14 4 1 8 10 16
0.35GrB
0.35LB
0.35L
0.5Gr
2.5Gr
0.35L
0.5L
后除霜器
Rear
066 067 068 预留
Reserved 预留
Reserved 069 070 071
defroster PEPS
PEPS
H-5 I-1 O-1 H-7 P-1 G-4
ETACS 外后视镜除霜
Outer 空调面板
A/C ETACS 前雾灯指示
Rear fog 前雾灯
Front fog
rearview panel light light
mirror Indicator
defrost
30
配电系统-11
FS03 FS13 FS14
FS11 FS09 FS18

FS19
FS12 FS08 FS22
FS07
10A
FS16 FS24 FS10
FS02
FS15 FS39 FS23
15A
FS01
FS28 FS25 FS21
FS04
20A
FS32 FS33 FS29
FS34
FS06 FS27 FS35
25A
FS30
FS17 FS20 FS37
FS05
30A
FS26
FS36
FS38 FS31
FS01-电动车窗（右）
FS01-Electric window (right) FS14-座椅加热
FS14-Seat heating reserved FS27-制动灯
FS27-Brake light
FS02-A/CFS02-空调 FS15-Relay control
FS15-继电器控制 FS28-Standby
FS28-备用
FS03-Rear wiper FS16-Right small light FS29-Standby
FS03-后雨刮
FS04-Electric window (left) FS16-右小灯
FS17-Rear defroster FS29-备用 control unit
FS30-Electric
FS04-电动车窗（左）FS18-DRL
FS05-Audio FS17-后除霜 FS30-电控单元
FS31-Center control door lock
FS06-Cigarette lighter FS19-High beam light FS32-Start relay
FS05-音响 FS18-日间行车灯 FS31-中控门锁
FS07-Low beam light FS20-Emergency light FS33-Transmission
FS06-点烟器
FS08-Outer rearview mirror FS19-远光灯
FS21-Airbag FS32-启动继电器
FS34-Instrument
defrost
FS07-近光灯 FS20-应急灯 FS33-变速器
FS09-Rear fog light FS22-Front fog light FS35-Standby
FS08-外后视镜除霜
FS010-Rearview mirror FS21-安全气囊
FS23-Sunroof FS34-仪表 light
FS36-Indoor
folding
FS09-后雾灯 FS22-前雾灯 FS35-备用
FS011-Front wiper FS24-Turning light FS37-Audio
FS10-后视镜折叠
FS012-Left small light FS23-天窗 controller
FS25-Transmission FS36-室内灯
FS38-ABS
FS013-Ignition
FS11-前雨刮 FS26-PEPS
FS24-转向灯 FS39-Reversing
FS37-ABS light
FS12-左小灯 FS25-变速器控制 FS38-音响

FS13-点火 FS26-PEPS FS39-倒车灯
31

配电系统-12 A-12
R/L16
R/L11
R/L12 R/L13 R/L14 R/L15
PED
R/L11-电动门窗继电器
R/L11-Electric door and window relay
1
R/L12-Low beam relay
R/L12-近光灯继电器
R/L13-High beam relay
R/L13-远光灯继电器 PEE PMJ
R/L14-Rear fog light relay
R/L14-后雾灯继电器
1 2 3 4 5 6 7 1 2 3 4 5 6
R/L15-Front fog light relay
R/L15-前雾灯继电器 8 9 10 11 12 13 14 15 16 17 18 7 8 9 10 11 12
R/L16-Flasher
R/L16-闪光器
PFA PEF PMK
1 1 2 3 4 5 6 1 2 3 4 5 6 7 8
6 1 2 3 4 5 6 7 8 9 10 11
10 11 12 13 9 10 11 12 13 14 15 16
7 7 8 9 14 15 16 16
12 13 14 15 16 17 18 19 20 21 22
PFB PMG PMM
1 2 3 4 5 6 7 1 2 3 4 5
1 2 3 4 8 9 10 11
8 9 10 11 12 13 14 6 7 12 13 14
7 8 9 10
5 6 11 12
PTC PMH PMN
1 2 3 4
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
5 6 7 8 9 10 8 9 10 11 12 13 14 10 11 12 13 14 15 16 17 18
32
起动系统-1
Start system-1 B -1
点火开关
IGN switch
A-6
037
B+
SF07保险
SF07 Fuse
A-1 A-2
ECU_57
001
010 D-9
072
0.5R
0.5R
PMK PMK
6 7
FS32
2.5R
10A
PCB R/L
30 Anti-theft
防盗继电器 relay 85
0.5P
87a 86
15W
25 PEF 6 PMK 4
EM1
0.5RW
30 R/L1 85
M56 1 2
0.5RW
启动控制继电器
Start control relay
启动继电器
Start relay
5 3
87 86
0.35G
0.35P
2RW
0.35B
BE1
1
2RW
1 B03
B02
1 073 074 075
E26 D-10 D-10 H-5

起动机
Starter ECU_56 ECU_52 BCM_A2
BE1
M56
B02 B03 E26
4
2 5 3 AC01A PD11A
2 GW RW 1
M6 1
0.5
IC13
2
IC12
4 OW R 3
0.35 0.75
EM1
PMK
PEF
29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 9 10 11 12 13 14 15 16
12 13 14 15 16 17 18 19 20 21 22
33
起动系统-2
Start system-2 B -2
元件位置索引
元件编码
Component code 元件名称
Component name
B02 B02 Starter启动机电源
power
B03 B03 Starter启动机线圈
coil
M56 M56 启动控制继电器
Start control relay
E26 发动机左接地2
E26 Engine left grounding 2
接头
Connector
BE1
BE1
EM1 EM1
PEF
PMK PEP
P<L
34
充电系统-1
Charging system-1 C-1
Instrument
charging
IGN coil fuse
点火线圈保险仪表充电指示
indicator BCM
A-3 P-3 H-4

076 077
026
0.35OW
0.75R
BE1 3 EM1 12
0.75R
0.35OW
B01 2
S B01 BE1
0.35OW
L
发电机
Generator 3 4
E G
1
B05
16.0R
002
A-1
F11保险
F11 Fuse
Generator
B05 发电机电源 B01 发电机S&L
Generator S&L EM1 BE1
power
29 30 31 32 33 34 35 36 37 38 39 40 41 42
15 16 17 18 19 20 21 22 23 24 25 26 27 28 AC01A PD11A
4 3 2 1 2 GW RW 1
0.5 2
1 2 3 IC13 IC12
4 5 6 7 8 9 10 11 12 13 14 4 OW R 3
0.35 0.75
35
Charging system-2
充电系统-2 C-2
元件位置索引
元件编码
Component code 元件名称name
Component
B05 B05 发电机电源
Generator
B01 B01 发电机S&L
Generator power
接头
Connector
BE1
BE1 EM1
EM1
36
Engine ECU system-1 D-1
Instrument Instrument Instrument

仪表A_28
A_28 A_14
仪表A_14 IMMO_4 EPS_1 仪表B_25
B_25
P-1 P-1 Q-1 T-1 P-2
078 079 081
082
083
IMMO_5
Q-1
080
0.75LBr
0.75BrW
0.5YG
0.75LY
ME2 22 ME1 11 ME1 24 ME2 12
Phase sensor
相位传感器
0.75BrW
0.5YG
0.75LBr
0.75LY
EC2 EC2 EC1 EC2

1 2 12 13
+ -
A16 1 2 3
0.75YB
0.75L
0.5PG
0.75YW
0.75LR
0.5WL
0.5RY
A24
31 11 71 08 32 79 36
MIL SVS 诊断
Diagnosis Engine speed
发动机转速信号
signal
ECU
A24 ECU
1 2 81 80 79 77 76 75 74 73 71 70 69 68 67 66 65 64
A16
A16 Phase
相位传感器sensor 62 60 54 52 50 49 48 47 44
3
43 42 41 40 39 38 37 36 35 33 30 27 26 25
3 2 1 4 5
24 23 21 20 17 10 9 8 7 6
37
D-2
Engine ECU system-2
D-3
084
Intake air pressure and temp sensor

进气压力温度传感器 Water temp
水温传感器sensor
Speed sensor
转速传感器
P
+ -
2 1 4 3 A13 1 2 3
A11
0.75BrG A8 1 3
0.5RY
0.5RL
0.5RL
0.5GY
0.5RY
0.5RL
0.5VW
0.5G
A24
37 17 42 15 39
ECU
A11 Intake air temp

A11pressure
进气温度压力传感器
sensor A13
A13Speed
转速传感器sensor
A8 水温传感器
A8 Water temp sensor
2
1 3 3 2 1
4 3 2 1
38
D-4
085
Electronic throttle
M19 油门踏板
Accelerator pedal 电控节流阀体 A14
valve body
爆震传感器
Knock sensor
M
A15
D-2
084 1 2
2 4 3 1 6 5 1 4 2 5 3 6
0.75BrL
0.75Lg
0.75WBr
0.5OL
0.5LR
0.75LW
0.75LR
0.75Y
0.5YW
0.5GY
0.5VW
0.5OR
ME1 30 39 29 ME2 37 ME1 15 ME1 3

0.75LW
0.5GY
0.75LR
0.5YW
0.5OR
0.5VW
EC2 21 22 16 20 19 18
0.5GrW
0.5WG
0.75LR
0.75BV
0.5W
0.75RY
0.5LW
0.75WBr
0.75BrL
0.75BrL
0.75WBr
A24
33 16 32 40 35 67 66 65 64 78 38 54 19 20
ECU
A14 Electronic throttle A15

M19M19
Accelerator
油门踏板 pedal A15 Knock
爆震传感器sensor
A14valve body
电控节流阀体
1 2 3
1 2 3 4 5 6
E66A E78 E32B
E64A E38 E54
4 5 6 E19 E20 EA
1 2 3
39

室外电器盒
Outdoor electricalbox
A-3
020
0.75R
0.75RB
D-3
PEE 1
EC1 A15 085
0.75BrW
PFA 1
0.75RB
后氧传感器 A6 前氧传感器sensor
1 Front oxygen
F33
3 Rear oxygen sensor
λ λ
1 2 4 2 3 4
0.5Br
0.5YW
0.75W
0.5R
0.5R
PFB 11 PFB 9 PFB 10
PEE 7 PEE 5 PEE 6

0.75RBr
0.5RB
0.75W
0.5Br
0.5YW
EC2 17 EC2 15 EC2 16

0.5R
0.75B
0.5PB
0.75R
A24
28 55 36 26 18
ECU
F33 Rear oxygen PFA
F33 sensor
后氧传感器
EC2
1 2 3 4 5 6 7 8 9 10 11 1 1 2 3 4 5 6 6
EC1
2 1 10 11 12 13
12 13 14 15 16 17 18 19 20 21 22 7 7 8 9 14 15 16 16
4 3 B14 B6 B1
A3 A8 A13
A16 B15 B7 B2
A2 A7 A12 B16 B8
B17 B9
A6 A11 A15
B18 B10
A6 oxygen
A6 Front 前氧传感器 sensor PFB PEE A5 A10 B19 B11 B3
A14 B20 B12 B4
A1 A4 A9
B21 B13 B5
4 3 2 1 1 2 3 4 5 6 7
1 2 3 4 5 6 7
E18 E36B E26 131 8 9 10 11 12 13 14 8 9 10 11 12 13 14 15 16 17 18
40
Outdoor Outdoor
electrical
室外电器盒 box electrical
室外电器盒 box
A-3 A-3
017 021
F02 City
86 30
1W
Variable
power Main FS30 IG1 R/L8 Fuel
燃油泵
0.5BrW
2.5BrW
pump Canister camshaft
supply
F02 常电 relay
主继电器 power
FS30 IG1电继电器
relay Control 可变凸轮轴正
timing (air
A-3 A-3 A-7 时（进气）
intake)
A7 1 碳罐控制阀
Valve A21
1
018 019 043
85 87
1Br
PEE 14 2 2
PFA 10
0.5R
0.5RB
0.75O
0.5OG
1Br
F10
1
pump
0.75YGr
0.75BG
Fuel燃油泵
EC1 A3 EC2 10 EC1 A8 EC1 A6 M

4
1B
0.75YR
0.75WY
0.75OB
0.75V
G_RL1 F45
A24
12 14 13 69 46 48
B+ Main relay
主继电器控制 ON
ON电
ECU
control power
A7 Carbon
EC1 canister solenoid
A7 碳罐电磁阀
valve
B14 B6 B1 EC2 F10Fuel
F10 燃油泵pump A21
A21 OCV
OCV阀valve
A3 A8 A13 B7 B2
A16 B15
A2 A7 A12 B16 B8
1 2 3 4 5 6 7 8 9 10 11
B17 B9
A6 A11 A15 1 2 3 4
A5 A10
B18
B19
B10
B11 B3
12 13 14 15 16 17 18 19 20 21 22
E46 138 143 E48
A1 A4 A9 A14 B20 B12 B4 1 2 2 1
B21 B13 B5
41
Outdoor
室外电器盒box
electrical
A-3
022
A23 A22
0.5BrW
0.5BrW
0.5BrW
0.5BrW
A20 1 A19 1 A18 1 A17

