H1 Service Manual

INTRODUCTION
THIS MANUAL IS THE FIRST VOLUME OF THE HAVAL H1 REPAIR AND MAINTENANCE
MANUAL (2 VOLUMES IN TOTAL).
Volume 1 Volume 2
01-Overview 08-Vehicle Body
02-Engine Accessories 09-Vehicle Interior/Vehicle Exterior
03-Transmission 10-HVAC (Heater, Ventilation and Air Conditioning)
04-Transmission System System
05-Suspension System 11-Safety and Protective Equipment
06-Steering System 12-Electrical Accessories
07-Brake System 13-Vehicle Body Control System
APPLICABLE MODELS:
4G15+5MT/6AMT (2WD), Left-hand Drive, China V/Euro V
THE FOLLOWING IS ONE OF THE MANUALS CONCERNING THIS VEHICLE. PLEASE

REFER TO IT.
Manual Name Edition Number
Haval H1 Circuit Diagram 01-14.06-01EM
ALTHOUGH THIS MANUAL HAS BEEN COMPILED WITH THE UTMOST DILIGENCE, WE
CANNOT GUARANTEE THAT ITS CONTENTS ARE COMPLETELY FREE FROM ERROR.
AS THE VEHICLE MODELS ARE CONSTANTLY BEING UPDATED, WE CANNOT GUAR-
ANTEE THAT THE LATEST INFORMATION WILL BE DELIVERED TO YOU IN A TIMELY
AND ACCURATE MANNER.
AS THE EDITOR'S SKILL IS LIMITED, THIS MANUAL INEVITABLY WILL BE DEFICIENT

IN SOME PLACES. WE ASK THE READERS TO BE GENEROUS WITH THEIR CRITI-
CISMS AND CORRECTIONS.
IF YOU HAVE ANY SUGGESTIONS REGARDING THE CONTENTS OR PRESENTATION

OF THIS MANUAL, PLEASE SEND THEM TO CYWX@GWM.CN. YOU WILL BE EX-
TREMELY GRATEFUL.
IF YOU ENCOUNTER OTHER TECHNICAL PROBLEMS DURING REPAIR, PLEASE CON-

TACT OUR CUSTOMER-SUPPORT TECHNICIANS AT: 0312-2192613.
THE FINAL RIGHTS OF INTERPRETATION FOR THIS MANUAL ARE RESERVED BY THE
GREAT WALL MOTOR CO., LTD.
Great Wall Motor Co., Ltd

All rights reserved
Information cut-off date: June 2014
Without the permission of the Great Wall Motor Co., Ltd, this manual, in part or in whole, may not
be reprinted, copied, stored, or transmitted.
Total Contents
Overview
Engine Accessories
Transmission
Transmission System
Suspension System
Steering System
Brake System
Vehicle Body
Vehicle Interior/Vehicle Exterior
HVAC (Heater, Ventilation and Air Conditioning) System
Safety and Protective Equipment
Electrical Accessories
Vehicle Body Control System
Overview 01-1
OVERVIEW
Vehicle Parameters........................................................01-2
Vehicle Dimensions......................................................01-2
Vehicle Performance....................................................01-2
Vehicle Weight.............................................................01-2
Engine..........................................................................01-3
Transmission................................................................01-3
Filling Volume and Specifications................................01-4
Labels..............................................................................01-5
Vehicle Identification Number......................................01-5
Engine Number............................................................01-7
Transmission Number..................................................01-7
Lifting and Supporting the Vehicle...............................01-8
Traction and Towing.......................................................01-9
Danger/Warning/Caution Labels...................................01-10
Regular Maintenance Check.........................................01-11
Service Schedule.........................................................01-11
Ignition Coil Check.......................................................01-12
Ignition Plug.................................................................01-12
Engine Coolant............................................................01-12
Fuel Filter.....................................................................01-12
Crankcase Ventilation System:....................................01-12
PCV Valve Assembly:..................................................01-12
Engine Oil....................................................................01-12
Generator Belt Tension Check.....................................01-12
Valve Clearance Check................................................01-13
Radiator and Hose.......................................................01-13
AMT.............................................................................01-13
Brake Fluid/Clutch Fluid...............................................01-13
Brake Pipeline..............................................................01-13
Brake Pedal Free Travel..............................................01-13
Clutch Pedal Free Travel.............................................01-13
Brake Pad and Brake Disc...........................................01-14
Line Leakage (Brake Line and Fuel Line)....................01-14
Critical Nuts and Bolts..................................................01-14
Lighting System...........................................................01-14
Battery..........................................................................01-14
Dust and Pollen Filter...................................................01-14
Wheel Alignment..........................................................01-14
Steering Tie Rod and Dust Boot..................................01-14
01-2 Overview
VEHICLE PARAMETERS
VEHICLE DIMENSIONS
Vehicle model GW4G15
Overall length (mm) 3898
Overall width (mm) 1729
Overall height (mm) 1621
Front suspension (mm) 800
Rear suspension (mm) 638
Wheel base (mm) 2460
Front (mm) 1465
Wheel track
Rear (mm) 1448
Angle of approach (°) 24
Angle of departure (°) 27
Minimum ground clear-
≥149.1
ance (mm)
Minimum turning diameter
≤11.5
(m)
VEHICLE PERFORMANCE
GW4G15
Vehicle model
5MT 6AMT
Maximum gradeability (%) ≥30
Maximum vehicle speed
175
(km/h)
VEHICLE WEIGHT
GW4G15
Vehicle model
5MT 6AMT
Full vehicle kerb mass
1145, 1185 1145, 1185
(kg)
Maximum allowable gross
1540, 1580 1540, 1580
weight (kg)
Overview 01-3
ENGINE
Vehicle model GW4G15
Engine type Inline four-cylinder, four-stroke, water-cooled, overhead-cam, gasoline engine
Cylinder bore × stroke
75×84.7
(mm × mm)
Total displacement (L) 1.497
Compression ratio 10.5:1
Idling speed (r/min) 700±25
Rated power (kW/rpm) 78/6000
Maximum net power (kW) 74
Maximum torque (N•m/
138/4000~5500
rpm)
TRANSMISSION
Vehicle model 5MT 6AMT
Model CC0011A 4520012325
Final drive ratio 4.313 4.529
1st gear 3.545 3.308
2nd gear 1.905 1.913
3rd gear 1.310 1.258
Tr a n s m i s - 4th gear 0.970 0.943
sion ratio 5th gear 0.816 0.763
6th gear — 0.643
Reverse
3.250 3.231
gear
01-4 Overview
FILLING VOLUME AND SPECIFICATIONS

Item Capacity Specification
3.2±0.1 (when not replacing
the fuel filter)
Engine lubricant (L) See oil recommendation
3.5±0.1 (when replacing the
fuel filter)
GL-5 140 for high-temperature regions
GL-4 75W-90 for high-altitude, low-temperature
Transmission lubricant 1.8±0.1(5MT) regions
(L)
GL-4 80W-90 doe all domestic regions
1.7±0.1(6AMT) GL-4 75W-90
-35 degrees, for domestic year-round general and
Primary filling amount: 5 high-temperature regions
Engine coolant (L) Secondary filling amount:
0.35 -45 degrees, for high-altitude, low-temperature re-
gions
Brake fluid/clutch fluid
0.57±0.02 DOT4
(L)
Air-conditioning refrig-
510±10 HFC-134a in general use outside the EU
erant (g)
Windshield washing
2.8 -35 °C
liquid (L)
Gasoline (L) 40 Unleaded gasoline rated 93 or above
OIL RECOMMENDATION
Ambi-
Above -30 degrees Cel-
ent tem- Above -25 degrees Celsius Even lower temperatures
sius
perature
SL SM SN SM SN SM SN
Recom- Recom- Higher Recom- Higher
API rating Higher grade
mended mended grade mended grade
Low ——→ High Low ——→ High Low ——→ High
Viscosity
10W-40 5W-30 0W-30
grade
Overview 01-5
LABELS
VEHICLE IDENTIFICATION NUMBER
LGWED2A4XEF010000
The vehicle identification number is unique. It is a 17-place code that identifies the vehicle. It appears
on three different locations in the vehicle.
Meaning
Location Code Definition Description

World manufacturer identifier
1-3 LGW Great Wall Motor Co., Ltd
(WMI) code
4 E Vehicle category E: M1 type 4x2
5 D Vehicle length 3501-4000
6 2 Engine type Gasoline 2: 60-80
7 A Body type Two-cabin, four-door passenger vehicle
8 4 Wheel base 2451-2600
9 X Check bit —
10 E Year of manufacture E: 2014
11 F Assembly plant Tianjin branch company
12-17 010000 Manufacturer S/N —
01-6 Overview
LOCATION
1. The vehicle identification number (1) is located
above the dashboard to the left. It can be seen
through the front windshield from the outside.
2. The vehicle identification number (2) is located on

the vehicle plaque on the center pillar.
3. The vehicle identification number (3) is located on

the front passenger seat beam.
Overview 01-7
ENGINE NUMBER
LOCATION
The GW4G15 engine number is marked on the exhaust
side, near the edge of the flywheel cylinder block.
TRANSMISSION NUMBER
LOCATION
The CM-series-transmission transmission number is
marked on the edge of the transmission's housing.
AMT
01-8 Overview
LIFTING AND SUPPORTING THE VEHICLE

Attention:
• Ensure that the vehicle is balanced before lifting, and when raising the vehicle, place the
lifting equipment at the indicated locations. Otherwise, the vehicle may be permanently
deformed, and the fuel tank, fuel filler, exhaust system, or undercarriage may be dam-
aged.
Overview 01-9
TRACTION AND TOWING

Warning:
• Under the following conditions you cannot use
rope to tow the vehicle: Steering failure, trans-
mission failure, brake failure, and light and sig-
naling failure.
Attention:
• When using a flexible connection for towing
device, the tethering device may only be con-
nected at the indicated locations on the ve-
hicle.
• The distance between the towing and the
towed vehicle should be between 4 and 10 me-
ters.
• When towing a broken-down vehicle, refrain
from towing a vehicle that is heavier than your
vehicle.
LOCATION (FRONT)
LOCATION (BACK)
01-10 Overview
DANGER/WARNING/CAUTION LABELS
1 2 3 4 5
1. Engine Bay Warning Label 4. Front Airbag Warning Label

2. Radiator Cover Warning Label 5. Side Airbag Warning Label
3. Battery Warning Label
Overview 01-11
REGULAR MAINTENANCE CHECK

SERVICE SCHEDULE
Carry out maintenance checks at the times specified in the Haval H1 Quality Assurance Booklet.
01-12 Overview
TIMING CHAIN AND TENSIONING DEVICE

1. Check that the timing chain and tensioning device have no abnormal sounds.
IGNITION COIL CHECK
1. Check that the exterior of the ignition coil has no damage.
IGNITION PLUG
1. Check the spark gaps of the ignition plug.
ENGINE COOLANT
1. Check the engine coolant level.
Confirm that it is between the scale marks on the reservoir.
FUEL FILTER
1. Check whether there is dirt and/or water precipitate inside the fuel filter.
2. If it is blocked or it is time for replacement, replace with a new filter.
3. If there is water inside, shake the fuel filter to eject the water from the inlet.
AIR FILTER ELEMENT
1. Check whether the air filter element is excessively damaged or oil stained.
CRANKCASE VENTILATION SYSTEM:
Regularly check the condition of each ventilation line. If there are signs of cracking, aging, etc., it
should be replaced immediately.
PCV VALVE ASSEMBLY:
The function of the PCV valve assembly is to control pressure within the crankcase. Fuel evaporated
within the crankcase passes through the PCV valve to the air inlet manifold. Then, it enters the engine
cylinder and takes part in combustion in order to prevent evaporated fuel from entering the air and
polluting the environment. Check whether the PCV valve is stuck or blocked every 5,000 km. If it is, it
must be replaced.
Procedure for a PCV valve check:
(a) Remove the rubber PCV hose and use a wrench to detach the PCV valve from the cylinder cover.
(b) Use unleaded gasoline to clean the PCV valve and then blow it dry. Then, use steel wire to slightly
push the other valves to check their mobility in order to confirm the other one-way ventilation func-
tions.
(c) Coat the PCV valve's threads with a silicone sealant. Then, install it on the cylinder cover using the
specified torque of 10 N•m-12 N•m. Finally, install the rubber PCV hose to the PCV valve.
ENGINE OIL
1. Check the engine oil level marked on the oil dipstick when engine is shut down.
(a) Park the vehicle on the horizontal surface.
(b) Shut down the engine, and wait for several minutes until oil flows back to the oil pan before checking
the oil level.
(c) Remove the oil dipstick and wipe it clean.
(d) Insert the oil dipstick to the bottom again, and ensure it is inserted properly and in the correct direc-
tion.
(e) Take out the oil dipstick, and record the readings. If the oil level is found lower than the scale market,
refill engine oil to the level between the lower scale mark and upper scale mark.
GENERATOR BELT TENSION CHECK
1. Tension check
Midway between the crankshaft-dampening-belt wheel and the engine-belt wheel, the generator belt
should have about 98 N of force exerted on it and should have a depression of 6 mm to 8 mm. If not,
the tension of the generator belt should be adjusted.
2. Adjustment:
After stopping the revolution of the engine, loosen the fixing bolts on the bottom of the generator and
the control arm bolt on the top of the generator. Push the generator outwards. After achieving the
Overview 01-13
specified requirements for the generator belt, tighten the aforementioned bolts. Check the tension,
tighten again when needed.
3. Replacement
Check the generator belt for signs of cracks, serious wear, or damage to the cloth-fiber layer. If there
are such signs, please replace it as soon as circumstances permit.
VALVE CLEARANCE CHECK
Intake valve clearance in cold conditions is 0.18 mm to 0.24 mm
Exhaust valve clearance in cold conditions is 0.28 mm to 0.34 mm
When measuring the valve clearance, point the VVT phase regulator sprocket and exhaust camshaft
sprocket timing mark upwards, and point the crankshaft dampening belt pulley timing mark at the tim-
ing cover's 0° position. Measure the clearance between the first and second cylinder intake and the
first and third cylinder exhaust valves. Then, turn the crankshaft 360° while still pointing the crankshaft
dampening-belt pulley timing mark at the timing cover's 0°position. Measure the clearance between
the third and fourth cylinder intake and the second and fourth cylinder exhaust valves. If it is out of tol-
erance, then you should replace the valve lifter immediately.
RADIATOR AND HOSE
1. Check the front of the radiator and ensure that it is clean and free of leaves, dirt, and insects.
2. Check whether the hose has cracks, or is twisted, decayed, or loosely connected.
AMT
1. Use the X-431 to clear the transmission fault code.
2. Visually inspect whether the various mounting bolts are loose and check the bolt's painted
line. Determine whether the bolts have become loose.
3. Visually inspect the transmission casing joint surface and the connections with the half shafts
for leakage. Determine whether the transmission vent cap is missing and whether the air vent
is blocked.
4. Check whether the transmission is loose with respect to the engine mounting bolts and clutch
actuator mounting bolts.
5. Check whether the transmission casing and off-case joint surface is seeping.
BRAKE FLUID/CLUTCH FLUID
1. Check the quantity and quality of brake fluid in the brake-fluid storage reservoir. If there are
color changes, blackening, sedimentation, suspension, or other such effects, replace it imme-
diately.
2. Check whether the vacuum booster and brake pump assembly accumulator is leaking, whether
the main cylinder body shows signs of seepage, whether the brake oil pipe connector is leak-
ing, and for other signs of brake fluid leakage.
BRAKE PIPELINE
1. Check that the surface of the oil line does not have any cracks, paint flaking, scratches, flat-
tening, oxidation, pitting, or other defects that would affect its operation.
2. Check whether the connector torque has declined or become loose.
BRAKE PEDAL FREE TRAVEL
1. Check whether the pedal operates smoothly.
2. Check the pedal's amount of free travel and travel allowance, and confirm that they are appro-
priate.
3. Start the engine and check the operation of the vacuum booster.
CLUTCH PEDAL FREE TRAVEL
1. Check whether the pedal operates smoothly.
2. Check the pedal's amount of free travel and ensure that it is appropriate.
3. Check the clutch linkage and ensure that there is a sufficient travel distance.
01-14 Overview
BRAKE PAD AND BRAKE DISC

1. Visually inspect the lining thickness through the brake-caliper inspection hole.
2. Check the brake disc. If the brake disc is worn or damaged, repair or replace it.
3. Measure the brake disc's jerk value.
LINE LEAKAGE (BRAKE LINE AND FUEL LINE)
1. The most important thing is to check whether the brake and fuel pipelines have any sign of
seepage.
CRITICAL NUTS AND BOLTS
1. To determine whether the mounting bolts are loose, visually examine the bolt's painted line
and see whether the bolts have become loose.
LIGHTING SYSTEM
1. Check whether the beam focus of the headlamps is accurate.
2. Check whether the brake lamps and steering lamps illuminate and blink.
BATTERY
1. Check whether the battery housing has cracks, breakage, or damage.
2. Check the battery ground cable.
DUST AND POLLEN FILTER
1. Check whether the dust and pollen filter is damaged, dirty, or oil stained.
WHEEL ALIGNMENT
1. Check the wear and tear of the tires.
STEERING TIE ROD AND DUST BOOT
1. Check the tie rod and ensure that its joint does not have an excessively large gap.
2. Check the dust seal ring and dust boot and ensure that they are undamaged.
3. Check the dust boot clip and ensure that it is not loose.
Memorandum
Memorandum
Engine Accessories 02-1
ENGINE ACCESSORIES
SUSPENSION DEVICES
Overview.........................................................................02-3
Schematics.....................................................................02-3
5MT..............................................................................02-3
6AMT...........................................................................02-4
Repair Specifications.....................................................02-5
Tightening Torque........................................................02-5
Procedures for Repair...................................................02-6
Left Engine Suspension...............................................02-6
Right Engine Suspension.............................................02-7
Rear Engine Suspension.............................................02-8
FUEL SYSTEM
Overview.........................................................................02-10
Schematics.....................................................................02-10
Fuel Tank.....................................................................02-10
Fuel Pipeline................................................................02-11
Accelerator Control Mechanism...................................02-12
Precautions..................................................................02-14
Fuel Tank.....................................................................02-14
Fuel Pump and Activated-Carbon Canister..................02-17
Fuel Filter Assembly.....................................................02-18
Refueling Pipe Assembly.............................................02-19
Fuel Pipeline................................................................02-20
INTAKE SYSTEM
Overview.........................................................................02-21
Schematics.....................................................................02-21
5MT..............................................................................02-21
6AMT...........................................................................02-22
Air Filter........................................................................02-24
02-2 Engine Accessories
EXHAUST SYSTEM
Overview.........................................................................02-25
Schematics.....................................................................02-25
Muffler and Catalytic Converter...................................02-27
Heat Shield..................................................................02-29
COOLING SYSTEM
Overview.........................................................................02-31
Schematics.....................................................................02-31
Fault Analysis and Troubleshooting.............................02-33
Engine Coolant............................................................02-35
Radiator Assembly.......................................................02-37
SUSPENSION DEVICES
OVERVIEW
The power assembly is mounted on the vehicle body and subframe, supported by the triple-point type
suspension. The left and rear suspension are rubber suspensions while the right suspension is a hy-
draulic suspension.
SCHEMATICS
5MT
1
4
N•m Specified torque
1. Left Engine Suspension Assembly 3. Rear Engine Suspension Assembly

2. Right Engine Suspension Assembly 4. Rear Engine Suspension Bracket
Welding Assembly
6AMT
1. Left Engine Suspension Assembly 3. Rear Engine Suspension Assembly

2. Right Engine Suspension Assembly 4. Rear Engine Suspension Bracket
Welding Assembly
REPAIR SPECIFICATIONS
TIGHTENING TORQUE
5MT
Fastener Quantity (units) Tightening torque (N•m)

Left suspension and transmission (bolt) 1 78±5
Left suspension and transmission (nut) 1 78±5
Left suspension and left stringer (bolt) 5 78±5
Right suspension and vehicle body (bolt) 3 78±5
Right suspension and engine (bolt) 2 78±5
Right suspension and engine (nut) 1 78±5
Rear suspension and subframe (bolt) 1 164±15
Rear suspension and bracket (bolt) 1 164±15
Rear suspension bracket and transmission (bolt) 4 55±5
6AMT

Left suspension and transmission (bolt) 1 78±5
Left suspension and transmission (nut) 2 78±5
Left suspension and left stringer (bolt) 5 78±5
Right suspension and vehicle body (bolt) 3 78±5
Right suspension and engine (bolt) 2 78±5
Right suspension and engine (nut) 1 78±5
Rear suspension and subframe (bolt) 1 164±15
Rear suspension and bracket (bolt) 1 164±15
Rear suspension bracket and transmission (bolt) 3 55±5
PROCEDURES FOR REPAIR

LEFT ENGINE SUSPENSION
Removal
1. Lift up the engine bay cover while providing ad-
equate support to the power assembly
Suspend the engine using a crane, or support the en-
gine using a jack to place it in an appropriate position.
At the same time, make sure that the engine is in a
stable position.
2. Remove battery carrier assembly
3. [5MT]
Remove the bolt and nut that connect the left sus-
pension and transmission
[6AMT]
Remove the bolt and two nuts that connect the left
suspension and transmission
4. [5MT]
Remove the five bolts that connect the left suspen-
sion and the vehicle body
[6AMT]
Remove the five bolts that connect the left suspen-
sion and the vehicle body
5. Remove left suspension assembly
Installation
Install in the reverse of the removal procedure.
Attention:
• Do not hurry to fully tighten the connecting
bolts and nuts during the process of instal-
lation. Only when the position of engine and
suspension are well adjusted, fully tighten all
the connecting bolts and nuts according to
specified torque.
RIGHT ENGINE SUSPENSION

Removal
stable position.
2. Remove the two bolts and one nut that connect the
right suspension and engine
3. Remove the three bolts that connect the right sus-

pension and the vehicle body
4. Remove right suspension assembly
Installation
Attention:
specified torque.
REAR ENGINE SUSPENSION

Removal
stable position.
2. Remove the bolts that connect the rear suspension
and rear suspension bracket
3. [5MT]
Remove the four bolts that connect the rear suspen-
sion bracket and the transmission
[6AMT]
Remove the three bolts that connect the rear sus-
pension bracket and the transmission
4. Remove the bolts that connect the rear suspension

and subframe
5. Remove rear suspension assembly

Remark:
• When replacing the power assembly, remove the
rear suspension prior to removing the left and right
suspensions.
Installation
Attention:
specified torque.
FUEL SYSTEM
OVERVIEW
The key parts of the fuel system are the fuel tank, fuel pump, fuel filter and fuel pipeline together with
components such as the fuel distribution pipe, fuel pressure regulator and the injection nozzle.
The fuel tank is made of metal, with a capacity of 40 L. Inside the tank are the electronic fuel pump
and the activated-carbon canister;
The fuel vapor control system relies on the use of the solenoid valve canister control method;
An electric accelerator pedal system controls fuel supply.
SCHEMATICS
FUEL TANK
7 8
3
5 6
4
10
11
13
14
12
1. Fuel Tank Lock Assembly 8. Fuel Filter

2. Refueling Pipe Protective Cover 9. Adsorption Hose
3. Refueling Pipe Assembly 10. Fuel Tank Assembly
4. Refueling Hose 11. Reinforcing Pad
5. Re-Intake Hose 12. Fuel Tank Cover
6. Rear Fuel Tank Bracket Assembly 13. Canister Ventilation Pipe
7. Fuel Pump with Carbon Canister Assembly 14. Refueling Pipe Protective Board
FUEL PIPELINE
2
3
4
1
16
6
7
15
8
14
9
13
12
10
11
1. Desorption Hose No. 2 9. Fuel Intake Hose No. 1

2. Canister Solenoid Valve Installa- 10. Upper Electronic Fuel Pump Plate
tion Protective Cover 11. Fuel Pump with Carbon Canister
3. Canister Solenoid Valve Assembly
4. Desorption Hose No. 3 12. Fuel Filter Bracket Assembly
5. Fuel Intake Hose No. 2 13. Washer
6. Fuel Pipe Protective Board 14. Fuel Filter Assembly
7. Fuel Intake Pipe 15. Fuel Intake and Return Line
8. Desorption Hose No. 1 16. Desorption Pipe
ACCELERATOR CONTROL MECHANISM
1. Accelerator Pedal Bracket Assembly 3. Accelerator Pedal Decorative Cover

2. Accelerator Pedal Assembly Assembly
TIGHTENING TORQUE
Refueling pipe assembly and vehicle body (bolt) 1 50
Rear fuel tank bracket and vehicle body (bolt) 6 26±3
Fuel tank and reinforcing pad (bolt) 4 26±3
Fuel tank cover and fuel tank (bolt) 4 9
Fuel filter bracket and fuel tank (bolt) 2 9
Upper electronic fuel pump bracket and fuel tank (bolt) 8 6
Accelerator pedal bracket and vehicle body (bolt) 3 10±1
Accelerator pedal and mounting bracket (bolt) 3 10±1

PRECAUTIONS
Warning! You must take the following protective
measures before beginning any maintenance on the
fuel system:
• Disconnect the negative terminal of the battery.
• Do not smoke within work premises, and put
up "NO SMOKING" signs in prominent loca-
tions.
• Dry chemical fire extinguisher should be avail-
able for use in the vicinity of workplace.
• You must conduct all maintenance and repair
in a well-ventilated environment well away
from naked flames (e.g., natural gas heater).
• Wear safety goggles at all times during work.
• The fuel injection nozzle system will still retain
some degree of pressure after the engine has
been turned off. Therefore, before disconnect-
ing any fuel pipeline you must discharge fuel
system pressure to prevent bodily injury or the
outbreak of fire.
• After disconnecting the fuel line, you may see
a small amount of fuel leakage. To minimize the
risk of accidents and injury, you should use a
clean piece of lintless cloth to plug the pipe ac-
cessories. Store the cloth into the designated
container after work has been concluded.
FUEL TANK
Removal
1. Lift up rear seat
2. Remove fuel tank maintenance access cover
3. Remove the electric components on top of fuel
pump
4. Remove the quick connectors that connect desorp-

tion hose No. 1, the fuel intake and return line, fuel
intake hose No. 1 and the fuel pump assembly, then
plug the opening with a piece of cotton cloth to pre-
vent fuel spurts
5. Squeeze open the elastic hoop that connects the

canister ventilation pipe and the fuel pump assem-
bly, then remove canister ventilation pipe
6. Lift and support vehicle

Take particular care when lifting and supporting the ve-
hicle. Make sure that you lift and support the vehicle at
the correct spots.
7. Remove the rear fuel tank refueling hose, the hoop
and clip on the hose, and then remove the fuel tank
refueling hose and the re-intake hose
8. Remove the four bolts that fix the fuel tank cover at
the bottom of the vehicle, and then remove fuel tank
cover.
9. Remove the four bolts that fix the fuel tank cover
reinforcing pads to the bottom of the vehicle, and
then remove fuel tank assembly.
Checks
1. Check the external appearance for any deformations.
2. Check if there is any leakage from the fuel tank, or
any other sort of damage.
3. Check for any leakage from the fuel pump and oil
level sensor pad.
4. Check for signs of leakage, loose parts, deterioration
or damage in the hose and pipes to and from the fuel
tank.
5. Check that the return loop containing active-carbon
canister is in good condition.
6. Check that the fuel tank cap is in good condition.
7. Check that the refueling pipe and limiter are in good
condition.
Installation
FUEL PUMP AND ACTIVATED-CARBON

CANISTER
Removal
1. Lift up rear seat
2. Remove fuel tank maintenance access cover
3. Remove the electric components on top of fuel
pump
4. Remove fuel pump

(a) Remove any dirt that has accumulated on or around the
grooved parts of the fuel pump.
(b) Disconnect the pipelines that are connected to the oil
pump.
(c) Use the wrench to remove the eight bolts on the fuel
pump base plate in diagonal order.
(d) Remove fuel pump assembly from the fuel tank.
Attention:
• Do not damage the oil level sensor.
• Do not fully discharge the fuel reservoir cham-
ber in the fuel pump component. When remov-
ing the component, there may be some fuel
leakage from the fuel reservoir chamber.
(e) Remove seal ring and discard.
Installation
1. Handle the fuel pump, the activated-carbon canister
assembly and fuel level sensor with care to avoid
damaging these components.
2. Make sure that the oil pump and the activated-car-
bon canister are connected correctly
3. Install seal strip and base plate, and tighten bolts
Tightening torque: 6 N•m
Attention:
• The base plate, fuel pump assembly and the
fuel tank reminder label must be consistent
with each other.
FUEL FILTER ASSEMBLY

Removal
1. Release fuel system pressure
2. Disconnect the negative terminal of the battery

the correct spots.
4. Remove the quick connectors from the two nylon
tubes that are connected to the fuel filter assembly
Attention:
• After disconnecting the fuel line, you may see
a small amount of fuel leakage. To minimize
the risk of accidents and injury, you should use
a piece of cloth to plug the pipe accessories.
Store the cloth into the designated container
after work has been concluded.
5. Remove the two bolts that connect the fuel filter support
and the fuel tank
6. Remove the fuel filter assembly
Installation
REFUELING PIPE ASSEMBLY

Removal
1. Remove fuel tank lock assembly and refueling pipe
protective cover
2. Remove the two refueling pipe protective plate

clips, then remove the refueling pipe protective
board from the refueling pipe assembly
3. Remove the fixing bolts that join the refueling pipe

assembly bracket to the vehicle body
4. Remove the hoops and clips on the refueling hose,

the re-intake hose, and the canister ventilation pipe
5. Remove refueling pipe assembly
Installation
FUEL PIPELINE
Warning:
• As there is some degree of pressure within the
fuel pipeline, take extra care when repairing or
maintaining this section.
Checks
Conduct a visual inspection for any leakage from the
fuel pipeline as well as for cracks, deterioration or dam-
age in the hoses. Check that all pipe clips are secure.
Replace parts when necessary.
Removal
1. Release fuel system pressure
3. Disconnect fuel hoses on both ends from various
pipes
Warning:
• After removing the fuel hose, you may see a
small amount of fuel leaked. To minimize the
risk of accidents and bodily injury, use a piece
of cloth to plug the hose and pipe opening.
Store the cloth into the designated container
after hose/pipe dismantling has been conclud-
ed.
4. Remove fuel pipe cover from the vehicle body
5. Mark the vehicle body and fuel pipe to indicate pipe
clip return positions for re-installation
6. Remove fuel pipe and pipe clips from the vehicle
body
7. Remove pipe clips from fuel pipe
Installation
1. Return pipe clips to positions marked on the fuel
pipe
If the pipe clips have gone out of shape or their claws
have become twisted or damaged, switch to new pipe
clips.
2. Use pipe clips to affix the fuel pipe onto the vehicle
3. Replace fuel pipe cover plate on the vehicle body.
You must use new nuts
4. Install fuel hose on the fuel pipe
5. Check for signs of leakage when the engine stop
and ignition switches have been connected
INTAKE SYSTEM
OVERVIEW
The air intake system comprises components such as the intake pipe assembly, the intake hose, the
crankcase ventilation pipe and the air filter. The system serves to provide the engine with sufficient
amounts of dry and clean air with temperature rise in the air intake minimized as much as possible.
SCHEMATICS
5MT
1
2
1. Intake Hose 4. Air Filter Element

2. Crankcase Ventilation Pipe 5. Lower Air Filter Housing
3. Upper Air Filter Housing 6. Intake Pipe Assembly
6AMT
1 2
1. Intake Hose 4. Air Filter Element

2. Crankcase Ventilation Pipe 5. Lower Air Filter Housing
3. Upper Air Filter Housing 6. Intake Pipe Assembly
TIGHTENING TORQUE
Intake pipe assembly and vehicle body (bolt) 1 9
Air filter assembly and air filter bracket (bolt) 3 9

Attention:
• Any metal particles inside the intake passage
may cause damage to the engine. Therefore,
when dismantling the intake system parts,
you should use a piece of cotton cloth, tape or
other suitable materials to seal any openings
in the system.
• When putting together the intake system parts,
you should check and make sure that no metal
particles have entered the system parts.
AIR FILTER
Removal
1. Pinch open the steel band elastic hoop on the
crankcase ventilation pipe and intake hose, then
disconnect the crankcase ventilation pipe from the
intake hose
2. Unscrew the type B worm drive hose hoop on both

ends of the intake hose and remove the intake hose
3. Open up the snap to remove the upper air filter
housing to allow removal of the air filter element for
cleaning or replacement
Attention:
• The air filter element must be cleaned regularly
to reduce intake resistance, to ensure good in-
take flow and to reduce fuel consumption.
• You may use compressed gas to remove dust
from, and clean, the air filter element.
4. Remove the three bolts that connect the lower air
filter housing and the air filter bracket, then remove
the bolt that joins the intake pipe assembly to the
vehicle body
Installation
EXHAUST SYSTEM
OVERVIEW
The exhaust system comprises the exhaust pipe, the three-way catalytic converter, the mufflers, heat
shields and oxygen sensor.
The exhaust gas in the engine cylinder is first processed for cleaning and noise reduction by the ex-
haust system before being released into the atmosphere.
SCHEMATICS
1
12
13
11
10
3
4
9
5
ƹ6
7
Non-reusable parts
1. Gasket 7. Three-Hole Rubber Block

2. Front Exhaust Pipe and Catalytic Con- 8. Rear Heat Shield
verter Assembly 9. Main Silencer Assembly
3. Gasket No. 2 10. Middle Heat Shield No. 2
4. Rubber Suspension 11. Middle Heat Shield No. 1
5. Secondary Silencer Assembly 12. Front Heat Shield
6. Seal Ring 13. Oxygen Sensor Assembly
TIGHTENING TORQUE
Heat shield and vehicle body (bolt) 4 9~12
Heat shield and vehicle body (nut) 6 9~12
Oxygen sensor assembly and front exhaust
1 42±4
pipe and catalytic converter assembly
Main silencer assembly and secondary si-
2 60±6
lencer assembly (bolt)
Secondary silencer assembly and front ex-
haust pipe and catalytic converter assembly 2 60±6
(bolt)
Front exhaust pipe and catalytic converter
2 60±6
assembly and exhaust manifold (bolt)

MUFFLER AND CATALYTIC CONVERTER
Removal
Warning:
• Confirm the surface temperature of all exhaust
system components prior to removal to avoid
burn injuries to the technician.
the correct spots.
2. Remove main silencer assembly
(a) Remove the bolts that join the main silencer assembly
flange to the secondary silencer assembly flange, re-
move seal ring between the flanges.
Attention:
• The seal ring between the main silencer as-
sembly flange and the secondary silencer as-
sembly flange acts mainly as a seal. It may be-
come deformed after one use and hence lose
its functional properties. We recommend that
the seal ring be replaced with a new one each
time it is removed. If necessary, the gasket
may be reused once.
(b) Remove the rubber suspension and the three-hole rub-
ber block from the main silencer assembly.
(c) Remove main silencer assembly.
Warning:
• For this task, there must be one technical per-
sonnel designated specifically to support the
main muffler to prevent any injury to the opera-
tor.
3. Remove secondary silencer assembly

(a) Remove the bolts that join the secondary silencer as-
sembly flange to the front exhaust pipe and catalytic
converter assembly flange, and remove seal ring be-
tween the flanges.
Attention:
• The seal ring between the secondary silencer
assembly flange and the front exhaust pipe
and catalytic converter assembly flange acts
mainly as a seal. It may become deformed after
one use and hence lose its functional proper-
ties. We recommend that the seal ring be re-
placed with a new one each time it is removed.
If necessary, the gasket may be reused once.
(b) Remove the three rubber suspensions on the secondary

silencer assembly.
(c) Remove secondary silencer assembly.
Warning:
• For this task, there must be one technical per-
sonnel designated specifically to support the
secondary silencer to prevent any injury to the
operator.
3. Remove the front exhaust pipe and catalytic con-

verter assembly
(a) Remove oxygen sensor assembly.
(b) Remove the bolts that join the front exhaust pipe and
catalytic converter assembly with the exhaust manifold
flange, and remove the flange gasket.
Attention:
• The seal ring between the front exhaust pipe
and catalytic converter assembly flange and
the exhaust manifold flange acts mainly as a
seal. It may become deformed after one use
and hence lose its functional properties. We
recommend that the seal ring be replaced with
a new one each time it is removed. If neces-
sary, the gasket may be reused once.
(c) Remove the front exhaust pipe and catalytic converter
assembly.
Installation
Attention:
• There must be a minimum of 15 mm gap be-
tween the exhaust pipe assembly and any oth-
er components on its sides.
• Apply an appropriate amount of silicone oil
inside the rubber suspension installation ap-
erture prior to suspension installation. The
weight should be spread evenly after the rub-
ber suspension has been installed.
• Check that the oxygen sensor assembly con-
nector has been installed properly after install-
ing the front exhaust pipe and catalytic con-
verter assembly.
HEAT SHIELD
Removal
Warning:
• Confirm the surface temperature of all exhaust
system components prior to removal to pre-
vent burn injuries to the technician.
Take extra care when lifting and supporting the vehicle.
Make sure that you lift and support the vehicle at the
correct spots.
2. Remove rear heat shield
(a) Remove main silencer assembly.
For specific instructions, please refer to the section on
the removal of the main silencer assembly.
(b) Remove the three nuts that connect the rear heat shield
and the vehicle body.
(c) Remove the rear heat shield.
3. Remove middle heat shield.

(a) Remove secondary silencer assembly.
the removal of the secondary silencer assembly.
(b) Remove the nut and the two bolts that connect the mid-
dle heat shield and the vehicle body.
(c) Remove middle heat shield No. 2.
(d) Remove the nut that connects the middle heat shield
and the vehicle body.
(e) Remove middle heat shield No. 1.
4. Remove front heat shield

(a) Remove the front exhaust pipe and catalytic converter
assembly.
For specific instructions, please refer to the section that
deals with the removal of the front exhaust pipe and
catalytic converter assembly.
(b) Remove the nut and the two bolts that connect the front
heat shield and the vehicle body.
(c) Remove front heat shield.
Installation
COOLING SYSTEM
OVERVIEW
The cooling system comprises components such as the radiator, electric fan and the expansion tank.
The cooling system serves to keep the working temperature of the engine within optimal levels.
Common faults with the cooling system include high coolant temperatures, low coolant temperatures,
coolant leakage and loud engine noises.
SCHEMATICS
6
4
13
11
12
10
1. Radiator Assembly 8. Expansion Tank Ventilation Pipe

2. Upper Radiator Suspension 9. Expansion Tank Suspension
3. Electric Fan Assembly 10. Radiator Intake Pipe
4. Radiator Intake Pipe Connection 11. Steel Band Elastic Hoop
5. Radiator Fuel Filler Cap Assembly 12. Radiator Outlet Pipe
6. Overflow Pipe 13. Lower Radiator Suspension
7. Expansion Tank Assembly
TIGHTENING TORQUE
Electric fan and radiator (bolt) 2 9
Expansion tank and electric fan (bolt) 2 9
Engine hood lock (bolt) 3 9
FAULT ANALYSIS AND TROUBLESHOOTING

COOLANT TEMPERATURE TOO HIGH
Fault description
The water thermometer needle is consistently in the red zone or the engine temperature alarm indi-
cator is lit up when the engine is running. Sometimes, the user may also notice other signs such as
boiling of the coolant, violent shakes of, or knocks, in the engine, or early ignition. The actual engine
water temperature taken using a tester is consistent with what is shown on the meter.
Reasons for fault
Causes lie in two key categories: impaired cooling performance of cooling system and increased heat
produced by the engine.
Reasons attributable to the cooling system include:
(1) Low water levels, or coolant leakage leading to low coolant levels;
(2) Blockages, rusting or incrustation in the radiator, cooling water jacket, and secondary pipes, etc.,
leading to impaired radiator performance;
(3) Electric fan wiring or motor fault leading to malfunctioning of the electric fan;
(4) Sliding of the water pump belt due to lack of tension or oil stains, damage to the water pump im-
peller, poor seal performance, etc., leading to insufficient pump flow;
(5) Malfunctioning of the thermostat, or temperature regulator cannot be started normally, leading to
poor coolant circulation;
(6) Coolant without anti-freeze properties added to the cooling system, or incompatible anti-freeze
used.
Reasons attributable to the engine include:
(1) Poor engine lubrication;
(2) Delayed engine ignition;
(3) Concentration of combustible gas mix too high or too low;
(4) Cylinder gasket damaged, leading to hot air entering the cooling system;
(5) Poor engine ventilation;
(6) Carbon accumulation leading to increased compression ratio and knocks in the engine.
Troubleshooting
(1) Check for signs of anti-freeze leakage in various cooling system connections and where the upper
and lower water chambers of the radiator meet.
(2) Check for signs of blockage on the radiator surface. If you find any signs of blockage on the radia-
tor surface, clean the radiator surface or make a replacement. If the check turns up no issues, move
on to the next step.
(3) Check if the water pump drive belt has slid off its proper position. If the water pump drive belt is
sliding, adjust the drive belt tension to the appropriate level. If drive belt tension is normal, move on to
the next step.
(4) Check that the electric fan is working properly. When the engine attains its open/shut temperature
(93 °C-96 °C), check to see if the electric fan is turning. If the electric fan is not turning, check the
electric fan wiring and motor for any malfunctioning. If the electric fan functions normally, move on to
the next step.
(5) Check that the radiator and thermostat are functionally normally. Allow the engine to work for some
time. When the thermometer needle shows that the thermostat valve has reached its opening tem-
perature (82 °C), use your hand to feel the temperature of the radiator water intake and outlet pipes.
If the intake pipe feels significantly warmer than the outlet pipe, it means that there is a radiator block-
age; when engine water temperature reaches the full opening temperature of the thermostat main
valve (96 °C), use your hand to feel the temperature of the radiator and of the radiator intake pipe. If
the radiator intake pipe feels significantly cooler than the radiator itself, it means that the thermostat is
no longer working properly.
Attention:
• When checking radiator and engine temperature using your hands, please make sure that
you have the appropriate protective gear on. Also, approach the component slowly to
avoid burn injury.
(6) Once engine water temperature reaches the thermostat main valve opening temperature, check
the performance of the water pump. To do so, hold the radiator intake pipe with your hand and then
increase engine speed quickly from idle. If you feel the radiator intake pipe flow to increase in tandem
with engine speed, it means that the water pump is working normally; on the other hand, if you do not
sense the increase, it means that the water pump is not working properly and you'd need to dismantle
the pump for inspection.
If the inspection does not show up a problem but 1) engine output decreases significantly when the
coolant is at an overly high temperature, and 2) when high-temperature gases or air bubbles are de-
tected when the radiator cover is lifted up or when steam is emanating from the exhaust pipe, check
to see if the cylinder gasket is damaged.
If the above checks do not show up a problem and where there are no signs of a damaged cylinder
gasket when engine water temperature is overly high, check the engine for related issues.
COOLANT CONSUMPTION LEVELS TOO HIGH

Fault description
The engine shows signs of leaking, with expansion tank coolant levels decreasingly rapidly and fre-
quent top-ups necessary.
Reasons for fault
(1) Radiator damage, poor sealing between the upper and lower water chambers and signs of anti-
freeze leakage;
(2) Expansion tank and water pump joint surfaces and various cooling system pipe connectors loose
or inadequately sealed;
(3) Cylinder gasket damaged, poor joint between the cylinder cover and the cylinder block, warping
and loose cylinder bolts, etc., leading to leaking of high-temperature pressurized gases from the cylin-
der into the cooling system.
Troubleshooting
(1) Check if there is any sign of coolant leakage from the various connectors/connections in the cool-
ing system. As anti-freeze is typically tinted, any leakage of the solution should be easy to spot. Focus
your inspection on various pipe connections, the expansion tank, the water pump joint surface, the
radiator and radiator cover, etc.
(2) Check that there are no leakages within the cooling system. In general, internal leaks will be ac-
companied by other signs such as weak engine output upon raising of engine speed, smoke emanat-
ing from the exhaust pipe, air bubbles in the radiator, raised engine oil levels, a milky appearance to
the engine oil, etc. If any leakage has been found, check the cylinder head and the cylinder gasket.

ENGINE COOLANT
Replacement
1. Drain engine coolant fully
Attention:
• To avoid scalds, do not remove the radiator
fuel fuel filler cap when the engine and radiator
are still at a high temperature, as the increased
pressure within may cause the engine coolant
and steam to surge out.
(a) Remove radiator fuel fuel filler cap.
(b) Loosen the radiator drain switch and drain engine cool-
ant.
Radiator filler cap sub assembly
Radiator drain switch sub assembly
2. Refill engine coolant

(a) Tighten the radiator drain switch and then top up the
coolant until it overflows.
Capacity: 5 L
Tips:
• Press the radiator inlet pipe and outlet pipe a few
times.
• If the coolant level falls, top up with more coolant.
(b) Tighten radiator fuel filler cap.
(c) Top up engine coolant into the reservoir until the fluid
level reaches the "full" line.
(d) Warm up the engine until the thermostat valve opens.
Remark:
• When warming up the engine, press the radiator
inlet and outlet pipes with your hand a few times.
(e) Shut down the engine and wait for the coolant to cool.
(f) Then, remove the radiator fuel filler cap and check the
coolant level.
(g) If the coolant level has dipped, repeat steps (a) to (f).
(h) If the coolant level has not dipped, top up engine cool-
ant to adjust reservoir coolant level.
3. Check for any leakage of engine coolant
(a) Top up the radiator with engine coolant, then connect
the radiator fuel filler cap detector.
(b) Increase pump pressure to 137 kPa and check for signs
of leakage.
RADIATOR ASSEMBLY
Cleaning
Attention:
• You should only conduct cleaning using water
when the engine is not running and when it
has cooled down completely.
1. Remove radiator assembly
Please refer to radiator removal procedure for specific
instructions.
2. Clean radiator surface
Direct the compressed air at the surface of the radiator
from back to front to remove debris such as dead in-
sects and leaves.
If you do not have access to a source of compressed
air, you may clean the radiator using a pressure water
jet.
3. Clean radiator fins
Clean radiator fins with the help of water or compressed
air. Compressed air or the pressure of water pressure
must not exceed 150 kPa.
Attention:
• Radiator fins are extremely critical to the de-
vice's function. Therefore, scrubbing or brush-
ing of radiator fins is strictly prohibited.
Removal
2. Drain engine coolant fully

topping up engine coolant.
3. Disconnect radiator intake pipe
4. Disconnect radiator outlet pipe
5. Remove front bumper assembly

For specific instructions on removing the front bumper,
please refer to the section on the vehicle body.
6. Remove engine hood lock assembly
Remove three bolts, separate the cable from the engine
hood lock assembly, then remove engine hood lock as-
sembly.
7. Remove two bolts and water top-up point

8. Remove the two bolts that fasten the expansion tank
and then separate the expansion tank assembly
9. Remove upper radiator crossbeam

Remove the eight bolts that hold the upper radiator
crossbeam in place as well as the crossbeam.
10. Remove radiator assembly

(a) Disconnect the connector from the cooling fan motor
and then remove the radiator assembly from the engine
bay.
(b) Remove the two upper radiator suspensions and the
two lower radiator suspensions from the radiator.
(c) Remove the two bolts and separate the electric fan as-
sembly.
Installation
1. Install radiator assembly
(a) Install the electric fan assembly using two bolts.
(b) Place the two upper radiator suspensions and the two
lower radiator suspensions on the radiator.
(c) Install the radiator assembly and join the connector to
the cooling fan motor.
2. Install upper radiator crossbeam

(a) Affix the upper radiator crossbeam using eight bolts.
(b) Install the water top-up point using two bolts.

(c) Install the expansion tank using two mounting bolts.
3. Install engine hood lock assembly

Use three bolts to install the engine hood lock assembly.
4. Tighten engine hood lock bolts after adjustments to
the engine hood have been completed
5. Install front bumper assembly
6. Refill engine coolant
7. Check for any leakage of engine coolant
8. Connect the negative terminal of the battery
Memorandum
Transmission 03-1
TRANSMISSION
CC0011A TRANSMISSION
Overview.........................................................................03-3
External Appearance......................................................03-3
Location Diagram...........................................................03-4
Transmission Assembly...............................................03-4
Transmission Gear Shift Controller..............................03-5
Cross-Sectional View.....................................................03-6
Schematics.....................................................................03-8
Clutch Housing.............................................................03-8
Input Shaft Assembly.....................................................03-9
Output Shaft Assembly..................................................03-10
Figure Of Outer Components I......................................03-11
Figure Of Outer Components II.....................................03-12
Differential Assembly.....................................................03-13
Release Mechanism Componentss..............................03-14
Fork and Fork Shaft Assembly.....................................03-15
Specified Torque............................................................03-17
Dedicated Tool................................................................03-18
Diagnosis and Inspection..............................................03-22
Basic Parameters.........................................................03-22
Synchronizer Gear Ring and Gear Axial
Clearance (δ)...............................................................03-22
Axial and Radial Clearance for Various Gear
Wheels (δ)....................................................................03-22
Troubleshooting Checklist............................................03-23
Precautions..................................................................03-24
Cleaning Instructions ..................................................03-34
Inspection Instructions.................................................03-34
Differential Assembly...................................................03-44
Input Shaft Assembly...................................................03-48
Output Shaft Assembly................................................03-55
Clutch Housing Assembly............................................03-64
Transmission Housing Assembly.................................03-70
Gear Forks and Fork Shafts.........................................03-74
Gear Synchronizers.....................................................03-75
Reverse Lamp Switch..................................................03-76
03-2 Transmission
Transmission Controller Assembly...............................03-77

Transmission Control Cable Assembly........................03-79
4520012325 TRANSMISSION
Schematics.....................................................................03-82
Transmission Housing Assembly.................................03-82
Clutch Housing Assembly............................................03-83
Shift Drum Assembly....................................................03-84
Release Fork Assembly...............................................03-85
Transmission Accessory..............................................03-86
Differential Assembly...................................................03-87
Shift Drive Module Assembly.......................................03-88
Output Shaft Assembly................................................03-89
Input Shaft Assembly...................................................03-90
Diagnostic Trouble Code..............................................03-92
Fault Description..........................................................03-94
Fault Tree Analysis Process.........................................03-104
Self-Learning................................................................03-105
Transmission Self-Learning.........................................03-106
Clutch Self-Learning....................................................03-107
Precautions..................................................................03-109
Clutch Actuator.............................................................03-137
Transmission Controller Assembly...............................03-139
Transmission 03-3
CC0011A TRANSMISSION
OVERVIEW
This transmission model is a front-drive, dual-shaft, graded mechanical transmission that comes with
a differential. It makes use of an inert synchronizer shift mechanism for the forward gears which pro-
vide a smooth and easy gear shift experience with reduced noise emissions, prolonged gear life and
hence high economy. The control mechanism contains steel ball positioners and springs for more
flexible and precise gear shifts with clearer 'hand feel'. In addition, the fifth gear transmission is also
equipped with an interlock mechanism that prevents accidental engagement of the reverse gear for
greater drive comfort and reliability.
EXTERNAL APPEARANCE
03-4 Transmission
LOCATION DIAGRAM
TRANSMISSION ASSEMBLY
Transmission 03-5
TRANSMISSION GEAR SHIFT CONTROLLER

03-6 Transmission
CROSS-SECTIONAL VIEW
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
34
35
36
37
38
39
40
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 6463 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41
Transmission 03-7
1. Oil Deflector Assembly 40. Output Shaft Cylindrical Roller Bearing

2. Fifth Gear Gear Hub Collar 41. Oil Seal
3. Fifth Gear Gear Hub 42. Differential Front Shim
4. Fifth Gear Synchronizer Slider 43. Front Tapered Roller Bearing
5. Fifth Gear Synchronizer Spring-Loaded 44. Differential Body
Piston Ring 45. Cylindrical Pin
6. Fifth Gear Needle Roller Bearing 46. Planetary Gear Shaft
7. Fifth Gear Gear Sleeve 47. Planetary Gear
8. Fifth Gear Synchronizer Gear Ring 48. Planetary Wheel Spherical Shim
9. Fifth Gear Gear Wheel Component 49. Flanged Bolt
10. Fifth Gear Needle Roller Bearing Spacer 50. Axle Shaft Gear
11. Input Shaft Rear Ball Bearing Shaft Ring 51. Side Gear Wheel Shim
Washer 52. Hexagon Flange Bolt
12. Pressure Plate Bolt and Washer Compo- 53. Differential Gear Ring
nent 54. Rear Tapered Roller Bearing
13. Rear Cover Bolt and Spring Washer As- 55. Differential Rear Shim
sembly 56. First Gear Thrust Washer
14. Rear Component 57. Differential Rear Oil Seal
15. Bearing Pressure Plate 58. Steel Ball Sφ4.7625
16. Input Shaft Rear Ball Bearing Stopper 59. First Gear Gear Wheel
Ring 60. First Gear Synchronizer Inner Ring
17. Input Shaft Rear Ball Bearing 61. First Gear Synchronizer Center Ring
18. Fourth Gear Needle Roller Bearing 62. First Gear Synchronizer Outer Ring
19. Fourth Gear Gear Wheel Component 63. First Gear Needle Roller Bearing
20. Fourth Gear Synchronizer Gear Ring 64. First Gear Synchronizer Gear Hub
21. Fourth Gear Needle Roller Bearing Spacer 65. First/Second Gear Gear Sleeve
22. Third/Fourth Gear Gear Hub Collar 66. Second Gear Synchronizer Outer Ring
23. Third/Fourth Synchronizer Spring-Loaded 67. Second Gear Synchronizer Center Ring
Piston Ring 68. Second Gear Synchronizer Inner Ring
24. Third/Fourth Gear Synchronizer Slider 69. First/Second Gear Gear Sleeve Collar
25. Third/Fourth Gear Gear Sleeve 70. Second Gear Needle Roller Bearing
26. Third/Fourth Gear Gear Hub Spacer
27. Third Gear Synchronizer Gear Ring 71. First/Second Gear Synchronizer Spring
28. Third Gear Needle Roller Bearing 72. First/Second Gear Synchronizer Slider
29. Third Gear Gear Wheel Component 73. Second Gear Gear Wheel
30. Transmission Housing 74. Second Gear Needle Roller Bearing
31. Dust Boot 75. Third Gear Driven Gear Wheel
32. Clutch Release Pump Sub-Assembly 76. Third/Fourth Gear Spacer
33. Clutch Housing 77. Fourth Gear Driven Gear Wheel
34. Release Fork Support Nail 78. Output Shaft Rear Ball Bearing
35. Input Shaft 79. Output Shaft Rear Ball Bearing Stopper
36. Input Shaft Cylindrical Roller Bearing Ring
37. Input Shaft Oil Seal 80. Fifth Gear Driven Gear Wheel
38. Output Shaft 81. Output Shaft Lock Nut
39. Output Shaft Guide Nozzle
03-8 Transmission
SCHEMATICS
CLUTCH HOUSING
5
8
3
6 7
9
4
2
10
11
12
13
14
1. Positioning Pin 8. Input Shaft Cylindrical Roller Bearing

2. Output Shaft Cylindrical Roller Bearing 9. Input Shaft Oil Seal
Pressure Plate 10. Clutch Housing
3. Bolt and Spring Washer Pressure Plate 11. Ball Lock Spring
4. Magnet 12. Ball Lock Spring Seat
5. Output Shaft Cylindrical Roller Bearing 13. Ball Lock Screw Plug
6. Output Shaft Guide Nozzle 14. Oil Seal
7. Oil Deflector
Transmission 03-9
INPUT SHAFT ASSEMBLY
1 2
4
6
5
7
8
1. Input Shaft Rear Ball Bearing Shaft Ring 5. Third/Fourth Gear Gear Hub Collar
Washer 6. Third/Fourth Gear Synchronizer Assembly
2. Input Shaft Rear Ball Bearing 7. Third Gear Needle Roller Bearing
3. Fourth Gear Gear Wheel Component 8. Third Gear Gear Wheel Component
4. Fourth Gear Needle Roller Bearing 9. Input Shaft
03-10 Transmission
OUTPUT SHAFT ASSEMBLY
2
3
5 6
4
7
13
8 10 11 12
9
14
15
16 18
17
20
19
1. Output Shaft 11. Second Gear Synchronizer Center Ring

2. Output Shaft Rear Ball Bearing 12. Second Gear Synchronizer Outer Ring
3. Fourth Gear Driven Gear Wheel 13. First/Second Gear Synchronizer Assembly
4. Third/Fourth Gear Spacer 14. First Gear Synchronizer Outer Ring
5. Third Gear Driven Gear Wheel 15. First Gear Synchronizer Center Ring
6. Second Gear Gear Wheel 16. First Gear Synchronizer Inner Ring
7. Second Gear Needle Roller Bearing 17. First Gear Needle Roller Bearing
8. Second Gear Needle Roller Bearing Spacer 18. First Gear Gear Wheel
9. First/Second Gear Gear Hub Collar 19. First Gear Thrust Washer
10. Second Gear Synchronizer Inner Ring 20. Steel Ball
Transmission 03-11
FIGURE OF OUTER COMPONENTS I
5
1
3 6
7
18
17
8
16 15
14
13
12
11
3
10 9
1. Reverse Gear Lock Plug 10. Reverse Lamp Switch Assembly

2. Reverse Gear Lock Shaft 11. Neutral Gear Positioning Seat Assembly
3. Oil Fill/Drain Screw Plug 12. Vent Plug
4. Differential Rear Oil Seal 13. Rear Linear Bearing
5. Bearing Pressure Plate 14. Ball Lock Spring
6. Input Shaft Rear Ball Bearing Stopper Ring 15. Ball Lock Spring Seat
7. Output Shaft Rear Ball Bearing Stopper 16. Ball Lock Screw Plug
Ring 17. Reverse Gear Lock Block
8. Transmission Housing 18. Reverse Gear Lock Torsion Spring
9. Reverse Gear Positioning Seat Assembly
03-12 Transmission
FIGURE OF OUTER COMPONENTS II
1 3
5 6
1. Left Suspension Bracket 5. Control Cover Assembly

2. Air Filter Bracket Assembly 6. Gear Shift Mechanism Assembly
3. Cabling Bracket No. 6 7. Gear Shift Rocker Assembly
4. Cabling Bracket Assembly 8. Rear Suspension Bracket
Transmission 03-13
DIFFERENTIAL ASSEMBLY
13
8 4
12
11
10 5
1. Differential Front Shim 8. Planetary Gear Shaft

2. Front Tapered Roller Bearing 9. Axle Shaft Gear
3. Flanged Bolt 10. Side Gear Wheel Shim
4. Differential Housing 11. Planetary Gear
5. Rear Tapered Roller Bearing 12. Planetary Wheel Spherical Shim
6. Differential Gear Ring 13. Cylindrical Pin
7. Differential Rear Shim
03-14 Transmission
RELEASE MECHANISM COMPONENTSS
2 4
6
5
9
7
1. Transmission Assembly 6. Release Fork Support Nail

2. Release Fork Circlip 7. Release Bearing Sub-Assembly
3. Dust Boot 8. Release Fork Sub-Assembly
4. Bolt and Spring Washer Assembly 9. Release Bearing Circlip
5. Clutch Release Pump Sub-Assembly
Transmission 03-15
FORK AND FORK SHAFT ASSEMBLY
2
13
12
3 4
5
14
11
10
1. Fifth Gear Gear Fork 8. First/Second Gear Fork

2. Fork Bolt 9. Reverse Gear Lever
3. Third/Fourth Gear Fork 10. First/Second Gear Fork Shaft
4. Third/Fourth Gear Block 11. Reverse Gear Induction Pin
5. Fifth/Reverse Gear Fork Shaft 12. Reverse Gear Induction Spring
6. Third/Fourth Gear Fork Shaft 13. Spring Pin
7. Steel Ball Sφ4.7625 14. Fork Shaft Limiter Ring
03-16 Transmission
6
2
1. Circlip No. 1 5. Plastic Retaining Ring

2. Card 6. Gear Shift Lever Ball
3. Transmission Control Cable Assembly 7. Transmission Controller Assembly
4. Circlip No. 2
Transmission 03-17
SPECIFIED TORQUE
Quantity Tightening
Location Remark
(units) torque (N•m)
Clutch housing x cabling bracket assembly 3 11.3±3.4 --
Clutch housing x release fork support nail 1 36.8±7.4 --
Clutch housing x oil deflector/output shaft cylindrical roller bear-
2 11.3±3.4 --
ing pressure plate
Transmission housing x ball lock screw plug 2 24.5±3.4 --
Fork shaft x fork (block) 4 15.7±3.1 --
Clutch housing x ball lock screw plug 1 24.5±3.4 --
Clutch housing x reverse gear rocker bracket component 2 17.2±3.4 --
Transmission housing x neutral gear positioning seat 1 29.4±5.9 --
Transmission housing x reverse gear lock plug 1 12.7±3.4 --
Transmission housing x input (output) shaft oil deflector 2 17.2±3.4 --
Transmission housing x reverse gear positioning seat assembly 1 39.2±11.7 --
Transmission housing x reverse lamp switch 1 40.2±12 --
Transmission housing x oil fill/drain screw plug 2 40±3 --
Transmission housing x clutch housing 13 29.4±5.9 --
Transmission housing x clutch housing 3 29.4±5.9 --
Transmission housing x rear housing 9 18.1±3.4 --
Transmission housing x gear shift rocker bracket 1 24.5±3.4 --
Transmission housing x shift lever cover assembly 1 19.6±3.4 --
Transmission housing x bearing pressure plate 5 27.4±5.9 --
Transmission housing x reverse idler shaft 1 29.4±8.8 --
Output shaft x output shaft lock nut 1 118±7.4 --
Gear shift rocker bracket x gear shift rocker assembly 1 11.8±2.4 --
Differential housing x differential gear ring 8 77.4±7.4 --
Clutch housing x separator pump assembly 2 11.8±2.4 --
Clutch housing x cabling bracket No. 6 1 11.3±3.1 --
Clutch housing x air filter bracket assembly 2 11.3±3.1 --
Clutch housing x gear shift rocker positioning bolt 1 24.5±3.4 --
Transmission controller assembly x vehicle body (bolt) 4 20±2 --
Transmission controller assembly x vehicle body (nut) 3 9 --
Apply screw
Left suspension bracket x transmission 4 55±5
thread glue
Apply screw
Rear suspension bracket x transmission 4 55±5
thread glue
Apply screw
Transmission x engine 7 46±5
thread glue
Air filter assembly x transmission 3 9 --
Clutch pipe bracket No. 2 x transmission 1 46 --
03-18 Transmission
DEDICATED TOOL
S/N Tool code Tool name Purpose Illustration of tool
For the installation position of

Differential shaft bear-
1 CC8057326 the differential shaft bearing
ing installation tool
on both sides
For the dismantling of the

Differential shaft bear- differential shaft bearing dis-
2 CC8047302
ing dismantling tool mantling tool in conjunction
with the chuck
For the installation of the

Output shaft bearing
3 CC8057232 output shaft bearing on both
installation tool
sides
Tools for the dismantling of

Axis channeling and
4 CC8047207 the input and output shaft
disassembly
bearings
For the installation of the dif-

Differential oil seal
5 CC8057327 ferential oil seal in conjunc-
installation tool (left)
tion with CC8027225
For the installation of the dif-

Differential oil seal
6 CC8057328 ferential oil seal in conjunc-
installation tool (right)
tion with CC8027225
For the installation of the in-

put shaft bearing (right)
Input shaft bearing
7 CC8057234 For the installation of the in-
installation tool (right)
put shaft oil seal in conjunc-
tion with CC8027225
Transmission 03-19

differential shaft bearing
outer ring in conjunction
8 CC8057329 ing outer ring installa-
with installation device cover
tion tool (right)
CC8057243 and installation
device CC8057245

differential shaft bearing
outer ring in conjunction
9 CC8027316 ing outer ring installa-
with installation device cover
tion tool (left)
device CC8057245

first and second gear output
Output shaft gear shaft wheel in conjunction
10 CC8057235
wheel installation tool with installation device cover
device CC8057245

third gear output shaft wheel
Output shaft gear in conjunction with installa-
11 CC8057236
wheel installation tool tion device cover CC8057243
and installation device
CC8057245

input shaft fifth gear syn-
chronizer gear hub wheel in
Output shaft gear
12 CC8057237 conjunction with installation
wheel installation tool
device cover CC8057243
and installation device
CC8057245
For the installation of the third

gear input shaft synchronizer
I n p u t s h a f t g e a r gear hub in conjunction with
13 CC8057238
wheel installation tool installation device cover
device CC8057245

Gear shift lever oil gear shift lever oil seal in
14 CC8057239
seal installation tool conjunction with oil seal han-
dle CC8027225
03-20 Transmission
To be used to fix the input

Input shaft fixation shaft in position during the
15 CC8057242
tool removal of output shaft lock
nuts
To be used with other tools

Installation device when installing the input or
16 CC8057243
cover output shaft gear wheels and
gear hubs

when installing the input or
17 CC8057244 Installation device
output shaft gear wheels and
gear hubs

when installing the input or
18 CC8057245 Installation device
output shaft gear wheels and
gear hubs
Differential shaft
For the removal of the gear
19 CC8027331 bearing dismantling
selector shaft pin
tool (punch) Φ4 mm
Differential shaft
For the removal of the differ-
20 CC8027330 bearing dismantling
ential shaft pin
tool (punch) Φ5 mm
To be used to clip together

components (e.g., various
21 CC8027223 Chuck
shaft bearings, gear wheels)
to be separated with a press
Transmission 03-21
Input shaft fifth gear

For the removal of the fifth
22 9101026 gear hub removal
gear synchronizer gear hub
tool
Output shaft fifth gear

For the removal of the fifth
23 9101027 driven wheel removal
gear driven gear
tool
Bearing outer ring re- For the removal of the differ-

24 CC8057241
moval device ential shaft bearing outer ring
Oil seal installation To be used with oil seal in-

25 CC8027225
handle stallation tools
03-22 Transmission
DIAGNOSIS AND INSPECTION

BASIC PARAMETERS
Max. input torque (N•m) 138
I II III IV V R
Gear ratios
3.545 1.905 1.310 0.969 0.816 3.250
Final Drive Ratio 4.313
Odometer ratio 31/35
Center distance (mm) 70
Lubricant capacity (L) 1.8±0.5
Within China, lubricant SAE 80W-90 GL-4; export markets
Lubricant type at high altitude/low temperatures, lubricant SAE 75W-90 GL-4;
export markets with high temperatures, lubricant SAE 140 GL-5
Net weight (kg) 36.2
SYNCHRONIZER GEAR RING AND GEAR AXIAL CLEARANCE (δ)
Gear position I (δ1) II (δ2) III (δ3) IV (δ4) V (δ5)

Standard
0.8~1.6 0.8~1.6 0.8~1.6 0.8~1.6 0.8~1.6
backlash (mm)
AXIAL AND RADIAL CLEARANCE FOR VARIOUS GEAR WHEELS (δ)