1
喷
Injector 1#
Injector 2#
Injector 3#
Injector 4#
喷喷喷
油油油油
嘴嘴嘴嘴
1# 2# 3# 4#
2 2 2 2
0.75Br
0.75BY
0.75Br
0.75BO
0.75Y
0.75RG
0.75LG
0.75Br
0.75Y
0.75GR
2.5B
0.75G
A24
27 6 7 47 44 45 63 51 53 03 61 80
ECU
Non-persistent Non-persistent Non-persistent
非持续电源
power 非持续电源
power 非持续电源
power
A17
A17Injector
喷油嘴4#4# A18
A18Injector
喷油嘴3#3# A19
A19Injector
喷油嘴2#2# A20
A20 Injector
喷油嘴1# 1#
132D E47 132C E07 132B E06 132A E27

1 2 1 2 1 2 1 2
42

F06保险
F06 fuse F04保险
F04 fuse
A-4 A-3
031 025
2.5LW
0.5W
0.75R
86 R/L5 30
空调继
A/C relay
电器
85 87
0.5GW
EB1 2 CYL1 CYL2 CYL3 CYL4

0.5OL
0.5GW
EC1 A13 B04 1

A2 1 A3 1 A4 1 A5 1
2 3 2 3 2 3 2 3
2.5B
0.75LW
0.75LW
0.75LW
0.75LW
0.75WV
空调压缩机
A/C compressor
A1
0.75L
0.75Gr
0.75W
0.75R
A24
70 05 01 02 04
ECU
A3 A4 A5
1 2 3 1 2 3 1 2 3
EC1 EB1 B04B04 压缩机

Compressor
B14 B6 B1
A3 A8 A13
A16 B15 B7 B2 A2
A2 A7 A12 B16
B17
B8
B9
1 2 AC01A
A6 A11 A15
B18 B10 GW 1 2 3
A5 A10
A14
B19
B20
B11
B12
B3
B4 3 4 0.5
A1 A4 A9
B21 B13 B5
43
D-8
Engine ECU system-8
F04保险
F04 fuse SF11 fuse
SF11保险
A-3 A-2
024
1.5R
015
2.5R
0.75R
0.75R
2.5R
86 R/L9 30
86 R/L10 30
Radiator
Cooling
冷凝风扇 fan 散热风
fan relay
relay 扇继电器
继电器
85 87
85 87
2.5R
2.5RB
Radiator
E04
2 散热风扇
fan 1
0.5G
0.5G
电阻器
Resistor
EC1 A10
EC1 A5 M
3
0.75RY
0.75WL
E08
2.5B
G_RH2
A24
68 50
ECU
EC1
E04 Radiator
E04 散热风扇 fan
B14 B6 B1
A3 A8 A13
A16 B15 B7 B2
A2 A7 A12 B16 B8
B17 B9
A6 A11 A15
B18 B10
A5 A10 B19 B11 B3 3 2 1
A14 B20 B12 B4
A1 A4 A9
B21 B13 B5
44
Three-way Three-way
G_LH1 M52 Instrument Low beam pressure pressure
ABS_33 仪表_B24
_B24 近光灯
light 鼓风机
Blower ICM_B26 三元压力开关
switch 三元压力开关
switch 启动系统
Start system
N-1 P-2 G-1 O-4 P-2 O-4 O-4 B-1
0.5B
086 087 088 089 090 091 092 072

2
Clutch
离合开关
switch 0.5V
M51
1
0.5V
ME1 28
0.5BrR
0.5G
ME2 11 ME1 36
0.5BrR
0.35P
0.5VY
0.5GY
0.5G
0.5V
0.5G
EC2 7 EC1 A16 EC1 B12 EC1 A11 EC1 A1 EC1 A2 EC1 A7 EC2 4
0.5BrGr
0.75BrW
0.75BR
0.5VL
0.5YL
0.5GW
0.5VY
0.5P
A24
74 59 23 76 9 60 75 57
车速信号
Vehicle Headlamp load 水温信号
鼓风机负载
大灯负载 Blower 空调中压开关
Water temperature A/C 空调开关
A/C
speed signal load signal intermediate switch
ECU
pressure
switch
ME2
EC2
1 2 3 4 5 6 7 8 9 10 11 39 38 37 36 25 343332 31302928 27
12 13 14 15 16 17 18 19 20 21 22
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2
1
EC1 ME1
M51Clutch
M51 离合开关 switch B14 B6 B1
A3 A8 A13 B7 B2
A16 B15
A2 A7 A12 B16 B8
B17 B9 42 41 40 39 38 37 36 35 34 33 32 31 30 29
1 A6 A11 A15
B18 B10
A5 A10 B3 28 27 26 25 24 23 22 21 20 19 18 17 16 15
B19 B11
2 A14 B20 B12 B4
A1 A4 A9 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B21 B13 B5
45
Brake
Brake light Start Start
Airbag
安全气囊制动开关
switch ICM_B27 制动灯开关
switch 启动系统
system 启动系统
system
F09保险
F09 Fuse
L-1 S-6 P-2 S-6 B-1 B-1
A-2
093 094 095 096 074 073
006
Horn
0.35Br
0.5Br
0.5LY
0.75WBr
relay
喇叭继电器
5 R/L6 3
PEF 15 ME1 14 ME1 41

4 1
0.35BrY
0.5Br
ME1 31
0.35BrY
0.75WBr
0.35PW
0.35O
0.5LY
0.5RW
0.35P
高音
Loudspeaker
喇叭
E25 2
7
0.35BrY
M35
EC2 12 EC1 A9 EC2 6 EC2 11 EC2 14 EC2 3
Horn
喇叭
1
1 按钮
button
0.75VB
0.75Gr
0.5LY
0.5BL
0.5PY
0.5RL
0.5B
097
A24
H-7
72 58 10 21 52 56
BCM_A14
碰撞信号
Collision 制动开关
Brake 瞬时油耗
Instantaneous 制动灯开关
Brake light
ECU
fuel consumption switch E26 G_LH2
signal switch
ECU
PEF
EC2
E25
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
2 1
12 13 14 15 16 17 18 19 20 21 22
12 13 14 15 16 17 18 19 20 21 22
EC1
ME1
M35M35 时钟弹簧
Clock spring
B14 B6 B1
A3 A8 A13
A16 B15 B7 B2
A2 A7 A12 B16 B8
42 41 40 39 38 37 36 35 34 33 32 31 30 29 B17 B9
A6 A11 A15
B18 B10
1 2 3 4 5 6 28 27 26 25 24 23 22 21 20 19 18 17 16 15 A5 A10 B19 B11 B3
7 8 9 10 11 12 A14 B20 B12 B4
14 13 12 11 10 9 8 7 6 5 4 3 2 1 A1 A4 A9
B21 B13 B5
46
D-11
发动机ECM系统-11
Engine ECU system-11
元件位置索引
Component
元件编码 code Component name
元件名称
A2 IGN coil 1
A2 点火线圈1
A3 IGN coil 2
A3 点火线圈2
A4 IGN coil 3
A4 点火线圈3
A5 IGN coil 4
A5 点火线圈4
A6 Front oxygen sensor
A6 前氧传感器
A7 Carbon canister solenoid valve
A7 碳罐电磁阀
A8 Water temperature sensor
A8 水温传感器
A11 Intake air temp pressure sensor
A11
A13 Speed sensor进气温度压力传感器
A13
A14 Electronic 速度传感器
throttle valve body
A14
A15 电控节流阀体
Knock sensor
A15
A16 爆震传感器
Phase sensor
A17
A16 相位传感器
Injector nozzle 4
A18
A17 喷油嘴4
Injector nozzle 3
A19
A18 喷油嘴3
Injector nozzle 2
A20
A19 喷油嘴2
Injector nozzle 1
A21
A20
OCV valve喷油嘴1
A24 Engine ECU
OCV阀
A21
M19 Accelerator发动机ECU
pedal
A24
F33 Rear oxygen sensor
油门踏板
M19
M19 Accelerator后氧传感器
pedal
F33
F10
M19 Fuel pump油门踏板
E04
F10 Radiator switch
燃油泵
M51
E04 散热风扇
Clutch switch
E25
M51 离合开关
Loudspeaker
E25
M35 高音喇叭
Clock spring
M35 时钟弹簧
B04 Compressor
B04 压缩机
Connector
接头
EC1 PFB ME1
EC2 PEE ME2
PFA EB1 PEF
Ground
接地wire
M52 A1
F45 A22
E08
A23
E26
47
倒车系统-1
Reversing system-1 E-1
Reversing
light switch
倒车灯开关
A25 EC2
0.75BrW 0.5R FS39保险
FS39 Fuse
2 8
045 A-7
1
0.75G
EC2 9
0.5Gr
PEE 4
F21
PFB 8
0.5Gr
Reversing
倒车雷达radar E ECU
C U
FS06 0.35Gr 8
Signal
信号 GND Signal
信号 Signal
信号
11 9 2 10
0.5Gr
FS05
0.5Gr
0.35Lg
MF1 38
1 1
0.5Lg
0.35Br
0.35Br
0.35B
0.35B
F28 F31 0.35B

左倒车灯
Left 右倒车灯
Right
reversing reversing
light 2 2 light
F25 2 1 F26 2 1
左探头
Left Probe 左探头
Left Probe
0.5B
0.5B
098
P-3
ICM_B23
F45 G_RL1 G_RR F42
F14 G_RL
MF1 PFB PEE

EC2
14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 1 2 3 4 5 6 7
28 27 26 25 242322 21 20 19 18 17 16 15
12 13 14 15 16 17 18 19 20 21 22 8 9 10 11 12 13 14 8 9 10 11 12 13 14 15 16 17 18
42 41 40 39 38 3736 35 34 33 32 31 30 29
F21 倒车雷达控制器
F21 Reversing radar controller F25 Left
F25 reversing
左倒车 F26
F26Right
右倒车reversing A25
A25 Reversing F28 Rear
F28 left F31 Rear
F31 right
radar sensor radar sensor
雷达传感器雷达传感器 light switch
倒车灯开关 reversing
左后倒车灯 light reversing
右后倒车灯 light
1 2 1 2
1 2 1 2
8 7 6 5 4 3 2 1 1 2
16 15 14 13 12 11 10 9
48
倒车系统-2
Reversing system-2 E-2
元件位置索引
元件编码
Component name
Reversing radar controller

F21 倒车雷达控制器
F25 Left 左倒车雷达传感器
reversing radar sensor
F26 Right右倒车雷达传感器
reversing radar sensor
F28 Rear左后倒车灯
left reversing light
F31 Rear右后倒车灯
right reversing light
A25 倒车灯开关
Reversing light switch
接头
Connector
PEE 室内电器盒与发动机线束接口E
Harness connector E of indoor electrical box and engine
PFB 室内电器盒与车身线束接口B
Harness connector B of indoor electrical box and body
EC2 发动机控制线束与发动机线束接口2
Connector 2 of engine control harness and engine harness
MF1 主线束与车身线束接口1
Connector 1 of main harness and body harness
接地点
GND
F45
F42
F14
49
ACC system - CD player

ACC系统-CD机 F-1
FS38保险
FS38 Fuse ILL+
A-9 G-3
054 099
1.0R
0.35G
M12-A A7 A6
记忆电源 ILL+
Memory
power
CD机
CD Player
GND ILL- GND SINGLE RL+ RL- RR- RR+
A8 A1 A2 A3 M12-B
B7 B8 B2 B1
0.35Lg
0.5YR
0.5YB
0.5VO
0.5VW
0.5VG
0.5W
Audio wire
100 音响线控开关
control switch
G-3 40
MF1 37 36 39
ILL-
1B
0.5VO
0.5VW
0.5VG
0.5W
Rear right
loudspeaker
右后扬声器
1 1
左后扬声器
Rear left
+ +
loudspeaker
G_AUDIO M31
- -
2 2
F16 F20
MF1 Connector of main harness and body

MF1 主线束与车身线束接口 M12-A CD.1 M12-B CD.2
harness
7 5 3 1 7 5 3 1
14 13 12 11 10 9 8 7 6 5 4 3 2 1
8 6 4 2 8 6 4 2
28 27 26 25 24 23 2221 20 19 18 17 16 15
42 41 40 39 38 37 3635 34 33 32 31 30 29 F16
F16 F20
F20
Rear left 1 Rear right 1
左后扬声器
loudspeaker 2 右后扬声器
loudspeaker 2
50
ACC system - CD player F-2

ACC系统-CD机
FS05保险
FS04 Fuse
A-6
天线
Antenna 033
放大器
amplifier
0.35RB
0.35R
A5 M12-A
A4
ANT ACC
CD机
CD Player
FL+ FL- FR+ FR-
M12-B B5 B6 B3 B4
0.5VY
0.5VR
0.5VL
0.5V
42 41 40 39
MF1 MF1
19 20 12 11
FD1 FD3
Internal connector 2 of Internal connector 2 of

front left door wire front right door wire
左前门线束内连点2 0.5VR 右前门线束内连点2
harness harness
High
左前门高音扬声器
Front right door speaker
High pitch speaker at front right door