Gear position I (δ1) II (δ2) III (δ3) IV (δ4) V (δ5)
Axial clearance
0.1~0.3 0.205~0.455 0.125~0.275 0.075~0.325 0.175~0.445
(mm)
Radial clearance
0.015~0.056 0.015~0.056 0.015~0.058 0.015~0.058 0.015~0.058
(mm)
Transmission 03-23
TROUBLESHOOTING CHECKLIST
Common faults Possible causes Troubleshooting
Clutch not used Use the correct driving method
Clutch did not disengaged fully Check and make adjustments
Difficulty in engaging
Severe damage to synchronizer gear
gear Replace component
ring
Self-locking spring overly stiff Replace component
Oil levels too low Top up oil to specified level
Poor lubricant quality Switch to recommended oils
Oil not changed out in time Change oil and damaged component
Overly-loud or abnormal
Inappropriate gear wheel shaft orien-
noises Check and make adjustments
tation and gap
Shaft bearing damaged Replace component
Burrs or bumps in gear wheel Repair or replace gear wheel
Oil levels too high Drain until oil level reaches stipulated level
Loose or missing bolts Replace bolts, tighten to specifications
Oil leakage
Vent plug failure Replace
Damaged seal Replace
Gear shift conducted with too much
Replace
force
Synchronizer damaged Clutch not used Use the correct driving method
Synchronizer spring-loaded piston
Replace
ring damaged
Control mechanism fault Check and make adjustments
Missing spring or steel ball Re-install
Self-locking spring failure Replace
Gear jump-out Small gear sleeve chamfer Replace
Severe damage to gear sleeve fork
Replace
groove
Severe wear to fork Replace
Oil levels too low Replace component and top up oil
Poor lubricant quality Replace component and lubricant
Burn damage to shaft
Oil not changed out in time, oil-stained Replace component and lubricant
bearing/gear wheel
Mix of oils used, or additive(s) pres-
Replace component and lubricant
ent
Synchronizer spring failure Replace
Wear to synchronizer gear ring inner
Replace
groove
Difficulty in engaging N
Synchronizer gear ring stuck on ta-
gear Replace
pered surface
Fork or fork shaft out of shape Replace
Severe wear to fork Replace
03-24 Transmission

PRECAUTIONS
• When removing or replacing the transmission or clutch assembly, you need to clean the
transmission shaft 1 spline and clutch driven plate spline (be careful not to damage the
splines)
• After cleaning, you need to apply a layer of grease on the transmission shaft 1 spline
(grease type: MI-SETRAL-43N; application position: on the transmission shaft 1 spline,
4 mm-8 mm from the separator shaft bearing to the spline end; application amount:
0.2 g-0.3 g).
• Apply with a small brush on the transmission shaft 1 spline from the inside to the outer
edge. Make sure that the entire spline shaft is lubricated evenly (just a thin layer of grease
is needed, and avoid applying too much grease on the release bearing so that excess
grease will not splash on the clutch driven plate during operations).
Dismantling requirements
1. Prior to dismantling, remove the drain screw plug and drain fully.
2. Prior to dismantling, clean the exterior of the transmission thoroughly to prevent any dirt from
the exterior entering the transmission proper during the dismantling process.
3. Prepare a clean container in which to hold dismantled components. This will help to prevent
component loss or mix-ups, and can also help the technician to determine if all components
have been re-installed later on.
4. During the course of dismantling, check that each component is working normally and that
there are no signs of damage, deformation or other faults.
Assembly requirements
1. Where there are working planes on the transmission housing, clutch housing, etc., there must
be no knocks as these are the primary cause of oil leaks. Prior to re-assembly, clean all parts
(apart from rubber parts and bearings) carefully using the appropriate method to try to keep
debris at a level below 100 mg. Attention: When drying parts using compressed air, you should
pay extra care to the dust and other debris that can be thrown up by the procedure. These can
cause injury to the eyes. Therefore, you should try as much as possible to wear protective
gear such as safety goggles.
2. Pay extra attention to the sliding surfaces of the gear wheels, shafts and splines, parts that see
grinding such as part ends, as well as gear teeth and take care not to cause knocks to these
parts. All oil seals, shaft retainer rings, spring pins and snap rings used on the transmission
are for single use only and should not be reused.
3. All bolts must be tightened according to their respective specified torque specifications.
4. When assembling various shaft bearings, press them in slowly using the dedicated tools and
press. Do not attempt to transmit pressure via the roller body, and do not tilt. Note that the
shaft bearing has a particular orientation so do not place it in the wrong way. Use bearing in-
ner and outer rings from the same manufacturer. Do not cause any knocks on the rotating sur-
faces and check components as you perform the assembly.
5. Apply gear oil on all friction bearing surfaces during assembly as well as grease on all oil seal
lips. Press the oil seals into place inside the transmission housing using the dedicated tool.
Make sure there is no tilt during installation, and that the oil seals have been installed in the
correct orientation. Take care during the assembly process not to scratch or cut the oil seals;
this will cause oil leaks.
6. With parts that slide, have a gap between them or are in each other's way, pay keen attention
to the correct component directionality and tilt degree during the assembly process. Never
use a tool like a hammer to ram a part into place. Unless otherwise specified, apply grease or a
specified lubricating oil to the aforementioned parts.
Transmission 03-25
7. When assembling synchronizer components, the two openings of spring-loaded piston ring at
the sides should form an angle of 120°.
8. Apply sealant at the spots specified. Prior to applying sealant, clean all traces of old sealant on
the joint surface, and assemble all components within 10 minutes of sealant application. Apply
screw thread glue where it is needed.
03-26 Transmission
Disassembly
1. Place the transmission, drained of oil, on the work
surface or on the dedicated scaffold
2. Remove reverse lamp switch
3. Remove neutral gear positioning seat
4. Remove air filter bracket assembly

Transmission 03-27
5. Remove left suspension bracket
6. Remove gear shift rocker assembly
7. Remove cabling bracket No. 6
8. Remove cabling bracket No. 6

03-28 Transmission
9. Remove rear suspension bracket
10. Unscrew control cover bolts, remove control cover

assembly
11. Remove rear cover and bolt spring washer assem-

bly
Remark:
• You should check the axial clearance between the
input and output shafts and create a table of mea-
surements.
12. Remove fifth gear gear hub collar

Transmission 03-29
13. Remove fork bolt
14. Remove fifth gear synchronizer assembly and fifth

gear gear fork
15. Remove fork shaft limiter ring
16. Remove output shaft lock nut

03-30 Transmission
17. Remove fifth gear driven gear wheel and fifth gear
gear wheel components
18. Remove fifth gear needle roller bearing
19. Remove fifth gear needle roller bearing spacer
20. Remove reverse gear idling shaft screw and flat

washer
Transmission 03-31
21. Remove pressure plate bolt and washer component,

and remove bearing pressure plate
22. Remove input shaft rear ball bearing stopper ring

and output shaft rear ball bearing stopper ring
23. Remove ball lock screw plug, ball lock spring seat,
ball lock spring and ball lock
24. Remove reverse gear positioning seat

03-32 Transmission
25. Remove transmission housing assembly

(a) Remove 13 hexagonal flange bolts.
(b) Turn the transmission over 90°, unscrew the 3 hexago-

nal flange bolts on the side of the clutch housing.
(c) Use the dedicated tool to pry open the clutch housing
and transmission housing. Press clutch housing and
hold on to the transmission housing. With some force,
remove the transmission housing assembly along the
shaft axis.
26. Remove reverse idling shaft, reverse gear idling

wheel components and reverse gear idling wheel
thrust pad
Transmission 03-33
27. Remove reverse gear rocker bracket bolts and re-

verse gear rocker bracket components
28. Pull out the input shaft assembly, output shaft as-
sembly and various fork shaft assemblies along the
vertical axis
29. Remove differential assembly

03-34 Transmission
CLEANING INSTRUCTIONS
After dismantling the transmission, please clean the
input shaft assembly, central axis assembly, gear shift
mechanism assembly, reverse gear idling wheel assem-
bly, clutch housing assembly, transmission housing as-
sembly, differential assembly, fork shaft assemblies and
other individual parts. Blow dry these components using
compressed air.
INSPECTION INSTRUCTIONS
1. Check all gear wheels to make sure that gear teeth
have not cracked, worn down or damaged by
knocks. Replace the gear wheel if any of the afore-
mentioned is found.
2. Check the various shaft bearings for signs of dam-
age as well as for damage to various seals and odd
sounds from the bearings during shaft rotation,
Replace the bearing if any of the aforementioned is
found.
3. Check for abnormal wear-and-tear in the first/sec-
ond, third/fourth and fifth/reverse gear forks. Re-
place the forks if such signs are found.
4. Check various fork shafts for signs of abnormal
wear-and-tear, deformation, etc., and replace parts if
any of the aforementioned is found.
Transmission 03-35
Assembly
1. Place the clutch housing assembly with the release
shaft facing down, then insert differential assembly
2. Assemble the first/second, third/fourth, and fifth/re-

verse gear fork shaft assemblies and then install on
their corresponding synchronizer gear sleeves
Attention:
• Do not forget to install the 2 interlock balls.
3. Then, insert the input shaft assembly, the output

shaft assembly and various fork shaft assemblies
03-36 Transmission
4. Insert reverse rocker bracket components, then

screw bracket bolts tight
Specified torque: (17.2±3.4) N•m
5. Insert reverse gear idling wheel components, re-

verse gear idling wheel thrust pad, reverse gear
idling wheel shaft
Attention:
• Align the direction mark on the reverse gear
idling wheel shaft with bolt hole A on the
clutch.
6. Apply sealant on the transmission housing assem-

Gluing position bly on the locations shown in the illustration
Transmission 03-37
7. Join the transmission housing assembly and the

clutch housing assembly together
8. Insert 13 hexagonal flange bolts

9. Insert reverse gear positioning seat
10. Insert ball lock screw plug, ball lock spring seat,
ball lock spring and ball lock
03-38 Transmission
11. Insert input shaft rear ball bearing stopper ring and
output shaft rear ball bearing stopper ring
12. Insert bearing pressure plate, plate bolt and flat

washer components
13. Insert reverse gear idling shaft screw and flat washer
14. Insert fifth gear needle roller bearing spacer

Transmission 03-39
15. Insert fifth gear needle roller bearing
16. Insert fifth gear driven gear wheel and fifth gear
gear wheel components
17. Install output shaft lock nut
18. Install fork shaft limiter ring

03-40 Transmission
19. Insert fifth gear synchronizer assembly and fifth

gear fork
20. Install fork bolt
21. Insert fifth gear gear hub collar
22. Install rear cover and bolt spring washer assembly

Remark:
• Apply sealant along the grooves on the joint sur-
face of the rear housing as well as screw thread
glue for the bolts.
Transmission 03-41
23. Turn the transmission over 90°, and screw the 3

hexagonal flange bolts on the side of the clutch
housing
24. Install control cover assembly

Attention:
• Apply glue on the 2 shift lever cover bolts on
the bottom.
25. Install rear suspension bracket
26. Install cabling bracket

03-42 Transmission
27. Install cabling bracket No. 6
28. Install gear shift rocker assembly
29. Install left suspension bracket
30. Install air filter bracket assembly

Transmission 03-43
31. Insert neutral gear positioning seat
32. Install reverse lamp switch
SELECTING THE RIGHT GASKETS FOR VARIOUS

SHAFT BEARINGS
If you have replaced the input shaft or output shaft, or
any of the gear wheels, gear hubs or bearings on ei-
ther shaft during maintenance, you must measure axial
clearance during assembly. Choose the appropriate
washers and shaft ring washer to help you meet axial
clearance requirements. If the any part of the transmis-
sion housing, clutch housing or differential front and rear
bearings have been replaced, the technician must mea-
sure differential rotation starting torque during assembly.
Starting torque specifications:
New bearing: (0.78-1.57) N•m
Post run-in bearing: (0.49-0.98) N•m
03-44 Transmission
Disassembly
Remark:
• Prior to dismantling the differential, check the axial
clearance and gear engagement clearance be-
tween the planetary gear wheel and the axle shaft
gear.
1. Remove the front and rear tapered roller bearings
from the differential using the dedicated tool
2. Remove 8 flanged bolts
3. Remove differential gear ring

Remark:
• Make marks to indicate the various positions of
the main reducer wheel gear ring and differential
housing prior to dismantling.
Transmission 03-45
4. Remove cylindrical pin that fixes the planetary gear

Tools shaft using dedicated tool
Cylindrical
pin
5. Remove planetary gear shaft
6. Rotate the two planetary wheels with a horizontal

90° turn, remove planetary wheel and planetary
wheel spherical Shim
7. Remove axle shaft gear and side gear wheel shim

03-46 Transmission
Installation
Attention:
• You must use new bearings for the front and
rear of the differential after removing them.
• With the exception of shaft bearings, all parts
must be cleaned prior to assembly. Also check
that all parts do not show signs of abnormal
wear-and-tear or damages.
• When dismantling, make sure that various
parts (especially gear wheels) are not subject-
ed to any knocks.
1. Place the two side gear wheel shims on the gear
wheel and then insert into differential housing
2. Place the spherical washer onto the planetary gear

sleeve and insert between the two axle shaft gears;
Then turn the two planetary gears at the same time
so that the holes on the gears are aligned with the
two holes for the planetary gear shaft on the differ-
ential housing
3. Place the planetary gear shaft through the two plan-

etary wheels, and align the pin holes on the shaft
with the pin holes on the differential housing
Transmission 03-47
4. Tap in the cylindrical pin with a tool. Rivet the differ-

ential housing shut after assembly to prevent cylin-
drical pin from falling out
5. Place the differential gear ring on the differential

housing, align and then install
Attention:
• The side of the inner ring with the large cham-
fer should be facing the differential housing.
• The relative positions of the differential gear
ring and differential housing.
6. Install 8 flanged bolts.

7. Press to install the front and rear tapered roller

bearings using the dedicated tool
03-48 Transmission

Attention:
• During the course of dismantling, place the
gear wheels, needle roller bearing and syn-
chronizer rings in groups categorized by the
gear assemblies they belong to, e.g., by third
gear, fourth gear, so on and so forth. Doing so
will help prevent mix-ups during re-assembly.
• After cleaning, check the tapered surfaces of
various gear wheels for signs of damage or
cracks. Replace parts if any of these signs are
found.
• Check synchronizer gear sleeves and gear
wheel locking pins for signs of wear-and-tear.
Replace both synchronizer and gear wheel
when damage is severe.
• If the synchronizer falls apart in the process of
dismantling (slider and spring fall out, or gear
sleeve falls off), please refer to the section
titled "Repair and Maintenance of Synchroniz-
ers".
• We recommend that you use new snap rings of
the appropriate thickness during assembly.
• During assembly, you must pay attention so
that the projection area of the synchronizer
ring is not damaged by pressure. Keep in mind
the correct orientations of various gear hubs
and gear sleeves during assembly.
• The gear ring for the third gear synchronizer
is different from the one used for the fourth
gear synchronizer (they are marked with the
corresponding numerals) and one may not be
substituted for the other. Please pay attention
to the difference between the two.
• All parts must be cleaned prior to re-installa-
tion.
Disassembly
1. Remove input shaft rear ball bearing shaft ring
washer
Transmission 03-49
2. Press down on the fourth gear gear wheel compo-

nents and input shaft rear ball bearing using the
dedicated tool
3. Remove fourth gear needle roller bearing
4. Remove third/fourth gear gear hub collar
5. Remove fourth gear synchronizer ring

03-50 Transmission
6. Press out the third gear gear wheel components

and third/fourth synchronizer assembly at the same
time using the dedicated tool
7. Remove third gear needle roller bearing
MEASURING THE AXIAL CLEARANCE FOR THE

THIRD AND FOURTH GEARS
1. Controlling wheel axial clearance
Item Data (mm)
Synchronizer ring reserve 0.8-1.6
Axial clearance for third gear gear wheel 0.125-0.275
Axial clearance for fourth gear gear wheel 0.075-0.325
Attention:
• All gear wheels and shafts should be mea-
sured only after they have been cleaned and
dried to ensure the accuracy and validity of
measurements taken.
Transmission 03-51
2. Controlling wheel radial clearance

Measure radial clearance for each wheel after compo-
nents have been cleaned and blown dry. Compared
measurements taken with the data in the table below.
Should your measurements exceeded the accepted
range, replace with new input shaft wheel and needle
roller bearing.
Item Data (mm)
Radial clearance for third gear gear wheel 0.015-0.058
Radial clearance for fourth gear gear wheel 0.015-0.058
3. Checking third/fourth gear synchronizer ring re-

serve
Press the various synchronizer rings flat onto the re-
spective gear wheel. Then, measure the gear wheel and
Synchronizer synchronizer ring reserve using a feeler gauge.
ring If the reserve measured is less than 0.8 mm or greater
Reserve than 1.6 mm, replace the synchronizer ring and mea-
capacity
Gear wheel
sure again; if the reserve of the new synchronizer ring
component is still less than 0.8 mm or greater than 1.6 mm, replace
the gear wheel with a new one at the same time.
Installation
1. Insert third gear needle roller bearing
03-52 Transmission
2. Insert third gear drive wheel components

Attention:
• Apply oil on the location of the third gear nee-
dle roller bearing prior to assembly.
Oiling location
3. Insert the third gear synchronizer ring (with the

number "3" on it)
Attention:
• Apply oil on the tapered surfaces of the third
gear gear wheel components prior to assem-
bly.
Oiling location
4. Insert third/fourth gear synchronizer assembly and

press the synchronizer into place using the tool
and press
Third and
fourth gear Attention:
synchronizer • During assembly, align the grooves on the
press-mounting synchronizer ring with the synchronizer slider.
tools
The side of the gear sleeve outer ring with the
gap indication should face downwards (to-
wards third gear).
Gap Input shaft
indication tools
5. Install the third/fourth gear gear hub shaft ring

washer using snap ring pliers
Remark:
• The shaft ring washers come in 6 specifications,
with clearance required to be below 0.1 mm.
Transmission 03-53
6. Insert fourth gear needle roller bearing spacer
7. Insert the fourth gear synchronizer ring (with the

number "4" on it)
Attention:
• During assembly, align the grooves on the syn-
chronizer ring with the synchronizer slider.
8. Insert fourth gear needle roller bearing
9. Install fourth gear gear wheel components

Attention:
• Apply oil on the tapered surfaces of the fourth
gear gear wheel components and the location
Oiling location of the needle roller bearing prior to assembly.
03-54 Transmission
10. Press in on the input shaft rear ball bearing using

the dedicated tool to install
11. Install input shaft rear ball bearing shaft ring washer
Remark:
• The shaft ring washers come in six specifications,
12. Complete input shaft assembly

Attention:
• After assembling the input shaft assembly, al-
low each synchronizer to stay in neutral gear;
then, use your hand to turn the third gear drive
wheel and fourth gear drive wheel to see if they
can turn freely. If the gears cannot be turned,
check and re-assemble.
Transmission 03-55

Attention:
• During the course of dismantling, place the
gear wheels, needle roller bearing and syn-
chronizer rings in groups categorized by the
gear assemblies they belong to, e.g., by first
gear, second gear, so on and so forth. Doing
so will help prevent mix-ups during re-assem-
bly.
• After cleaning, check the tapered surfaces of
various gear wheels for signs of damage or
cracks. Replace parts if any of these are found.
• Check synchronizer gear sleeves and gear
wheel locking pins for signs of wear-and-tear.
Replace both synchronizer and gear wheel
when damage is severe.
• If the synchronizer falls apart in the course of
dismantling, please refer to the section titled
"Repair and Maintenance of Synchronizers".
• We recommend that you use new snap rings of
the appropriate thickness during assembly.
• During assembly, you must pay attention so
that the projection area of the synchronizer
ring is not damaged by pressure. Keep in mind
the correct orientations of various gear hubs
and gear sleeves during assembly.
• The gear ring for the first gear synchronizer
is different from the one used for the second
gear synchronizer (they are marked with the
corresponding numerals) and one may not be
substituted for the other. Please pay attention
to the difference between the two.
• All parts must be cleaned prior to re-installa-
tion.
Disassembly
1. Press out the fourth gear driven gear wheel and the
Output shaft rear output shaft rear ball bearing using the dedicated
ball bearing
Fourth gear driven
tool
gear wheel Remark:
• Press out both components together.
03-56 Transmission
2. Remove third/fourth gear spacer
3. Press out the second gear gear wheel and the third
gear driven gear wheel using the dedicated tool
Third gear driven Remark:
gear wheel • Press out both components together.
Second gear
gear wheel
4. Remove second gear needle roller bearing
5. Remove second gear needle roller bearing spacer

Transmission 03-57
6. Remove second gear synchronizer gear ring
7. Install the first/second gear gear hub shaft ring

8. Press out the first gear gear wheel components,

first gear synchronizer ring assembly and first/
First and second gear synchronizer assembly using the dedi-
second gear
cated tool and press
synchronizer
assembly Remark:
First gear • Press out all three components together.
synchronizer
gear ring
assembly
First gear
gear wheel
component
9. Remove first gear needle roller bearing

03-58 Transmission
10. Remove first gear thrust washer and steel ball

Transmission 03-59
MEASURING THE AXIAL CLEARANCE FOR THE

FIRST AND SECOND GEARS
1. Controlling wheel axial clearance
Gear position I (mm) II (mm)
Synchronizer ring reserve 1.0-1.6 1.0-1.6
Gear wheel axial clearance 0.1-0.3 0.205-0.455
2. Controlling wheel radial clearance for first/second

gears
Measure radial clearance for each wheel after compo-
nents have been cleaned and blown dry. Compared
measurements taken with the data in the table below.
Should your measurements exceeded the accepted
range, replace with new input shaft wheel and needle
roller bearing.
Gear position Data
Radial clearance for first gear gear wheel 0.015-0.056
Radial clearance for second gear gear
0.015-0.056
wheel
3. Checking first/second gear synchronizer reserve

Press the various synchronizer rings flat onto the re-
spective gear wheel. Then, measure the gear wheel and
synchronizer ring reserve capacity using a feeler gauge.
Synchronizer If the reserve capacity measured is less than 0.8 mm or
ring
greater than 1.6 mm, replace the synchronizer ring and
Reserve
capacity measure again; if the reserve of the new synchronizer
Gear wheel ring is still smaller than 0.8 mm or greater than 1.6 mm,
component replace the gear wheel with a new one at the same
time.
03-60 Transmission
Assembly
1. Install steel ball Sφ4.7625 and first gear thrust
washer
2. Install the first gear needle roller bearing and first

gear gear wheel
Attention:
• Apply oil on the location of the first gear nee-
dle roller bearing before assembling the first
gear gear wheel components.
First gear
gear wheel
First gear needle

roller bearing
3. Install the first gear synchronizer ring assembly

Attention:
• The three claws of the center ring in the first
gear synchronizer gear ring assembly must be
inserted into the three slots of the gear wheel
end while the three claws of the inner ring
must be inserted into the three slots on the
outer ring.
Oiling location
Transmission 03-61
4. Press in the first/second gear synchronizer assem-

bly using the press and relevant tools
Attention:
• Pay attention to the orientation of the synchro-
nizer. During installation, make sure that the
grooves on the outer ring of the center gear
ring are aligned with those on the gear hub.
5. Install the first/second gear gear hub shaft ring

Attention:
• Snap ring openings must not come into con-
tact with the input shaft second gear spigot to
prevent scratch damage.
Remark:
• The shaft ring washers come in six specifications,
6. Install the second gear needle roller bearing spacer
7. Install second gear synchronizer gear ring assem-

bly
Attention:
• First assemble the second gear synchronizer
ring assembly. Then insert the three claws of
the inner ring into the two slots on the outer
ring, then insert the three projections on the
outer ring into the three slots on the gear hub.
03-62 Transmission
8. Install second gear needle roller bearing

Attention:
• Apply lubricating oil on the second gear needle
roller bearing beforehand.
9. Install second gear gear wheel

Attention:
• Prior to assembly, apply gear oil on the needle
roller bearing and tapered surfaces of gear
wheel components. Assemble the second gear
synchronizer ring assembly. Then insert the
Oiling location three claws of the inner ring into the two slots
on the outer ring, then insert the three projec-
tions on the outer ring into the three slots on
the gear hub. Apply lubricating oil on the sec-
ond gear needle roller bearing beforehand.
10. Install the third gear driven gear wheel using the
dedicated tool
Attention:
• Apply grease on the spline surface prior to in-
stallation.
11. Insert third/fourth gear spacer

Transmission 03-63
12. Install the fourth gear driven gear wheel using the
relevant tool
Attention:
• Apply grease on the spline surface prior to in-
stallation.
13. Complete output shaft assembly

Attention:
• After assembling the output shaft assembly, al-
low the first/second gear synchronizer assem-
bly to stay in neutral gear; then, use your hand
to turn the first gear gear wheel components
and second gear gear wheel components to
see if they can turn freely. If the gears cannot
be turned, check and re-assemble.
03-64 Transmission
CLUTCH HOUSING ASSEMBLY

Disassembly
1. Remove clutch release pump sub-assembly
2. Remove release bearing sub-assembly
3. Remove release fork sub-assembly

Transmission 03-65
4. Use the dedicated tool to remove the input shaft cy-

lindrical roller bearing
Attention:
• You must replace with a new bearing.
5. Use the dedicated tool to remove the input shaft oil

seal
Attention:
• You must replace with a new oil seal.
6. Remove pressure plate bolt and washer compo-

nents, and remove bearing pressure plate and out-
put shaft cylindrical roller bearing using the dedi-
cated tool
7. Remove output shaft guide nozzle

03-66 Transmission
8. Use the dedicated tool to remove the differential

front oil seal
Attention:
9. Remove differential front tapered roller bearing out-

er ring and differential front shim
10. Remove oil deflector, bolt and spring washer as-

sembly
11. Remove magnet and clean thoroughly

Transmission 03-67
Assembly
1. Install the cleaned magnet
2. Insert oil deflector, bolt and spring washer assem-

bly
3. Insert differential front shim, press differential front

tapered roller bearing into place using tool
03-68 Transmission
4. Insert oil guide nozzle
5. Press output shaft cylindrical roller bearing into

place using tool, install bearing pressure plate and
pressure plate bolt and washer components
6. Press input shaft oil seal into place using tool

Attention:
• Do not tilt part during pressing in. Use the
housing joint surface as support and press in
vertically.
7. Press input shaft cylindrical roller bearing into

place using tool
Attention:
• Do not tilt part during pressing in. Use the
housing joint surface as support and press in
vertically.
Transmission 03-69
8. Turn the clutch housing over 180 degrees, press the

differential front oil seal into place using dedicated
tool
9. Tap in 4 positioning pins, insert release fork sub-

assembly
10. Insert release bearing sub-assembly (with grease

applied)
11. Insert clutch release pump sub-assembly and com-

plete assembly
03-70 Transmission
TRANSMISSION HOUSING ASSEMBLY

Disassembly
1. Unscrew oil fill/drain screw plug and flat washer
Attention:
• The oil fill/drain screw plug is fitted together
with a flat washer, it is best to use a new wash-
er during assembly.
2. Use the dedicated tool to remove the differential

rear oil seal
3. Remove differential rear tapered roller bearing outer

ring using dedicated tool, then take down differen-
tial rear shim
Transmission 03-71
4. Remove rear linear bearing using dedicated tool
5. Remove reverse gear lock mechanism assembly

03-72 Transmission
Assembly
1. Install reverse gear lock mechanism assembly in
place, then tap in spring pin
2. Tighten reverse gear lock plug

3. Press in the rear linear bearing using the relevant

tool
Transmission 03-73
4. Insert differential rear shim, press differential rear

tapered roller bearing outer ring into place using
tool
Attention:
• You should choose the correct adjusting gas-
ket beforehand.
5. Press in the differential rear oil seal using tool

Attention:
6. Tighten drain screw plug and flat washer

Attention:
• Do not forget the flat washer when re-assembling
the oil fill/drain screw plug.
03-74 Transmission
GEAR FORKS AND FORK SHAFTS

Removal
The maintenance of various forks and fork shafts are
relatively straightforward. Use a pair of snap ring pli-
ers to remove fork shaft limiter rings, then remove fork
bolts, and bring down the forks.
Attention:
• Once dismantled, old snap rings cannot be
reused and must be replaced with new ones.
During dismantling, take care to protect the
fork and fork shaft working surfaces from dam-
age.
Installation
The maintenance and assembly of various forks and
fork shafts are rather straightforward. Simply place the
parts in the correct positions, screw fork bolts tight, and
install fork shaft limiter ring. Remember to install the two
interlock balls when installing the reverse gear lever.
Attention:
• During assembly, take care to protect the fork
and fork shaft working surfaces from damage.
• Apply thread fastening glue prior to screwing
fork bolts.
• Check after assembly, taking care not to miss
out on the interlock balls and other parts.
Transmission 03-75
GEAR SYNCHRONIZERS
There are three synchronizer assemblies within the
transmission system: the first/second gear synchronizer
assembly, the third/fourth gear synchronizer assembly,
and the fifth gear synchronizer assembly. Each synchro-
nizer is made up of the gear sleeve, gear hub, slider
and spring-loaded piston ring.
Attention:
• The spring-loaded piston rings should be posi-
tioned such that the openings are staggered.
• Install the first/second synchronizer with the
tapered surfaces side of the gear hub facing up
(towards second gear) and the gear wheel side
of the gear sleeve facing up (towards second
gear).
• Install the third/fourth synchronizer with notch
mark of the gear sleeve facing down (towards
third gear).
• Install the fifth gear synchronizer with the big-
ger end of the gear hub inner ring facing down
(towards fifth gear) and the notch mark of the
gear sleeve facing down (towards fifth gear).
The sloped side of the slider should face up.
ASSEMBLY INSTRUCTIONS
The three synchronizers are assembled in a similar
fashion. Below are the assembly instructions for the fifth
gear synchronizer.
1. Installation procedure for the fifth gear synchronizer
As shown in the illustration: insert the slider into the
Gear sleeve
slider slot on the gear hub; place gear sleeve; clip on
spring-loaded piston ring.
Attention:
• The notches on the gear sleeve should be po-
sitioned to face the three slots on the gear hub.
Slider
• The opening of spring-loaded piston ring
Gear hub
should be staggered at 120°.
Spring-loaded
piston ring
03-76 Transmission
2. Characteristics of the fifth gear synchronizer

Attention:
• Install with the bigger end of the gear hub in-
ner ring facing down (towards fifth gear) and
the notch mark of the gear sleeve facing down
(towards fifth gear). The sloped side of the
slider should face up.
3. Installation characteristics of the third/fourth gear

synchronizer
Attention:
• Install the third/fourth synchronizer with notch
mark of the gear sleeve facing down (towards
third gear).
4. Installation procedure for the first/second gear syn-

chronizer
As shown in the illustration: place the spring into the
rounded groove of the gear hub and then insert the slid-
er into the three slots of the gear hub supported by the
spring. Finally, use the dedicated guide tool to place the
gear sleeve on the gear hub.
Attention:
• The notches on the gear sleeve should be po-
sitioned to face the three slots on the gear hub.
REVERSE LAMP SWITCH

The reverse lamp switch is designed as a single unit.
During repair and maintenance, you only have to un-
screw the reverse lamp switch by wrench in order to
replace with a new one. Tighten the new reverse lamp
switch to specified torque to complete the procedure.
Transmission 03-77
TRANSMISSION CONTROLLER ASSEMBLY

Removal
Attention:
• You must turn off the engine before disman-
tling any transmission components to avoid
bodily injury when the vehicle lurches forward.
1. Remove shift lever ball, ball protective cover, and
plastic retaining ring
2. Remove auxiliary dashboard assembly
3. Remove transmission controller assembly
(a) Remove circlips 1 and 2, disconnect transmission con-
trol mechanism from gear shift cabling.
(b) Disconnect the gear shift cabling and the U-shaped

groove of the transmission control mechanism using a
flathead screwdriver.
4. Remove transmission control mechanism

Remove 4 fastening bolts.
03-78 Transmission
Installation
Install in the reverse order of removal procedure.
Transmission 03-79
TRANSMISSION CONTROL CABLE AS-

SEMBLY
Removal
1. Remove shift lever ball, ball protective cover, and
plastic retaining ring
3. Remove air filter assembly
4. Remove emissions catalyst and insulating plate
5. Remove transmission control cable assembly
(a) Remove circlip 1 and the card that hold the control wir-
ing and transmission together to allow the transmission
wiring to pop out of the transmission fixing support.
(b) Remove circlips 1 and 2, disconnect transmission con-

trol mechanism from gear shift cabling.
(c) Disconnect the gear shift cabling and the U-shaped
groove of the transmission control mechanism using a
flathead screwdriver.
(d) Remove 3 nuts.
Installation
03-80 Transmission
4520012325 TRANSMISSION
LOCATION DIAGRAM
Transmission 03-81

03-82 Transmission
SCHEMATICS
TRANSMISSION HOUSING ASSEMBLY
1 2
4
5 6
12
43±4
7
11
8
10

Non-reusable parts
1. Snap Ring 7. Reverse Idler Shaft

2. Ball Bearing 8. Fixing Bracket
3. Cradle Bolt 9. Flanged Bolts
4. Transmission Housing Amt 10. Temperature Sensor
5. Six-Sided Bolt and Large Washer Assem- 11. Oil Fill/Drain Screw Plug
bly 12. Differential Oil Seal
6. Clutch Actuator
Transmission 03-83
CLUTCH HOUSING ASSEMBLY
1 4
3
10
8
6

Non-reusable parts
1. Clutch Housing Assembly 6. Cylindrical Pin

2. Input Shaft Oil Seal 7. Cylindrical Roller Bearing
3. Drawn Cup Roller Bearing 8. Output Shaft Guide Cover
4. Differential Oil Seal 9. Waveform Bracket
5. Oil Fill/Drain Screw Plug 10. Flanged Bolts
03-84 Transmission
SHIFT DRUM ASSEMBLY
4
20±1
10±1
1. Gear Wheel Lock Assembly 4. Shaft

2. Gear Shift Hub No. 1 5. Shift Hub Gear Wheel No. 2
3. Shift Hub Gear Wheel No. 1 6. Gear Shift Hub No. 2
Transmission 03-85
RELEASE FORK ASSEMBLY
1
2
25±3
3
25±3
25±3
5
25±3
1. Guide Sleeve 5. Guide Positioning Sleeve

2. Reverse Gear Fork Assembly 6. Second/Fourth Gear Fork Assembly
3. Diamond-Shaped Slider 7. Fifth/Sixth Gear Fork Assembly
4. First/Third Gear Fork
03-86 Transmission
TRANSMISSION ACCESSORY
1 2
27±1
4
10±1
6
8
7
25±3

Non-reusable parts
1. Oil Deflector 5. Output Shaft Guide Cover

2. Transmission Sensor 6. Adjust Snap Ring
3. Clutch Separator Component 7. Seal Cover
4. Magnet 8. Air Filter Bracket
Transmission 03-87
4
2
3
1 81±2
1. Planetary Gear 5. Differential Housing

2. Elastic Cylindrical Pin 6. Main Reducer Driven Gear Wheel
3. Axle Shaft Gear 7. Ball-Shaped Liner
4. Cone Bearing 8. Planetary Gear Shaft
03-88 Transmission
SHIFT DRIVE MODULE ASSEMBLY
23±2
1. Shift Motor Assembly 3. Vent Plug Cap

2. Motor Cabling Bracket
Transmission 03-89

13
12
11
10
7 8
6
5
4
3

Non-reusable parts
1. Output Shaft 8. Safety Ring

2. Output Shaft First Gear Gear Wheel 9. Output Shaft Second Gear Gear Wheel
3. Synchronizer Ring Assembly (Steel Base) Component
4. First/Third Gear Synchronizer Assembly 10. Second/Fourth Gear Synchronizer Assem-
5. Adjust Snap Ring bly
6. Output Shaft Third Gear Gear Wheel Com- 11. Output Shaft Fourth Gear Gear Wheel
ponent 12. Output Shaft Fifth Gear Gear Wheel
7. Half-Ring 13. Output Shaft Sixth Gear Gear Wheel
03-90 Transmission
1 3
4
5
6
7
8
9
10

Non-reusable parts
1. Reverse Gear Idling Wheel Assembly 6. Synchronizer Ring

2. Side Retaining Ring 7. Input Shaft Fifth Gear Gear Wheel
3. Input Shaft Sixth Gear Gear Wheel Component
Component 8. Input Shaft Fourth Gear Gear Wheel
4. Needle Roller Bearing With Lining 9. Input Shaft Third Gear Gear Wheel
5. Fifth/Sixth Gear Synchronizer Assembly 10. Input Shaft
Transmission 03-91
1. Gear Shift Lever 3. Center Floor Passage Block Pres-

2. Transmission Controller Assembly sure Plate
4. Center Floor Passage Block
03-92 Transmission

DIAGNOSTIC TROUBLE CODE
P-code
S/N Signal definition Max. Min. Signal Signal
value value lost unreliable
1 Clutch actuator signal out of expected range P0901
2 Actuator or power supply fault P0900
3 Clutch actuator system error P0805
4 Clutch actuator not separated P0810
5 Clutch torque transmission capability lost P0811
6 Use diagnostics to reset P0700
7 Communication with ECU lost U0100
8 Communication with ABS controller lost U0121
9 Communication with dashboard lost U0140
10 Gear shift lever error P1752
11 Startup at high gear P1999
Transmission temperature sensor values
12 P0711
unreliable
Transmission speed sensor values unreli-
13 P0716
able
14 Transmission sensor No. 1 unreliable P1100
Transmission encoder No. 1 value higher
15 P1101
than reference value
Transmission encoder No. 1 value lower
16 P1102
17 Transmission encoder No. 1 signal error P1103
Transmission encoder No. 1 stopped unex-
18 P1104
pectedly
Transmission encoder No. 1 moved unex-
19 P1105
pectedly
20 Transmission sensor No. 2 unreliable P1110
Transmission encoder No. 2 value higher
21 P1111
Transmission encoder No. 2 value lower
22 P1112
23 Transmission encoder No. 2 signal error P1113
Transmission encoder No. 2 stopped unex-
24 P1114
pectedly
Transmission encoder No. 2 moved unex-
25 P1115
pectedly
26 Unable to calculate non-drive wheel speed P1200
27 Unable to calculate drive wheel speed P1201
28 Shutdown state, AMT relay error P1300
29 Powered state, AMT relay error P1301
30 First gear synchronizer fault P1401
31 Second gear synchronizer P1402
32 Third gear synchronizer P1403
33 Fourth gear synchronizer P1404
34 Fifth gear synchronizer P1405
35 Sixth gear synchronizer P1406
36 Reverse gear gear shift procedure P1500
37 First gear gear shift procedure P1501
Transmission 03-93
P-code
S/N Signal definition Max. Min. Signal Signal
value value lost unreliable
38 Second gear gear shift procedure P1502
39 Third gear gear shift procedure P1503
40 Fourth gear gear shift procedure P1504
41 Fifth gear gear shift procedure P1505
42 Sixth gear gear shift procedure P1506
43 Transmission initialization not successful P1600
Transmission interlock system outside of ex-
44 P1601
pected range
Transmission initialization caused by refer-
45 P1602
ence value being exceeded
Transmission initialization caused by invalid
46 P1603
EEPROM and NVRAM values
Transmission initialization caused by shift
47 P1604
drum moving when system is shutting down
03-94 Transmission
FAULT DESCRIPTION
CODE: P0901
Clutch fault
Actuator signal outside of expected range.
Description
The clutch works to detect the final position of the actuator on a regular basis. If the actuator functions
normally, its position signal must be within the permissible range. If not, a problem will occur.
State
Actual clutch position higher than when gear is engaged, or lower than when gear is disengaged
If the fault occurs for a period longer than the specified delay time, it will be recognized as an error.
CODE: P0805
Clutch fault
Clutch actuator system fault.
Description
Tests the functioning of the clutch actuator system on an actual basis. This includes a mechanical er-
ror involving the incremental encoder sensor, power, actuator, clutch motor, wiring or clutch actuator
system (separator, separator shaft, clutch).
If error P0805 occurs but not error P0900 (clutch actuator does not move), then error P0805 indicates
that there is a problem with the incremental encoder sensor.
State
The shortest delay possible must be considered.
Max. TCU power current and time permissible.
Max. actuator power current and time permissible.
Ambient environment, e.g., temperature, power voltage and level.
Therefore, the minimum time for maximum load has been set at 500 ms, and this period is regarded
as the delay time.
CODE: P0900
Clutch fault
Actuator or power supply fault.
Description
Actuator does not move.
State
Clutch actuator engages Safe Return Home clutch position in shortest time possible, fault P0805
present.
When the following conditions have been met, the number of delay counter-related errors will also in-
crease:
• Deviation between engine and transmission speeds greater than permissible values.
• Vehicle speed lower than calibration table limits.
If the delay counter exceeds a certain set value, fault P0900 will also arise.
Transmission 03-95
CODE: P0810
Clutch fault
Clutch cannot separate.
Description
This fault means that there is a clutch fault and will appear if the clutch cannot be disengaged.
State
The difference between engine and transmission speeds is greater than permissible values, and ac-
tual engine speed is lower than engine idling speed, as the vehicle comes to a complete rest. If the
delay counter exceeds a certain set value, fault P0810 will also arise.
CODE: P0811
Clutch fault
Clutch torque transmission capability lost.
Description
Functional test of clutch torque engine capability.
State
Functional test of clutch torque engine capability.
Therefore, difference between engine and transmission speed is observed when the clutch is closed.
CODE: P0700
Clutch fault
Use diagnostics to reset.
Description
The clutch monitoring function can trigger a software reset. This will be stored in the fault registry (it is
able to read fault inputs).
State
The clutch monitoring function can trigger a software reset. The specific ambient data will be stored in
EEPROM with error code P0700.
CODE: U0100
Clutch fault
Communication between Engine Control Unit and Transmission Control Unit lost.
Description
One or more ECU signals unusable.
State
If CAN communications have been interrupted or when CAN frames that include ECU signals have
exceeded maximum values, code U0100 will arise.
CODE: U0121
Clutch fault
Communication between ABS/electronic vehicle stabilization system and TCU lost.
Description
One or more ABS/ESP signals unusable.
State
If CAN communications have been interrupted or when CAN frames that include ABS/ESP signals
have exceeded maximum values, code U0121 will arise.
03-96 Transmission
CODE: U0140
Clutch fault
Communication between control panel and TCU lost.
Description
One or more control panel signals unusable.
State
If CAN communications have been interrupted or when CAN frames that include control panel signals
have exceeded maximum values, code U0140 will arise.
CODE: P1752
Clutch fault
Shift-lever error.
Description
Signals received from gear shift module invalid.
State
Gear shift lever signals delayed during permitted time. Delayed gear shift lever signal represents lever
position. If the lever position is invalid for the time specified, an error will arise. Due to this invalid lever
position, the value of internal_diagnosis_reaction_type will be between 1 and 4.
CODE: P1999
Clutch fault
Vehicle started in high gear.
Description
Driver has been barred from starting vehicle in certain gear(s).
State
If start in high gear has been detected, the fault has been established. This situation arises when the
low gears cannot be used.
Transmission 03-97
CODE: P0711
Fault description
Values transmitted by temperature sensor outside of expected range.
Possible causes
• Connector loose
• Temperature sensor cabling damaged
• Temperature sensor damaged
• TCU damaged
Diagnostic interval
100 ms
System response(s)
• Temperature at set value
• Leads to no temperature correction with shift force, possibly with loud sounds during gear shifts
Action/troubleshooting
• Check connectors
Check temperature sensor cabling and replace it if necessary.
Check temperature sensor resistor and replace it if necessary.
• Replace TCU
CODE: P0716
Fault description
Values transmitted by speed sensor outside of expected range.
Possible causes
• Speed sensor connector(s) loose
• Speed sensor damaged or installed incorrectly
• Short circuit, or sensor line disconnected
• TCU damaged
Diagnostic interval
10 ms
System response(s)
• Does not change current driving behavior
• Input shaft speed replaced by engine speed or vehicle speed
Error simulation
Disconnect sensor and drive in first gear.
• Check connectors
• Check sensor cabling
• Replace sensor
• Replace TCU if no problems have been found with the above
03-98 Transmission
CODE: P1100
Fault description
Value from transmission incremental encoder 1 outside of expected range.
Possible causes
• TCU or transmission replaced, transmission unable to undergo self-learning
• Crack or break in double helical gear wheel (break/crack located between gear shift motor and shift
drum)
Diagnostic interval
5 ms
System response(s)
• First, third, fifth and sixth gears cannot be used
• N, R, second and fourth gears can be used
• Current gear retained when driver tries to engage first, third, fifth or sixth gears
• Transmission conducts self-learning at next cycle
Fault tree analysis.
CODE: P1101
Fault description
Upper reference value error from transmission incremental encoder 1.
Possible causes
• Shift drum end-stop position cracked or broken
• Incremental encoder No. 1 value invalid
Diagnostic interval
10 ms
System response(s)
• First, third and fifth gears cannot be used
• Only sixth gear can be used
Transmission 03-99
CODE: P1102
Fault description
Lower reference value error from transmission incremental encoder 1.
Possible causes
Diagnostic interval
10 ms
System response(s)
• Third, fifth and sixth gears cannot be used
• Only first gear can be used
CODE: P1103
Fault description
Signal from transmission incremental encoder 1 outside of expected range.
Possible causes
• Short circuit, or open transmission incremental encoder 1 circuit wiring
• Transmission motor circuiting damaged
• TCU damaged
Diagnostic interval
10 ms
System response(s)
• First, third, fifth and sixth gears cannot be used
• N, R, second and fourth gears can be used
• Current gear retained when driver tries to engage first, third, fifth or sixth gears
03-100 Transmission
CODE: P1104
Fault description
Transmission incremental encoder 1 stopped unexpectedly.
Possible causes
• Open transmission motor circuit
• Transmission motor damaged
• TCU damaged
• Transmission incremental encoder 1 damaged
Diagnostic interval
10 ms
• First, third, fifth and sixth gears cannot be used, N, R, second and fourth gears can be used. Cur-
rent gear retained when first, third, fifth or sixth gears selected.
CODE: P1105
Fault description
Transmission incremental encoder 1 moved unexpectedly.
Possible causes
• Oil leakage on motor
• Motor short-circuited
• TCU damaged
Diagnostic interval
10 ms
System response(s)
• Clutch opens suddenly
• AMT relay turned off
• Vehicle comes to stop slowly
Transmission 03-101
CODE: P1110
Fault description
Possible causes
• TCU or transmission replaced, transmission unable to undergo self-learning
• Crack or break in double helical gear wheel (break/crack located between gear shift motor and shift
drum)
Diagnostic interval
5 ms
System response(s)
• R, second and fourth gears cannot be used
• N, first, third, fifth and sixth gears can be used
• Transmission stuck at R, second or fourth gear if it has been selected
CODE: P1111
Fault description
Upper reference value error from transmission incremental encoder 2.
Possible causes
Diagnostic interval
10 ms
System response(s)
• R and second gear cannot be engaged
• The fourth gear can be used
03-102 Transmission
CODE: P1112
Fault description
Lower reference value error from transmission incremental encoder 2.
Possible causes
Diagnostic interval
10 ms
System response(s)
• Second and fourth gear cannot be engaged
• R gear can be used
CODE: P1113
Fault description
Possible causes
• Short circuit, or open transmission incremental encoder 2 circuit wiring
• Transmission motor circuiting damaged
• TCU damaged
Diagnostic interval
10 ms
System response(s)
Transmission 03-103
CODE: P1114
Fault description
Transmission incremental encoder 2 stopped unexpectedly.
Possible causes
• Open transmission motor circuit
• Transmission motor damaged
• TCU damaged
• Transmission incremental encoder 2 damaged
Diagnostic interval
10 ms
System response(s)
CODE: P1115
Fault description
Transmission incremental encoder 2 moved unexpectedly.
Possible causes
• Oil leakage on motor
• Motor short-circuited
• TCU damaged
Diagnostic interval
10 ms
System response(s)
• Clutch opens suddenly
• AMT relay turned off
• Vehicle comes to stop slowly
03-104 Transmission
FAULT TREE ANALYSIS PROCESS

Fault trees for gear shift motor, incremental encoder, wiring and mechanical components.
Battery Abnormal Replace the

voltage power supply
Normal
Relay error Yes

code P1301 Relay error tree
No
Perform routine
Normal No Diagnostic No learning service
gearbox trouble code and function tests.
system P1601
Yes Abnormal
Additional The gear wheel

locking system is Perform a Perform
shifting test Yes Yes
damaged; change routine-service routine
the gearbox Actuator test reference
drives
Abnormal
Abnormal
Remove the
damaged The machinery
actuator is abnormal;
connection and replace the
plug in the gearbox
spare actuator
The wiring is
Perform a Yes normal;
routine-service replace the
actuator test actuator
Replace
Abnormal the wire
or TCU
Transmission 03-105
SELF-LEARNING
Transmission self-learning is conducted along the procedures and sequence outlined below:
Time needed for

Steps Code Function
completion
1 $04 Clutch EEPROM initialization (corresponding value) < 1500 ms
2 $03 Clutch EEPROM initialization (clutch protection data) < 1500 ms
3 $0A Clutch EEPROM initialization (system initialization value) < 1500 ms
4 $19 Transmission EEPROM < 1500 ms
5 $1A Transmission self-learning < 10 s
6 $01 Clutch engagement self-learning < 3 s
7 $02 Clutch biting point self-learning < 12 s
8 — TCU restart (KL15 off) UAES
03-106 Transmission
TRANSMISSION SELF-LEARNING
The transmission undergoes self-learning under the following circumstances:
After the vehicle has been assembled, the transmission must seek its working reference values and
conduct self-learning; there is no dashboard indication during the self-learning process, which will take
10 s. When successfully completed, "N" gear will be indicated on the dashboard.
After the TCU has been dismantled and re-assembled, the transmission must seek its working refer-
ence values and conduct self-learning; at this time, the number "0" will appear on the dashboard dur-
ing the self-learning process, which will take 10 s. When successfully completed, "N" gear will be indi-
cated on the dashboard.
In the aforementioned two situations, the vehicle must be stationary and the engine must not be run-
ning.
With transmission self-learning, the TCU control software will automatically compensate when there is
wear to synchronizer rings and the shift drive mechanism.
Transmission 03-107
CLUTCH SELF-LEARNING
CODE: $01
Function
Clutch engagement self-learning.
Description
Clutch engagement self-learning, and data storage in EEPROM.
Conditions
The engine is not running.
The vehicle is stationary.
Power connected.
To be used
Offline: When establishing vehicle initialization settings.
Servicing: After clutch actuator has been installed.
After the TCU has been replaced.
CODE: $02
Function:
Clutch biting point self-learning.
Description:
Clutch biting point self-learning, and data storage in EEPROM.
Conditions
The engine is running.
The transmission is in N gear.
Power connected.
To be used
Servicing: After clutch actuator has been installed.
After the TCU has been replaced.
After clutch or clutch components have been replaced.
CODE: $03
Function
Clutch EEPROM initialization (clutch protection data).
Description
Initialization includes the corresponding clutch protection EEPROM data range.
Conditions
Power connected
To be used
Servicing: EOL after TCU replacement.
03-108 Transmission
CODE: $04
Function
Clutch EEPROM initialization (corresponding value).
Description
Initialization includes the corresponding clutch EEPROM value range.
Conditions
Power connected
To be used
Servicing: EOL after TCU replacement.
CODE: $0A
Function
Clutch EEPROM initialization (system initialization value).
Description
Initialization includes the corresponding clutch system EEPROM value range.
Conditions
The engine is not running.
Power connected.
To be used
Servicing: after the TCU has been replaced.
Transmission 03-109

PRECAUTIONS
• When changing out transmission lubricant, you should work to prevent the oil from spill-
ing onto other vehicle parts. If oil has been spilled onto other parts, wipe the affected
parts clean after completing the oil change. Pay special attention to parts made out of or-
ganic material such as rubber.
• After dismantling the transmission and the clutch, wipe clean the transmission input
shaft spline and lubricate using ESD-M1C220-A(GL261) lithium-based grease for high
temperatures.
03-110 Transmission
Disassembly
1. Remove motor bracket screws
2. Remove shift motor assembly, air filter bracket

Attention:
• Mark motor initial position and shift hub as-
sembly installation position.

Transmission 03-111
4. Remove clutch housing assembly
5. Remove differential assembly
6. Remove magnet
7. Remove flanged bolt to separate gear wheel lock as-

sembly from the transmission housing groove
03-112 Transmission
8. Remove transmission sensor
9. Remove reverse idling shaft flanged bolt
10. Remove reverse idling shaft
11. Remove input shaft seal cover

Attention:
• Do not reuse seal covers.
Transmission 03-113
12. Remove input shaft guide cover

Attention:
• Do not reuse input shaft guide covers.
13. Remove output shaft seal cover

Attention:
• Do not reuse seal covers.
14. Remove input shaft snap ring using the snap ring
pliers
Attention:
• Do not reuse snap rings.
15. Remove output shaft snap ring using the snap ring
pliers
Attention:
03-114 Transmission
16. Remove input and output shaft snap rings using the
snap ring pliers
Attention:
17. Remove the input shaft assembly, output shaft as-

sembly, various fork components and shift drum as-
sembly by using the hammer on the dedicated tool
to tap them out.
18. Remove transmission housing assembly
19. Remove shift drum assembly

Transmission 03-115
20. Remove shift drum assemblies 1 and 2 and the gear

wheel lock assembly
21. Remove shaft
22. Remove the fixing bracket, reverse gear idling

wheel assembly and various shift fork assemblies
23. Separate input shaft assembly and output shaft as-

sembly
03-116 Transmission
24. Remove side retaining ring
25. Remove input shaft sixth gear gear wheel compo-

nents
26. Remove synchronizer ring
27. Remove needle roller bearing with lining

Transmission 03-117
28. Press out the fifth/sixth gear synchronizer assembly
29. Remove synchronizer ring, input shaft fifth gear

gear wheel components and needle roller bearing
30. Press out input shaft fourth gear gear wheel
31. Remove input shaft fourth gear gear wheel

03-118 Transmission
32. Press out input shaft third gear gear wheel
33. Press out output shaft sixth gear gear wheel
34. Press out output shaft fifth gear gear wheel
35. Remove output shaft fourth gear gear wheel compo-

nents, synchronizer ring and needle roller bearing
with lining
Transmission 03-119
36. Press out the second/fourth gear synchronizer as-

sembly
37. Remove synchronizer ring assembly and output

shaft second gear wheel components
38. Remove needle roller bearing
39. Remove safety ring

03-120 Transmission
40. Remove half-ring
41. Remove output shaft third gear gear wheel compo-

nents and synchronizer ring assembly
42. Remove needle roller bearing
43. Remove adjusting snap ring using the snap ring pli-
ers
Attention:
Transmission 03-121
44. Press out the first/third gear synchronizer assem-

bly using the press
45. Remove synchronizer ring assembly and output

shaft first gear gear wheel
46. Output shaft

03-122 Transmission
48. Remove elastic cylindrical pin
49. Remove planetary gear shaft
50. Remove axle shaft gear and planetary gear
51. Remove differential ball-shaped liner

Transmission 03-123
Assembly
1. Place the input shaft third gear gear wheel and in-
put shaft into the base of the respective tool and
position well; then start up the press to push the
third gear gear wheel into place
2. Press the input shaft fourth gear gear wheel into

the input shaft
3. Insert the needle roller bearing and input shaft fifth

gear gear wheel components into the input shaft;
apply a small amount of gear oil onto the needle
roller bearing and various working surfaces of the
fifth gear assembly prior to assembly
Fifth gear synchronizer ring reserve:
1.30 mm±0.29 mm
03-124 Transmission
4. Clamp the fifth/sixth gear synchronizer assembly

and a synchronizer ring (copper ring) together us-
ing the synchronizer clamping device and press
into position at the same time
5. Insert synchronizer ring
6. Press needle roller bearing with lining into position

Needle roller bearing with lining installation
force: 2 kN-20 kN
7. Insert the input shaft sixth gear gear wheel com-

ponents and side retaining ring into the input shaft
assembly; apply a small amount of gear oil onto the
needle roller bearing and various working surfaces
of the sixth gear assembly prior to assembly
Sixth gear synchronizer ring reserve:
1.275 mm±0.325 mm
Transmission 03-125
8. Check that the fifth and sixth gears are turning free-
ly and then place the input shaft assembly into the
input shaft tray
9. Place the output shaft on the base of the tool and

position well; insert first gear needle roller bearing
into output shaft, with a small amount of gear oil
applied on the first gear needle roller bearing
10. Insert output shaft first gear gear wheel into the
output shaft; apply a small amount of gear oil prior
to inserting the first gear gear wheel
11. Clamp the first/third gear synchronizer assembly

and two synchronizer ring assemblies (steel) to-
gether using the synchronizer clamping device and
press into position at the same time
First gear synchronizer ring reserve:
1.30 mm±0.28 mm
First/third gear synchronizer assembly force:
5 kN-40 kN
03-126 Transmission
12. Select the appropriate adjusting snap rings. Install

using a pair of snap ring pliers and insert the needle
roller bearing and output shaft third gear gear wheel
components into the output shaft. At the same time,
install two half-rings and the safety ring. Check that
the snap ring is in its slot. Apply a small smount
of gear oil on the needle roller bearing and various
working surfaces of the third gear gear wheel com-
ponents prior to installation
Third gear synchronizer ring reserve:
1.275 mm±0.325 mm
13. Insert the needle roller bearing and output shaft

second gear gear wheel components into the out-
put shaft; apply a small amount of gear oil onto the
needle roller bearing and various working surfaces
of the second gear assembly prior to assembly
14. Clamp the second/fourth gear synchronizer assem-

bly and two synchronizer rings together using the
synchronizer clamping device and press into posi-
tion at the same time
Second gear synchronizer ring reserve:
1.30 mm±0.29 mm
Second/fourth gear synchronizer assembly
15. Press the needle roller bearing with lining into

place; at the same time, insert fourth gear gear
wheel components; apply a small amount of gear oil
onto the needle roller bearing and various working
surfaces of the second gear assembly prior to as-
sembly
Fourth gear synchronizer ring reserve:
1.30 mm±0.29 mm
Needle roller bearing with lining installation
Transmission 03-127
16. Press output shaft fifth gear gear wheel in position

Output shaft fifth gear gear wheel installation
17. Press output shaft sixth gear gear wheel in position

Output shaft sixth gear gear wheel installation
18. Place the output shaft assembly into the transmis-

sion tray, secure and join with input shaft assembly
19. Place shift drum into the corresponding base of the

assembly bench and position well; insert shift drum
gear wheel into corresponding shift drum, tighten
three countersunk screws at the same time
Tightening torque: (10±10) N•m
03-128 Transmission
20. Insert 1 mm-thick gasket into shaft (long end); at the

same time, insert shift drum 2 assembly into shaft,
and insert shift drum 1 assembly and shift drum 2
assembly into the corresponding positions on the
gasket selection machine for positioning; start the
machine to select the gasket the meets require-
ments and enplace shift drum 1 assembly at the
same time
"S" gasket selection requirements:
W1 +W2 +"S"=147.57-0.120
21. Place the shift drum assembly on the shift drum as-
sembly tray
22. Place the reverse gear fork into the correspond-

ing base on the assembly bench, insert diamond-
shaped slider into fork, tighten fork set screw at the
same time; tap guide sleeve and guide positioning
sleeve into the two ends of the fork
23. Place the fifth/sixth gear fork into the correspond-

Transmission 03-129
24. Place the first/third gear fork into the correspond-

25. Place the second/fourth gear fork into the cor-

responding base on the assembly bench, insert
diamond-shaped slider into fork, tighten fork set
screw at the same time; tap guide sleeve and guide
positioning sleeve into the two ends of the fork
26. Place the shift fork assembly onto the dedicated

tray and join with the shift drum assembly and in-
put/output shaft assemblies; secure on dedicated
tool 452ASG and install gear wheel lock assembly
into place
27. Position the two ball bearings, cone bearing outer

ring, and differential oil seal in the respective press
positions, place transmission housing into press
base and secure in place; start up the press to push
the aforementioned parts into place, insert two snap
rings into their respective slots using a pair of snap
ring pliers, install temperature sensor and oil fill/
drain screw plug at same time
03-130 Transmission
28. Place the transmission housing component on the

assembly bench in position and secure; then, in-
stall the reverse idling wheel shaft, fixing support,
flanged bolts and oil deflector into position
29. Place the transmission housing onto the assembly

bench and secure, tighten the two cradle bolts into
position
30. Place the transmission housing assembly onto the

shaft assembly tray and position; start the press to
push the two transmission assembly ball bearings
into the input and output shaft assemblies
31. Select the appropriate snap rings for input and out-
put shaft assembly rear snap ring positions using
the dedicated feeler gauge; at the same time, install
snap ring into position using tool or snap ring pliers
Transmission 03-131
32. Tighten screws for the gear wheel lock assembly on

the shift drum assembly
33. Place the input shaft oil deflecting cover into the
input shaft; at the same time, insert two seal covers
into the corresponding apertures on the housing;
use the press to push the two seal covers into posi-
tion one at a time
Max. seal cover axial compressive loading
speed: 100 mm/min
Max. pressure on seal cover: 5 kN
34. First, insert ball-shaped liner into housing and

press flush against inside cavity
35. Then, insert the two planetary gears and the plan-
etary gear shaft together
03-132 Transmission
36. Then, insert the two axle shaft gears into the differ-
ential housing
37. Install elastic cylindrical pin
38. Place cone bearing inner rings on the top and bot-
tom of the differential housing; use press to push
both bearings into position at the same time
39. Install main reducer driven gear wheel and cone

bearing, and tighten 8 flanged bolts
Tightening torque: 80.0 N•m
Transmission 03-133
40. After tightening, place the differential housing as-

sembly onto its position inside the transmission
housing assembly; then, place the transmission
housing assembly and shift drive module assembly
onto the dedicated tray as shown in the illustra-
tion; check the joint surfaces of the transmission
housing assembly and shift drive module assembly
for oil stains, burrs, or signs of knocks, then apply
sealant on joint surfaces
41. Install the shift drive module assembly into posi-

tion; at the same time, insert the motor cabling
bracket and tighten 4 motor bracket screws using
your hands before tightening them into position
with an electric wrench
Tightening torque: (22.5±2.5) N•m
42. Place the differential cone bearing outer ring and

the two cylindrical pins for the drawn cup roller
bearings (input shaft front bearing and output shaft
front bearing) on the corresponding press position;
place clutch housing onto corresponding press
position; at the same time, insert the output shaft
guide cover, then start the press to push all afore-
mentioned parts into position
43. Place the differential oil seal, input shaft oil seal and
ball-shaped support onto the corresponding press
positions; place clutch housing component onto
corresponding press position; start press to push
all aforementioned parts into position
03-134 Transmission
44. Place the bearing baffle in the corresponding posi-

tion, and tighten 2 flanged bolts at the same time
45. Place the clutch housing assembly into the corre-

sponding engraving machine and secure; start the
machine to engrave model number and serial num-
ber; check that the numbers engraved are correct
and can be read easily
46. Place the input shaft oil seal inside the input shaft
spline and check the external appearance of the
housing at the same time; close the box and secure
18 flanged bolts, one waveform bracket, and one air
filter bracket on the clutch housing using the corre-
sponding bolt holes; tighten the flanged bolts using
a pneumatic wrench in symmetrical sequence
47. Install onto the clutch housing bracket and tighten

flanged bolts at the same time
Transmission 03-135
48. Insert the transmission sensor into the transmis-

sion housing speed sensor aperture, tighten sensor
screw at the same time
49. Install release bearing block into clutch housing,

tighten 2 release bearing block bolts at the same
time
50. Place the release fork components and release

bearing components on the release shaft block
together, push release fork components into ball-
shaped support at the same time
51. After the tray has been raised and secured, two dif-
ferential oil seals (top and bottom) and one vent
plug will be applied automatically to the transmis-
sion assembly, with an air tightness test conducted
on the transmission assembly
Remark:
• Air of pressure 40 kPa-50 kPa will be channeled
into the assembly for 9 seconds, with pressure
kept for 30 seconds and measured for 5 seconds.
Pressure decrease value has been set at 10 Pa.
03-136 Transmission
52. Top up assembly oil of volume (1.7±0.01) L and tem-

perature (30-50) ºC
53. Test the assembly on the offline test bench; move

the transmission assembly from the diagnostic line
tray to the test bench, connect three connectors to
the corresponding shift drive module and transmis-
sion sensor ports; press the clamp button to secure
the transmission; the test bench then automatically
proceeds to initialize the transmission and test the
R gear as well as gears 1, 2, 3, 4, 5 and 6 in turn
54. Drain assembly oil; then, install the vent plug cap,
two motor six-pin protective sleeves, and transmis-
sion sensor two-pin protective sleeve in the cor-
responding positions; affix barcode sticker, install
input shaft protective cover and differential oil seal
cover at the same time
Transmission 03-137
CLUTCH ACTUATOR
Removal
Attention:
• Never open up the clutch actuator.
• Never run the clutch actuator on zero load.
• Never let the tappet pop up quickly. Always
make sure that the tappet is carrying some
load and pops up gradually.
• Never lift the clutch actuator tappet.
1. Shut down ignition and wait for TCU to shut down
(approx. 1 minute)
Remark:
• Make sure that the clutch is fully closed (at this time
the load on the clutch actuator tappet is lower).
• If the clutch does not return to the closed position,
please perform the following steps:
(a) Step on brake pedal.
(b) Turn on the ignition.
(c) Wait for at least 10 seconds.
(d) Turn off the ignition.
(e)  Wait for TCU to shut down (approximately 1 minute).
2. Disconnect the clutch actuator connector
3. Unscrew three bolts slowly in specified sequence
and remove actuator from transmission
Warning:
• Please work carefully as the actuator may
move at this time. Please do not place your
hands too close to the actuator, particularly at
its rear.
Specified torque: (10±1) N•m
03-138 Transmission
Installation
Remark:
• If there is a tappet securing device for logistics
reasons, remove the device slowly and make
sure that the tappet pops up slowly.
• You should support the bottom of the clutch
actuator using both hands.
• Apply sealant on the three clutch actuator
bolts, then screw into the elliptical holes on
the clutch actuator housing, tighten bolts until
they are one screw thread away from the ac-
tuator housing.
• Slide the clutch actuator slowly until the front
of the actuator tappet comes into normal con-
tact with the release fork.
• Slide the clutch actuator in the direction of fork
for another 2-4 blocks from the contact point:
the various elliptical bolt holes on the clutch
actuator come with prominent scales based on
bolt washers or flange faces; beginning with
the contact point, move the clutch actuator
another 2-4 blocks (with one block measuring
2 mm) to press down on the preload spring in-
side the clutch actuator.
Transmission 03-139
TRANSMISSION CONTROLLER ASSEMBLY

Removal
Attention:
• You must turn off the engine before disman-
tling any transmission components to prevent
bodily injury when the vehicle lurches forward.
1. Disconnect negative terminal of the battery
2. Remove the gear selector lever handle cover ring
washer and handball; then, pull out the gear selec-
tor lever along the shaft axis
Remark:
• Place the handball in a clean and dry spot.
3. Open up the four-sided clip and lift the shield in the

vertical direction
Remark:
• Place the shield in a clean and dry spot.