0.5VL
0.5VR
0.5VL
左前门扬声器
door speaker
pitch speaker at front left door
右前门高音扬声器
右前门扬声器
Front left
0.5VY
0.5V
2 1 2 1
+ + + +
- D05 -
- D28 -
1 2 1 2
0.5VY
D08
0.5V
0.5VY
D25
0.5V
左前门线束内连点1
Internal connector 1 of 右前门线束内连点1
Internal connector 1 of
front left door wire front right door wire
harness harness
MF1Connector
MF1 主线束与车身线束接口
of main harness and body harness I/P-KIndoor
I/P-K 室内电器盒Kelectric box K
Antenna
14 13 12 11 10 9 8 7 6 5 4 3 2 1 天线放大器
amplifier
28 27 26 25 24 23 2221 20 1918 17 16 15 1 2 3 4 5 6 7 8
42 41 40 39 38 37 3635 34 33 32 31 30 29
9 10 11 12 13 14 15 16 1
FD1 Harness connector of front left door

FD1 左前门与车身线束接口and body
FD3 右前门与车身线束接口
FD3 Harness connector of front right door and
body D08
D08 左前门扬声器
Front left door speaker D25 Front
D25 右前门扬声器right door
1 2 speaker 1 2
6 5 4 3 2 1 6 5 4 3 2 1
12 11 10 12 11 10
15 14 13 9 8 7 15 14 13 9 8 7
D05 High左前门高音扬声器
pitch speaker at D28 High pitch speaker at
24 23 22 21 20 19 18 17 16 24 23 22 21 20 19 18 17 16 D05 D28 右前门高音扬声器
front right door
front left door 2 1 2 1
33 32 31 30 29 28 27 26 25 33 32 31 30 29 28 27 26 25
51
ACC system - Cigarette lighter

ACC系统-点烟器 F-3
FS06 Fuse
FS06保险
A-6
034
1.5R
ILL+
1.5R
G-3
M30
101 2
Vehicle-mounted
车载电源
1.5R
power supply
0.35G
1
M29 2
点烟器照明
Cigarette lighter
M28 2
lighting
Cigarette
点烟器
lighter
1
1.5B
G_LH3 M42
M28M28
Cigarette M30 Vehicle-mounted
M30 车载电源power supply
点烟器lighter
M29 Cigarette lighter lighting
M29 点烟器照明
1 1
2 1 2
52
灯光照明-前照灯
Lighting – headlamp G-1
IG2
A-6
009
ME2 PMM
SF08
2.0 O
SF08保险 2R
A-2
012
Fuse
24 10
PMK 16
FS07 FS19
15A 15A
M52
5 3 5 3
G_LH1 Low beam High beam
近光远光
0.50B
relay
继电器 relay
继电器
ON R/L12 ON R/L13
OFF OFF
0.5L
4 1 4 1
PMG 2 PMH 3 PMN 16
0.75LW
0.35LW
0.35L
ILL+ PEF 11 PEF 20
0.75L
ME2 10
G-3
0.5L
104 105 106
0.75LW
102 G-5 P-1 G-5
组合开关
Combination 远光指示
Low beam 组合开关
Combination
ECU_23
D-9
switch indicator switch

088
0.50G
0.35G
0.5B
0.75L
0.75LW
0.75LW
0.75L
0.75L
0.75L
M47 2
6 1
ME2 9 7 6 9 7 6
Headlamp
大灯
Left high beam
Right low beam
Right high beam

low beam
0.35Br
右近光灯
adjusting
M M
左近光灯
左远光灯
调节开关 0.35Br 右远光灯

switch
5 4 4 4
左前照灯
Adjusting motor 右前照灯
Adjusting motor
Left
of front left of front right

调节电机调节电机
3 4
headlamp headlamp
10 1 10 1
0.35Lg
E23 E11
0.35BrW
0.35BrW
0.75B
0.75B
0.75B
0.75B
103
ME2
0.35BrW
G-3
15
ILL-
G_LH2
G_RH2
E26 E08
ME2
M47 E11 E23
39 38 37 36 25 34 333231 30 29 28 27
2 1 5 4 3 2 1 5 4 3 2 1
10 9 8 7 6 10 9 8 7 6
26 25 24 23 22 21 20 19 18 17 16 15 14
6 5 4 3 13 12 11 10 9 8 7 6 5 4 3 2
1
53
Lighting - small light G-2

灯光照明-小灯 SF08 Fuse Warning警示灯开关
light switch
SF08保险
A-2 G-6
011 108
Small lights in
小灯并电
parallel
G-3
2.5 R
107
0.35G
0.35G
室内电
0.5 R
Indoor electric
1 1 器盒
box PEE 12
license light
license light
右牌照灯
左牌照灯
F29 PCB R/L

F30 Small light
0.5G
PCB R/L
relay
小灯继电器 FS20
Right
Left
3 10A
2 2 PMN
PMN
ON 7
0.35B
0.35B
0.5G
OFF
PMN
FS12 FS16
10A 10A
0.35Y
PEE 10 PEE 15 PFB 1 PFA 9
1.5B
0.5G
0.5G 109
G_RL1 F45
0.5G
H-7
0.5G
BCM_A13
0.35 G
8 8 2 2
Front left position
右前位置灯
左前位置灯
Rear left position

右后位置灯
左后位置灯
position light
position light
Front right
Rear right
light
E11 E23 110

light
F44 F22
R-1
1 1 6 6 玻璃升降主控开关
Master switch for
0.5B
0.5B
glass lifting control

0.75B
0.75B
E08 G_RH.2 G_LH2 E26 G_RL1 F45
F44 F22 PFA
E11 E23
1 2 3 1 2 3
5 4 3 2 1 5 4 3 2 1 1 1 2 3 4 5 6 6
4 5 6 4 5 6 10 9 8 7 6 10 9 8 7 6 10 11 12 13
7 7 8 9 14 15 16 16
PEE F29 F30

PFB PMN
1 2 3 4 5 6 7
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
8 9 10 11 12 13 14 15 16 17 18 8 9 10 11 12 13 14
10 11 12 13 14 15 16 17 18
2 1 2 1
54
灯光照明-小灯
Lighting - small light
G-3
G-2
107
Headlamp
大灯调节
0.50G
adjusting
开关
switch
G-1
102
内联点
Internal MS23 MS23
connectors
2 5 7 6 4 8
0.35G
0.35G
0.35G
0.35G
0.35G
0.35G
0.35G
099 111 113 115 101

CDCD背景
backlight 仪表照明
Instrument 空调面板
A/C panel 报警灯开关
Warning light 点烟器照明
Cigarette
lighting
光照明 lighting 照明
lighting switch lighter lighting
G-6 F-3
F-3
F-1 P-1 O-1 G-6
Headlamp Instrument A/C panel Warning light CD backlight

6 大灯调节
adjusting 空调面板照明 CD背景光照明
开关仪表照明
lighting lighting 报警灯开关
switch lighting
switch
G-1 P-1 O-1 G-6 F-1
调光开关
Dimming switch
103
112 114 116 100
3 5 4
M48
0.35Lg
0.35Lg
0.35LG
0.35LG
0.35LG
0.35Lg
0.35Lg
0.5B
内联点 MS24MS24
Internal connectors
M52 G_LH1
M48
M48调光开关
Dimming switch
2 1
6 5 4 3
55
灯光照明-前后雾灯
Lighting - front and rear fog light G-4
Front前雾灯继电器
fog light relay Rear fog light relay
后雾灯继电器
A-10 A-8
071 053
内联点ES09
Internal
connectors ES09
0.5L
0.5L
E29 E09
Internal
1 1 connectors FS11
内联点FS11
左前雾灯
右前雾灯
Front right fog
Front left fog
light
light
0.5 L
0.5 L
2 2
F24 1 F27
1
左后雾灯
右后雾灯
Right rear fog
Rear left fog
light
light
0.5B
0.5B
2 2
0.5B
0.5B
内联点ES12
Internal connectors
ES12
内联点FS21
Internal connectors
FS21
E26 G_LH2 G_RR

F42
F27 F24 E29 E09

2 1 2 1 2 1 2 1
56
灯光照明-组合灯光开关
Lighting - combination light switch G-5
大灯开关 switch
ETACS
0.35BW 0.35BW
H-3
117
Headlamp
M45
4 10
P T 1 2 3 4 5 6 7 8 9 10
OFF
小灯light
Small
近光beam
Low
远光
High beam
AUTO
超车
Overtaking
Front fog
前雾灯
light
Rear fog light
后雾灯（自动复位）
(Auto reset)
1 2 5
0.35B 6 7 8 9
0.35B
0.35L
0.35YW
0.35GrB
0.35LW
0.35LW
M42 G_LH3
M42 G_LH3
119
118 ETACS
ETACS Front fog light
前雾灯开关
switch
Small light
小灯开关
switch H-2
H-3
120
ETACS
Rear fog light
后雾灯开关
switch
H-1
104
G-1
Low beam relay
近光灯继电器
106
G-1
远光灯继电器
High beam relay
M45 组合灯光开关
Combination light 13 12 11 10 9 8 7 6 5 4 3 2 1
switch
57
灯光照明-转向灯、危险报警灯
Lighting - turning light, hazard warning light G-6
FS20保险
FS20 Fuse
G-2 FS24保险
FS24 Fuse ILL+ ILL-
108
A-7
042 G-3 G-3
115 116
0.5G
0.5R
0.35Lg
0.35G
0.5R
0.5R
Warning
2 1 10 9 6 7 8 5 2 3 报警灯开关
light switch
危险警告
Warning
light relay
灯继电器 OFF M13
M55 + -
ON ILL
3 4 5
0.5GW
0.5GW
0.5GR
0.5R
0.35Y
0.5L
0.5GW
0.5GR
0.5R
0.5GW M45
11
PMK 2 PMN 13
123
13 12
H-8 左转向
Combination L B
Left steering
组合开关
switch R/L16
BCM_A18 闪光器
Flasher
左变道 Left E
lane-change
中间位
Middle
position
右转向 PMN 1
0.5GW
Right
steering
右变道
Right
lane-change
0.5B
Left turning
0.5GR
左转向指示灯
indicator light
P-1
121
Right turning
PMM 2 右转向指示灯
indicator light
PMM 1
P-1
122
PEE 2 PFA 7 PEE 3 PFA 8
DF1 2 DF3 15
0.5GR
0.35GW
0.35GR
0.5GW
0.5GW
0.5GR
E23 3 D04 3 F22 1 E11 D24 3 F44

3
Right turning
light
light
1
右侧转向灯
Front right
左侧转向灯
Rear right
右后转向灯
左前转向灯light
左后转向灯 light
右前转向灯
Left turning
Front left
Rear left
light
turning
turning
light
turning
turning
2 6 4 6
4 2
0.5B
0.5B
0.5B
0.5B
0.5B
0.5B
E26 F04 F45 E08 F36 F42 M52
DF1 DF3
E23 M55 M13
1 2 3 4 5 6 1 2 3 4 5 6
4
10 12 10 12
7 8 9 11 13 14 15 7 8 9 11 13 14 15
5 4 3 2 1 2 3 4 3 2 1
19 21 19 21 5
16 17 18 20 22 23 24 16 17 18 20 22 23 24
10 9 8 7 6 10 9 8 7 6 5
25 26 27 28 29 30 31 32 33 25 26 27 28 29 30 31 32 33
1
E11 F44 F22 M45

D04 D24
5 4 3 2 1 1 2 3 1 2 3 1 2 3 1 2 3
13 12 11 10 9 8 7 6 5 4 3 2 1
10 9 8 7 6 4 5 6 4 5 6 4 5 6 7 8 4 5 6 7 8
58
灯光照明
Lighting G-7
元件位置索引
元件编码 code
Component 元件名称
Component name
M47 Headlamp
大灯调节开关 adjusting switch
E11 右前组合灯
Front right combination light
E23 左前组合灯
Front left combination light
F22 左后组合灯
Rear left combination light
F44 右后组合灯
Rear right combination light
F29 左牌照灯
Left license light
F30 右牌照灯
Right license light
M48 调光开关switch
Dimming
F24 左后雾灯
Rear left fog light
F27 右后雾灯
Rear right fog light
E29 左前雾灯
Front left fog light
E09 右前雾灯
Front right fog light
M45 组合灯开关
Combination light switch
D04 左外后视镜
Left outer rearview mirror
D24 右外后视镜
Right outer rearview mirror
M13 警示灯开关
Warning light switch
M55 危险警告继电器
Hazard warning relay
59
灯光照明 G-8
Lighting
元件位置索引
接头
Connector
ME2
PFA
PFB
PMN
PEE
PMM
DF1
DF3
接地点
GND
M52
E26
E08
F45
F42
M42
F36
F04
60
BCM系统
BCM system H-1
B C M
Driver side door Rear fog light Front wiper Mechanical key Mechanical key lock
驾驶席门开关
switch 后雾灯开关
switch 前雨刮低速开关
low-speed switch 前洗涤开关
Front washer switch 机械钥匙开锁
unlock 机械钥匙闭锁
M11 M11 M11 M11 M11 M11
1 2 3 4 5 6
0.35LBr
0.35Br
0.35LW
0.35LR
0.35G
0.75V
GND
3 MF1
0.35Br
124 120 125 126 127 128

S-4 G-5 K-1 K-1 S-2 S-2
Combination
组合灯开关 Combination
组合开关前雨刮低速switch wiper 组合开关洗涤电机
Combination switch 左前门锁
Front left door 左前门锁
Front left door
light switch low-speed washer motor lock lock
M11 ETACS
ETACS接口B
connector B
MF1 Connector
主线束与车身线束接口1
1 of main harness and body harness
14 13 12 11 10 9 8 7 6 5 4 3 2 1
9 8 7 6 5 4 3 2 1
28 27 26 25 2423 22 21 20 19 18 17 16 15
18 17 16 15 14 13 12 11 10
24 23 22 21 20 19 42 41 40 39 38 37 36 35 34 33 32 31 30 29
61
BCM系统
BCM system H-2
Front fog light

B C M Door contact switch
Rear defroster
后除霜开关
switch 前雾灯开关
switch IG2 门触开关信号
signal Key insert switch
钥匙插入开关 Keyhole
钥匙孔照明 lighting
M11 M11 M11 9 M11 10 M11 11 M10 20

7 8
0.35W
0.35L
0.35Gr
0.35YW
0.35P
0.5RB
MF1 32
4 6
钥匙插入开关
Key insert switch
0.35W
M34
ILL
3 5
0.35R
0.35R
130
Main harness internal
S-4 主线束内联点MS02
connectors MS02
048
A-8
0.5G
Indoor electric box

室内电器盒
129 119
O-1 G-5 058
A/C
空调面板panel Combination
组合灯开关 light A-9
switch
Indoor electric box
室内电器盒
M11 ETACS
ETACS接口B
connector B MF1 M34
Connector 1 of main harness and Key insert switch
钥匙插入开关
body harness
9 8 7 6 5 4 3 2 1 14 13 12 11 10 9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 28 27 26 25 24232221201918 17 16 15 2 1
24 23 22 21 20 19 6 5 4 3
42 41 40 39 38 373635343332 31 30 29
62
BCM系统
BCM system H-3
B C M
Driver seat door lock Front wiper high-speed Front wiper inching
大灯开关
Headlamp switch 小灯开关
Small light switch 驾驶席门锁开关信号
switch signal 前雨刮高速开关 switch 前雨刮点动开关
switch
M11 M11 M11 M11 15 M11 16

12 13 14
0.35V
0.35GrB
0.35Lg
0.35BW
0.35L
5 MF1
0.35V
FD1 23
0.35V
118
117 131 132 133
G-5 G-5 K-1 K-1
Combination
组合灯开关
S-2
Combination
组合灯开关左前门闭锁器
Front left door lock Combination
组合开关雨刮 switch 组合开关雨刮
Combination switch
light switch light switch
wiper wiper
MF1 FD1
M11 ETACS
ETACS接口B
connector B Connector 1 of main harness and
Harness connector of body and front
车身线束与左前门线束接口
body harness
left door
14 13 12 11 10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1
9 8 7 6 5 4 3 2 1
12 10
28 27 26 25 24 232221201918 17 16 15 15 14 13 11 9 8 7
18 17 16 15 14 13 12 11 10
24 23 22 21 20 19 18 17 16
42 41 40 39 38 373635343332 31 30 29
24 23 22 21 20 19 28
33 32 31 30 29 27 26 25
63
BCM system
BCM系统 H-4
B C M
Front wiper clearance Front wiper clearance
故障诊断
Failure diagnosis IG1 前雨刮间隙开关switch 碰撞信号
Collision signal 前雨刮间隙调节
adjuster 发动机L端
Engine terminal L
M11 17 M11 18 M11 19 M11 21 M11 22 M11 23
0.35OW
0.35WB
0.35O
0.5Y
PMH 1
0.35O
0.5BL
0.5R
PMJ 6
0.35O
134 039
M-1 A-7 136 137 077
135
Indoor electric
室内电器盒
box K-1 L-1 K-1 C-1
Combination
组合开关雨刮
switch 安全气囊控制器
Airbag controller Engine terminal L
组合开关雨刮
Combination switch 发电机L端
wiper wiper
ME1
M11 ETACS
ETACS接口B
connector B Connector 1 of main harness and
主线束与发动机线束接口1
engine harness
9 8 7 6 5 4 3 2 1
42 41 40 39 38 37 36 35 34 33 32 31 30 29
18 17 16 15 14 13 12 11 10
28 27 26 25 24 23 22 21 20 19 18 17 16 15
24 23 22 21 20 19
14 13 12 11 10 9 8 7 6 5 4 3 2 1
64
BCM system
BCM系统 H-5
ETACS
B C M
Rear ceiling Rear defroster Front wiper high-speed Rear fog light
ETACS天线
Antenna 后顶灯门控
light door lock 防盗继电器
Anti-theft relay 前雨刮继电器
Front wiper relay 后除霜继电器
relay 前雨刮高速继电器relay 后雾灯继电器
relay
M11 24 M10 1 M10 2 M10 3 M10 4 M10 5 M10 6

0.5Lg
0.35Gr
PMK 1
0.35LY
0.5Lg
0.35GrB
0.35Br
0.35G
0.5B
PTC 5
J-1
0.5Lg
139
Front wiper high speed

前雨刮高速继电器 A-8
T07 T06 relay
1 051
3
右遮阳板灯
Right sunvisor
Right
0.35G
后顶灯
ceiling light
light
3 1 2 Rear fog light relay

后雾灯继电器
关闭
门控
开启
2
1 2
0.35B
0.5G
0.5B
预留天线
Reserved
antenna
075 138 066
PTC
7 B-1 J-1 A-10
防盗继电器
Anti-theft relay 前雨刮继电器
Front wiper relay 室内电器盒
Indoor electric
box
057 PMK
11
A-9
PS36 fuse
FS36保险 G_LH.3 M42
9 8 7 6 5 4 3 2 1
M10 ETACS接口A
ETACS connector A 18 17 16 15 14 13 12 11 10
24 23 22 21 20 19
65
BCM system
BCM系统 H-6
B C M
Front wiper Door unlock
前雨刮回位
return 门闭锁信号
Door lock signal B+ 门开锁信号
signal
M10 7 M10 8 M10 10 M10 11

0.5W
ME1 16
0.35L
0.5R
0.35G
1.5W
140 141 060 142

J-1 S-1 A-9 S-1
Front wiper
前雨刮电机 Door lock relay FS36保险
FS36 fuse Door lock relay
门锁继电器
门锁继电器
motor
M10 ETACS
ETACS接口A
connector A FD1
MF1 Harness connector of body and front left
Connector 1 of main harness and body 车身线束与左前门线束接口
主线束与车身线束接口1 door
harness
14 13 12 11 10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1
9 8 7 6 5 4 3 2 1
12 11 10
15 14 13 9 8 7
18 17 16 15 14 13 12 11 10 28 27 26 25 24 23 22 21201918 17 16 15
24 23 22 21 20 19 18 17 16
24 23 22 21 20 19 42 41 40 39 38 37 36 35343332 31 30 29 28
33 32 31 30 29 27 26 25
66
BCM系统
BCM system H-7
Electric window
行李箱灯开关
Trunk light switch 小灯继电器
Small light relay 防盗警铃信号
Burglar alarm signal 电动窗继电器
relay 前雾灯继电器
Front fog light relay
M10
0.35LW
12 M10 13 M10 14 M10 15 M10 16
0.35BrY
0.35LBr
0.35LB
0.35Y
MF1 27
0.35LW
ME1 31
Body harness internal

车身线束内联点FS13
connectors FS13
0.35LW
0.35LW
0.35LW
0.35BrY
F18 1
Truck
后备箱灯
light
F17 1
0.35G
FS08
Floor line
地板线短路器
1 F23 144
breaker R-1
143 109 097 069
0.35G
P-2 行李箱
Trunk light G-2 D-10 A-10
Instrument
组合仪表灯开关
switch 小灯继电器
Small light 防盗警铃继电器
Burglar alarm relay 前雾灯继电器
Front fog light
cluster relay relay
056
A-9
FS36 fuse
FS36保险
F17 后备箱灯
Truck light
ME1
M10 ETACS
ETACS接口A
connector A Connector 1 of main harness and engine
主线束与发动机线束接口1 1
harness
9 8 7 6 5 4 3 2 1
42 41 40 39 38 37 36 35 34 33 32 31 30 29 F18 后备箱灯
Truck light
18 17 16 15 14 13 12 11 10
28 27 26 25 24 23 22 21 20 19 18 17 16 15
24 23 22 21 20 19 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
67
BCM系统
BCM system H-8
Front left door

右前门开关
switch 危险警告灯继电器
Warning light relay 搭铁
Grounding 车速信号
Vehicle speed signal
M10 17 M10 18 M10 19 M10 24
0.5VR
0.35Y
0.5B
0.35V
主线束内联点MS25
Main harness internal
connectors MS25
0.5VR
0.5VR
147
T-1
EPS_2
G_LH1
M52
145 123 146

S-4 G-6 P-2
右前门开关
Front right Hazard warning
危险警告继电器 Instrument cluster
组合仪表
door switch relay
M10 ETACS接口A
ETACS connector A
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
24 23 22 21 20 19
68
线路图-BCM系统
BCM system H-9
元件位置索引
元件编码
Component code 元件名称 name
Component
M34 钥匙插入开关
Key insert switch
F23 Trunk
行李箱灯开关light switch
F17 Truck
后备箱灯 light
F18 Truck
后备箱灯 light
M10 ETACS A
M11 ETACS B
接头
Connector
ME1 主线束与发动机线束接口1
Connector 1 of main harness and engine harness
FD1 车身线束与左前门线束接口
Harness connector of body and front left door
接地点
GND
M42
M52
69
电动后视镜-1
Electric rearview mirror-1 I-1
Indoor electrical
室内电器盒
box
FS05保险 0.5R
A-10 FS05 fuse
067
A-6 032
电动后视镜开关
Electric rearview mirror switch M46
7
0.5GR
上
Up
下
R Down
左
Left
PFA Right右
5
上
Up
Down 下
L
左
Left
0.5GR
Right右
Body harness internal

车身线束内联点FS01
connectors FS01 0.5Lg
M46
8 1 3 6 4 5
0.5WL
0.5BrY
0.5WG
0.5GB 0.5GB
0.5GR
MF1
18 22 19
20 22 21
0.5GR
0.5BrY
0.5Lg
0.5GB
0.5WL
0.5WG
0.5GB
0.5B
FD1
FD3
FD1 1 5 3 4 2 6 4 5
0.35GW
0.5GB
0.5Lg
0.5GB
0.5WL
0.5BrY
0.5WG
0.35GR
D04 2 8 1 3 FD3 15 3 2 8 1 D24
右下右下
0.35GR
Right Down Right Down
M M M M
Left左上Up 左
Left 上
Up
FD3 7 Left 左电动后视镜

electric rearview mirror
左转向灯信号
右转向灯信号
Right 右电动后视镜
Right turning light signal
electric rearview mirror

Left turning light signal
G_LH1 M52
0.5GR
0.5GR
7 6 4 4 6 7
0.5B
0.5B
FD1 14 FD3 10
0.5GR 0.5GR
G_FL2 F04 G_FR F36
MF1 车身线束接口
Body wire harness connector FD1 Front
左前门线束接口
left door wire harness connector FD3 Front
右前门线束接口
right door wire harness connector
14 13 12 11 10 9 8 7 6 5 4 3 2 1
6 5 4 3 2 1 6 5 4 3 2 1
28 27 26 25 24 2322 2120 1918 17 16 15 15 14 13
12 11 10 9 8 7 15 14 13
12 11 10
9 8 7
24 23 22 21 20 19 18 17 16 24 23 22 21 20 19 18 17 16
42 41 40 39 38 3736 3534 33 32 31 30 29 33 32 31 30 28 28
29 27 26 25 33 32 31 30 29 27 26 25
Left electric rearview Right electric rearview