5. Remove wiring connector that joins the shift mecha-
nism and vehicle body
Attention:
• Removal of the shift mechanism sensor and
sensor cover is strictly prohibited.
03-140 Transmission
6. Remove the four bolts that join the vehicle body and
the mount using the dedicated tool
Remark:
• Place the shift mechanism in a clean and dry spot.
Installation
Memorandum
Memorandum
Transmission System 04-1
TRANSMISSION SYSTEM
CLUTCH
Schematics.....................................................................04-2
Clutch Pedal Assembly................................................04-2
Clutch Pipeline.............................................................04-3
Clutch Assembly..........................................................04-4
Torque Specifications....................................................04-5
Precautions..................................................................04-6
Fault Symptom Checklist.............................................04-6
Checks and Adjustments.............................................04-7
Clutch Pedal Assembly................................................04-9
Clutch Master Cylinder.................................................04-11
Clutch Release Pump Sub-Assembly..........................04-13
Clutch Assembly..........................................................04-14
Clutch Switch Assembly...............................................04-18
Discharging Air From Clutch Hydraulic system............04-19
FRONT AXLE DRIVE SHAFT
Schematics.....................................................................04-21
MT Model.....................................................................04-21
6AMT Model.................................................................04-22
Torque Specifications....................................................04-23
Front Axle Transmission Shaft.....................................04-24
04-2 Transmission System
CLUTCH
SCHEMATICS
CLUTCH PEDAL ASSEMBLY
23±3
x2
23±5
6 4
4
8 4
1. Bracket and Pedal Arm Component 5. Foot Pedal Pad

2. Return Spring 6. Clutch Pin Shaft Collar
3. Clutch Switch Assembly 7. Cotter Pin
4. Limiter Cushion 8. Pin Shaft
CLUTCH PIPELINE
11.8±2.4
x2 7 23
5
12 46±5
16±2
9 3
33±3
8
10
16±2
5
11 3
4
23
16±2
16±2
1. Clutch Oil Inlet Pipe Assembly 7. Clutch Hose Assembly

2. Clutch Master Cylinder 8. Clutch Pipe Bracket No. 2
3. Single-Hole Pipe Clamp No. 2 9. Clutch Pipe Bracket No. 4 Assembly
4. Clutch Master Cylinder Pipe Assembly 10. Clutch Pipe Bracket No. 3
5. Retaining Spring 11. Clutch Slave Cylinder Pipe Assembly
6. Clutch Pipe Bracket No. 1 12. Clutch Release Pump Sub-Assembly
CLUTCH ASSEMBLY
1 19
×6
2
3
36.8±7.4
5

Release hub grease
Transmission spline grease
1. Clutch Driven Plate Assembly 5. Dust Boot

2. Release Bearing Sub-assembly 6. Release Fork Circlip
3. Clutch Release Bearing Circlip 7. Clutch Slave Cylinder Pipe Assembly
4. Release Fork Support Nail 8. Clutch Cover Assembly
TORQUE SPECIFICATIONS
Fasteners Quantity Tightening torque (N•m)
Clutch pedal and clutch master cylinder 2 23±5
Clutch pedal and dashboard reinforcing beam 1 23±3
Clutch pipe bracket No. 1 and vehicle body 1 23
Clutch pipe bracket No. 2 and transmission 1 46±5
Clutch pipe brackets No. 3 and 4 1 23
Clutch pipe brackets No. 3 and 4 1 33±3

PRECAUTIONS
1. When removing or replacing the transmission or clutch, you must clean the transmission shaft
1 spline and clutch driven plate spline (be careful not to damage the splines) using a cleaning
agent.
2. After cleaning, you must apply a layer of grease on the transmission shaft 1 spline (lubricant
type: MI-SETRAL-43N; application position: on the transmission shaft 1 spline, 4 mm-8 mm
from the separator shaft bearing to the spline end; application amount: 0.2 g-0.3 g).
3. Apply with a small brush on the transmission shaft 1 spline from the inside to the outer edge.
Make sure that the entire spline shaft is lubricated evenly (just a thin layer of grease is needed,
and avoid applying too much grease on the release bearing so that excess grease will not
splash on the clutch driven plate during operations).
FAULT SYMPTOM CHECKLIST
Symptoms Possible causes
1. Engine suspension (loose)
2. Clutch driven plate assembly (excessive runout)
3. Clutch driven plate assembly (oil-stained)
Clutch shake 4. Clutch driven plate assembly (wear and tear)
5. Clutch driven plate torsion damper (damaged)
6. Clutch driven plate assembly (worn out)
7. Diaphragm spring (top end not aligned)
1. Clutch pipeline (air ingress into the pipeline)
Clutch pedal feels slack 2. Clutch master cylinder cup (damaged)
3. Clutch slave cylinder cup (damaged)
1. Clutch release bearing sub-assembly (worn, dirty or damaged)
2. Clutch driven plate torsion damper (damaged)
Abnormal clutch noises 3. Pressure plate
4. Clutch pedal
5. Fork
1. Clutch pedal (free travel needs adjustment)
3. Clutch driven plate assembly (wear and tear)
Clutch slip
4. Diaphragm spring (worn)
5. Pressure plate (deformed)
6. Flywheel sub-assembly (deformed)
1. Clutch pedal (free travel needs adjustment)
2. Clutch pipeline (air ingress into the pipeline)
3. Clutch master cylinder cup (damaged)
4. Clutch slave cylinder cup (damaged)
5. Clutch driven plate assembly (not installed correctly)
Clutch not fully disengaged
6. Clutch driven plate assembly (excessive runout)
7. Clutch driven plate assembly (cracks)
8. Clutch driven plate assembly (filthy or burnout)
10. Clutch driven plate assembly (spline not lubricated)
CHECKS AND ADJUSTMENTS

Clutch switch
1. Check and adjust clutch pedal assembly
(a) Turn the carpet over.
(b) Check clutch pedal assembly to make sure that clutch
pedal is at the right height.
Push rod travel
Clutch pedal height as measured from front
wall: (126-132) mm
(c) Adjust clutch pedal height.
Push rod travel Loosen clutch switch nut until the correct clutch pedal
and free travel Clutch height has been achieved. Tighten locking nut.
adjustment points Pedal height Tightening torque: 12 N•m
(d) Check clutch pedal free travel and push rod travel and
make sure that they are correct.
Step on clutch pedal until you can feel the resistance of
the clutch.
Clutch pedal free travel: (3-10) mm
Step gently on the clutch pedal until you begin to meet
increasing resistance.
Clutch pedal push rod travel at top end: (1.0-
5.0) mm
(e) Adjust clutch pedal free travel and push rod travel to
correct levels.
• Loosen locking nut and rotate push rod until you
achieve the correct free travel and travel distance.
• Tighten locking nut.
• After adjusting clutch pedal free travel, check
clutch pedal height.
Clutch pedal free travel
(f) Check clutch separation point.

• Pull up the parking brake handle and lay wheel
stopper in place.
At least 25 mm • Start the engine and allow it to idle.
Separation point • Without stepping on the clutch pedal, shift the
gear selector lever to reverse gear until the gear
engages.
Clutch pedal • Step on the clutch pedal slowly and measure the
final position travel distance between the time the gear noises
following travel
stop (separation point) to the point clutch pedal
travel terminates.
Standard distance: At least 25 mm
(From clutch pedal final position to separation
point)
If the distance measured is not in line with specifica-

tions, please perform the following:
• Check clutch pedal height.
• Check push rod stroke and clutch pedal free travel.
• Discharge air from clutch pipes.
• Check clutch cover assembly and disc assembly.
• Check clutch pedal free travel.
Clutch pedal free travel distance: 120.2 mm

CLUTCH PEDAL ASSEMBLY
Removal
2. Remove steering column lower guard assembly
3. Disconnect clutch switch connector
4. Remove clutch switch assembly
(a) Loosen locking nut, remove clutch switch assembly.
5. Remove clutch pedal return spring

6. Remove cotter pin and pin shaft
7. Remove clutch pedal assembly

(a) Remove 2 nuts, 1 bolt, and the clutch pedal assembly.
Installation
1. Install clutch pedal assembly
Install clutch pedal assembly onto the vehicle using 2
nuts and 1 bolt.
Tightening torque:
Nut: (23±5) N•m
Bolt: (23±3) N•m
2. Install pin shaft and cotter pin

(a) Apply some universal grease on the contact surface be-
tween the pin shaft and the clutch pin set.
(b) Connect the U-clip (push rod) to the clutch pedal as-
sembly using the pin shaft.
Note:
• Install pin shaft from the left side of the vehicle.
(c) Install cotter pin on pin shaft.
Universal grease
3. Install clutch pedal return spring

4. Install clutch switch assembly
(a) Install clutch switch assembly, making sure that its end
is in contact with the clutch pedal limiter cushion.
(a) Tighten locking nut to secure clutch switch assembly.
5. Check and adjust clutch pedal assembly and clutch

switch assembly
6. Connect clutch switch connector
7. Install steering column lower guard plate assembly
8. Connect negative terminal of the battery
CLUTCH MASTER CYLINDER

Removal
1. Remove the vacuum booster with brake pump as-
sembly
3. Remove clutch pedal return spring
4. Remove cotter pin and pin shaft
5. Drain brake fluid

6. Disconnect clutch oil inlet pipe assembly
Loosen clamp and disconnect clutch oil inlet pipe as-
sembly from clutch master cylinder.
7. Disconnect clutch master cylinder pipe assembly

Note:
• Catch the brake fluid drained with a container.
8. Remove clutch master cylinder
(a) Remove 2 nuts and clutch master cylinder.
Installation
1. Install clutch master cylinder assembly
(a) Secure clutch master cylinder using 2 nuts.
2. Connect clutch master cylinder pipe assembly to
clutch master cylinder
3. Install clutch oil inlet pipe assembly

Install clutch oil inlet pipe assembly onto the clutch mas-
ter cylinder with the aid of the clamp.
Attention:
• Make sure not to twist the clutch oil intake pipe
during installation.
4. Install pin shaft and cotter pin

(a) Apply some universal grease on the contact surface be-
tween the pin shaft and the clutch pin set.
(b) Connect the U-clip (push rod) to the clutch pedal as-
sembly using the pin shaft.
Note:
• Install pin shaft from the left side of the vehicle.
(c) Install cotter pin on pin shaft.
Universal grease
5. Install clutch pedal return spring

6. Install steering column lower guard assembly
7. Install vacuum booster with brake pump assembly
8. Discharge air from the clutch system
Top up brake reservoir with brake fluid and discharge air
from the clutch system.
9. Check brake reservoir fluid levels
10. Check and adjust clutch pedal assembly
CLUTCH RELEASE PUMP SUB-ASSEMBLY

Removal
1. Disconnect clutch slave cylinder pipe assembly
from clutch slave cylinder pipe assembly
Note:
• Catch the brake fluid drained with a container.
2. Remove clutch release pump sub-assembly

(a) Remove 2 bolts and clutch release pump sub-assembly.
Installation
Note:
• Top up brake reservoir with brake fluid and dis-
charge air from the clutch system.
• Check for signs of leakage from the clutch system.
CLUTCH ASSEMBLY
Removal
1. Remove transmission assembly
2. Remove release fork sub-assembly
Remove release fork sub-assembly (including release
bearing) from transmission assembly.
3. Remove release fork dust boot

4. Remove release bearing sub-assembly
(a) Remove release bearing sub-assembly from clutch re-
lease fork.
5. Remove clutch release bearing circlip
6. Remove release fork support nail
7. Remove clutch cover assembly
(a) Make installation markings on the clutch cover assem-
bly and flywheel sub-assembly.
(b) Each time, unscrew each fixing bolt one round until
spring tension is completely released.
(c) Remove fixing bolts and then remove clutch cover as-
sembly.
Attention:
• Do not allow the clutch driven plate assembly
Assembly marking
to fall.
8. Remove clutch driven plate assembly
9. Inspect clutch driven plate assembly
(a) Measure rivet depth using a pair of vernier calipers.
Min. rivet depth: 0.3 mm
Replace clutch driven plate assembly when necessary.
(b) Install clutch driven plate assembly onto engine assem-
bly.
Attention:
• Make sure to install the clutch driven plate as-
sembly in the correct orientation.
(c) Measure clutch driven plate assembly runout using a

dial indicator.
Max. runout permitted: 0.8 mm
Replace clutch driven plate assembly when necessary.
Side of trans-
mission bridge
10. Check clutch cover assembly

B Measure depth and width of diaphragm spring wear us-
ing a pair of vernier calipers.
A
Max. value:
A (depth): 0.5 mm
B (width): 6.0 mm
Replace clutch cover assembly when necessary.
11. Check flywheel sub-assembly

Check for flywheel sub-assembly runout using a dial in-
dicator.
Max. runout permitted: 0.1 mm
Replace flywheel sub-assembly when necessary.
12. Check clutch release bearing sub-assembly

Rotate release bearing while applying pressure along
the shaft.
Note:
• The bearing is permanently lubricated and does
not require cleaning or further application of lubri-
cating oil.
• When necessary, replace release bearing sub-
assembly.
Installation
1. Install clutch driven plate assembly
(a) Insert SST into the clutch driven plate assembly and
SST then install the entire assembly into the flywheel sub-
assembly.
Attention:
Flywheel
• Make sure to install the clutch driven plate as-
side
sembly in the correct orientation.
2. Install clutch cover assembly

5
SST 1 (Temporarily) (a) Align installation markings on the clutch cover assembly
and flywheel sub-assembly.
3
(b) Tighten 6 bolts beginning from the bolt closest top posi-
tioning pin in the sequence shown in the illustration.
6 Tightening torque: 19 N•m
4 Note:
• Tighten bolts little by little in the sequence shown
2 Assembly marking
in the illustration.
• After ensuring that the driven plate is centered,
move the SST from left to right, and from top to
bottom, gently to tighten bolts.
3. Check and adjust clutch cover assembly
(a) Measure the height difference with the top of the dia-
phragm spring using a dial indicator equipped with a
roller instrument.
Max. deviation: 0.5 mm
(b) Adjust using SST if difference measured is not within

permissible range.
SST
4. Install release fork support nail

5. Install release fork dust boot
6. Install clutch release bearing circlip
7. Install release fork sub-assembly

(a) Apply release hub grease on the contact surfaces be-
tween the release fork and release bearing sub-assem-
bly, as well as between the release fork and release fork
pivot.
(b) Install release bearing sub-assembly onto release fork.
Release hub grease
8. Install release bearing sub-assembly

(a) Apply clutch spline grease on the input shaft spline.
(b) Install bearing onto release fork, then install the entire
assembly onto the transmission assembly.
Attention:
• Following installation, move the release fork
back and forth. Make sure that the clutch re-
lease bearing is able to move freely.
9. Install transmission assembly
CLUTCH SWITCH ASSEMBLY

On-board Inspection
1. Check engine status at start-up
(a) Check and make sure that the engine cannot be started
when the clutch pedal is released.
(b) Check and make sure that the engine can be started
when the clutch pedal is fully depressed.
When necessary, replace clutch switch assembly.
Check
1. Check clutch switch assembly
(a) Check that there is contact between the corresponding
terminals when the switch is in the ON and OFF posi-
tions.
Switch position Conditions

ON (press) Connected
OFF (release) Not connected
7 +1.6
0 mm
Removal
3. Remove clutch switch assembly
(a) Disconnect clutch switch connector.
(b) Loosen locking nut, remove clutch switch assembly.
Installation
1. Install clutch switch assembly
(a) Install clutch switch assembly using nut.
(b) Connect clutch switch connector.
2. Check clutch switch assembly
3. Install steering column lower guard plate assembly
DISCHARGING AIR FROM CLUTCH HY-

DRAULIC SYSTEM
Note:
• Following repair and maintenance of the clutch
hydraulic pressure control system, air may enter
the pipelines; the process of topping up brake fluid
may also introduce air into the hydraulic system.
After the entry of air, the clutch may not disen-
gaged fully due to the shortened main cylinder
push rod travel and pedal work distance.
1. Top-up reservoir with brake fluid
Brake fluid: DOT4 synthetic brake fluid
Attention:
• The brake fluid level inside the reservoir
should be somewhere between the MIN and
MAX marks indicated.
2. Lift the vehicle

Elevate the vehicle to the appropriate height using the
vehicle lift.
3. Discharge air from clutch hydraulic system
(a) Connect the plastic tube to the air bleed screw.
(b) Step on the clutch pedal several times and then loosen
the air bleed screw when depressing the clutch pedal.
(c) Tighten the air bleed screw when the brake fluid stops
flowing out, then release clutch pedal.
(d) Repeat steps (b) and (c) until all air has been dis-
C
charged from the brake fluid.
Note:
• Two persons must work together on the air dis-
charge procedure at any time.
• When performing the air discharge, use a well-
sealed container to prevent the brake fluid from
spilling out;
• During the air discharge procedure, pay attention
to reservoir brake fluid levels and top up when
necessary in a timely fashion.
4. After air has been fully discharged, you would need
to check and adjust clutch pedal free travel again
and top up brake fluid
FRONT AXLE DRIVE SHAFT

LOCATION DIAGRAM
SCHEMATICS
MT MODEL
1. Front Drive Shaft Nut 3. Left Drive Shaft Assembly

2. Right Drive Shaft Assembly
6AMT MODEL
1. Front Drive Shaft Nut 3. Left Drive Shaft Assembly

2. Right Drive Shaft Assembly
Fasteners Quantity Tightening torque (N•m)
Front drive shaft nut 2 225±20

Fault description Possible causes
1. Outside cardan joint (worn out)
Noise (drive shaft)
2. Inside cardan joint (worn out)

FRONT AXLE TRANSMISSION SHAFT
Removal
Note:
• Conduct repair and maintenance on the right side
by repeating the procedure listed for the left.
1. Drain transmission oil
2. Remove front wheel
3. Remove front left drive shaft nut
(a) Pry out the sunken part of the front left drive shaft nut
using SST and hammer.
Attention:
• Loosen nut completely to avoid damage to the
screw thread on the drive shaft.
(b) Apply brake force and remove front left drive shaft nut.
SST
4. Separate front left wheel speed sensor

(a) Remove bolt and clip, separate front left wheel speed
sensor and brake hose from front left damper assembly.
(b) Remove bolt and separate front left wheel speed sensor
from knuckle.
Attention:
• Do not damage the wheel speed sensor.
• Prevent foreign matter from adhering to the
surface of the wheel speed sensor.
5. [MT model]
Remove front left axle drive shaft assembly using
the dedicated tool
Attention:
• Do not damage the oil seals and dust boot.
• Do not drop the drive shaft assembly.
SST
[6AMT model]
Remove front left axle drive shaft assembly using
the dedicated tool
Attention:
6. [MT model]
Remove front right axle drive shaft assembly
Attention:
[6AMT model]
Remove front right axle drive shaft assembly
Attention:
7. Secure front left bridge wheel hub assembly and

front right bridge wheel hub assembly
Attention:
• If the entire weight of the vehicle is placed on
SST the wheel hub bearing, it may be damaged as a
result, for example when the vehicle is moved
when the drive shaft has been removed.
• Therefore, when necessary place the weight of
the vehicle on the wheel hub bearing only after
providing support in the form of the SST.
Installation
1. Check front axle drive shaft assembly
Attention:
• Ensure that the drive shaft is placed in a hori-
zontal position during the check.
(a) Check and make sure that there are no visible gaps on
the outside cardan joint along the radius.
(b) Check and make sure that the inside cardan joint slides
smoothly along the shaft.
(c) Check and make sure that there are no visible gaps on
the inside cardan joint along the radius.
(d) Check for signs of damage in the dust boot.
2. Install front left axle drive shaft assembly
(a) Apply gear oil on the spline of the inside cardan joint
shaft assembly.
(b) Align with shaft spline, then install front left drive shaft
assembly using brass rod rod and hammer.
Attention:
• Install snap ring with the open end facing
downwards.
• Do not damage dust boot and oil seals.
Tips:
• You can determine if the inside cardan joint is in
contact with the small gear shaft based on the
sound and feel from pushing in the joint.
3. Install front right axle drive shaft assembly
Tips:
• Repeat the same procedure with the right side.
Attention:
• Install snap ring with the open end facing
downwards.
• Do not damage dust boot and oil seals.
4. Install front left bridge wheel hub assembly
Install left drive shaft assembly on front left bridge wheel
hub assembly
Attention:
• Do not damage the dust boot of the outside
cardan joint.
• Do not apply excessive pushing force or pres-
sure on the front left bridge assembly.
5. Install front left wheel speed sensor
(a) Install front left wheel speed sensor and brake hose
onto front left wheel damper assembly using bolt and
clip.
(b) Install front left wheel speed sensor onto the steering
knuckle using bolt.
Specified torque: 9.0 N•m
Attention:
• Keep the wheel speed sensor clean.
• Do not twist sensor cabling during sensor in-
stallation.
6. Install front left drive shaft nut

(a) Install a brand new front drive shaft nut.
(b) Tighten the front drive shaft nut with the aid of a punch
and hammer.
7. Install engine left bottom cover

8. Install front wheel
9. Top-up transmission oil
10. Check and adjust transmission oil levels
11. Check and adjust front wheel alignment
12. Check front wheel speed sensor signal
Memorandum
Suspension System 05-1
SUSPENSION SYSTEM
WHEEL ALIGNMENT
Overview.........................................................................05-3
Wheel Alignment..........................................................05-3
Diagnostic Parameters.................................................05-5
Precautions..................................................................05-6
Preliminary Checks......................................................05-6
Front Wheel Alignment.................................................05-7
Rear Wheel Alignment.................................................05-9
FRONT SUSPENSION
Front Suspension.........................................................05-10
Schematics.....................................................................05-11
Front Damper With Helical Spring Assembly...............05-11
Lower Arm Assembly...................................................05-12
Front Tie Rod Assembly...............................................05-13
Subframe Assembly.....................................................05-14
Knuckle, Front Wheel Hub Bearing Assembly.............05-15
On-board Inspection....................................................05-17
Front Damper With Helical Spring Assembly...............05-18
Front Lower Arm Assembly..........................................05-20
Front Tie Rod Assembly...............................................05-24
Subframe Assembly.....................................................05-26
Knuckle, Front Wheel Hub Bearing Assembly.............05-30
REAR SUSPENSION
Rear Suspension.........................................................05-34
Schematics.....................................................................05-35
Rear Damper Assembly...............................................05-35
Rear Helical Spring......................................................05-36
Rear Torsion Beam Assembly......................................05-37
Rear Wheel Hub Assembly..........................................05-38
05-2 Suspension System

On-Board Inspection....................................................05-40
Rear Damper Assembly...............................................05-41
Rear Helical Spring......................................................05-43
Rear Torsion Beam Assembly......................................05-44
Rear Wheel Hub Assembly..........................................05-48
WHEELS AND TIRES
Schematics.....................................................................05-50
Wheels and Tires.........................................................05-50
Diagnosis Flowchart.....................................................05-51
Check...........................................................................05-53
Wheel...........................................................................05-54
TIRE PRESSURE MONITORING SYSTEM
Overview.........................................................................05-56
Tire Pressure Monitoring System.................................05-57
Schematics.....................................................................05-58
Tire Pressure Monitoring Device..................................05-58
Dedicated Tools..............................................................05-60
THA13 Setter...............................................................05-60
Electrical Schematics...................................................05-61
TPMS Display..............................................................05-62
Troubleshooting...........................................................05-63
Tire Pressure Monitoring Device..................................05-64
Tire Pressure Monitoring Device Learning...................05-66
WHEEL ALIGNMENT
OVERVIEW
WHEEL ALIGNMENT
Wheel alignment means that the installation position of every wheel, knuckle, axle and frame are
maintained in the same position relative to each other. The process of wheel alignment includes front
and rear wheel alignment, and together the two are known as four-wheel alignment.
The four front wheel alignment parameters are: kingpin caster, kingpin inclination, front wheel camber
and front wheel toe-in.
The two rear wheel alignment parameters are: rear wheel camber and rear wheel toe-in.
The main purpose of wheel alignment is to maintain drive stability and 'road feel' so as to ensure easy
vehicle operations. Also, the process ensures automatic steering return to reduce tire wear and ulti-
mately ensure drive safety.
SPECIFIED TORQUE
Below is a table of torque specifications that you may find useful.
Tightening Quantity Surface

State Remark
torque (N•m) (units) sealant
Apply screw
Subframe assembly and vehicle body 120±10 2 Grade 10.9
thread glue
Apply screw
Subframe assembly and vehicle body 180 2 Grade 10.9
thread glue
Apply screw
Subframe assembly and vehicle body 120±10 2 Grade 10.9
thread glue
Apply screw
Lower left arm assembly and subframe 200±15 1 Grade 10.9
thread glue
Lower arm ball pin assembly and lower left arm 145±8 1 — Grade 10.9
Lower arm ball pin assembly and lower left arm 145±8 2 — Grade 10
Arm ball and left steering knuckle 80±10 1 — —
Apply screw
Lower right arm assembly and subframe 200±15 1 Grade 10.9
thread glue
Lower arm ball pin assembly and lower right arm 145±8 1 — Grade 10.9
Lower arm ball pin assembly and lower right arm 145±8 2 — Grade 10
Arm ball and right steering knuckle 80±10 1 — —
Front left damper and left steering knuckle 164±8 2 — —
Front left damper and left steering knuckle 164±8 2 — —
Front left damper and upper base plate 40±5 1 — Grade 10
Front left damper and front helical spring upper bracket 145±6 1 — Grade 10
Front right damper and right steering knuckle 164±8 2 — —
Front right damper and right steering knuckle 164±8 2 — —
Front right damper and upper base plate 40±5 1 — Grade 10
Front right damper and front helical spring upper bracket 145±6 1 — Grade 10
Front tie rod and connecting rod assembly 63±5 4 — —
Apply screw
Front tie rod bracket and subframe 63±5 4 —
thread glue
Rear bridge guard bracket and vehicle body 26±3 4 — —
Apply screw
Rear torsion beam assembly and vehicle body 120±10 2 Grade 10.9
thread glue
Apply screw
Rear damper and rear torsion beam 80±10 2 Grade 10.9
thread glue
Rear damper and washer 35±3 2×2 — —
Aluminum
Wheel 110±10 16 —
wheel
Spare tire and vehicle body 23 1 — —

DIAGNOSTIC PARAMETERS
Front suspension
Suspension type
Item Description
Front suspension type MacPherson strut
Helical spring, hydraulic cylinder-type damper, lateral stabilizer bar,
Front suspension assembly
control arm, etc.
Front wheel alignment parameters
Item Range Left/right wheel deviation

Front-wheel camber -0°13′±30′ ≤30′
Front-wheel kingpin inclination angle 10°00′±30′ ≤30′
Front-wheel kingpin caster angle 4°42′±45′ ≤36′
Front-wheel toe-in angle 0°2′±15′ —
Rear suspension
Suspension type
Item Description
Rear suspension type Trailing arm and torsion beam assembly bracket
Helical spring, hydraulic cylinder-type damper, torsion beam weld-
Rear suspension assembly
ment, etc.
Rear wheel alignment parameters
Left/right wheel
Item Range
deviation
Rear-wheel camber -0°41′±30′ ≤30′
Rear-wheel toe-in angle 0°07′±15′ —

PRECAUTIONS
1. Before checking wheel alignment, press down on
the vehicle 3 times to minimize the impact of the
suspension system on alignment readings so as to
prevent erroneous readings.
2. You must check wheel toe-in after adjusting wheel
camber.
3. Adjust alignment for all four wheels in the following
sequence
• Rear wheel camber
• Rear wheel toe-in
• Front-wheel camber
• Front wheel toe-in and steering angle
PRELIMINARY CHECKS
Prior to taking any action that will impact on wheel align-
ment you must conduct the following checks and adjust-
ments to ensure that you get the correct readings:
Check Operation
Check tire pressure levels and extent of tire wear.
Pressurize tire to correct pressure levels. Replace
Check that all four tires are worn down evenly, es-
tire when necessary.
pecially across the same axle.
Check wheel and tire jitter distance. Measure and correct tire jitter distance.
Make sure that the wheel hub bearing is not loose.
Tighten axle nuts to specified torque levels. Replace
Make sure that clearance distance does not exceed
wheel hub bearing when necessary.
specifications.
Make sure that the ball joint and steering tie-rod tip
Tighten ball joint and steering tie rod bolt.
are not loose.
Make sure that the damper is not worn and leaked.
Tighten steering gear bolt.
Make sure that there is no obvious noise.
Check damper for signs of wearr and leaks and for
Replace strut assembly.
obvious noise.
Make sure that control arm and lateral stabilizer bar Tighten connecting bolts. Replace front tie rod sleeve
are not loose or worn. when necessary.
Measure vehicle height, and make adjustments when
Check vehicle height.
necessary.
FRONT WHEEL ALIGNMENT

Adjustments
1. Check tire
2. Measure vehicle height
(a) Press down on each corner of the vehicle 3-4 times.
Check vehicle height when vehicle has stabilized.
Attention:
• Before checking wheel alignment, make sure
that vehicle height is at specified values.
3. Check wheel steering angle
A-B B A
Turn steering wheel to full lock to measure steering
angle.
Front Wheel steering angle:
Inside wheel Outside wheel

steering angle steering angle
A: Inside
B: Outside 35.5°±2.5° 31°±2.5°
If the inside steering angle of the left and right wheels

do not meet specifications, check the length of the left
and right power steering gear tie rods.
4. Check front wheel camber, front-wheel kingpin cast-
er angle and front-wheel kingpin inclination angle
If the front-wheel kingpin caster angle and inclination
Instrument
angles do not meet specified values, first check if sus-
pension parts for signs of damage or wear, then adjust
Aligner caster angle.
5. Adjust camber
Attention:
• After you complete camber adjustments, check
wheel toe-in.
(a) Lift the vehicle.
(b) Remove front wheel.
(c) Remove the 2 nuts at the bottom of the damper.
(d) Clean damper and knuckle installation surfaces.
(e) Install 2 nuts temporarily.

(-) (+) (f) Push or pull the damper along the distance required by
caster adjustment to adjust caster angle.
(g) Tighten nuts.
(h) Install front wheel.

(i) Lower vehicle to ground level, and push down on the
front of the vehicle a few times to stabilize the suspen-
sion.
(j) Check camber.
If caster angle does not meet requirements, you may
use the dedicated adjustment bolt and repeat the above
procedure by replacing one or two bolts mentioned in
step (c).
6. Check toe-in
C A D If the toe-in is not within specified values, adjustment is
Front necessary.
7. Adjust toe-in
Note:
• Adjust camber prior to checking toe-in.
(a) Secure steering wheel so that it is kept vertical.
(b) Move rack dust boot clip aside.
(c) Loosen tie rod joint lock nut.
(d) Turn the left and right gear rack connectors the same
distance to adjust toe-in.
(e) Make sure that the lengths of the left and right gear rack
connectors are the same.
(f) Tighten tie rod joint lock nut.
(g) Place dust boot onto mount and install clip.
Note:
• Be careful not to twist the dust boot.
REAR WHEEL ALIGNMENT

Check
1. Check tire
2. Measure vehicle height
Attention:
• Before checking wheel alignment, make sure
that vehicle height is at specified values.
3. Check camber
(a) Install the front wheel alignment detector, or place ve-
hicle onto detector.
(b) Check camber.
If measurements are not within specified range, check
suspension parts for signs of damage and/or wear. As
camber cannot be adjusted, replace parts when neces-
sary.
4. Check toe-in
C A D If toe-in is not within specified range, check and replace
Front suspension parts when necessary.
B
FRONT SUSPENSION
LOCATION DIAGRAM
FRONT SUSPENSION
SCHEMATICS
FRONT DAMPER WITH HELICAL SPRING ASSEMBLY
1. Front Damper Upper Dust Boot with Nut 5. Front Damper Buffer Block
2. Front Damper Upper Base Plate 6. Front Damper Dust Boot
3. Front Damper Upper Bracket 7. Front Helical Spring
4. Front Helical Spring Upper Rubber Pad 8. Front Damper Strut Assembly
LOWER ARM ASSEMBLY
5
4
1
1. Lower Arm Small Bushing Assembly 4. Cotter Pin

2. Lower Arm Weld Assembly 5. Castellated Nut
3. Lower Arm Large Bushing Assembly 6. Lower Arm Ball Pin Assembly
FRONT TIE ROD ASSEMBLY
1. Front Tie Rod and Connecting Rod Assembly 3. Front Tie Rod Sleeve
2. Front Tie Rod Bracket 4. Front Tie Rod Assembly
SUBFRAME ASSEMBLY
1. Subframe Assembly
KNUCKLE, FRONT WHEEL HUB BEARING ASSEMBLY
1. Internal Circlip 5. Wheel Bolt

2. Front Wheel Hub Bearing Assembly 6. Front Wheel Hub Flange Plate Assembly
3. Knuckle 7. Front Brake Disc
4. Front Brake Disc Cover 8. Front Brake Caliper Assembly

Fault
Reasons for fault Troubleshooting
description
Front damper, knuckle, lower control arm bolts
Re-tighten bolts that have loosened
loose
Severe oil leak from front damper, or severe wear
Noises in front to front damper piston rod and cylinder Replace front damper
suspension
Lower control arm (trapezoid arm) front or back
Replace bushing
rubber bushing worn, deteriorated or damaged
Helical spring failure or broken Replace helical spring
Pressurize both wheels to normal pres-
Tire pressure inconsistent between both tires
sure levels
Both front tires worn out, reduced grip Replace tire
Front right helical spring damaged or permanently
Replace helical spring
Front wheel deformed
yaw Front right damper damaged or deformed Replace front damper
Check again and adjust front wheel
Incorrect front wheel alignment
alignment
Lateral stabilizer bar rubber sleeve damaged, or Replace rubber sleeve and re-tighten
bolt loose bolt
Tighten steel ring bolt according to
Wheel rim steel ring bolt loose
specified torque parameters
Tighten knuckle, front damper and low-
Front suspension bolt/nut loose
er control arm bolts (nuts)
Front wheel hub bearing worn, creating wider
Replace bearing
clearance distance
Front wheel
wobble Wheel hub run-out Replace wheel hub
Wheels not balanced Balance wheels
Lower control arm (trapezoid arm) ball pin (ball
Replace ball pin (ball connector)
connector) worn or loose
Steering tie rod ball pin worn or loose Replace ball pin
Incorrect front wheel alignment Correct front wheel toe-in and camber
Pressurize to correct levels, making
Front tire not pressurized to correct levels sure that tire pressure is not too high or
Abnormal front too low
tire wear
Incorrect front wheel alignment Correct front wheel toe-in and camber
Front wheel wobble Remedy various wobble faults
ON-BOARD INSPECTION
1. Check front differential swing axle and clearance
(a) Remove front wheel.
(b) Remove front brake caliper assembly.
(c) Remove front brake disc.
(d) Check bearing clearance.
Check for clearance near the center of the bridge and
wheel hub using a dial indicator.
Max. value: 0.05 mm
If clearance exceeds maximum value permissible, re-
place front wheel hub bearing assembly.
(e) Check wheel hub run-out.