M46 电动后视镜开关
Electric rearview mirror D04 左电动后视镜
mirror D24 右电动后视镜
mirror
switch
1 2 3 PFA Indoor
PFA electrical
室内电器盒接口A box connector A 1 1 2 3 4 5 6 6
1 2 3
3 2 1 7 7 8 9
10 11 12 13
14 15 16 16
4 5 6 7 8
8 7 6 5 4 4 5 6 7 8
70
电动后视镜-2
Electric rearview mirror-2 I-2
元件位置索引
元件编码 code
Component
M46 电动后视镜开关
Electric rearview mirror switch
D04 左电动后视镜
Left electric rearview mirror
D14 右电动后视镜
Right electric rearview mirror
接头
Connector
FD01 车身线束与左前门线束接口
Harness connector of body and front left door
FD03 车身线束与右前门线束接口
Harness connector of body and front right door
PFA 车身线束与室内电器盒接口A
Connector A of body harness and indoor electrical box
接地点
GND
M52
F04
F36
71
雨刮洗涤系统 J-1
Wiper/washer system
喷水电机 motor
Water injection
Indoor electrical
室内电器盒
box
A-8
M
050
E10 1 2
1.5R
1.5R 1.5V
148 K-1
1.5R
1.5R
1.5R
R/L4
R/L3 Front
R/L4wiper
3 前雨刮继电器
Front wiper relay 5 3 前雨刮高速继电器
high-speed relay 5
1 4 1 4
1.5B 0.35Gr
GND
1.5Gr
1.5Br
1.5R
G_LH1 E19
0.35Br
139
H-5
138
H-5
E18
1
HI LO 2
M 3
140 H-6
E18 4
1.5B
G_LH1 E19
PEE 室内电器盒接口E
Indoor electrical box connector E
E18 Front
前雨刮电机 wiper motor
E10 前洗涤电机
Front washer
motor
1 2 3 4 5 6 7
1 2 3 4 2 1
8 9 10 11 12 13 14 15 16 17 18
72
K-1
组合开关-刮水器
Combination switch - wiper
ETACS前喷
主线束内联点MS16
ETACS front
Main harness internal connectors MS16
1.5V
injection
switch
water
水开关
126
1.5V
ME1
1.5V
M32
11 17
Front前雨刮洗涤开关
wiper/washer switch
1.5V
引脚
Pin
5 6 7 8 9 10 11 12 13 14
档位 1 2
Gear
position
3 4
MIST
OFF 148
INT J-1
LO 前洗涤电机
Front washer
HI motor
WASHER
INT(T)
1 3 8 9 13 10 12
1.5B
0.5B
0.35WB
0.35Lg
20
0.35G
0.35L
1.25B
0.5Y
M42 G_LH.3
133 125 135 132 137
H-3
H-1 H-4 H-3 H-4
ETACS前雨
ETACS front ETACS
ETACS前雨front ETACS前雨
ETACS front ETACS前雨
ETACS front ETACS前雨
ETACS front
刮点动控制
wiper inching wiper
刮低速开关 wiper
刮间隙开关 wiper
刮高速开关 wiper
刮间隙调节
control low-speed clearance high-speed clearance
switch switch switch adjuster
ME1 主线束与发动机线束接口
Connector of main harness and engine harness
M32 雨刮洗涤开关
Wiper/washer switch
42 41 40 39 38 37 36 35 34 33 32 31 30 29
7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9 8 14 13 12 11 10 9 8 7 6 5 4 3 2 1
73
安全气囊-1
Airbag -1 L-1
FS21保险
FS 21 fuse
A-7
046
Driver airbag
驾驶员气囊 Front passenger airbag
助手席气囊
M83
1 2
M82
诊断
149Diagnosis
0.75R
M-1
4 3
0.5 OW
0.5 OB
0.5 OG
0.5 OL
0.5 OR
5 10 11 18 19 9
DAB+
DAB-
PAB-
PAB+
K_LINE
安全气囊模块
Air bag module M84
6 46 7 17 16 13 14
0.35 O
0.5 OR
0.5 OW
0.5 O
0.5 0V
0.35 BR
0.75B
2 1 2 1
驾驶员侧
Driver seatbelt 副驾驶员侧
Front passenger
安全带预紧
pretension 安全带预紧
seatbelt pretension
M89 M92
057 093 150
H-4 D-10 P-3
BCM_B21 ECU_72 Air bag
安全气囊
warning
警示灯light
M86 G_SRS
安全气囊
Airbag ECU M84
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 30 29 28 27 26
25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
助手席气囊
Front passenger PAB M83 M82 时钟弹簧
Clock spring 驾驶员侧
Driver seatbelt M89 M92 副驾驶员侧
Front passenger
airbag 安全带预紧
pretension 安全带预紧
seatbelt pretension
1 2
1 1
2 2
1 2 3 4
74
安全气囊-2
Airbag -2 L-2
元件位置索引
元件编码 code
Component 元件名称 name
Component
M84 安全气囊
Airbag ECUECU
M82 时钟弹簧
Clock spring
M83 助手席气囊
Front passenger airbag
M89 司机安全带预紧
Driver seatbelt pretension
M92 乘客安全带预紧
Passenger seatbelt pretension
接地点
GND
M86
75
诊断系统-2
Diagnosis system - 2 M-2
元件位置索引
元件编码 code
Component
M60 诊断接口 interface
Diagnostic
接地点
GND
M52
76
ABS、制动系统-1
ABS/Brake system - 1 N-1
SF01保险
SF 01 fuse SF12保险
SF 12 fuse FS37保险
FS 37 fuse ECU_59
A-4 A-2 A-7 D-9
027 016 047 086

M-1 P-3 P-3
ABS ABS
ABS EBD
ABS诊断
diagnosis instrument
EBD
仪表指示 instrument
indicator 仪表指示
indicator
151 154 155 Brake
制动灯
light
开关
switch
S-6
0.35YL
0.35YG
4.0 RL
1.5RY
0.5R 156
ME2 7 6
0.5L
0.5R
0.35YG
0.35PW
0.35YL
1 25 28 28 6 27 3 30
ABS报警
ABS EBD报警
EBD
alarm alarm
E15 ABS ECU

ABS ECU
19 8 16 4 18 31 29 17 13 38
0.35GW
0.35YW
0.35G
0.35O
EF1 6 5 4 3
4.0 B
1.5B
0.35Br
0.35GB
0.35Y
0.35W
0.50O/B
0.50G/L
0.50Br
0.50W
E30 E13 F13 F41

2 1 2 1
1 2 1 2
FL FR LR RR
左前轮速
Front left wheel
speed sensor 右前轮速
Front right
wheel speed 左后轮速
Rear left wheel
speed sensor
右后轮速
Rear right
wheel speed
E16 G_ABS
传感器传感器
sensor 传感器传感器
sensor
E15 ABS ECU
13 12 11 10 9 8 7 6 5 4 3 2 1
39 38 37 36 25 3433 32 31302928 27
24 23 22 21 20 19 18 17 16 15 14
26 25 24 23 22 21 20 19 18 17 16 15 14 38 37 36 35 34 33 32 31 30 29 28 27 26 25
13 12 11 10 9 8 7 6 5 4 3 2
1
EF1 Connector
发动机线束与车身线束接口
of engine harness and body harness
F13/F41/E13/E30
Speed sensor
轮速传感器 2 1 1 2 3 4 5 6 7
8 9 10 11 12 13 14
77
ABS、制动系统-2
ABS/Brake system - 2 N-2
元件位置索引
元件编码 code
Component
E15 ABS
ABS ECU
ECU
F13 左后轮速传感器
Rear left wheel speed sensor
F41 右后轮速传感器
Rear right wheel speed sensor
E30 左前轮速传感器
Front left wheel speed sensor
E13 右前轮速传感器
Front right wheel speed sensor
接头
Connector
EF1 发动机线束与车身线束接口
Connector of engine harness and body harness
接地点
GND
E16
78
Auto A/C system - 1

自动空调系统-1 O-1
F05保险
F 05 fuse ILL+ ILL-
A-4 G-3 G-3
M05 G_RH
030 113 114
BCM_B7 F08保险
F 08 fuse
H-2 A-10
0.5R 129 068
PEF 7
0.35GR
0.35L
PMG 5
0.5B 0.5B 0.35G 0.35LG
0.5R
M71 A3 M71 A10 M71 A20 M71 A2 M71 A1 M71 A8 M71 A18
Rear defroster
GND GND
后除霜
ILL+ ILL-
Rear defroster
B+
后除霜继电器
relay
空调控制面板
A/C control panel
M71 空调控制面板A M72 空调控制面板B

A/C control panel B
A/C control panel A PMG
PEF
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 7 8 9 10
12 13 14 15 16 17 18 19 20 21 22 5 6 11 12
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
79
空调系统-模式、温度执行器
A/C system - Mode, Temp actuator O-2
模式执行器
Mode actuator 温度执行器
Temp actuator
蒸发器表面温度传感器
Evaporator surface temp
M M
2 1 M16
M18 1 3 4 5 2 M07 1 3 4 5 2
0.35B
0.35G
0.35G
0.35B
0.35B
0.35GY
0.35L
0.5RW
0.35G
0.5GrW
0.35LW
0.5GrB
0.35B
0.5RB
M71 M72
M72
B13 B8 B15 B16 B12 A6 A6 A16 B4
M+
DUCT SENSOR
M+
Ref(5V)
M-
Sensor GND
Mode PBR
M-
Temp PBR
A/C 空调控制面板
control panel
M18 M07
M71 空调控制面板A M72 空调控制面板B
A/C control panel B
A/C control panel A 模式执行器
Mode actuator 温度执行器
Temp actuator
M16
Evaporator surface
蒸发器表面温度传感器
temp sensor
2 1 2 1
10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 2 1 7 6 5 4 3
7 6 5 4 3
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
80
空调系统-压缩机
A/C system - compressor O-3
Internal and external

Outdoor temp sensor circulation actuator
室外温度传感器 motor
内外循环执行电机
GND 12V M+ M-
M
E75 1 2 M06 1 2
阳光传感器
Solar sensor
室内温度传感器
Indoor temp sensor
0.35GW
0.35B
M
GND
18
SIGN
4
M-
5V
12V
M+
GND
PWR
GND
ME1
M74 1 2 3 4 M61 1 2 6 5 4
0.35GrW
0.35GR
0.5B
0.5R
0.35GW
0.5GrW
0.35GO
0.5RY
Reserved Reserved Reserved

0.35B
预留预留预留
M72 M71
B1 B9 B10 B16 B3 A7 A17 M71 A14 A13
AMB(5V)
AI MOTOR+
AI MOTOR-
INCAR(5V)
SENSOR GND
FRE/OSA_MTR+
FRE/OSA_MTR-
SUN SENSOR(5V)
SUN SENSOR GND
A/C空调控制面板
control panel
ME1 M06
circulation
内外循环执行电机 actuator M61 M74
motor E75
Outdoor temp sensor 阳光传感器
Solar sensor 室内温度传感器
Indoor temp sensor
室外温度传感器
42 41 40 39 38 37 36 35 34 33 32 31 30 29 2 1
1 2 6 5 4 3 2 1 1 2 3 4
28 27 26 25 24 23 22 21 20 19 18 17 16 15 7 6 5 4 3
14 13 12 11 10 9 8 7 6 5 4 3 2 1
81
空调系统-模式、温度执行器
A/C system - Mode, Temp actuator O-4
FS15保险
SF 15 fuse
A-8
049
SF04保险
SF 04 fuse
A-4
029
ECU_76 ECU_60 ECU_75
0.35R
3R
D-9 D-9 D-9

30 86
089 091 092
风机继电器
Blower relay
87 85
0.5VY
0.5GY
14 3 E35 1
0.35G
ME2
3R
Three-way
三元压
M09 2 MI pressure LO
0.5G
力开关
switch HI
Blower
鼓风电机
motor
M
4 2
M09 1
FET
2 4
3G
S
0.5G
0.5G
D
G
ME1 38
M76 1
PMM 9
3B
0.5G
FS02
26
0.5G
ME1
10A G_RH M05
0.5LY
0.5RB 0.5RB
PMK 14
0.5G
0.5GB
M72 B2 M71 A5 M71 A4 M71 A9 M71 A19 M71 A11
IG2 IG2
FET(D)
FET(G)
A/C output high

BLOWER ON SIGNAL
空调控制面板
A/C control panel
M76
PMK FET M09
鼓风电机
Blower motor
2 1
1 2 3 4 5 6 7 8 Connector 2 of main harness and
1
4 3 ME2 主线束与发动机线束接口2
engine harness
9 10 11 12 13 14 15 16
2
ME1
39 38 37 36 25 343332 31302928 27 E35
PMM E35
Three-way
26 25 24 23 22 21 20 19 18 17 16 15 14 三元压力开关
pressure switch
42 41 40 39 38 37 36 35 34 33 32 31 30 29
1 2 3 4 5 13 12 11 10 9 8 7 6 5 4 3 2
1
8 9 10 11 12 13 14 28 27 26 25 24 23 22 21 20 19 18 17 16 15 2 1
6 7
14 13 12 11 10 9 8 7 6 5 4 3 2 1 4 3
82
O-5
A/C空调系统-6
system - 5
元件位置索引
元件编码 code
Component
M71 空调控制面板A
A/C control panel A
M72 空调控制面板B
A/C control panel B
M76
FET
FET
Evaporator
蒸发器表面温度传感器surface temp sensor
M16
Mode actuator
模式执行器
M18
Temp actuator
M07 温度执行器
Internal and external circulation
M06 内外循环执行电机
actuator motor
E35 三元压力开关
Three-way pressure switch
E75 室外温度传感器
Outdoor temp sensor
M74 室内温度传感器
Indoor temp sensor
M09 鼓风电机
Blower motor
接头
Connector
EM1
EM2
PEF
PMG
PMK
PMM
接地点
GND
M05
83
手动空调系统-鼓风机
Manual A/C system - blower O-1
F05保险
F 05 fuse SF04保险
SF 04 fuse FS15保险
FS 15 fuse
A-4 A-4 A-8
030 029 049
0.5R
EM1
ECU_76
35
0.35R
D-9
3R
089 30 86
PEF 7 R/L 2 风机继电器

Blower relay
0.35G
87 85
ME2 14
0.35G
EM1
0.5R 0.5G
13
3R
2
鼓风机
Blower
motor
电机
M09
M
1
PMG 5
Speed regulation
调速电阻
resistance
3G
G_RH M05
0.5RB
0.5R 3 1 2 4
M08
0.5G 0.5G
3B
2.5B 2.5YB 2.5Y 3G
M15 A22 A4 B2 M14 B6 B5 B1 B4 B3 A23
LOW ML MH HI
A/C空调控制面板
control panel
M08 M09 EM1

M15 A/C
空调控制面板A
control panel A Speed
M14 M09
Blower
M14
A/C 空调控制面板B regulation
control panel B M08 调速电阻鼓风机电机
motor
29 30 31 32 33 34 35 36 37 38 39 40 41 42
resistance
10 9 8 7 6 5 4 3 2 1 15 16 17 18 19 20 21 22 23 24 25 26 27 28
3 2 1 2 1 1
23 22 21 20 19 18 17 16 15 14 13 12 11
6 5 4 4 3 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14
84
手动空调系统-模式、温度执行器
Manual A/C system - Mode, Temp actuator O-2
Mode actuator
模式执行器 Temp actuator
温度执行器
Indoor temp sensor
M M
2 1 M16
M18 1 3 4 5 2 M07 1 3 4 5 2
0.35B
0.35G
0.35G
0.35B
0.35B
0.35GY
0.35L
0.5RW
0.35G
0.5GrW
0.35LW
0.5GrB
0.35B
0.5RB
M15
A20 A17 A18 A16 A19 A5 A6 A7 A3
M+
Ref(5V)
Sensor GND
Mode PBR
M-
Temp PBR
M+
M-
空调控制面板
A/C control panel
M18 M07
M15 A/C
空调控制面板A
control panel A
M16 温度执行器
Temp actuator
模式执行器
Mode actuator
Indoor temp sensor
10 9 8 7 6 5 4 3 2 1
2 1 2 1
2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 7 6 5 4 3 7 6 5 4 3
85
手动空调系统-
Manual 压缩机
A/C system - compressor O-3
BCM_B7 F08保险
F08 fuse ILL+ ILL- ECU_60 ECU_75
H-2 A-10 G-3 G-3 D-9 D-9
M05 G_RH 129 068 113 114 091 092
0.5VY
0.5GY
3 E35 1
Three-way
三元压
MI pressure LO
力开关
switch HI
4 2
0.35Lg
0.35GR
0.35G
0.35L
0.5G
0.5G
0.5B

0.5G
circulation actuator motor

M
EM1 26
M06 1 2
0.5B
0.5B
0.5R
M15 A21 A8 A9 A13 A12 A2 A15 A14

后除霜
defroster
Rear defroster
A/C output high

ILL-
后除霜继电器
ILL+
GND
M+
Rear
M-
relay
空调控制面板
A/C control panel
M06
InternalM06
and external EM1
E35
M15 A/C
空调控制面板A
control panel A circulation actuator
motor
Three-way
三元压力开关
pressure switch 29 30 31 32 33 34 35 36 37 38 39 40 41 42
10 9 8 7 6 5 4 3 2 1 15 16 17 18 19 20 21 22 23 24 25 26 27 28
2 1 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 7 6 5 4 3 4 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14
86
手动空调系统
Manual A/C system O-4
元件位置索引
元件编码 code
Component
M15 空调控制面板A
A/C control panel A
M14 空调控制面板B
A/C control panel B
M08 调速电阻
Speed regulation resistance
M16 室内温度传感器
Indoor temp sensor
M18 模式执行器
Mode actuator
M07 温度执行器
Temp actuator
M06 内外循环执行电机
Internal and external circulation actuator motor
E35 三元压力开关
Three-way pressure switch
M09 鼓风机电机
Blower motor
接头
Connector
EM1
接地点
GND
M05
87
组合仪表-1cluster - 1
Instrument P-1
F03保险
F03 fuse
A-3
023
0.75G
Left Right Front fog Rear fog

远光继电器
High beam relay 左转向
steering 右转向
steering 前雾灯
light 后雾灯
light 小灯
Small light
PEE
G-1 G-6 G-6 A-10 A-8 G-3
1
105 121 122 070 052 111
PMK 12
0.35L
0.5GR
0.5GW
0.35G
0.5L
0.5RB
0.5LW
M43 29 M43 32 M44 17 M43 17 M44 31 M44 28 M44 12

Instrument cluster
组合仪表
场置发光照明
Field lighting
右转向指示
前雾灯指示
远光指示
后雾灯指示
Front fog light
左转向指示
Right turning
Rear fog light
小灯指示
Left turning
Small light
High beam
indicator
indicator
indicator
indicator
indicator
EOBD
indicator
EPC
M43
28 14 16 27
M43 M44 M43
0.35Lg
0.75LBr
0.75BrW
0.5B
078 079 112
D-1 D-1 G-3

ECU_31 ECU_11 M52 G_LH1 ILL-
PMK PEE
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7
9 10 11 12 13 14 15 16 8 9 10 11 12 13 14 15 16 17 18
M43 Instrument
组合仪表A cluster A M44 Instrument
组合仪表B cluster B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
88
组合仪表-2cluster - 2
Instrument P-2
FS36保险
FS36 fuse
A-9
061
组合仪表
Instrument cluster
0.5R
M44 32
B+
车门开指示
Open door
Buzzer
蜂鸣器 Instantaneous
indicator
瞬时油耗 fuel
consumption
车速表
Speed
meter 转速表
Revolution
meter 燃油表
Fuel
gage
MCU
door switch (reserved)
Front compartment
Engine anti-theft
Instantaneous
前舱门开关(预留)
Vehicle speed
Vehicle speed
signal output
驾驶员安全带开关
Rotate speed
signal input
signal input
door switch
Water temp
indicator
Driver seat
belt switch
发动机防盗指示
Fuel level
Front left
转速信号输入
车速信号输出
signal
车速信号输入
signal
fuel
行李箱开关
switch
Truck
瞬时油耗
左前门开
油量信号
水温信号
M43 2 M43 25 M43 24 M44 27 M44 26 M44 24 M44 25 M44 1 M44 22 M43 3 M43 21
0.5BrY
0.35GW
0.75WBr
0.35LW
0.5BrR
0.75LY
0.5VR
0.5V
0.35Br
0.35WG
MF1 26 MF1 14
0.5BrY
0.35GW
F10 3
燃油 F32 1
Fuel
传感
sensor
器安全
Seat
belt
157 143 095 090 087 083 146 带开 158
switch
2 关
Q-1 H-7 D-10 D-9 D-9 D-1 H-8 S-4
0.5B
2 Front
左前门 left door
防盗控制器行李箱 ECU_10 ECU_9 ECU_59 ECU_8 BCM_A24
0.35B
Immobilizer Trunk light

灯开关
switch 开关
switch
F14 G_RL
MF1
F32 F10
14 13 12 11 10 9 8 7 6 5 4 3 2 1
驾驶员安全带开关
Driver seat belt switch 燃油传感器
Fuel sensor
28 27 26 25 2423222120 19 18 17 16 15
42 41 40 39 38 37363534 33 32 31 30 29 2 1 1 2 3 4
M43 Instrument
组合仪表Acluster A M44 Instrument
组合仪表Bcluster B
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
89
Instrument
组合仪表-3cluster - 3 P-3
FS34保险
FS34 fuse
A-7
038
组合仪表
0.5R
Instrument cluster
M44 15
KL15
brake
驻车制动警告
warning
Water temp
水温表
安全带警告
燃油量警告
level
胎压报警 alarm
belt
warning
warning
indicator
meter Parking
failure
indicator
Oil机油压力警告
安全气囊指示
pressure
Seat
Fuel
充电指示
warning
EPSEPS指示
Tire pressure
TPMS失败
Charging
indicator
TPMS
Airbag
MCU ABS
Front right door
Rear right door
Rear left door
Control
Reversing
左后门开open
右后门开open
右前门开open
radar
发电机"L"
倒车雷达
Genera
ABS报警
EBD报警
alarm
alarm
EBD
ABS
tor L
Oil
机油
M43 22 M43 23 M43 26 M44 23 M43 5 M43 20 M43 6 M43 30 M43 15 M44 14 M44 30 M43 16 M43 1
0.35YG
0.35LBr
0.35 OW
0.35OW
0.35Lg
0.35YG
0.35Br
0.35LB
0.35YL
0.35LY
0.5Br
0.5Lg
0.35W
ME2 9
0.35YG
ME2 9 MF1 10
EC1 A4
0.35 OW
0.35 OW
0.5RL
E17 2 F34 1
手制动开关brake
制动液位传感器
1
sensor
A12
switch
Brake fluid
Manual
level
1
159 160 161 098 154 155 076 150 162 176 177
0.35B
S-4 S-4 S-4 E-1 N-1 N-1 C-1 L-1 T-1 U-1 U-1
右前门
Front 右后门
right Rear Rear left 倒车雷达
right 左后门 Reversing ABS_27 ABS_3 发电机
Engine ACU_7 EPS指示
EPS 胎压报警
Tire TPMS失败
TPMS
door
开关switch door
开关 switch door
开关 switch radar L端 L
terminal indicator pressure failure
E19 G_LH1 alarm
ME2 EC1
MF1 A12
B14 B6 B1
A3 A8 A13
A16 B15 B7 B2
14 13 12 11 10 9 8 7 6 5 4
机油压
Oil pressure
B16 B8 3 2 1
39 38 37 36 25 34333231 302928 A2 A7 A12 switch
27
B17 B9 力开关
A6 A11 A15 28 27 26 25 24 23 22 21 201918 17 16 15
26 25 24 23 22 21 20 19 18 17 16 15 B18 B10
14 A5 A10 B3
B19 B11
13 12 11 10 9 8 7 6 5 4 3 2
1 A1 A4 A9
A14 B20
B21
B12
B13
B4
B5
42 41 40 39 38 37 36 35 3433 32 31 30 29 101
Brake fluid level Manual brake

M43 Instrument
组合仪表A cluster A M44 Instrument
组合仪表B cluster B E17 制动液位传感器 F34 手制动开关
switch
sensor
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 2 1
1
90
IMMO-1 Q-1
Indoor electric Indoor electric

室内电器盒
box 室内电器盒
box ECM_71 ECM_11
A-7 A-9 D-1 D-1
040 059 081 080
0.75BrW
0.5G
0.5YG
0.35R
M21 03 02 04 05
IG1
R_LINE
W_LINE
B+
发动机防盗控制器
Engine immobilizer
K_LINE
ANT_2
ANT_1
LED
GND
01 06 08 10
07
0.35LB
0.35WG
0.5YG
0.35LW
0.5B
防盗线圈
Anti-theft coil 157 152
M52 G_LH1 P-2 M-1

仪表指示灯
Instrument 诊断接口
Diagnostic
indicator light interface
M21 发动机防盗控制器
Engine immobilizer
5 4 3 2 1
10 9 8 7 6
91
SF03保险
SF03 fuse R-1
Electric glass lifting - 1 FS04
A-4
30A 028
FS01
30A
PFB 13 11 PFA PEE 11
Electric
1.5 RB
电动门窗
door and
1.5RB
1.5 R
继电器
window
1.5 RB
1.5 R
relay
PMH 14
DF1 13
0.35 LBr
DF1 7
R-3 R-4
R-2
164 165
163
1.5 RB
1.5 R
144
H-7
BCM_A15
11 10 玻璃升降主控开关
Master switch for glass lifting control
R-3
166
R-2
167
02
D06
DOWN UP
自动升
Auto
lifting 玻璃升降
Glass lifting
DF1 21 降控制
control
锁止开关
lock switch
单元unit
R-2
168
1.5 B
5 6 4
1.5 Br
1.5 O
0.35 G
D03 D03
F04 G_FL2 DOWN 2 1 UP DF1 26
R-3
172
M
0.35 G
Front left electric

左前电动门窗电机
door/window motor
110
G-2
小灯继电器
Small light relay
DF1 Body wire harness connector D06 Master switch for front left D03 Front left glass lifting PFA Indoor electrical box
DF1 车身线束接口 D06 左前玻璃升降主控开关 D03 左前玻璃升降电机 PFA 室内电器盒接口
glass lifting control motor interface
1 2 3 4 5 6
10 12
7 8 9 11 13 14 15
6 5 4 3 2 1 1 1 2 3 4 5 6 6
19 21
16 17 18 20 22 23 24 10 11 12 13
25 26 27 28 29 30 31 32 33 14 13 12 11 10 9 8 7 2 1 7 7 8 9 14 15 16 16
92
Electric glass lifting - 2 R-2
玻璃升降主控开关
R-1
167
Rear left door and

左后门窗开关
window switch
DOWN UP
R-1
R-3
168 169
12 9
D06
1.5 G
1.5 G
DF1 6 DF1 8
1.5 G
FD2 7 FD2 1.5 G 9

FD2 1.5R
R-1
1.5 G
163
8
8 6 4
Rear left
左后玻璃
glass lifting
升降开关
switch DOWN UP
D33-1
3 1
1.5 Br
1.5O
D32-1 D32-1
2 1
M
Rear left glass lifting motor
左后玻璃升降电机
D33-1 Rear left door glass lifting D32-1 Rear left glass lifting FD2 D06 Master switch for front left
D33-1 左后门玻璃升降开关
switch
motor
D06 左前玻璃升降主控开关
1 2 3
4 5 6 7 8 9
3 2 1 6 5 4 3 2 1
10 11 12 13 14 15
8 7 6 5 4 14 13 12 11 10 9 8 7
2 1
93
Electric glass lifting - 3 R-3
R-4
R-1
166 171
Front right door and

右前门窗开关
window switch
DOWN UP
R-2
R-4
169 170
3 1
D06
1.5L
1.5P
DF1 9 DF1 10
1.5L
1.5P
G_FR F36
DF3 1 DF3 2
1.5L
1.5P
1.5 RB DF3 1.5 RB FD3 10