Check for any run-out on the surface of the front wheel
hub flange plate using a dial indicator.
Max. value: 0.07 mm
place front wheel hub flange plate assembly.
(f) Install front brake disc.
(g) Install front brake caliper assembly.
(h) Install front wheel.

FRONT DAMPER WITH HELICAL SPRING
ASSEMBLY
Removal
1. Open up engine hood
2. Remove left/right vent cover assembly
3. Remove front damper upper dust boot with nut
4. Lift the vehicle
6. Separate front wheel speed sensor assembly
7. Separate front brake hose assembly
8. Disconnect stabilizer bar rod
9. Disconnect damper and knuckle
10. Disconnect damper connection point

Remove 1 nut.
11. Remove front damper upper base plate

12. Remove front damper upper bracket
13. Remove front damper with helical spring assembly
Installation
FRONT LOWER ARM ASSEMBLY

Removal
1. Lift the vehicle
3. Remove front lower arm assembly
(a) Disconnect front lower arm ball pin assembly
Remove 1 cotter pin and 1 nut, and then disconnect
the front lower arm ball pin assembly from the steering
knuckle.
(b) Remove 2 bolts, disconnect front lower arm assembly

from subframe.
(c) Remove front lower arm assembly.

Checks and Replacements

1. Check lower arm ball pin
(a) Check that it moves freely.
(b) Check for signs of damage in the ball pin.
(c) Check for signs of damage in ball pin dust boot, and re-
place if necessary.
Attention:
• Do not separate the lower arm weld assembly
and the lower arm ball pin. If it does not move
freely and there is damage to the ball pin, the
entire lower arm ball pin assembly must be re-
placed.
2. Replace ball pin dust boot
Turn the dedicated tool in order to remove the snap ring
that secures the ball pin dust boot; when replacing the
ball pin dust boot, you can use the same tool to install
the snap ring.
3. Check state of wear with lower control arm large

and small bushings
Clean the surfaces of the lower arm large and small
bushings with water, and check for signs of damage,
wear, cracks, etc. Replace when necessary.
4. Replace lower arm large bushing

(a) Before dismantling, use a marker to make two marks on
the lower arm to indicate the position of the bushing for
reference during re-installation.
(b) Push out lower arm large bushing using the dedicated
tool on the press and replace with a new large bushing.
(c) Check that the lower arm large bushing mounting hole
measures Φ60-0.10 mm; if measurements fall outside of
this range, replace the lower arm weld assembly.
(d) Make sure markings have been aligned prior to press-

ing into place.
Make markings at the corresponding positions on the
new lower arm large bushing for ease of alignment dur-
ing re-installation and to ensure the correct alignment.
(e) Install new lower arm large bushing into place using the
dedicated tool on the press.
5. Replace lower arm small bushing

(a) Use the grinder to cut off the rubber block protruding
from the lower arm small bushing as well to sand the
area flat.
Attention:
• When using the grinder, you must take special
care to avoid damage to the lower control arm.
(b) Push out lower arm small bushing using the dedicated
tool on the press and replace it with a new small bushing.
(c) Install lower arm small bushing into place using the ded-
icated tool on the press.
FRONT TIE ROD ASSEMBLY

Removal
1. Lift the vehicle
3. Remove subframe assembly
4. Disconnect lateral stabilizer bar and connecting rod
assembly
5. Remove front tie rod assembly

(a) Remove 4 bolts.
(b) Remove stabilizer bar bracket and bushing.
(c) Remove stabilizer bar.

1. Front tie rod assembly
Check for signs of damage and deformation. If you find
any such signs, please replace the part.
2. Front tie rod sleeve
Check for signs of damage, wear or deterioration. If you
find any such signs, please replace the part.
3. Front tie rod and connecting rod assembly
4. Stabilizer bar linkage
(a) Check that it moves freely.
(b) Check for signs of damage in ball head.
(c) Check for signs of damage in rubber part.
Attention:
• Do not separate the connecting rod assembly.
If there is damage to any part of the front tie
rod and connecting rod assembly, the entire
assembly has to be replaced as a whole.
Installation
Attention:
• Make sure that the opening of front tie rod
sleeve is installed in the correct orientation.
• Make sure that the front tie rod is installed in
the correct orientation.
• Check front wheel alignment and adjust if nec-
essary.
SUBFRAME ASSEMBLY
Removal
1. Lift the vehicle
3. Separate front brake hose assembly
Attention:
• Use a container to catch any brake fluid that
spills out.
5. Remove drive shaft

(a) Remove front drive shaft nut.
(b) Remove front damper and knuckle bolt, then pull out
drive shaft.
6. Remove knuckle
(a) Remove steering gear outer ball cotter pin and nut.
(b) Knock on the outer tapered surface of the steering gear
with a hammer in order to tap out the steering gear out-
er ball.
(c) Remove lower arm ball cotter pin and nut.

(d) Tap out control arm ball pin from knuckle in the same
manner.
7. Separate stabilizer bar and connecting rod assembly

Remove 1 nut, and remove connecting rod assembly
from damper.
8. Remove steering column cover

9. Separate steering and transmission shaft assembly
Remove the bolt that connects the steering gear and the
steering and transmission shaft assembly, then remove
steering and transmission shaft assembly.
10. Disconnect rear engine suspension assembly and

rear engine suspension bracket welding assembly
Remove 1 bolt.

(a) Hold subframe using tool.
(b) Remove the 6 bolts that secure the part to the vehicle
body.
(c) Remove subframe assembly.
12. Remove steering gear assembly

(a) Remove steering gear and subframe bolt.
(b) Remove steering gear assembly.
13. Remove connecting rod

Remove stabilizer bar and bar nut, then remove con-
necting rod.
14. Remove stabilizer bar assembly

(a) Remove 4 bolts.
(b) Remove stabilizer bar bracket and bushing.
(c) Remove stabilizer bar assembly.
15. Remove front lower arm assembly

Remove subframe and control arm bolt.
Installation
Attention:
• Discharge air from brake pipeline.
• Check front wheel alignment.
• Check front wheel speed sensor signal.
KNUCKLE, FRONT WHEEL HUB BEARING

ASSEMBLY
Removal
2. Remove front drive shaft nut
4. Remove front brake caliper assembly
(a) Remove 2 bolts, then remove front brake caliper assem-
bly from knuckle.
Attention:
• Use a rope or another tool to prevent the brake
caliper from dangling.
5. Remove front brake disc

6. Separate front lateral stabilizer bar and connecting
rod
7. Separate front lower arm assembly
8. Separate steering gear outer ball assembly
9. Separate front damper assembly
(a) Remove 2 bolts and 2 nuts, then separate front damper
assembly from knuckle assembly.
10. Remove front wheel hub internal circlip

(a) Remove front wheel hub internal circlip using a pair of
snap ring pliers.
11. Remove front wheel hub flange plate assembly

(a) Remove front wheel hub flange plate assembly using
SST.
SST
(b) Remove front wheel hub bearing inner seat from front
SST
wheel hub flange plate assembly using the SST.
12. Remove front brake disc cover

(a) Remove three bolts and front brake disc cover.
13. Remove front wheel hub bearing assembly
(a) Remove inner seat ring from front wheel hub bearing
onto the bearing outer seat ring.
SST
(b) Remove front wheel hub bearing outer seat ring from
knuckle using SST and press.
Attention:
• Do not place the knuckle horizontally.
SST
Installation
1. Install front wheel hub bearing assembly
(a) Install new front wheel hub bearing assembly onto
SST
knuckle using SST and press.
2. Install front brake disc cover

(a) Install front brake disc cover using 3 bolts.
Tightening torque: 9 N•m
3. Install front wheel hub flange plate assembly
(a) Install front wheel hub flange plate assembly using SST
and press.
SST
SST
4. Install front wheel hub internal circlip

(a) Install new front wheel hub internal circlip using a pair of
snap ring pliers.
5. Install front damper assembly

(a) Install 2 bolts, one nut and front damper assembly onto
knuckle assembly.
Attention:
• When reusing bolts and nuts, apply a small
amount of engine oil on the nut screw thread.
6. Install steering gear outer ball assembly

7. Install front lower arm assembly
8. Install front tie rod and connecting rod assembly
9. Install front brake disc
10. Install front brake caliper assembly

(a) Install front brake caliper assembly onto knuckle using
two bolts.
11. Install front drive shaft nut

(a) Install a new front drive shaft nut.
Attention:
14. Check front bridge for runout and clearance
15. Install front brake disc.
16. Install front brake caliper assembly
17. Install front wheel speed sensor assembly
18. Tighten front drive shaft nut
(a) Tighten the front drive shaft nut with the aid of a punch
and hammer.

21. Check front wheel speed sensor signal
REAR SUSPENSION
LOCATION DIAGRAM
REAR SUSPENSION
SCHEMATICS
REAR DAMPER ASSEMBLY
5
6
1. Washer 5. Rear Damper Washer

2. Rear Damper Upper Sleeve 6. Rear Damper Buffer Block
3. Rear Damper Bottom Sleeve 7. Rear Damper Dust Boot
4. Rear Damper Bushing Support 8. Rear Damper Assembly
REAR HELICAL SPRING
1. Rear Helical Spring Upper Rubber Pad 3. Rear Helical Spring Bottom Rubber Pad
2. Rear Helical Spring
REAR TORSION BEAM ASSEMBLY
1. Trailing Arm Bushing Assembly 3. Rear Bridge Guard Bracket

2. Rear Torsion Beam Assembly
REAR WHEEL HUB ASSEMBLY
4
3
1. Rear Brake Caliper Assembly 3. Rear Wheel Hub Assembly

2. Rear Brake Disc 4. Rear Brake Disc Cover

Fault
Reasons for fault Troubleshooting
description
Rear wheel rim run-out Replace rear wheel rim
Rear wheel not balanced Balance rear wheel
Rear wheel hub bearing clearance too large Adjust
Rear wheel hub bearing damaged Replace bearing
Rear wheel
wobble Rear wheel tire pressure abnormal Pressurize to correct levels
Rear bridge deformed Replace rear bridge
Rear damper malfunction Replace rear damper
Needle roller bearing between control arm and rear
Replace needle roller bearing
axle tube bracket assembly damaged or worn
Rear damper oil leak or damage Replace rear damper
Rear damper buffer pad damaged Replace buffer pad
Rear wheel hub bearing damaged Replace bearing
Rear suspension bolts (nuts) loose Tighten bolts (nuts)
Noises in rear
suspension Rear bridge rubber support damaged Replace rear bridge rubber support
Torsion bar and control arm, rear axle tube bracket
Replace torsion bar
assembly spline worn or loose
Needle roller bearing between control arm and rear
Replace needle roller bearing
axle tube bracket damaged or worn
ON-BOARD INSPECTION
1. Check rear differential swing axle and clearance
(a) Remove rear wheel.
(b) Remove rear brake caliper assembly.
(c) Remove rear brake disc.
(d) Check bearing clearance.
Check for clearance near the center of the bridge and
wheel hub using a dial indicator.
Max. value: 0.05 mm
place rear wheel hub assembly.
(e) Check wheel hub run-out.

Check for any run-out on the surface of the rear wheel
hub outside of wheel bolts using a dial indicator.
Max. value: 0.07 mm
If run-out exceeds maximum value permissible, replace
rear wheel hub assembly.
(f) Install rear brake disc.
(g) Install rear brake caliper assembly.
(h) Install rear wheel.

REAR DAMPER ASSEMBLY
Removal
1. Support rear torsion beam
2. Remove interior cover
3. Disconnect damper upper connection point
4. Disconnect damper lower connection point
5. Remove rear damper assembly

6. Check rear damper assembly

Compress and extend the damper rod; check and make
sure that there is no abnormal resistance or sound in
the course of operations.
Replace damper with a new one if you find any abnor-
malities.
Installation
1. Connect damper upper connection point
After installing the first nut, place it such that its top end
is (14-16) mm away from the top of the push rod
2. Connect damper lower connection point
3. Install interior cover
4. Lower the vehicle

REAR HELICAL SPRING

Removal
1. Lift the vehicle
2. Remove rear wheel
3. Disconnect damper lower connection point
4. Remove helical spring
Dismantle bolt with some force by pushing upwards,
lower slowly and remove helical spring.
Installation
1. Install rear helical spring
(a) Install rear helical spring upper rubber pad and make
sure that its gap aligns with the end of the rear helical
spring.
(b) Install rear helical spring bottom rubber pad and rear
helical spring onto rear torsion beam.
Attention:
• When installing helical spring, make sure that
the paint markings are at the bottom of the ve-
hicle.
Paint marking
2. Connect damper lower connection point

3. Install rear wheel
4. Check rear wheel alignment
REAR TORSION BEAM ASSEMBLY

Removal
1. Lift the vehicle
3. Separate wheel speed sensor cabling
(a) Remove cabling from wheel speed sensor bracket on
torsion beam.
(b) Remove wheel speed sensor fixing bolt on brake.
4. Separate rear brake hose
5. Separate parking brake cable assembly

(a) Remove torsion beam clip.
(b) Remove fixing bolt on torsion beam.
(c) Remove fixing bolt on brake.
6. Remove rear bridge guard bracket

Remove bracket bolt, then remove rear bridge guard
bracket.
7. Remove rear brake caliper assembly

8. Remove rear brake disc
9. Remove rear wheel hub assembly
(a) Remove 4 bolts and rear wheel hub assembly.
10. Remove rear brake disc cover
11. Remove rear damper
12. Remove rear helical spring
Attention:
• Place rear torsion beam down slowly, with your
hand supporting the spring to prevent the heli-
cal spring from popping out.
13. Remove rear torsion beam assembly
Attention:
• When installing bolt, you should first pre-load
the rear torsion beam and then tighten bolt
to install. This way, you will align the bushing
lock position with the working position and
thus reduce the possibility of premature wear-
and-ter of the small rubber structure.

1. Check and test trailing arm bushing
(a) Check trailing arm bushing for signs of deformation,
movement, de-centering and severe cracking, and if the
seal remains in place.
(b) If you cannot determine if the trailing arm bushing is

damaged, adopt the following measures: wash the rub-
ber parts of the bushing using clean water while wiping
with a piece of cotton. Check the rubber part for afore-
mentioned problems.
(c) If such issues are found, replace trailing arm bushing.
2. Remove trailing arm bushing

(a) Create markings with a white paint marker to indicate
the orientation of the trailing arm bushing assembly.
(b) The trailing arm bushing is a single-use part. If it is dam-
aged, first pry out the edge of the bushing using a steel
skid so that you may then install the dedicated tool.
(c) With the dedicated tool, hold the bushing installation de-
SST vice in place, then tighten bolts using a wrench to push
out the bushing. Use the press if necessary.
Attention:
• During the press-out process, you must make
sure that the trailing arm bushing is being
pushed in the perpendicular direction.
3. Install new trailing arm bushing assembly

(a) Before pressing in the new trailing arm bushing assem-
Steering bly, you should first determine the assembly orientation.
alignment
The direction marked on the trailing arm bushing as-
sembly should point towards the bottom of the torsion
SST
beam weld assembly.
Attention:
• Make sure to install the trailing arm bushing
assembly in the correct orientation.
(b) Position the trailing arm bushing assembly using the
dedicated tool, and push in slowly using the press.
Attention:
• During the press-in process, you must make
sure that the trailing arm bushing is being
pushed in the perpendicular direction.
REAR WHEEL HUB ASSEMBLY

Removal
2. Separate rear wheel speed sensor assembly
(a) Remove rear wheel speed sensor fixing bolt.

(a) Remove 2 bolts, then remove rear brake caliper assem-
bly from rear torsion beam.
Attention:
5. Remove rear wheel hub assembly
(a) Remove 4 bolts and rear wheel hub assembly.
Installation
1. Install rear wheel hub assembly
(a) Install rear wheel hub assembly using four bolts.
2. Check for run-out and clearance on rear axle
3. Install rear brake disc
4. Install rear brake caliper assembly
5. Connect transmission sensor
Attention:
• Take care not to twist sensor cabling when
connecting.
6. Install rear wheel

7. Check rear wheel speed sensor signal
WHEELS AND TIRES

SCHEMATICS
WHEELS AND TIRES
8 9
10
1. Spare Tire Bolts 6. Wheel Rim Assembly

2. Spare Tire Wheel Rim Assembly 7. Tire Pressure Monitoring Device
3. Valve 8. Valve
4. Spare Tire Assembly 9. Wheel Nut
5. Tire Assembly 10. Aluminum Wheel Hub

DIAGNOSIS FLOWCHART
Tire vibrations
1 Tighten the wheel nuts
Next step
2 Check the tires
Abnormal Move on to step 3
Normal Move on to step 4
3 Repair or replace the tires
Next step
4 Check and/or adjust the wheel balance
Next step
5 Check the looseness of the front wheel hub bearing assembly and the front-wheel-hub axial run-out
6 Repair the looseness of the front wheel hub bearing assembly and the front-wheel-hub axial run-out
Next step
7 Check the looseness of the rear wheel hub bearing assembly and the rear-wheel-hub axial run-out
8 Repair the looseness of the rear wheel hub bearing assembly and the rear-wheel-hub axial run-out
Next step
9 Perform a road test
Next step
10 Return the vehicle to the customer

Uneven tire wear
1 Check the tires
Next step
2 Repair or replace the tires
Next step
3 Check and/or adjust the front wheel alignment
Next step
4 Check and/or adjust the rear wheel alignment
Next step
5 Perform a road test
Next step
6 Return the vehicle to the customer

CHECK
1. Check tire
(a) Check for signs of tire wear, and make sure that tire
pressure is normal.
Cold-temp tire pressure:
Tire specifications Tire pressure (kPa)

205/60 R16 92H(V) (Front/rear) 220±10
T125/90 R16 98M (Spare tire) 420±10
(b) Measure tire lateral run-out using a dial indicator.

Max. tire lateral run-out: 1.4 mm
Front Front 2. Tire rotation

Perform tire rotation as shown in the illustration.
A: Non-directional tires and wheels
B: Directional tires and wheels
A B
3. Check wheel balance

(a) Check and adjust vehicle balance.
Max. imbalance permissible following adjust-
ment
Single side: ≤10 g
Two sides: ≤15 g
Note:
• Check and adjust vehicle balance when neces-
sary.
4. Check for slackness in front wheel hub bearing as-

sembly
5. Check for slackness in rear wheel hub bearing as-
sembly
6. Check front wheel hub axial run-out
7. Check rear wheel hub axial run-out

WHEEL
Removal
1. Loosen wheel nut
Unscrew wheel nut for (1-2) rounds.
2. Lift the vehicle
3. Remove wheel
(a) Remove 4 wheel nuts.
(b) Remove wheel.
Attention:
• Never use heat to loosen a hard-to-remove
wheel. Doing so can overheat the wheel and
undermine its use life and also damage the
wheel hub bearing at the same time.
• Use a tire-changing machine to remove the
tire. Do not remove tire from wheel using a
manual tool or tire iron. Doing so will damage
the tire bead or wheel rim.
• Inspect wheel installation surface. If you find
signs of bending, depressions or excessive ax-
ial/radial run-out, you must replace the wheel.
Installation
Install wheel in the reverse of the removal procedure.
Attention:
• Before installing a wheel, you must first clean
off any corroded material on the wheel instal-
lation surface and brake drum or brake disc
installation surface using a steel wire brush to
ensure good contact between metal surfaces
when the wheel has been installed. Otherwise,
wheel nuts may loosen and even cause wheels
to fall off in the course of the drive. This will
cause your vehicle to go out of control and in-
jury in such an event is very likely.
• You may not clear dust from the surface of the
brake device with compressed air.
• If the vehicle is fitted with tires with directional
treads, make sure that the directional mark on
the outside of the tire points towards the front
of the tire before tire fitting.
• Wheel nuts must be tightened to specified
torque levels to protect the wheel or brake disc
from deformation.
2 Tightening torque: (110±10) N•m
3
1 4

OVERVIEW
The tire pressure monitoring system (TPMS) on this vehicle comprises four tire pressure monitoring
devices (not for the spare tire), one vehicle body controller (BCM) and one dashboard. When one or
more vehicle tires are experiencing low or excessive tire pressure levels, the requisite data will be
sent and shown on the dashboard in graphic form alongside the fault warning indicator. At the same
time, a sound alert will also be provided to the driver in order to maintain drive safety and reliability.
The tire pressure monitoring system (TPMS) is a new technology that enhances drive safety. The sys-
tem makes use of electronic, sensor, and wireless transmission and reception technologies, etc., in its
operations.
The TPMS can monitor tire pressure levels in all tires in real time and issue timely alarms in situations
of abnormality such as when tire pressure is too low or too high to remind the driver to remedy the
issue before a flat tire occurs; the system can also help lower vehicle fuel consumption levels and ex-
tend tire life for a safer driver and greater drive economy.
LOCATION DIAGRAM
×4
1. Combination Instrument (Tire Pressure 2. Vehicle Body Controller (BCM)

Display) 3. Tire Pressure Monitoring Device
SCHEMATICS
TIRE PRESSURE MONITORING DEVICE
4±0.5
3
2
1. Tire Pressure Monitoring Device 3. Locking Nut

2. Valve Cover 4. Tire Pressure Monitoring Device Body
SPECIFIED TORQUE
Name State Tightening torque (N•m) Quantity
Valve nut Valve lock nut to valve 3-5 (recommend: 4) 1x4
DEDICATED TOOLS
THA13 SETTER
Overview
The THA13 setter is a tool that complements the TPMS. With the THA13 setter, you can perform tire
pressure monitoring device initialization, replace monitors, and perform tire rotation; this helps you to
repair and maintain the TPMS more quickly and efficiently.
Exterior features
Indicator light
Button
Power supply switch
Technical Parameters
Working voltage DC 9 V battery
Working curent <3 mA
LF trigger distance 0.5 m<L<1 m
RF transmission distance 1.5 m<L<3 m
Attention:
• In the course of operations, if the indicator becomes dimmer or if all indicator lights flash
when the power supply switch is turned on, it means that setter battery levels are low and
you should change out the battery.
• The trigger distance becomes shorter when battery levels are low. At this juncture, please
try to get as close as possible to the tire valve in order to trigger it and open vehicle door
at the set time to access the OK button inside the cab as part of the settings procedure.

ELECTRICAL SCHEMATICS
Tire pressure
monitoring device
Tire pressure RF
monitoring device CAN_HI
Combination
BCM instrument
Tire pressure CAN_LO
monitoring device
Tire pressure
monitoring device
TPMS DISPLAY
About its operations
Tire pressure failure indicator Instrument liquid crystal display
4 100 120
80
3 5
60 140
2 6 Tire pressure
monitoring 40 160
1 7 20 180
0 8 0 200
C H E F /h
00
0
X1 km
in
r/ m
1. Normal display
After the engine starts running, press the corresponding button on the steering wheel to bring up the
tire pressure display through which both pressure and temperature values will be shown at the same
time.
If no BCM data is received by the dashboard, "--" will be shown in both the tire pressure and tempera-
ture value positions.
Note:
• After the battery has been replaced/recharged following a full drain, the tire pressure and tem-
perature values for all four tires as shown on the dashboard will be "--" as the BCM has been re-
started and previous tire pressure and temperature values have been cleared as a result. At this
juncture, start the vehicle and tire pressure and temperature values will begin to appear on the
display.
2. Abnormal tire state display

When there is one or more tire abnormality (excessively high or low tire pressure/high temperatures),
the corresponding alarm will automatically appear on the dashboard display; at the same time, the tire
pressure failure indicator on the panel will also light up.
When there is a system fault (such as when BCM cannot receive RF signals or when monitor battery
levels are low, etc.), the tire pressure fault indicator will flash for 60 s and then stay lit. When BCM sig-
nals a normal state, the alarm interface on the instrument display will be taken down.
TROUBLESHOOTING
Diagnostic Trouble Code
Please refer to the BCM fault code table for the "Vehicle Body Control System".

Attention:
• Please read the information in this section
carefully to ensure the reliability of receiver-
monitor communications as well as the worthi-
ness of the seal between the monitoring device
and the wheel hub.
Removal
1. Lift the vehicle
2. Remove wheel assembly
3. Remove tire bead from wheel assembly
4. Remove valve cover and valve lock nut (A) from
valve (B) in sequence
Attention:
• Place removed valve nut in a clean location
that is dust- and water-free.
A
B
5. Remove tire pressure monitoring device from wheel

Attention:
• Place valve nut in a clean location.
Installation
Installation requirements:
• The valve is suitable for use with wheel hubs
with mounting holes measuring Φ11.5±0.2 mm.
• The outside diameter of the valve lock nut is
Φ14 mm with a length of 19 mm.
1. Clear all dirt and debris from seal ring seal position
2. Unscrew monitoring device valve lock nut (A)
3. Thread the tip of the valve through the wheel hub

cover valve hole
Note:
• Try to have the surface of the monitor and wheel
rim surface as parallel as possible. After instal-
lation, the curved surface of the monitor and the
curved surface of the wheel hub should meet
nicely. Make sure that there is a 0-3 mm clearance
before the wheel hub.
4. Screw on valve lock nut (A) manually and then tight-

en using tool
A
Tightening torque: (4±0.5) N•m
5. Install tire bead

6. Pressurize tire to standard pressure levels, then
check valve core and locking nuts using soapy wa-
ter for signs of air leakage
7. Install valve cap to complete monitor installation
8. Adjust wheel balance, then install tire
Attention:
• You must conduct balance test and adjustment
after installing the tire pressure monitoring de-
vice.
9. Conduct initialization with newly installed tire pres-
sure monitoring device

LEARNING
After replacing a tire pressure monitoring device or per-
forming tire rotation, the tire pressure monitoring device
must undergo learning again.
1. Connect diagnostic tester to vehicle network via
CAN-Bus II connector plug
2. Operate diagnostic tester, enter tire pressure learn-
ing interface in BCM
3. Learning procedure as follows (with front left tire
pressure monitoring device used as example)
(a) Operate diagnostic tester to take front left tire pressure
monitoring device into learning mode.
(b) Trigger front left tire pressure monitoring device using
the setter.
(c) After the BCM antenna receives the high-frequency
signal from the tire pressure monitoring device, the di-
agnostic tester display will indicate device learning has
been conducted successfully.
(d) The learning process for the front left tire pressure mon-
itoring device has been completed successfully.
(e) Only at this point will you be able to move on to the
learning process for the next tire pressure monitoring
device.
Memorandum
Memorandum
Steering System 06-1
STEERING SYSTEM
STEERING WHEEL AND STEERING COLUMN

Schematics.....................................................................06-2
Diagram.......................................................................06-3
DTC Checklist.................................................................06-5
Steering Wheel............................................................06-7
Steering Column..........................................................06-9
Steering-Drive Shaft Connection.................................06-12
MECHANICAL STEERING GEAR
Schematics.....................................................................06-13
Steering Gear Assembly..............................................06-16
Steering Gear Outer Ball Assembly.............................06-20
06-2 Steering System
STEERING WHEEL AND STEERING COLUMN

SCHEMATICS
50±4
1
25±3
x2
2
25±3
33±3
33±3
33±3 3
1. Steering Wheel Assembly 4. Steering Column Cover

2. Steering Column Assembly 5. Power Steering Unit
3. Steering and Transmission Shaft Assembly
DIAGRAM
6 V, 10 mA
B1 1 VCC1
6 V, 10 mA Black 12 V, 0-65 A
B2 11 VCC2 MB 24
0-5 V, 5 mA Turn
B3 2 PWM-P right
Torque sensor
0-5 V, 5 mA Turn
B4 12 PWM-T1 M
left
0-5 V, 5 mA
B5 3 PWM-T2
MR 23
0-5 V, 5 mA Red 12 V, 0-65 A
B6 13 PWM-S
0 V, 10 mA Controller assembly
B7 4 GND2
0 V, 10 mA
B8 14 GND1
Housing GND
SG 5
Ignition switch 0-16 V, 400 μA

10 IG1
MAIN EPS
21 +BB
Red 9-16 V, 0-65 A CAN high power
+
level
CANH 15
22 E1
CANL 16
- CAN low power
Black 0 V, 0-65 A level
PIN DEFINITIONS
Torque sensor port
5 6 7 8
1 2 3 4
Controller port
20 CANL CANH GND1 PWM-S PWM-T1 VCC2 +BB 21 MB 23
10 IG1 SG GND2 PWM-T2 PWM-P VCC1 E1 22 MR 24
1. Controller port definitions
Signal Name Port definition

1 VCC1 Sensor power supply 1
2 PWM-P Steering signal P
3 PWM-T2 Torque signal 2
4 GND2 Sensor ground 2
5 SG Housing GND
10 IG1 Ignition signal
11 VCC2 Sensor power supply 2
12 PWM-T1 Torque signal 1
13 PWM-S Steering signal S
14 GDN1 Sensor ground 1
15 GDNH GDN high power level
16 GDNL GDN low power level
21 +BB Power supply
22 E1 Ground wire
23 MB Motor output
24 MR Motor input
2. Torque sensor port definitions
Port No. Signal code

1 VCC1
2 VCC2
3 PWM-P
4 PWM-T1
5 PWM-T2
6 PWM-S
7 GND2
8 GDN1
DTC CHECKLIST
Diagnos-
tic Trouble Description Reasons for fault
Code
Main torque sensor signal lost ➀Sensor main circuit open, or poor circuit
C1111 (1S cannot detect main torque sig- contacts
nal on sustained basis) ➁Sensor fault
C1112 Normal
➀Sensor main or secondary circuit open, or
Difference between main torque signal
C1113 poor circuit contacts
and secondary torque signal too high
➁Sensor fault
Torque sensor power sup-
C1114 ECU sensor circuit fault
ply voltage too high or too low
➀Sensor secondary circuit open, or poor
Torque sensor secondary cir-
C1115 circuit contacts
cuit disconnected or shorted
➁Sensor fault
➀Main torque signal line fault
C1116 Torque sensor main signal abnormal
➁Sensor fault
➀Torque signal line fault
C1117 Torque sensor secondary signal abnormal
➁Sensor fault
➀P-signal line broken, or poor line contacts
C1118 Angle signal P lost
➁Sensor fault
➀P-signal line fault
C1119 Angle signal P abnormal
➁Sensor fault
➀S-signal line broken, or poor line contacts
C111A Angle signal S lost
➁Sensor fault
➀S-signal line fault
C111B Angle signal S abnormal
➁Sensor fault
Angle signals P and S incon- ➀P- or S-signal line fault
C111C
sistent with each other ➁Sensor fault
➀Sensor power line fault

C111F Torque sensor power supply voltage too low ➁Controller fault
➂Sensor fault
➀CAN bus fault
C1121 No engine speed signal input detected
➁Engine speed sensor fault
C1122 No engine RPM signal input detected As above
No vehicle speed signal detected under ➀CAN bus fault
C1123
normal drive conditions ➁Vehicle speed sensor fault
C1124 Invalid vehicle speed signal As above
➀Motor cabling fault
C1141 Motor voltage too high or too low ➁Motor fault
➂Controller fault
Motor current too high ➀Motor fault
C1142
(Motor current greater than 75 A) ➁ECU fault
Motor current difference too high
➀Motor fault
C1143 (Actual current greater than current
➁ECU fault
command by by 10 A or more)
Motor current too low
➀Motor fault
C1145 (Current command greater than 4 A,
➁ECU fault
motor current lower than 2 A)
C1151 Relay contacts do not close together ECU fault
C1152 Relay contacts stuck together ECU fault
Battery voltage lower than ➀Battery fault
C1153
7.8 V following self-check ➁Power line fault
C1154 Battery voltage greater than 17.5 V Battery fault
C1155 EPS controller fault ECU fault
C1131 Controller thermal resistor fault ECU fault
CANH/L disconnected;
C1132 BUS OFF fault
CAN bus interference
C1133 Retain
C1134 Retain
C1135 Retain
C1136 Retain
C1137 Retain
C1138 Retain

ON-BOARD INSPECTION
1. Check steering wheel free travel distance
(a) Stop the vehicle and align tires to the front.
Maximum
(b) Check steering wheel free travel distance by turning the
free travel
steering wheel clockwise and anti-clockwise until resis-
tance increases.
Max. free travel distance: 30 mm
STEERING WHEEL
Removal
2. Align front wheels to the front
3. Remove driver-side airbag
(a) Loosen clamp.
(b) Disconnect cabling.
4. Remove steering wheel