R-1
164
3
8 6 4 0.5B 7
Front right
glass 右前玻璃
lifting
升降开关
switch
DOWN UP
D26
3 1 5
0.35G
1.5 Br
1.5 O
DF3 16
D23
0.35G
D23
2 1
M 172
R-1
右前玻璃升降电机
Front right glass lifting motor
D26 Front right door glass lifting D23 Front right glass lifting DF3 Body wire harness D06 Master switch for front left
D26 右前门玻璃升降开关
switch D23 右前玻璃升降电机
motor DF3 connector
车身线束接口 D06 左前玻璃升降主控开关
1 2 3 4 5 6
10 12
7 8 9 11 13 14 15
3 2 1 19 21 6 5 4 3 2 1
16 17 18 20 22 23 24
8 7 6 5 4
2 1 25 26 27 28 29 30 31 32 33
14 13 12 11 10 9 8 7
94
Electric glass lifting - 4 R -4
R-3
171
Rear right door and

右后门窗开关
window switch
DOWN UP
R-3
170
8 7
D06
1.5Y
1.5W
DF1 11 DF1 12
1.5Y
1.5W
FD4 7 FD4 9
1.5G
1.5G
FD4 1.5R
R-1
165
8
8 6 4
D33-2
Rear right
右后玻璃
glass升降开关
lifting DOWN UP
switch
3 1
1.5 Br
1.5 O
D32-2 D32-2
2 1
M
Rear右后玻璃升降电机
right glass lifting motor
D33-2 Rear right door glass D32-2 Rear right glass lifting FD4 D06 Master switch for front left
D33-2 右后门玻璃升降开关
lifting switch D32-2 右后玻璃升降电机
motor D06 左前玻璃升降主控开关
1 2 3
4 5 6 7 8 9
3 2 1
6 5 4 3 2 1
10 11 12 13 14 15
8 7 6 5 4 2 1
14 13 12 11 10 9 8 7
95
R-5
Electric glass lifting - 5
元件位置索引
元件编码 code
Component
D06 左前玻璃升降主控开关
Master switch for front left glass lifting control
D03 左前玻璃升降电机
Front left glass lifting motor
D26 右前玻璃升降开关
Front right glass lifting switch
D23 右前玻璃升降电机
Front right glass lifting motor
D33-1 左后玻璃升降开关
Rear left glass lifting switch
Rear left glass lifting motor
D33-2 右后玻璃升降开关
Rear right glass lifting switch
D32-2 右后玻璃升降电机
Rear right glass lifting motor
接头
Connector
PFA
PFB
PEE
PMH
DF1
DF3
FD2
FD4
接地点
GND
F04
F36
96
Door lock FS31保险

FS 31 fuse
S-1
A-9
064
1R
1R
1R
1R
开锁
Unlock 2 7 9 闭锁
Lock
门锁继电器
Door lock
relay
M41
1 5 6 8 3 4
0.35L
0.35G
1W
1B
1V
1B
Master switch for electric

电动窗主控开关
window control
MF1 FD1 D06
0.35L 0.35L
29 18 14 开锁
Unlock
MF1
0.35G
FD1
0.35G 闭锁
Lock
30 17 13
2
MF1 25 MF1 12
0.35L
0.35G
DF1 21
1W
1V
1.5 B
F04 G_FL2
174 M42 G_LH3
173 142 141
S-2 H-6 H-6 S-2
BCM_A11 BCM_A8
FD1
MF1 M41
M41Door lock relay
门锁继电器 D06D06 左前门闭锁器
Front left door lock
6 5 4 3 2 1
12 10
15 14 13 11 9 8 7 14 13 12 11 10 9 8 7 6 5 4 3 2 1
19 18 17 16 4 3 2 1 6 5 4 3 2 1
24 23 22 21 20 28 27 26 25 242322 21 20 19 18 17 16 15
28
42 41 40 39 38 3736 35 34 33 32 31 30 29 9 8 7 6 5
33 32 31 30 29 27 26 25 14 13 12 11 10 9 8 7
97
门闭锁
Door lock S-2
BCM BCM
H-1 H-3
S-1 S-1
128 131 173 174
BCM
H-1
127
0.35LR
0.35V
DF1 15 DF3 FD2

8 3 FD4 3
0.35LBr
1V
1V
1V
1V
Front left door Front right Rear left door Rear right
D09 左前门闭锁器
lock 右前门闭锁器
door lock D29 左后门闭锁器
lock D34-1 右后门闭锁器
door lock D34-2
6 5 8 4 4 4 4
UNLOCK M
M M M
LOCK
7 1 1 1 1
1W
1W
1W
1W
FD4
0.35B
DF1 DF3 9 FD2 4 4

16
DF1 14
G_FL2 F04
FD4 FD4
DF3
1 2 3 1 2 3
4 5 6 7 8 9 4 5 6 7 8 9 1 2 3 4 5 6
10 12
7 8 9 11 13 14 15
10 11 12 13 14 15 10 11 12 13 14 15 16 17 18
19
20
21
22 23 24
25 26 27 28 29 30 31 32 33
D09左前门闭锁器
D09 Front left door lock D29D29右前门闭锁器
Front right door lock
4 3 2 1 4 3 2 1 DF1
10 9 8 7 6 5 10 9 8 7 6 5
1 2 3 4 5 6
D34-1
D34-1 左后门闭锁器
Rear left door lock D34-2Rear
D34-2 右后门闭锁器
right door lock 10 12
7 8 9 11 13 14 15
19 21
16 17 18 20 22 23 24
25 26 27 28 29 30 31 32 33
4 3 2 1 4 3 2 1
10 9 8 7 6 5 10 9 8 7 6 5
98
Door lock S-3
元件位置索引
元件编码
Component code 元件名称name
Component
M41 门锁继电器
Door lock relay
D06 左前门闭锁器
Front left door lock
D34-1 左后门闭锁器
Rear left door lock
D29 右前门闭锁器
Front right door lock
D34-2 右后门闭锁器
Rear right door lock
接头
Connector
MF1
FD1
DF1
接地点
GND
M42
F04
99
门开关
Door switch S-4
FS36保险
FS 36 fuse
A-9
055
0.35G
FS08
0.35G
0.35G
FD3 13 FD1 24
0.35G
0.35G
D27 1 1
D07
右前
Front 左前 left
Front
right door
P-3 门灯
door
P-2 门灯light
light
2 2
P-3 P-3
159 158
0.35Br
0.35V
161 160
FD3 FD1
0.35W
MF1 14 MF1 25
0.35Br
31 31 MF1 11 MF1 17
0.35LB
0.35V
0.35LY
0.35W
0.35Br
0.35W
0.35W
0.35W
F09 F11 F40

F38 1 2 1 2 1 2 1 2
Front left Rear left Rear right
Front 右前门
right 左前门
door 左后门
door 右后门
door
door switch 开关
switch switch switch
开关开关
0.35W
开关
0.35BR
0.35V
MF1 32
145 124 130

ETACS ETACS H-2
H-8 H-1 ETACS
Front 右前门开关
right door switch 左前门开关
Front left door switch 车门开关
Door switch
F09F09 左前门开关
Front left door switch F11F11
Rear左后门开关
left door switch F38
F38 左后门开关
Rear left door lock F40Rear
F40 右后门开关
right door lock D07D07
Front left door light
左前门灯
2 1 2 1 2 1 2 1
2 1
FD1 FD3
MF1
14 13 12 11 10 9 8 7 6 5 4 3 2 1 D27 right
D27 Front 右前门灯 door light
6 5 4 3 2 1 6 5 4 3 2 1
12 10 12 11 10 9 8 7
15 14 13 11 9 8 7 15 14 13 28 27 26 25 24 23 2221201918 17 16 15
19 18 17 16 24 23 22 21 19 18 17 16
24 23 22 21 20 20
42 41 40 39 38 37 3635343332 31 30 29 2 1
33 32 31 30 29 28 27 26 25 33 32 31 30 29 28 27 26 25
100
Door switch S-5
元件位置索引
元件编码
Component name
D07 左前门灯
Front left door light
D27 右前门灯
Front right door light
F38 右前门开关
Front right door switch
F09 左前门开关
Front left door switch
F11 Rear左后门开关
left door switch
F40 Rear右后门开关
right door switch
接头
Connector
MF1
FD1
FD3
101
门开关-制动灯，高位刹车灯 FS27保险
FS 27 fuse S-6
Door switch - brake light,
high-mounted brake A-9
062
0.5R
FS34保险
FS 34 fuse
0.5R 18
A-7 041 ME2
0.5R
4 2
M17
制动
Brake
开关
switch
3 1
0.5PW
0.5LY
0.35PW 0.35PW
FM1 28
0.5PW
0.5PW
0.5PW
0.5PW
F44
1
brake light
094 096 3 3 156

brake light
Rear left左后制动灯
brake light
高位刹车灯
右后制动灯
D-10 D-10 N-1

F19 F22
High-mounted
ECU_58 ECU_21
Rear right
2 6 6 ABS_30
0.5B
0.5B
0.5B
G_RL1 F45 G_RR F42 G_RL1 F45
F19
F19 High-mounted
高位刹车灯 brake light F44F44
Rear left brake light
左后制动灯 F22F22Rear right brake light
右后制动灯 M17 Brake
M17 switch
制动开关
1 2 3 1 2 3
2 1 2 1
4 5 6 4 5 6
4 3
ME2 Connector
ME2 2 of main harness and engine harness
主线束与发动机线束接口2
FM1
FM1 Connector 1 of main harness and body harness
42 41 40 39 38 37 36 35 34 33 32 31 30 29
39 38 37 36 25 34 3332313029 28 27
28 27 26 25 24 23 22 21 20 19 18 17 16 15
26 25 24 23 22 21 20 19 18 17 16 15 14
14 13 12 11 10 9 8 7 6 5 4 3 2 1
13 12 11 10 9 8 7 6 5 4 3 2
1
102
S-7
Door switch
元件位置索引
元件编码
Component code 元件名称 name
Component
F19 High-mounted
高位刹车灯 brake light
左后制动灯
Rear left brake light
F44
F22 Rear right brake light
右后制动灯
M17 制动开关
Brake switch
接头
Connector
FM1
ME2
接地点
GND
F42
F45
103
EPS电子助力转向-1
-1 T-1
Diagnostic EPS fault

ECM_8 BCM_A24 FS30保险
FS 30 fuse 诊断接口
interface EPS故障灯
indicator light
D-1 H-8 A-7 M-1 P-3
082 147 044 153 162
FF12保险
12 fuse
A-1
005
0.35LBr
0.5LY
6R
0.5VR
0.5Br
0.5L
E39 1
M
助力转
Power
steering
向电机
motor
2
M40 1 2 4 5 7
indicator light
signal
EPS fault EPS故障指示灯

speed signal
IG1
车速信号
K_LINE
发动机转速信号
Vehicle speed
6B
Engine
EPS信号
EPS signal
G_EPS G06
M40 EPS
M40 EPS信号
signal E39Power
E39 助力转向电机
steering motor
1 2 3 4 1
5 6 7 8
2
104
U-1
TPMS-1
TPMS -1
ICM_A1 ICM_A16 FS13保险

FS 13 fuse
P-3 P-3 A-8
177 176 175 F42
G_RR
0.5Br
0.5Lg
0.5G
0.5B
MF1 MF1 MF1 9
8 7
0.5Br
0.5Lg
0.5G
F43 3 4 8 16
failure
alarm
胎压报警
TPMS失败
IG2
GND
Tire pressure
TPMS
TPMS
TPMS
F43 TPMS
F43 TPMS MF1 车身线束接口
MF1 Body wire harness connector
14 13 12 11 10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8
28 27 26 25 2423 22 21 20 19 18 17 16 15
9 10 11 12 13 14 15 16
42 41 40 39 38 37 36 35 34 33 32 31 30 29
105
J4 Service Manual Component Position
ABS wire harness
ABS front right wheel speed

sensor
ABS ECU
E13 E15
ABS front left whell

speed sensor ABS Brake switch
E 30 M17
106
CD audio
USB interface CD host 1
AUX interface
Front right door CD host 2
speaker
D25 M12A M12B
ESP power
supply
F20 rear right F16 rear left speaker

speaker
E39 F16 F20
107
Rearview mirror & door wire harness
D24 right rear D04 front left door rearview

rearview mirror mirror wire harness
D24 D04
M48 dimming switch

M46 rear rearview mirror
adjusting switch
D06 door lock actuator

interface
M47 headlamp height

adjusting switch
M46 M47 M48 D06
D04 left rearview

mirror wire harness
D03 left front glass lifting

motor
D03 D04
108
D24 right rearview mirror

wire harness
D07 Front left
Door Light
D06 Front left door glass lifting D09 front right glass lifting motor
switch
D06 D07 D09 D24
D26 front right door glass lifting

switch
D34-1 front left

Door and Lock
D26 D34-1
F38 front right door control

switch
FD01 to left front door wire

harness
F38 FD01
109
FD02 left front door wire

harness interface
F09 front left door

contact switch FD03 to right front door
wire harness
F09 FD02 FD03
FD04 to right rear door wire

harness D34-2 Right Rear
FD04 D34-2
Right rear door glass lifting

switch
Rear right glass lifting

motor
D32-2 D33-2
110
D05 front left door high

pitch horn
D08 front left low pitch

D09 front left door Horn
lock motor
D05 D09 D08
D27 front right door

light
D28 front right high

pitch horn
D25 front right low
pitch horn
D25 D28 D27
111
A/C wire harness
E35 three-membered
pressure switch M06 inside and outside
circle control
E35 M06
M08 speed control
resistance
M16 evaporator surface

sensor
M16 M08
M15 A/C control panel B
M09 air blower
M14 A/C control panel A
M09 M14 M15
112
M07 temperature
ventilation door motor
M07
113
Airbag wire harness
M89 front left seatbelt M84 air bag ECU

deadlock
M89 M84
M92 front right seatbelt

deadlock Airbag interface of
driver
M92
M87 right side air

bag
M87
114
Front wall wire harness
E09 front right E10 water washing cam

headlamp port
E09 E10
E25 high pitch
horn E29 front left fog
light
E25 E29
115
Tail door wire harness and sensor wire harness
F13 left rear wheel sensor
F41 left rear wheel

sensor
F13 F41
F17, F18 trunk light

F19 high-mounted
brake light
F17 F18 F19
F22 rear left

combination light
F24, F27 left & right rear

fog light
F22 F24 F27
116
F25, F26 left & right

probe light
F28 rear left
reversing light
F25 F26 F28
F29, F30 left & right

license plate light
F44 rear right
combination light
F29 F30 F44
117
Wire harness of instrument panel
M04 radio antenna

M10 ETACSS A
M11 ETACSS B
M04 M10 M11
M13 hazard warning light

switch
M21 engine IMMO

module
M13 M21
M22 steering lock module M3 vehicle power
supply
M28 cigarette
lighter
M35 clock spring

M29 cigarette lighter
lighting
M22 M35 M3 M28 M29
118
M32 wiper combination M34 ignition switch

switch backlight
M32 M34
M41 door control relay
M36 ignition switch
M33 engine anti-theft coil
M33 M36 M41
M43 instrument cluster 2 M44 instrument cluster 2

(green) (blue)
M43 M44
119
M45 lighting M51 clutch switch

combination switch
M45 M51
M55 warning light relay
M82 To main airbag of clock

spring
M55 M82
120
Seat room wire harness
F34 manual brake switch
F32 switch of driver's

seatbelt
F32 F34
F40 rear right door

contact switch
F11 rear left door contact
switch
F40 F11
F09 front left door F38 front right door

contact switch control switch
F09 F38
121
T03 front ceiling light
T06 make-up mirror

light
T03 T06
F21 reversing radar control

module
F15 rear defrost

positive pole
F15 F21
F45 G-RL1
F23 rear door

lock
F23 F45
122
Engine cabin wire harness
A1 grounding A2 grounding
A3 grounding
A1 A2 A3
A3 Ignition coil 3
A5 Ignition coil 4
A2 Ignition coil 1 A4 Ignition coil 2
A2 A3 A4 A5
A7 carbon canister
A6 front oxygen solenoid valve
sensor
A6 A7
123
A8 water temperature
sensor
A9 main wire harness

1
A10 main wire harness

2
A8 A9 A10
A11 absolute pressure

transducer A12 oil pressure sensor
A11 A12
A13 Hall sensor A14 position sensor of

(crankshaft) throttle valve
A13 A14
124
A15 knock sensor A16 Hall sensor (camshaft)
A15 A16
A17 injector 4
A19 injector 2
A18 injector 3
A20 injector 1
A17 A18 A19 A20
A21 OCV valve
A25 reversing light

switch
A21 A25
125
B05 Generator power
B01 generator S＆L
A24 Engine ECU
A24 B01 B05
B02 starter positive

terminal
B03 to starter coil

B04 A/C compressor
B02 B03 B04
E11 front right

headlamp
E04 cooling fan
E04 E11
126
E18 wiper motor
E17 brake fluid sensor
E17 E18
E23 front left

headlamp
E35 A/C pressure sensor
E23 E35
127
Ground point
E08 G-RH
E16 G-ABS
E08 E16
E19 G-LH1 E26 G-LH2
E19 E26
F14 G-RL
F36 G-FR
F14 F36
128
F42 G-RR G04 GND from engine to

body
F42 G04
A1 grounding
G05 frame ground
G05 A1
M42 G-LH.3
M42
129
Main wire harness
线束
M43
M45 M42
M44
M32
J4 Service Manual
M47 M48
M46
M12 M13
M05
M18
M33 M55
M19 M11 M06
130
M34 M21 M15

M35 M14
M07 M04
M36 M10
M28
M31 M30 M08 M09
M29
Wire harness layout

MF1 M56
M41
M16
J4 Service Manual Wire Harness Layout
Specification of main wire harness
ME1 Engine wire harness interface 1 M29 Cigarette lighter lighting
Front vehicle-mounted
M04 Radio antenna M30
power supply
M05 Right grounding M31 CD player ground
M06 Circle control M32 Combination wiper switch
M07 Temperature air door actuator M33 Burglar-alarm coil
M08 Speed regulation resistance M34 Ignition switch backlight
M09 Blower motor M35 Clock spring
M10 Body control module 1 M36 IGN switch
M11 Body control module 2 M41 Automatic door lock relay
M12-A CD Player interface 1 M42 Left ground 3
M12-B CD Player interface 2 M43 Instrument cluster 1
M13 Hazard warning switch M44 Instrument cluster 2
M14 Blower switch M45 Combination light switch
Outside rearview mirror

M15 A/C controller M46
switch
Temperature sensor of Headlamp height adjusting
M16 M47
evaporator surface switch
M18 Mode control M48 Dimming switch
M19 Accelerator pedal M55 Warning lamp relay
M21 IMMO
M56 Start control relay
M28 Cigarette lighter
131
Engine wire harness
E18
E17
E19
J4 Workshop Manual
E30
E01
E23
G01
G05
E26
132
EB1
G04 E29
E15
E13 E25
E35 B02
B03 G03
E11
Wire harness layout

E10 E04
B05
E08 E09 B04 B01
Instructions of engine cabin wire harness
EB1 Power supply wire harness interface
B05 Generator power supply
E01 Battery positive cable
E04 Cooling fan
E08 Right grounding 2
E09 Front right fog light
E10 Washer pump
E11 Front right headlamp
E13 Front right wheel speed sensor
E15 ABS module
E17 Brake fluid level sensor
E18 Wiper motor
E19 Left ground
E23 Front left headlamp
E25 High pitch horn
E26 Right grounding 2
E29 Front left fog light
E30 Front left wheel speed sensor
E35 A/C pressure sensor
133
Indoor junction box
PEF
PEF
M51
M51 PMG
PMG
PEE
PEE
PMN
J4 Service Manual
PMN
M52
M52
PMK
PMK
E39
E39 ME1
ME1
G06
G60 PMM
PMM
ME2
134
ME2
M40
M40
M60
M60
PMH
PMH
Wire harness layout

PED
PED
Indoor junction box wire harness specification

Indoor electrical box Indoor electrical box interface
PEE PMK
interface 1 3
PEF PMM
interface 2 4
PED PMG
interface 3 5
Engine wire harness interface
E39 EPS motor ME2
2
G06 EPS ground M40 EPS signal
Indoor electrical box

PMH M51 Clutch switch
interface 1
M52 Left ground 1

Indoor electrical box
PMN
interface 2
M60 Diagnostic interface
135
Body wire harness
J4 Service Manual
FD3
FD3
F36
F36
FD4
FD4
FD1 FD1 F38
F38
PFA
PFA
PFB
PFB
FE1 FE1 F33

F33
F40 F40
F20
F20
FM1
FM1 F16
F16 F19 F19
F34
F34
F32
F32 F17/F18
F04 FD2 FD2 F17、F18
136
F04
F10
F10
Wire harness layout

F44
F44
F31
F31
F30 F30
F29 F29
F27 F27
F11 F26
F26
F11 F15
F15
F21 F21 F28

F28
F22
F22 F25
F25
F24
F24
J4 Service Manual Wire harness layout
Body wire harness specification
PFA Indoor electrical box interface 1 F28 Rear left reversing light
PFB Indoor electrical box interface 2 F29 Left license light
F04 Body left groun2 F30 Right license light
F10 Fuel pump F31 Rear right reversing light
F11 Left rear door contact switch F32 Switch of driver's seatbelt
F15 Defrost positive pole F33 Rear oxygen sensor
F16 Rear left loudspeaker F34 Manual brake switch
F17 Trunk light 1 F36 Body front right ground
F18 Trunk light 2 F38 Right front door contact switch
F19 High-mounted brake light F40 Right rear door contact switch
F20 Rear right loudspeaker F44 Rear right combination light
Front left door wire harness

F21 Reversing radar model FD1
connector
F22 Rear left combination light FD2 Rear left door wire harness connector
Front right door wire harness

F24 Rear left fog light FD3
connector
Rear right door wire harness
F25 Left rear probe FD4
connector
F26 Rear right probe FE1 Engine wire harness interface
F27 Right rear fog light FM1 Main wire harness interface 1
137
Airbag wire harness
J4 Service Manual
PMJ
PMJ
M82
M82
M87
M87
M86
M86
A
M89
M89
B
B
138
C
C
Wire harness layout

M84
M84
M81
M81 M92
M92
Airbag wire harness specification
PMJ Indoor electrical box interface
M82 Clock spring interface
M84 Airbag ECU
M86 Airbag ground
M89 Driver seat belt tensioner
M92 Co-driver seat belt pretensioner
139
Ceiling wire harness
T06
T06 T07
T07
J4 Service Manual
A
A
140
A
A
A
A
Wire harness layout

D
PTC
PTC
Ceiling wire harness specification
PTC Indoor electrical box interface
T06 Right make-up mirror light
T07 Right ceiling light
141
Left/right front door wire harness
J4 Service Manual
D03/D23
D03/D23
A D05/D28
D05/D28
A
D
D
D04/D24
D04/D24
D09/D29
D09/D29
D
D
C
A
A D
DF1/DF3
DF1/DF3
C
142
A A
D
Wire harness layout

A
A
A
A
D08/D25
D08/D25
B
B
D07/D27
D07/D27
D06/D26
D06/D26
Specification of left/right front door wire harness
DF1 Body wire harness interface
D03 Glass lifting motor
D04 Rearview mirror interface
D05 High pitch speaker
D06 Front left door glass lifting switch
D07 Front left door light
D08 Low pitch speaker
D09 Front left door lock
D24 Rearview mirror interface
D25 Low pitch speaker
D26 Front right door glass lifting switch
D27 Front right door light
D28 High pitch speaker
D29 Front Right door lock
143
Rear door wire harness
J4 Service Manual
D32
D32
DF2
DF2
D
D
144
D
D
D
Wire harness layout

D34
D34 D D D
D D
D33
D33
Rear door wire harness
D33 Glass lifting switch
D34 Door lock
145

Manual motor j 4

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Manual motor j 4

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Service MANUAL

AND MF70B 5MT TRANSSIMISSION

General Information and Maintenance

 Do not operate the engine for an GI001

 Before jacking up the vehicle, put wheel GI002

 When removing a heavy component such GI003

 Before starting repairs which do not GI004

 Before repairing the vehicle:

Precautions for hoses: GI007 Do not scratch tube

2. Hose clamp GI009 Trace of clamping

How to follow trouble diagnoses:

Body number Engine model Manual transmission number

Vehicle identification number (VIN):

2) Vehicle identification number description

Geographic region Serial number

Country Vehicle feature code Assembly plant

Maker Check digit Year

A letter or number A number

① The first section: World Manufacturer Identifier (WMI) composed of 3 digits

Code Name of maker Applicable vehicle types

Trucks, non-complete vehicles, buses, passenger

② The second section: Vehicle Descriptive Section (VDS) code composed of 6

Engine type/rated power

Wheel base of truck/length of passenger

① Vehicle type: 2 represents passenger vehicle.

④ Wheel base of truck/length of passenger vehicle, bus and chassis: R>2390~2600

4: Passenger vehicle manufacturer/car plant/general assembly

Manual transmission model:

the Location Transmission

Overall body size

Overall length (mm) 4435

Overall width (mm) 1725

Overall height (mm) 1505

Front tread (mm) 1470

Rear tread (mm) 1460

Wheel base (mm) 2560

Front overhang (mm) 880

Rear overhang (mm) 995

No. of seats (occupants) 5

Back axle 430

Gross mass (kg) Fore axle 775

Back axle 710

Size 15×5 1/2J

Regular 185/65R15 88H

Tool name Description

Safety stand attachment

 All applicable local laws regarding the

Vehicle recovery (freeing a stuck vehicle):

Tightening Torques of Standard Bolts

Tightening torque (without lubricant)

M6 6.0 1.0 5.5 7

M14 14.0 1.5 80 100

M14 14.0 1.5 190 170

M6 6.0 1.0 11 13.5

1.75 100 130

M14 14.0 1.5 170 210

Nominal diameter of bolt threads (unit: mm)

Metric screw threads

TF-W Coolant temperature sensor

ZSK Ignition coil

FPM Accelerator pedal

ECU Electronic control unit (commonly referred to as Computer)

EKP Fuel pump

EMS Engine management system