Attention:
• Make assembly markings during removal.
(a) Remove steering wheel locking nut, then screw in nut 2-3
rounds.
(b) Hold the steering wheel and shake it from left to right,
and from front to back a few times; then pull upwards to
remove the steering wheel.
(c) Disconnect cabling from corresponding gap.
Attention:
• Secure clock spring to prevent it from moving.
Installation
1. Install steering wheel
(a) Install steering wheel along the axis in accordance with
reference markings.
(b) Reconnect cabling connector.
(c) Install steering wheel locking nut.
2. Install driver-side airbag

STEERING COLUMN
REMOVAL
2. Align front wheels to the front
3. Remove driver-side airbag
5. Remove combination switch cover
(a) Remove 3 screws.
(b) Remove upper combination switch cover.
(c) Remove lower combination switch cover.
6. Remove clock spring sub-assembly

(a) Open up 3 clips.
7. Remove combination switch

(a) Disconnect combination switch and ignition switch ca-
bling.
(b) Remove combination switch. (The left and right switch-
es are a single unit)
8. Remove ignition switch
Remove 2 ignition switch bolts, then remove ignition
switch.
9. Separate steering drive shaft

(a) Remove steering column cover, then remove bolt at
center of steering drive shaft
(a) Make assembly markings on the steering drive shaft
and steering column.
(b) Remove 1 bolt, move downwards along axis, separate
steering drive shaft.
10 Remove steering column

(a) Remove 2 nuts connected to the dashboard reinforcing
strut.
(b) Remove 1 bolt connected to the dashboard reinforcing
strut.
(c) Pull steering column upwards along the top end of the
column axis to remove.
Installation
1. Install steering column
(a) Align assembly markings, insert steering column as-
sembly downwards along the axis on the upper end of
the column.
(b) Install 2 nuts connected to the dashboard reinforcing
strut.
(c) Install 1 bolt connected to the dashboard reinforcing
strut.
(d) Reconnect cabling connector.
2. Connect steering drive shaft

(a) Install 1 bolt.
(b) Install steering-drive shaft connection center bolt, then
install steering column cover
3. Install left and right combination switch and ignition

switch
4. Install clock spring sub-assembly
5. Install combination switch cover
6. Install steering wheel
7. Install driver-side airbag
STEERING-DRIVE SHAFT CONNECTION

Removal
1. Separate steering column and steering drive shaft
(a) Turn plastic tube anti-clockwise.
(b) Remove steering column cover from steering drive
shaft.
3. Remove steering drive shaft

and steering cardan joint.
(b) Remove bolt A that connects the steering-drive shaft
connection.
A
(c) Remove bolt B.
(d) Remove steering-drive shaft connection.
B
Installation
1. Install steering-drive shaft connection
(a) Install steering drive shaft and steering drive cardan
joint according to markings.
A (b) Connect the steering-drive shaft connection to the pow-
er steering gear assembly.
(c) Apply screw thread glue, then tighten to specifications.
B Tightening torque: 33±3 N•m
2. Install steering column dust boot

(a) Install steering dust boot onto steering-drive shaft con-
nection.
(b) Install 2 plastic snaps.
3. Check steering wheel to make sure that it is cen-

tered
MECHANICAL STEERING GEAR

SCHEMATICS
107±7
49±5
x2 1
x2
x2
74±7
3
107±7
x2
1. Steering Transmission Shaft Dust Boot 3. Steering Gear Outer Left Ball Assembly
and Collar Assembly 4. Steering Gear Assembly
2. Steering Transmission Shaft Dust Boot 5. Steering Gear Outer Right Ball Assembly
Fault description Reasons for fault Troubleshooting
1. Gap between steering gear wheel and 1. Check gap and adjust if necessary; re-
gear rack too big place steering gear when adjustments are
not possible
2. Steering rod internal/external ball pin 2. Check ball pin, replace if necessary
worn down
3. Steering cardan joint worn down 3. Replace lower section of steering col-
Steering wheel umn
Free travel too long/ 4. Connection between steering drive 4. Tighten connecting bolt again according
abnormal noises shaft and steering gear loose to specified torque
5. Connection between steering wheel 5. Tighten steering wheel locking nut; if
and steering column loose spline is damaged, replace steering wheel
or steering column
6. Steering gear bolt loose 6. Tighten steering gear bolt
7. Drive shaft spline worn, loose 7. Replace lower section of steering col-
umn
1. Insufficient tire pressure 1. Pressurize tire to specifications
2. Incorrect front wheel alignment 2. Check and adjust front wheel alignment
3. Steering gear pressure block clear- 3. Replace steering gear, or have clear-
ance too small ance adjusted by a professional
4. Steering column cross head bearing 4. Replace lower section of steering col-
damaged umn
Steering feels 'heavy' 5. Steering rod ball pin needs greasing, 5. Replace steering rod ball head
or is damaged
6. Bearing in upper front damper bracket 6. Replace upper front damper bracket
damaged connector
7. Lower control arm ball damaged 7. Replace lower control arm
8. Power steering electronic control unit 8. Replace power steering ECU
9. Motor fault and ECU fault 9. Replace motor
1. Median turning point (zero) not cor- 1. Adjust median turning point (zero)
rectly marked
2. Front tire (incorrect tire pressure, un- 2. Check front tires
even tire wear)
3. Inaccurate four-wheel alignment 3. Check alignment of all four wheels
4. Steering rod ball pin needs greasing, 4. Grease steering rod ball pin, or replace
Left and right steer-
or is damaged
ing force unequal
5. Lower control arm ball damaged 5. Replace lower control arm ball
6. Internal steering gear assembly fault 6. Replace steering gear assembly
7. Torque sensor fault 7. Replace torque sensor
8. Motor fault 8. Replace motor
9. Power steering electronic control unit 9. Replace power steering electronic con-
fault trol unit
Fault description Reasons for fault Troubleshooting

Steering force does 1. Lower control arm ball damaged 1. Replace lower control arm ball
n o t c h a n g e a l o n g 2. Wheel speed sensor fault 2. Replace wheel speed sensor
with vehicle speed, or 3. Torque sensor fault 3. Replace torque sensor
steering wheel does 4. Motor fault 4. Replace motor
not return to original 5. Power steering electronic control unit 5. Replace power steering electronic con-
position fault trol unit
Note:
• After re-assembly and replacement of steering system components, you must calibrate the pow-
er steering system turn angle sensor. Failure to do so will cause abnormal functioning and yaw-
ing.

STEERING GEAR ASSEMBLY
REMOVAL
1. Align front wheels so that they face the front
3. Separate steering-drive shaft connection
and steering-drive shaft connection.
(b) Remove 2 bolts, then separate steering-drive shaft con-
A
nection from the steering gear drive shaft.
Assembly B
marking
4. Open up engine hood

6. Separate steering gear outer left ball assembly
(a) Remove cotter pin and nut.
(b) Separate steering gear outer left ball assembly from
knuckle.
7. Separate steering gear outer right ball assembly

8. Separate front left lower control arm
(b) Separate front left lower control arm from knuckle.
9. Separate front right lower control arm
10. Separate lateral stabilizer bar linkage from damper
Engine hanger 11. Suspend engine assembly

Hang the engine lift chain onto the engine hanger.
Attention:
• Do not hang chain on any other part in order to
suspend the engine.
12. Separate rear engine suspension

Remove engine rear suspension bolt and nut.

(a) Support subframe assembly using a jack.
(b) Remove the 6 bolts that connect the subframe to the
vehicle body.
14. Separate steering transmission shaft dust boot and

collar assembly
(a) Open up the 2 clips on the steering transmission shaft
dust boot
Attention:
• Do not damage clips.
15. Remove steering gear assembly

(a) Remove 2 bolts, one nut and the steering gear assem-
bly.
16. Remove steering gear outer left ball assembly

(a) Make assembly markings on the steering gear outer left
ball assembly and steering gear.
(b) Remove locking nut.
17. Remove steering gear outer right ball assembly
Assembly marking
18. Check steering gear outer ball assembly

(a) Secure steering gear outer ball assembly on vise.
(b) Install nut onto ball pin.
(c) Pull ball pin back and forth for 5 times.
(d) Turn nut continuously 2-4 times per second using box
wrench and obtain torque reading at fifth turn.
INSTALLATION
1. Install steering gear outer left ball assembly
(a) Install locking nut and steering gear outer left ball as-
sembly onto steering gear assembly until assembly
markings align.
Tightening torque: (74±7) N•m
Note:
Tighten locking nut following adjustment of front cabling.
Assembly marking 2. Install steering gear outer right ball assembly
3. Install mechanical steering gear

(a) Use 2 bolts and a nut to attach the steering gear assem-
bly to the subframe.
Front
4. Install subframe sub-assembly
(a) Support subframe sub-assembly using a jack.
A (b) Install the 6 bolts that connect the subframe to the ve-
A
hicle body.
B B
C C
5. Install rear engine suspension

Install bolt and nut.
6. Install front left suspension lower control arm

Install nut and cotter pin.
7. Install front right suspension lower control arm
8. Install lateral stabilizer bar linkage
9. Install steering gear outer left ball assembly

Install nut and cotter pin.
10. Install steering gear outer right ball assembly

12. Install steering transmission shaft dust boot and
collar assembly
(a) Secure the 2 clips on the steering transmission shaft
dust boot and collar assembly.
13. Install steering-drive shaft connection

Apply screw thread glue, fastening bolt.
A
Assembly B
marking
14. Align front wheels so that they face the front

15. Install steering column cover assembly
STEERING GEAR OUTER BALL ASSEMBLY

REMOVAL
1. Lift vehicle to appropriate position
3. Remove steering gear outer ball assembly
(b) Make assembly markings on the steering gear outer left
ball assembly and steering gear.
(c) Remove locking nut.
Memorandum
Memorandum
Brake System 07-1
BRAKE SYSTEM
HYDRAULIC BRAKE
Schematics.....................................................................07-3
Brake Pipeline..............................................................07-3
Vacuum Booster with Brake Pump Assembly..............07-4
Brake Pedal.................................................................07-5
Brake Fluid...................................................................07-6
Front Brake Hose.........................................................07-8
Rear Brake Hose.........................................................07-9
Vacuum Booster with Brake Pump Assembly..............07-10
Brake Master Cylinder.................................................07-12
Brake Pedal.................................................................07-13
Brake Lamp Switch Assembly......................................07-14
FRONT WHEEL BRAKE
Schematics.....................................................................07-15
Front Brake Caliper......................................................07-15
Repair Parameters.......................................................07-16
Brake Pad Assembly....................................................07-17
Front Brake Disc..........................................................07-20
REAR WHEEL BRAKE
Schematics.....................................................................07-22
Rear Brake Calipers.....................................................07-22
Repair Parameters.......................................................07-23
Brake Pad Assembly....................................................07-24
Rear Brake Disc...........................................................07-25
PARKING BRAKE
Schematics.....................................................................07-27
Clearance Adjustment..................................................07-29
Parking Brake Controller..............................................07-30
Parking Brake Cable....................................................07-31
07-2 Brake System
ANTI-LOCK BRAKING SYSTEM

Schematics.....................................................................07-32
Diagram...........................................................................07-33
ECU Connectors and Circuit........................................07-34
Torque Specifications...................................................07-36
Troubleshooting.............................................................07-37
Matters of Note During Troubleshooting......................07-37
Dealing with No-Code Faults.......................................07-43
Dealing with Intermittent Faults....................................07-44
DTC Checklist..............................................................07-45
Fault Diagnosis............................................................07-47
System Air Discharge...................................................07-53
Cross-Validation...........................................................07-55
Abs Hydraulic Control Unit...........................................07-56
Front Wheel Speed Sensor..........................................07-56
Rear Wheel Speed Sensor..........................................07-57
ESP
Schematics.....................................................................07-58
Diagram...........................................................................07-59
ECU Circuit Diagram....................................................07-60
Troubleshooting.............................................................07-62
Matters of Note During Troubleshooting......................07-62
Dealing with No-Code Faults.......................................07-67
Dealing with Intermittent Faults....................................07-68
DTC Checklist .............................................................07-69
Fault Diagnosis............................................................07-72
System Air Discharge...................................................07-77
Cross-Validation...........................................................07-78
ESP Assembly.............................................................07-79
ESP Switch..................................................................07-79
Brake System 07-3
HYDRAULIC BRAKE
SCHEMATICS
BRAKE PIPELINE
2
1
3
1. Rear Brake Hose Assembly 4. Front Left Brake Hose Assembly

2. Rear Left Brake Hose Assembly 5. Front Right Brake Hose Assembly
3. Rear Right Brake Hose Assembly
07-4 Brake System
VACUUM BOOSTER WITH BRAKE PUMP ASSEMBLY
5
2
1. Brake Fluid Reservoir Assembly 4. Check Valve

2. Brake Fluid Reservoir Connecting Pin 5. Brake Vacuum Hose Assembly
3. Brake Master Cylinder Assembly 6. Brake Vacuum Hose Bracket
Brake System 07-5
BRAKE PEDAL
5 4
1. Brake Pedal Assembly 4. Foot Pedal Pad

2. Brake Lamp Switch 5. Locking Pin
3. Pin Shaft 6. Return Spring
07-6 Brake System

BRAKE FLUID
ON-BOARD REPAIR AND MAINTENANCE
1. Check reservoir brake fluid levels
Brake fluid: DOT4 synthetic brake fluid
Remark:
• The brake fluid level inside the reservoir should
be somewhere between the MIN and MAX marks
indicated.
BLEEDING THE HYDRAULIC SYSTEM

Attention:
• Prior to conducting any repair or maintenance
of the brake system, or if you suspect the
presence of air inside the brake pipeline, you
should first try to discharge air from the brake
system.
Remark:
• If there is air inside the brake pump, you must first
release the air in the brake master cylinder prior to
discharging the air in the brake pump sub-assem-
bly or the brake calipers.
1. Release air from brake master cylinder
(a) After shutting down the engine, step on the brake pedal
repeatedly until booster pressure has been completely
discharged.
(b) Disconnect front brake pipe from brake master cylinder.
(c) Top up brake fluid until it begins to flow out of the brake
pipe connection.
(d) Connect brake pipe to the brake master cylinder.
Brake System 07-7
(e) Step on the brake pedal slowly and remain in this posi-
tion.
(f) Remove the front brake pipe from the brake master cyl-
inder, release air from the master cylinder.
(g) Secure brake pipe, then release brake pedal slowly.
(h) Repeat steps (e) to (g) 3 to 4 times until all the air inside
the master cylinder has been discharged.
Remark:
• Discharge air via the other brake pipe connection
using the same method.
2. Release air from brake pipeline

(a) Connect the plastic tube to the air bleed screw and then
place the other end of the plastic tube into the desig-
nated container to prevent spilling of the brake fluid.
(b) Step on the brake pedal a few times and then loosen
the air bleed screw while stepping on the pedal to dis-
charge air from the brake pipeline.
(c) Continue until there are no longer any air bubbles in the
brake fluid. Then, tighten the air bleed screw and then
finally release the brake pedal.
Air bleed screw tightening torque: 11 N•m
(d) Repeat steps (b) and (c) until all air has been dis-
charged from the brake fluid.
(e) Repeat the aforementioned steps, discharging air from
each wheel's brake pipeline in sequence from furthest
to nearest.
07-8 Brake System
FRONT BRAKE HOSE

REMOVAL
3. Remove front brake hose
(a) Remove brake hose clip, disconnect oil pipe.
Attention:
spills out.
(b) Remove brake hose from front damper.
(c) Remove the bolt on the brake caliper.

(d) Remove seal ring and brake hose.
Installation
Attention:
• Replace seal rings.
• Release air from the system.
Brake System 07-9
REAR BRAKE HOSE

Removal
3. Remove rear brake hose
(a) Remove brake hose clip, disconnect oil pipe.
Attention:
spills out.
(b) Remove brake hose from torsion beam.
(c) Remove the bolt on the brake hub.

(d) Remove seal ring and brake hose.
Installation
Attention:
07-10 Brake System
VACUUM BOOSTER WITH BRAKE PUMP

ASSEMBLY
ON-BOARD INSPECTION
1. Check vacuum booster
(a) Check air tightness.
(1) Start the engine and then stop it after 1 or 2 minutes.
Good Poor Step on the brake pedal slowly a few times.
Tips:
• If you are able to step on the pedal all the way
on the first instance but you encounter resistance
increasingly earlier on the second and third at-
tempts, it means that the booster is well-sealed.
Third time (2) Step on the brake pedal when the engine is working
Second time
First time and then turn off the engine with your foot still on the
pedal.
Tips:
• Keep your foot on the pedal for 30 seconds. If the
pedal stroke margin remains the same, it means
that the booster is well-sealed.
(b) Conduct check.
AC
C ON
AC
C ON (1) With the ignition switch in the shut position, step on
L O CK
START
the brake pedal repeatedly and check the pedal travel

L O CK
START
margin remains the same.

(2) Step on the brake pedal and start the engine.
Tips:
• If the pedal shifts downwards gently, it means that
it is working normally.
2. Check vacuum check valve

Ventilation No ventilation
(a) Slide the clip and disconnect the vacuum booster hose.
(b) Remove vacuum check valve.
(c) Check that the passage between the booster and the
engine is well-ventilated, and that the space between
the engine to the booster is air tight.
(d) If a malfunction is found, replace vacuum check valve.
Brake System 07-11
REMOVAL
Slide the clip and disconnect the clutch reservoir pipe.
4. Disconnect fluid level warning indicator switch con-

nector
5. Disconnect the two brake oil pipes on the brake

master cylinder
6. Disconnect the brake vacuum hose assembly
7. Remove the vacuum booster with brake pump as-

sembly
(a) Remove brake pedal pin shaft and locking pin.
(b) Remove the 4 nuts that connect the brake pedal and
booster.
Installation
Attention: Remember to change out the oil.
07-12 Brake System
BRAKE MASTER CYLINDER

REMOVAL
4. Disconnect fluid level warning indicator switch con-
nector
5. Disconnect the 2 brake oil pipes on the brake mas-
ter cylinder
6. Remove brake master cylinder reservoir assembly
Remove 2 nuts and then pull out the brake master cylin-
der reservoir assembly.
7. Remove brake master cylinder assembly

(a) Pull out brake reservoir pin shaft.
Installation
Attention:
Brake System 07-13
BRAKE PEDAL
ON-BOARD INSPECTION
1. Check brake pedal height
(a) Loosen the brake switch until it is no longer in contact
with the brake pedal.
(b) Check brake pedal height.
Brake pedal height as measured from front
wall: 130 mm
2. Check pedal free travel
(a) Shut down the engine and step on the brake pedal a
number of times until there is no longer any vacuum in
the vacuum booster.
(b) Step on the brake pedal until you meet resistance, then
measure the distance traveled
Pedal free travel: 6-9 mm
REMOVAL
2. Remove dashboard
3. Separate main cylinder pushrod U-shaped clip
(a) Disconnect brake lamp switch connector
(b) Remove brake pedal return spring
(c) Remove the locking pin and the pin shaft, separate main
cylinder pushrod U-shaped clip from the brake pedal as-
sembly.
4. Dismantle brake pedal bracket assembly

(a) Remove bolt from brake pedal bracket assembly.
(b) Remove 4 nuts and brake pedal bracket assembly.
Installation
07-14 Brake System
BRAKE LAMP SWITCH ASSEMBLY

Removal
1. Remove brake switch
Depress the brake pedal as much as possible until the
switch piston cannot be pushed up further. Then, turn
the switch 45° clockwise and pull upwards to remove.
Installation
1. Install brake switch
Insert the brake lamp switch into the mounting hole.
Then, turn anti-clockwise 45° until you hear a "click"
sound. This means that it has been installed into posi-
tion.
Brake System 07-15
FRONT WHEEL BRAKE

SCHEMATICS
FRONT BRAKE CALIPER
1
2
10
×2
3
×2
×4
5 4
1. Bleed Screw Cap 6. Caliper Bracket

2. Bleed Screw 7. Guide Pin Dust Boot
3. Caliper Body 8. Sub-Pin
4. Brake Pad Spring 9. Brake Pad Assembly
5. Kingpin 10. Alarm Piece
07-16 Brake System
REPAIR PARAMETERS
Brake disc diameter (mm) Standard 295
Brake disc run-out (mm) Max. value 0.04
Standard 22
Brake disc thickness (mm)
Min. 19
Standard 12
Friction plate thickness (mm)
Min. value 2
Brake System 07-17

BRAKE PAD ASSEMBLY
CHECKS
3. Check thickness of inner and outer brake pad fric-
tion linings
Observe the thickness of the friction linings of the in-
ner and outer brake pad via the aperture on the caliper
body. If the thickness measured is thinner than the
minimum thickness stipulated, replace with a new brake
pad.
Min. thickness: 2.0 mm
Remark:
• If you hear a continuous shrill sound from the
front wheel when braking during the drive, check
the friction lining wear indicator for both the inner
and outer brake pads. If the wear indicator shows
signs of friction with the brake disc, replace the in-
ner and outer brake pad assemblies.
Removal
3. Separate caliper body assembly
(a) Remove the bolt that connects the caliper body with the
lower part of the caliper bracket.
(b) Lift the caliper body assembly and suspend the brake
oil pipeline using a rope for protection.
Attention:
• Do not loosen the brake oil pipe and air bleed
screw.
07-18 Brake System
4. Remove brake pad assembly

5. Remove friction plate spring
6. Measure thickness of inner and outer brake pad as-
semblies
Standard thickness: 8.5 mm
Replace brake pad if it is thinner than minimum thick-
nesses stipulated or if it shows signs of uneven wear.
INSTALLATION
1. Install yoke spring
Place the brake pad circlip on the caliper bracket.
2. Install inner and outer brake pad assemblies on the

caliper bracket
Attention:
• There should be no signs of oil/grease or dyes
on the inner and outer brake pad assemblies
or the working surfaces of the brake disc.
3. Install caliper body assembly

(a) Remove a small amount of brake fluid from the reservoir
(prevent brake fluid from spilling from the reservoir).
SST (b) Press the piston in using the SST tool.
Brake System 07-19
(c) Untie and lower caliper body assembly, tighten hexago-

nal flange bolt.
Tightening torque: (22-30) N•m

5. Check brake reservoir fluid levels
07-20 Brake System
FRONT BRAKE DISC

CHECK
3. Check front brake disc run-out
Tighten 2 diagonally-placed wheel nuts when measur-
ing, and measuring within the friction zone. If the mea-
sured distance exceeds guidelines, repair or replace.
Attention:
• The front brake disc brake surface run-out on
both sides must not exceed 0.04 mm.

Remove 2 bolts.
Attention:
Remove the front brake caliper and use a tool
such as steel wire to hang up and secure the
caliper (make sure that the brake oil pipeline is
not overly twisted, bent or otherwise discon-
nected).
5. Check front brake disc thickness

For the check, select 5 points scattered evenly around
the friction zone. Turn the disc one round after measur-
ing each spot before moving on to the next one.
Replace brake discs when the thickness measured is
thinner than the stipulated minimum thickness.
6. Check surface of front brake disc

Replace brake disc if you find significant scratches on it.
Brake System 07-21
Removal

The brake disc may become difficult to remove after a
period of use. At this juncture, you may screw two M8
bolts into the brake disc removal screw holes and then
use a wrench to screw the two bolts in turn to push out
the brake disc.
Installation
07-22 Brake System
REAR WHEEL BRAKE

SCHEMATICS
REAR BRAKE CALIPERS
6 ×2
×2
5
×2
4
×2
1. Caliper Body Assembly 5. Brake Pad Assembly

2. Bleed Screw 6. Pin Dust Boot
3. Yoke Spring Assembly 7. Guide Pin
4. Bracket
Brake System 07-23
REPAIR PARAMETERS
Brake disc diameter (mm) Standard 283.5
Brake disc run-out (mm) Max. value 0.08
Standard 9
Brake disc thickness (mm)
Min. 7.5
Standard 10
Friction plate thickness (mm)
Min. value 2
07-24 Brake System

BRAKE PAD ASSEMBLY
CHECK
3. Check thickness of inner and outer brake pad fric-
tion linings
Observe the thickness of the friction linings of the in-
ner and outer brake pad via the aperture on the caliper
body. If the thickness measured is thinner than the
minimum thickness stipulated, replace with a new brake
pad.
Remark:
• If you hear a continuous shrill sound from the
rear wheel when braking during the drive, check
the friction lining wear indicator for both the inner
and outer brake pads. If the wear indicator shows
signs of friction with the brake disc, replace the in-
ner and outer brake pad assemblies.
Removal
3. Separate caliper body assembly
(a) Remove the bolt that connects the caliper body with the
lower part of the caliper bracket.
(b) Lift the caliper body assembly and suspend the brake
oil pipeline using a rope for protection.
Attention:
• Do not loosen the brake oil pipe and air bleed
screw.
4. Remove brake pad assembly

5. Remove friction plate spring
Brake System 07-25
REAR BRAKE DISC

CHECK
3. Check rear brake disc run-out
Tighten 2 diagonally-placed wheel nuts when measur-
ing, and measuring within the friction zone. If the mea-
sured distance exceeds guidelines, repair or replace.
Attention:
• The rear brake disc brake surface run-out on
both sides must not exceed 0.08 mm.

Remove 2 bolts.
Attention:
Remove the rear brake caliper and use a tool
such as steel wire to hang up and secure the
caliper (make sure that the brake oil pipeline is
not overly twisted, bent or otherwise discon-
nected).
5. Check rear brake disc thickness

For the check, select 5 points scattered evenly around
the friction zone. Turn the disc one round after measur-
ing each spot before moving on to the next one.
Replace brake discs when the thickness measured is
thinner than the stipulated minimum thickness.
6. Check surface of rear brake disc

Replace brake disc if you find significant scratches on it.
07-26 Brake System
Removal

The brake disc may become difficult to remove after a
period of use. At this juncture, you may screw two M8
bolts into the brake disc removal screw holes and then
use a wrench to screw the two bolts in turn to push out
the brake disc.
Installation
Brake System 07-27
PARKING BRAKE
SCHEMATICS
1. Right Parking Brake Cable Assembly 3. Parking Brake Controller Assembly

2. Left Parking Brake Cable Assembly 4. Parking Brake Controller Bracket
07-28 Brake System
1. Parking brake lever throw (malfunction)
2. Parking brake cable (cracks or broken)
3. Parking brake shoe gap (malfunction)
Poor parking brake performance 4. Parking brake lining (broken or deformed)
5. Retaining spring or return spring (damaged)
6. Parking brake drum (worn or deformed)
7. Parking brake lining and brake drum contact surface insufficient
Brake System 07-29

CLEARANCE ADJUSTMENT
ON-BOARD INSPECTION
1. Check parking brake handle throw
Apply parking brake downwards; parking brake lock
should be applied within specified lock teeth count
range.
No. of lock teeth: (5-9).
If the lock teeth count is not within the stipulated range,
adjust parking brake.
SMALLER ADJUSTMENTS
3. Pull up parking brake handle
4. Remove upper auxiliary dashboard cover
5. Remove cigarette lighter mount
6. Remove auxiliary dashboard
7. Adjust locking nut tightness
07-30 Brake System
PARKING BRAKE CONTROLLER

Removal
2. Separate brake cable
Loosen adjusting nut.
3. Remove parking brake control mechanism

(a) Disconnect parking brake switch connector.
(b) Remove 2 bots and the parking brake control mecha-

nism.
Installation
Brake System 07-31
PARKING BRAKE CABLE

Removal
2. Separate brake cable
4. Remove exhaust pipe rear protective bracket
5. Remove secondary silencer
6. Remove front panel middle thermal insulating plate
7. Remove parking brake cable
(a) Remove 1 bolt and 1 clip (single-sided) from the bottom
torsion beam.
(b) Separate cable connector and brake caliper.
(c) Remove 6 bolts and 1 clip.

07-32 Brake System
ANTI-LOCK BRAKING SYSTEM

SCHEMATICS
1
2 3
12
13
6
14
11
10
15
9 7
1. Rear Right Wheel Speed Sensor Bracket No. 1 9. Front Left Wheel Speed Sensor Bracket No. 2
2. Rear Wheel Speed Sensor Assembly 10. Abs Bracket Assembly
3. Rear Right Wheel Speed Sensor Bracket No. 2 11. Abs Hydraulic Pump Damping Pad
4. Rear Left Wheel Speed Sensor Bracket No. 1 12. Abs Hydraulic Control Unit
5. Rear Wheel Speed Sensor Assembly 13. Front Wheel Speed Sensor Assembly
6. Rear Left Wheel Speed Sensor Bracket No. 2 14. Front Right Wheel Speed Sensor Bracket No. 1
7. Front Wheel Speed Sensor Assembly 15. Front Right Wheel Speed Sensor Bracket No. 2
8. Front Left Wheel Speed Sensor Bracket No. 1
Brake System 07-33
DIAGRAM
The system uses a X-type layout. The ABS 9 hydraulic regulator comprises a motor, two reflux pumps,
two accumulators and eight solenoid valves.
MC2 MC1
RP2 RP1
M
RLEV A2 FREV FLEV A1 RREV
RLAV FRAV FLAV RRAV
RL FR FL RR
MC1 Brake master cylinder loop No. 1 RR Rear right wheel

MC2 Brake master cylinder loop No. 2 FLEV Front left wheel intake valve
M Motor FLAV Front left wheel fluid outlet valve
RP1 Reflux pump No. 1 FREV Front right wheel fluid intake valve
RP2 Reflux pump No. 2 FRAV Front right wheel fluid outlet valve
A1 Accumulator No. 1 RLEV Rear left wheel fluid intake valve
A2 Accumulator No. 2 RLAV Rear left wheel fluid outlet valve
FL Front left wheel RREV Rear right wheel fluid intake valve
FR Front right wheel RRAV Rear right wheel fluid outlet valve
RL Rear left wheel — —
07-34
Valve block
FL FR RL RR
IN OUT IN OUT IN OUT IN OUT

RFP-motor
D0 T0 T1
M
4A 4B 2A 2B 1A 1B 3A 3B
Valve relay Motor relay
UZP
UVR
VRG
UMR
MRG
ECU CONNECTORS AND CIRCUIT
C101
C102
SW Wheel speed
Sensor output
ASIC
VSO
GND_ECU
NEBD_SLAMP
NABS_SLAMP
BLS
DIAGK
CAN1P
CAN1M
WSS_FL
WSP_FL
WSS_FR
WSP_FR
WSS_RL
WSP_RL
WSS_RR
WSP_RR
WSO_FR
Brake System
WAU_IN1
GND_MR
GND_ECU
UB_MR
UB_VR
K2
13 38 1 25 28 3 27 30 2 33 6 26 14 8 19 4 16 18 31 2917
K1
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
4.0
2.5
4.0
2.5
0.5
0.5
0.5
0.5
K12 K14 K16 K18
5A
VSO
40 A
25 A
K11 K13 K15 K17
+
BLS H L
K1.15
( ignition ) K2 FL FR RL RR
1 2 12 13 Active wheel speed
14 24
25 26 37 38 sensor
Brake System 07-35
ECU PIN DEFINITIONS
2 3 4 5 6 7 8 9 10 11 12
1 13
14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38
Pin Function Pin Function

1 Motor anode 20 Undefined
2 Undefined 21 Undefined
Wheel speed sensor signal terminal
4 23 Undefined
(front right)
6 Undefined 25 Valve relay power terminal
7 Undefined 26 CAN H (CAN Hi)
8 27 Undefined
(front left)
ECU power terminal (ignition power sup-
9 Undefined 28
ply cord)
Wheel speed sensor signal terminal (rear
10 Undefined 29
right)
11 Undefined 30 Brake lamp switch
Wheel speed sensor power terminal (rear
12 Undefined 31
left)
13 Motor ground terminal 32 Undefined
14 CAN L (CAN Lo) 33 Speed output
Wheel speed sensor power terminal
16 35 Undefined
(front right)
17 36 Undefined
(rear right)
18 37 Undefined
(rear left)
19 38 ECU ground terminal
(front left)
07-36 Brake System
Tightening
Tightening locations Quantity
torque (N•m)
ABS bracket assembly and vehicle body 23±3 4
Front wheel speed sensor cabling bracket and steering knuckle 10 2
Front wheel speed sensor assembly and steering knuckle 10 2
Rear wheel speed sensor cabling assembly and rear wheel hub 10 2
Rear wheel speed sensor cabling bracket 2 and vertical arm assembly 23 2
Rear wheel speed sensor bracket 3 and vertical arm assembly 23 2
Rear wheel speed sensor bracket 1 and vehicle body 10±2 2
Brake System 07-37
TROUBLESHOOTING
MATTERS OF NOTE DURING TROUBLE-
SHOOTING
The ABS is a part of the vehicle that relates to safety.
Therefore, when carrying out diagnostics and/or repair
on the ABS, apart from adopting all general safety and
preventive measures you must also abide by the follow-
ing items.
1. When ABS system components need to be repaired
or replaced, please use parts from the original
equipment manufacturer
2. Prior to conducting diagnostics on the ABS, you

must first eliminate any faults with the basic brake
system, for instance:
(a) Brake system noise.
(b) Brake pedal overly stiff.
(c) Brake pedal or vehicle vibrations with regular braking.
(d) Braking deviation.
(e) Parking brake system fault.
3. ABS assembly (refers to ABS electronic control unit

and hydraulic regulator assembly, but does not in-
clude accessories such as brake pipeline, sensor,
etc.) should only be replaced as a whole and must
not be dismantled or have its parts substituted.
4. The following two situations indicate that the ABS
has detected a fault
(a) Turn on the ignition switch, and the Warning indicator
will remain lit after system self-check is complete.
(b) Warning indicator will remain lit during the drive.
When an ABS fault has been detected, the driver will
still be able to brake normally. However, the driver
should try to minimize the braking force applied in order
to reduce the risk of wheel lock. Once the Warning indi-
cator comes on, drive carefully and head immediately to
a service center for repair to prevent the occurrence of
more faults and traffic accidents.
07-38 Brake System
5. Pay attention to the following when connecting the

ABS and sensor cabling
(a) You must turn off the ignition switch before removing
ABS and sensor cabling.
(b) Check that the connector is dry and clean to prevent the
entry of any foreign matter.
(c) The ABS cabling connector must be installed horizon-

tally and vertically into position to prevent any damage
to the connector.
6. Make sure that ABS brake pipelines are correctly

connected
The ABS ECU cannot determine if brake pipelinecon-
nections have been made correctly. Incorrect connec-
tions can cause serious consequences. When connect-
ing the brake pipeline you must follow the marks on the
ABS assembly:
(a) MC1: brake pipeline No. 1 that is connected to the brake
master cylinder;
(b) MC2: brake pipeline No. 2 that is connected to the brake
master cylinder;
(c) FL: brake pipeline that is connected to the front left
wheel brake cylinder;
(d) FR: brake pipeline that is connected to the front right
(e) RL: brake pipeline that is connected to the rear left
(f) RR: brake pipeline that is connected to the rear right
7. The ABS will produce noise in the following circum-
stances
(a) You will hear a short buzzing sound when the vehicle
has just been powered or when the engine has been
started. This is the sound of the ABS self-check process
and is normal.
(b) When EBD intervenes in the braking process, the sole-
noid valve will produce a certain level of noise. This is
normal.
Brake System 07-39
(c) ABS will produce sounds as part of its normal function-

ing and which are produced from the following sources.
Sounds from the workings of the ABS hydraulic unit mo-
tor, solenoid valve and reflux pump.
Sounds from the bounce back of the brake pedal.
Sounds from the contact between the suspension and
vehicle body due to emergency braking.
07-40 Brake System
PRELIMINARY CHECKS
Before conducting diagnostics of the ABS, first check
the components that may cause ABS faults and which
are easily accessible. Also, the visual inspection and
exterior examination procedure can help to identify the
fault quickly without the need for further diagnostics.
1. Check the the vehicle is fitted with tires and wheels
of the recommended size. Tires on the same axis
must have a similar tire tread design and tread depth.
2. Check for signs of leakage from the ABS hydraulic
regulator, brake pipeline and connections.
3. Check the ABS fuse for signs of burnout and to en-
sure that the right model is being used.
The ABS system has three fuses, which are the:
(a) Pump motor fuse (40 A)
(b) Solenoid valve fuse (25 A)
(c) Electronic control unit fuse (5 A)
4. Check battery voltage as well as for signs of corro-
sion or displacement of the battery terminals.
The normal working voltage range for the ABS
system is 9.3 V-16.8 V
5. Check that the ABS grounding point is not loose or
if its position has changed.
6. The ABS ground wire must be well-sealed to pre-
vent any water or water vapor from seeping into the
ABS electronic control unit via the cable and thus
rendering it ineffective.
Measures to be taken:
Apply sealant to exposed sections of cable and then
use heat shrink tubing as further protection.
Apply sealant to exposed sections of cable and

then use heat shrink tubing as further protection.
Ignition coil/ 7. Conduct a visual inspection and exterior examina-

Ignition cable/ tion of the following electric components
Ignition plug (a) Check that the relevant ABS component cabling and
Gear ring
connectors are connected properly and that they have
not been cut or otherwise damaged.
Generator
(b) Check that the cabling is not situated too close high-
voltage or high-current installations or components, mo-
Wheel speed sensor
tors and generators, or stereo amplifiers added follow-
ing the purchase of the vehicle.
Attention:
• High-voltage or high-current equipment can
cause noise in the circuitry and hence affect
its normal functioning.
(c) ABS components are highly sensitive to electromagnetic
interference. If you suspect an intermittent fault, check
that lamps, portable phones and anti-theft devices ac-
quired following the purchase of the vehicle have been
installed correctly.
Brake System 07-41
8. The ABS is an active safety system. Its key function

Hydro-
planing
is to maximize ground grip to maintain vehicle con-
Hydroplaning
Water trol and drive stability. However, when physical lim-
layer
its have been exceeded or when the vehicle is being
Cannot be attached
driven on wet and slippery roads, the ABS will not
be able to prevent instances of vehicle sliding in all
instances.
9. Overly loud ABS noises can be due to the following

(a) Loosening of ABS assembly with bracket.
(b) Loosening of ABS bracket with vehicle body.
(c) ABS bracket plastic gasket missing or damaged.
07-42 Brake System
DIAGNOSIS FLOWCHART
1 Vehicle to be sent to manufacturer for repair
2 Analyse the issue
3 Obtain DTC
DTC present Move on to step 4
No DTC found Move on to step 6
4 Record DTC, then delete code.
Confirm and recreate fault: Accelerate vehicle to a speed above 25 km/h in order to
5
simulate the fault environment and to obtain DTC
DTC present Current DTC. Move on to step 7
DTC has arisen before. Move on to

No DTC found
step 8
6 Deal with no-code fault, then move on to step 9
7 Conduct troubleshooting according to DTC Checklist, then move on to step 9
8 Conduct troubleshooting according to fault symptoms, then move on to step 9
9 Confirm that the fault has been remedied, conduct post-repair test
10 Prevent fault from re-occurring
End
Brake System 07-43
DEALING WITH NO-CODE FAULTS

If there is a fault with the brake system but no DTCs have been saved in the ABS, the fault is known
as a no-code fault. No-code faults are typically caused by faults in the basic brake system. For in-
stance:
• Brake fluid leak (may lead to 'softer' brakes, overly long brake pedal travel, and even total loss of
brake performance in severe cases)
• Use of poor-quality brake fluid (use of poor-quality brake fluid can lead to corrosion of the brake pipe-
line and ABS hydraulic pressure regulator components and even total loss of brake performance in
severe cases)
• Air present inside brake pipeline (may lead to 'softer' brakes or even loss of brake performance en-
tirely)
• Blockage in brake pipeline (may lead to 'stiffer' brakes, brake deviation or even loss of brake perfor-
mance entirely)
• Excessive brake disc wear (may lead to 'softer' brakes, overly-long brake pedal travel)
• Booster fault (may lead to 'softer' or 'stiffer' brakes, overly long brake pedal travel, and even total loss
of brake performance in severe cases)
• Incorrect brake pipeline connections (may lead to compromised ABS performance, drifting, long brak-
ing distances, etc.) For the correct connection method, please refer to the markings near the oil ap-
ertures on the ABS hydraulic pressure regulator module: MC1 indicates main cylinder pipeline No. 1;
MC2 indicates main cylinder pipeline No. 2; FL stands for front left wheel cylinder pipeline; FR stands
for front right wheel cylinder pipeline; RL stands for rear left wheel cylinder pipeline; RR stands for
rear right wheel cylinder pipeline)
Attention:
• Lack of power or abnormal cutting off of power supply to ABS will cause the ABS/EBD in-
dicator to light up without a DTC recorded.
Suggestion for fault elimination: Check the corresponding parts based on fault symptoms and elimi-
nate faults using the vehicle repair and maintenance manual.
07-44 Brake System
DEALING WITH INTERMITTENT FAULTS

Within the electrical system, spontaneous contact issues may arise in the electric circuit and input/
output signal transmission points to cause intermittent faults. Sometimes, the cause for the fault may
go away on its own, which is why identifying the cause may be somewhat of a challenge. When you
encounter an intermittent fault, take the following steps to try and simulate the fault.
Possible causes Fault simulation Remark

Shake the ABS electronic controller unit Replace parts if the cabling has been
connector gently on the ground from left twisted broken or has broken due to ten-
to right and from top to bottom sion.
Shake the ABS cabling connector gently When the vehicle is moving, the wheel
When vibrations
on the ground from left to right and from speed sensor cabling may cause momen-
may be the chief
top to bottom tary open circuits/short circuits as it moves
cause
Shake the sensor gently on the ground up and down together with the suspension
from left to right and from top to bottom system. Therefore, you must conduct a
Shake other components (including the drive test of the vehicle when checking
wheel bearing) gently sensor cabling.
Use a blower to warm up the part you
When temperature
suspect to be at fault
may be the chief —
Use a cold spray to check for signs of
cause
cold welding
When an overly
Turn on all appliance switches, including
high power load
the headlamp and wiper switches, etc., to —
may be the chief
have the vehicle work on high load.
cause
If the fault does not appear at this juncture, you will have to wait for the next time it occurs in order to
conduct another round of diagnostics and repair. Generally speaking, intermittent faults will become
eventually become reproducible faults that will not disappear on their own.
Brake System 07-45
DTC CHECKLIST
DTC Fault description
C190004 ECU voltage too high
C190104 ECU voltage too low
C100004 ECU fault (hardware, microcontroller error)
C101008 ECU malfunction (software error)
C006B06 Unexpected ABS controller command (control time too long)
Front left wheel speed sensor fault: outside of expected range, lost, noise, intermittent dis-
C003108
connection
C003200 Front left wheel speed sensor wiring fault: open circuit
C00A000 Front left wheel speed sensor wiring fault: shorted to ground
C00A100 Front left wheel speed sensor wiring fault: shorted to power supply
C00A900 Front left wheel speed sensor fault: cause unknown
Front right wheel speed sensor fault: outside of expected range, lost, noise, intermittent
C003408
disconnection
C003500 Front right wheel speed sensor wiring fault: open circuit
C00A200 Front right wheel speed sensor wiring fault: shorted to ground
C00A300 Front right wheel speed sensor wiring fault: shorted to power supply
C00AA00 Front right wheel speed sensor fault: cause unknown
Rear left wheel speed sensor fault: outside of expected range, lost, noise, intermittent dis-
C003708
connection
C003800 Rear left wheel speed sensor wiring fault: open circuit
C00A400 Rear left wheel speed sensor wiring fault: shorted to ground
C00A500 Rear left wheel speed sensor wiring fault: shorted to power supply
C00AB00 Rear left wheel speed sensor fault: cause unknown
Rear right wheel speed sensor fault: outside of expected range, lost, noise, intermittent
C003A08
disconnection
C003B00 Rear right wheel speed sensor wiring fault: open circuit
C00A600 Rear right wheel speed sensor wiring fault: shorted to ground
C00A700 Rear right wheel speed sensor wiring fault: shorted to power supply
C00AC00 Rear right wheel speed sensor fault: cause unknown
Wheel speed sensor assembly fault (interchanging of wheel speed sensors, wheel speed
C109904
differentials too high, faults with multiple sensors)
07-46 Brake System
U000500 CAN bus voltage too high

U000700 CAN bus voltage too low
C100104 CAN bus hardware fault
U000104 CAN bus shut
U100104 CAN bus passive error
C001004 Front left inlet valve fault
C001104 Front left outlet valve fault
C001404 Front right inlet valve fault
C001504 Front right outlet valve fault
C001804 Rear left inlet valve fault
C001904 Rear left outlet valve fault
C001C04 Rear right inlet valve fault
C001D04 Rear right outlet valve fault
C109504 Valve relay fault
C002004 Reflux pump motor faults
C007208 Valve assembly fault (overheating protection, invalid signal, damaged hardware)
C121208 Variable coder fault
Brake System 07-47
FAULT DIAGNOSIS
ECU VOLTAGE TOO HIGH OR TOO LOW
1. DTCs: C190004; C190104
2. Fault conditions
This fault will arise when one or more of the following ECU power voltage conditions occurs:
(a) Vehicle start-up voltage lower than 4.5 V.
(b) Ignition switch in ON position with voltage lower than 7.7 V or higher than 16.8 V.
(c) Voltage between 7.7 V and 9.2 V when vehicle speed is greater than 6 km/h.
3. Possible causes
(a) Battery voltage too high or too low.
(b) ECU damaged.
4. Troubleshooting steps
Steps Operation Yes No
Conduct pre-
1 Have you conducted a preliminary check? Go on to step 2
liminary check
Check battery voltage Have you discovered a fault and rem-
2 edied it? For pin definitions, refer to the specific circuit diagram Go on to step 4 Go on to step 3
in question.
Conduct cross-validation on ABS (for specific steps, please re-
fer to the selection titled "Disassembly and Installation"); if the
3 Go on to step 4 -
electronic control unit is found to be damaged, replace ABS.
Have you remedied the fault?
End trouble-
4 Diagnose again to see if fault has re-appeared? -
shooting
SOLENOID VALVE AND VALVE RELAY FAULTS

1. DTCs: C101004; C101104; C101404; C101504; C101804; C101904; C101C04; C001D04; C109504;
C007208
2. Fault conditions
(a) Valve power supply malfunction. (Power supply shorted to ground, or ground circuit open)
(b) Solenoid valve temperature too high. (Overheating protection)
(c) More than 5 solenoid valve short circuits. (Fuse)
(d) The corresponding solenoid valve is actuated to no feedback.
(e) Solenoid valve fault.
(f) Solenoid valve relay fault.
3. Possible causes
(a) Solenoid valve shorted to power supply or ground, open circuit (poor connections).
(b) Fuse fault.
(c) System overheating protection (solenoid valve working time too long, commonly seen during the cre-
ating of vacuum/topping up of pipelines and offline tests).
(d) ABS damaged.
07-48 Brake System

1 Cool the vehicle for 5 minutes. Has the fault been eliminated? - Go on to step 2
Conduct pre-
liminary check
Test connector solenoid valve pin voltage, check fuse, external
relay, connectors, cabling and ground wire. Have you discov-
3 Go on to step 5 Go on to step 4
ered a fault and remedied it? For pin definitions, refer to the
ABS9 ECU circuit diagram
Conduct cross-validation on ABS (for specific steps, please
refer to the selection titled "Disassembly and Installation"); if
4 Go on to step 5 -
the ABS is found to be damaged, replace ABS. Have you rem-
edied the fault?
Accelerate vehicle to 25 km/h, then stop the vehicle. Conduct End trouble-
5 -
diagnosis again. Is the fault still present? shooting
PUMP MOTOR FAULT

1. DTC: C002004
2. Fault conditions
(a) Pump motor overloaded, temperature too high. (Overheating protection)
(b) Reflux pump monitor unable to detect voltage signal after reflux pump motor relay works for 60 ms.
(c) Reflux pump monitor detects voltage for longer than 2.5 s when the reflux pump motor relay is not
working.
(d) Reflux pump monitor does not detect voltage decrease when the reflux pump motor relay stops work-
ing.
3. Possible causes
(a) Pump motor not grounded properly.
(b) System overheating protection.
(c) Abnormal pump motor power supply. (Fuse, battery terminal)
(d) Pump motor relay fault.
(e) Pump motor fault.

1 Cool the vehicle for 5 minutes. Has the fault been eliminated? - Go on to step 2
Conduct pre-
liminary check
Test connector pump motor pin voltage, check connectors,
cabling and ground wire. Have you discovered a fault and
remedied it? For pin definitions, refer to the ABS9 ECU circuit
diagram
4 Go on to step 5 -
edied the fault?
5 -
Brake System 07-49
WHEEL SPEED SENSOR WIRING FAULTS

1. DTCs: C003200; C00A000; C00A100; C00A900; C003500; C00A200; C00A300; C00AA00;
C003800; C00A400; C00A500; C00AB00; C003B00; C00A600; C00A700; C00AC00; C109904
2. Fault conditions
(a) Electronic control unit detects wheel speed sensor signal line shorted to ground.
(b) Wheel speed sensor circuit is open.
3. Possible causes
(a) Wheel speed sensor circuitry open, or connectors loose/broken.
(b) Wheel speed sensor signal and power cords connected the wrong way round.
(c) Signal line shorted to earth.
(d) Sensor head or connector pin damaged.

Conduct pre-
liminary check
Check wheel speed sensor connections and sensor cabling
for poor connections, open circuits or short circuits. Have you
discovered a fault and remedied it? For pin definitions, refer to
the ABS9 ECU circuit diagram
3 Go on to step 4 -
edied the fault?
4 -
WHEEL SPEED SENSOR SIGNALING FAULTS

1. DTCs: C003108; C00A900; C003408; C00AA00; C003708; C00AB00; C003A08; C00AC00;
C109904
2. Fault conditions
(a) Electronic control unit detects wheel speed sensor signal line shorted to power supply.
(b) Electronic control unit detects wheel speed sensor power cord shorted to ground.
(c) Abnormal wheel speed sensor signals.
3. Possible causes
(b) Wheel speed sensor signal line shorted to power supply.
(c) Wheel speed sensor power cord shorted to ground.
(d) Gear ring not installed, missing teeth, foreign matter in gear ring, gear ring de-magnetized, gear ring
off-center.
(e) Sensor and gear ring clearance too large.
(f) Wheel speed sensor experienced magnetic interference from external sources. (wheel or axis not de-
magnetized)
(g) Wheel speed sensor fault.
(h) Gear teeth count error.
(i) Tire size incorrect.
(j) ECU damaged.
07-50 Brake System

Conduct pre-
liminary check
Check wheel speed sensor connections and sensor cabling for
poor connections, open circuits or short circuits. Have you dis-
covered a fault and remedied it? For pin definitions, refer to the
specific circuit diagram in question.
Check the gap between wheel speed sensor and gear ring for
dirt, foreign matter, missing teeth as well as make sure that the
gear tooth count is correct. Have you discovered a fault and
remedied it?
Raise the vehicle using a lift, rotate wheels. Obtain wheel
speed sensor signal output using the diagnostic tester to check
if signals are within specified range. Have you discovered a
fault?
Disconnect wheel speed sensor connector, insert the two con-
nector pins into the 12 V power source and connect ammeter To replace the
with the power source cathode connected to the power pin and wheel speed
5 Go on to step 2
the anode, to the signal pin. Turn wheels slowly and observe sensor, perform
ammeter. Is the current reader between approx. 7 mA and step 7
14 mA?
Conduct cross-validation on ABS (for specific steps, please re-
fer to the selection titled "Disassembly and Installation"); if the
6 Go on to step 7 -
electronic control unit is found to be damaged, replace ABS.
Have you remedied the fault?
7 -
Attention:
• With wheel speed sensor signal faults, after remedying the fault you must start the ve-
hicle and bring it to a speed above 25 km/h to turn off the ABS indicator.
• Do not measure the power voltage from the wheel speed sensor to the ECU. As long as
the sensor return circuit is open somewhere along the line the ECU will automatically cut
off power supply and will only resume power supply after conducting a self-check at the
next ignition.
Brake System 07-51
ECU FAULTS
1. DTCs: C100004; C101008
2. Fault conditions
(a) ECU power supply malfunction.
(b) ECU damaged.
3. Possible causes
(a) ECU fault.

Conduct pre-
liminary check
refer to the selection titled "Disassembly and Installation");
2 Go on to step 3 -
if the electronic control unit is found to be damaged, replace
ABS. Have you remedied the fault?
End trouble-
shooting
UNEXPECTED ABS CONTROLLER INSTRUCTIONS

1. DTC: C106B06
2. Fault conditions
(a) ABS receives continuous stream of commands (for longer than 1 minute).
3. Possible causes
(a) Continuous braking action on icy surface.
(b) Wheel speed differential too high.

Conduct pre-
liminary check
Check the wheel speed sensor and gear ring, has the fault
been remedied?
refer to the selection titled "Disassembly and Installation");
3 Go on to step 4 -
if the electronic control unit is found to be damaged, replace
ABS. Have you remedied the fault?
End trouble-
shooting
07-52 Brake System
CAN BUS FAULT

1. DTCs: U000500; U000700; C100104; U000104; U100104;
2. Fault conditions
Vehicle CAN bus communications, settings, cabling fault.
3. Possible causes
(a) CAN controller malfunction.
(b) Incompatible CAN settings.
(c) CAN shut down.

Conduct pre-
liminary check
Diagnose CAN bus hardware and software. For details, please
2 refer to the vehicle repair and maintenance manual. Have you Go on to step 4 Go on to step 3
discovered a fault and remedied it?
If you have found the ECU to be damaged, replace ABS. Have
3 Go on to step 4 -
you remedied the fault?
End trouble-
shooting
VARIABLE CODER FAULT

1. DTC: C121208
2. Possible causes
(a) Settings not established.
(b) Incompatible settings.

Conduct pre-
liminary check
2 Write in the correct settings using the diagnostic tester. Go on to step 3 -
End trouble-
shooting
Brake System 07-53
SYSTEM AIR DISCHARGE

ABOUT THE AIR DISCHARGE PROCEDURE
You must discharge air from the brake system after replacing system components (such as brake
fluid, brake pipeline, hydraulic unit) or when the brake pedal feels 'soft'.
The new hydraulic unit to be installed must be an ABS hydraulic regulator with electronic controller
which has been topped up with oil.
When discharging air, you must make sure that the brake system is structurally complete and that all
hydraulic units have been properly connected.
The hand brake must be engaged prior to air discharge.
Brake fluid is corrosive; therefore, wash off immediately if it comes into contact with skin.
DISCHARGING USING THE EXHAUST/FILLING UNIT (DISCHARGE PRESSURE 2 BAR)
Connect the exhaust/filling unit to the reservoir, and make sure that there
A is sufficient brake fluid to turn on the switch, set pressure at 2 bar
Open wheel cylinder air bleed screw until all air bubbles are discharged
B Sequence: rear left, front left, front right, rear right
Check brake pedal travel

C
If unsuccessful, conduct discharge with every wheel again

D
Check brake fluid level and ensure that it is

E
somewhere between the MIN and MAX levels marked
HYBRID MANUAL AND 2 BAR DISCHARGE METHOD

A is sufficient brake fluid to turn on the switch, set pressure at 2 bar
Step on brake pedal repeatedly

B1

C

D

E
07-54 Brake System
MANUAL DISCHARGE
Top up reservoir (to neck of filter)
A
Discharge air from each wheel cylinder via the steps below
Open air bleed screw

C

D
Close air bleed screw

E
Release brake pedal

F

G
If unsuccessful, conduct discharge procedure again

H
Check brake fluid level and ensure that it lies

I
Remark:
• Recommended X-loop sequence: rear left, front left, front right, rear right.
• The reservoir brake fluid level must not fall below the MIN level marked through the entire dis-
charge process.
Brake System 07-55
CROSS-VALIDATION
1. Remove ABS and install on another working vehicle
of similar make
(You can simply connect the controller unit connector
and not the oil pipe. However, you must make sure that
the connector does not loosen when the vehicle is mov-
ing.)
2. Calibrate and adjust ABS as needed
3. Drive the vehicle, making sure that vehicle speed
does not go lower than 25 km/h; allow the ABS to
perform a dynamic self-test and then obtain DTC.
07-56 Brake System

ABS HYDRAULIC CONTROL UNIT
REMOVAL
2. Remove ABS hydraulic control unit
(a) Disconnect ABS hydraulic control unit cabling.
(b) Disconnect six brake pipes.
(c) Remove ABS hydraulic control unit from its mounting
bracket.
Installation
FRONT WHEEL SPEED SENSOR

REMOVAL
4. Remove front wheel speed sensor
(a) Disconnect wheel speed sensor cabling.
(b) Open up vehicle body clip.
(c) Remove wheel speed sensor cabling from damper.
(d) Remove wheel speed sensor cabling from steering
knuckle.
(e) Remove 1 wheel hub bolt.
Installation
Brake System 07-57
REAR WHEEL SPEED SENSOR

REMOVAL
4. Remove rear wheel speed sensor
(a) Disconnect wheel speed sensor cabling.
(b) Remove wheel speed sensor cabling from torsion beam.
(c) Remove 1 wheel hub bolt.
Installation
07-58 Brake System
ESP
SCHEMATICS
1
2 3
5
12
13
6
14
11
10
15
9 7
1. Rear Right Wheel Speed Sensor Bracket No. 1 9. Front Left Wheel Speed Sensor Bracket No. 2
2. Rear Wheel Speed Sensor Assembly 10. ESP Bracket Assembly
3. Rear Right Wheel Speed Sensor Bracket No. 2 11. ABS Hydraulic Pump Damping Pad
4. Rear Left Wheel Speed Sensor Bracket No. 1 12. EPS Hydraulic Control Unit
5. Rear Wheel Speed Sensor Assembly 13. Front Wheel Speed Sensor Assembly
6. Rear Left Wheel Speed Sensor Bracket No. 2 14. Front Right Wheel Speed Sensor Bracket No. 1
7. Front Wheel Speed Sensor Assembly 15. Front Right Wheel Speed Sensor Bracket No. 2
8. Front Left Wheel Speed Sensor Bracket No. 1
Brake System 07-59
DIAGRAM
The system is based on a type-X hydraulic layout. The ESP 9 hydraulic regulator comprises one mo-
tor, one pressure sensor, two reflux pumps, two accumulators and twelve solenoid valves.
MC2 MC1
P
U
HSV2 USV2 USV1 HSV1
sRP2 sRP1
M
FREV RLEV RREV FLEV

RVR2 RVR1
A2 A1
FRAV RLAV RRAV FLAV
FR RL RR FL
MC1 Brake master cylinder loop No. 1 FLEV Front left wheel oil intake valve
MC2 Main brake cylinder loop No. 2 FLAV Front left wheel oil outlet valve
M Motor FREV Right left wheel oil intake valve
RP1 Reflux pump No. 1 FRAV Front right wheel oil outlet valve
RP2 Reflux pump No. 2 RLEV Rear left wheel oil intake valve
A1 Accumulator No. 1 RLAV Rear left wheel oil outlet valve
A2 Accumulator No. 2 RREV Rear left wheel oil intake valve
FL Front left wheel RRAV Rear right wheel oil outlet valve
FR Front right wheel HSV1 High-pressure switch valve No. 1
RL Rear left wheel HSV2 High-pressure switch valve No. 2
RR Rear right wheel USV1 Reflux control valve No. 1
UP Pressure transducer USV2 Reflux control valve No. 2
07-60
Valve block
FL FR RL RR USV1 USV2 HSV1 HSV2
IN OUT IN OUT IN OUT IN OUT

RFP-motor
D0 T0 T1 D1 T3
DRS AX/AY M DS8

ECU CIRCUIT DIAGRAM
4A 4B 2A 2B 1A 1B 3A 3B 7 5 8 6
Valve relay Motor relay IFS
UZP
IFS
UVR
VRG
UMR
MRG
PS_1D
PS_VS
PS_test
C101
C102
SW
PS_GND
Wheel speed
Sensor output
ASIC
MFL
WSS_FL
WSP_FL
WSS_FR
WSP_FR
WSS_RL
WSP_RL
WSS_RR
WSP_RR
GND_ECU
PALA
ESP_OFF
BLS
WSO_FR
HID_SW
CAN1P
CAN1M
CLUTCH
REV_GEAR
DIAGK
NEBD_SLAMP
NABS_SLAMP
VSO
Brake System
WAU_IN1
GND_MR
GND_ECU
UB_MR
UB_VR
K2
13 38 1 25 28 3 33 34 23 12 30 10 2 36 26 14 15 9 6 8 19 4 16 18 31 2917
K1
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
4.0
2.5
4.0
2.5
0.5
0.5
0.5
0.5 1
1
0.5 K12 K14 K16 K18
0.5
40 A
25 A
PATA +BLS K11 K13 K15 K17
0.5
0.5
+
VSO WSO_FR
5A
LH SAS FL FR RL RR
K2
K1.15
( ignition ) 1 2 12 13 Steering angle Active wheel speed
14 24
sensor sensor
25 26 37 38
Brake System 07-61
ECU PIN DEFINITIONS
2 3 4 5 6 7 8 9 10 11 12
1 13
14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38
Pin Function Pin Function

1 Motor anode 20 Undefined
2 Wheel speed output (front right) 21 Undefined
4 23 Undefined
(front right)
6 Undefined 25 Valve relay power terminal
7 Undefined 26 CAN1P (Hi)
8 Wheel speed sensor signal terminal (front left) 27 Undefined
9 Undefined 28 ECU power terminal (ignition power cord)
10 Speed output 29
(rear right)
11 Undefined 30 Brake light switch
12 ESP switch 31 Wheel speed sensor power terminal (rear left)
13 Motor ground terminal 32 Undefined
14 CAN1M (Lo) 33 Undefined
16 35 Undefined
(front right)
17 36 Undefined
(rear right)
18 Wheel speed sensor signal terminal (rear left) 37 Undefined
19 Wheel speed sensor power terminal (front left) 38 ECU ground terminal
07-62 Brake System
TROUBLESHOOTING
MATTERS OF NOTE DURING TROUBLE-
SHOOTING
The ESP is a part of the vehicle that relates to safety.
Therefore, when carrying out diagnostics and/or repair
on the ABS, apart from adopting all general safety and
preventive measures you must also abide by the follow-
ing items.
1. When ESP system components need to be repaired
or replaced, please use parts from the original
equipment manufacturer
2. Prior to conducting diagnostics on the ESP system,

you must first eliminate any faults with the basic
brake system, for instance:
(a) Brake system noise.
(b) Brake pedal overly stiff.
(c) Brake pedal or vehicle vibrations with regular braking.
(d) Braking deviation.
(e) Parking brake system fault.
3. ESP assembly (refers to ESP electronic control unit

and hydraulic regulator assembly, but does not in-
clude accessories such as brake pipeline, sensor,
etc.) should only be replaced as a whole and must
not be dismantled or have its parts substituted.
4. The following two situations indicate that the ESP
system has detected a fault
(a) Turn on the ignition switch, and the Warning indicator
will remain lit after system self-check is complete.
(b) Warning indicator will remain lit during the drive.
At this time, the driver will still be able to brake normally.
However, he or she should try to minimize the braking
force applied in order to reduce the risk of wheel lock.
Once the Warning indicator comes on, drive carefully
and head immediately to a service center for repair to
prevent the occurrence of more faults and traffic acci-
dents.
Brake System 07-63
5. Pay attention to the following when connecting the

ESP and sensor cabling
(a) You must turn off the ignition switch before removing
ESP and sensor cabling.
(b) Check that the connector is dry and clean to prevent the
entry of any foreign matter.
(c) The ESP cabling connector must be installed horizon-

tally and vertically into position to prevent any damage
to the connector.
6. Make sure that ESP brake pipelines are correctly

connected
The ESP electronic controller cannot determine if brake
pipeline connections have been made correctly. Incor-
rect connections can cause serious consequences.
When connecting the brake pipeline you must follow the
marks on the ESP assembly:
(a) MC1: brake pipeline No. 1 that is connected to the brake
master cylinder;
(b) MC2: brake pipeline No. 2 that is connected to the brake
master cylinder;
(c) FL: brake pipeline that is connected to the front left
(d) FR: brake pipeline that is connected to the front right
(e) RL: brake pipeline that is connected to the rear left
(f) RR: brake pipeline that is connected to the rear right
7. The ESP will produce noise in the following circum-
stances
(a) You will hear a short buzzing sound when the vehicle
has just been powered or when the engine has been
started. This is the sound of the ESP self-check process
and is normal.
(b) ESP will produce sounds as part of its normal function-
ing and which are produced from the following sources.
Sounds from the workings of the ESP hydraulic unit mo-
tor, solenoid valve and reflux pump.
Sounds from the bounce back of the brake pedal.
Sounds from the contact between the suspension and
vehicle body due to emergency braking.
07-64 Brake System
PRELIMINARY CHECKS
Before conducting diagnostics of the ESP system, first
check the components that may cause ESP system
faults and which are easily accessible. Also, the visual
inspection and exterior examination procedure can help
to identify the fault quickly without the need for further
diagnostics.
1. Check the the vehicle is fitted with tires and wheels
of the recommended size. Tires on the same axis
must have a similar tire tread design and tread
depth
2. Check for signs of leakage from the ESP hydraulic
regulator, brake pipeline and connections.
3. Check the ESP fuse for signs of burnout and to en-
sure that the right model is being used.
The ESP system has three fuses, which are the:
(a) Pump motor fuse (40 A)
(b) Solenoid valve fuse (25 A)
(c) Electronic control unit fuse (5 A)
4. Check battery voltage as well as for signs of corro-
sion or displacement of the battery terminals.
The normal working voltage range for the ESP
system is 9.3 V-16.8 V
5. Check that the ESP grounding point is not loose or
if its position has changed.
6. The ESP ground wire must be well-sealed to prevent
any water or water vapor from seeping into the ESP
electronic control unit via the cable and thus ren-
dering it ineffective.
Measures to be taken:
Apply sealant to exposed sections of cable and then
use heat shrink tubing as further protection.
Apply sealant to exposed sections of cable and

then use heat shrink tubing as further protection.
7. Conduct a visual inspection and exterior examina-

Ignition coil/
Ignition cable/ tion of the following electric components
Gear ring Ignition plug (a) Check that the relevant ESP component cabling and
connectors are connected properly and that they have
not been cut or otherwise damaged.
Generator
(b) Check that the cabling is not situated too close high-
voltage or high-current installations or components, mo-
Wheel speed sensor tors and generators, or stereo amplifiers added follow-
ing the purchase of the vehicle.
Attention:
• High-voltage or high-current equipment can
cause noise in the circuitry and hence affect
its normal functioning.
Brake System 07-65
(c) ESP components are highly sensitive to electromagnetic

interference. If you suspect an intermittent fault, check
that lamps, portable phones and anti-theft devices ac-
quired following the purchase of the vehicle have been
installed correctly.
8. The ESP is an active safety system. Its key function
Hydro-
planing
is to maximize ground grip to maintain vehicle con-
Hydroplaning
Water trol and drive stability. However, when physical lim-
layer
its have been exceeded or when the vehicle is being
Cannot be attached
driven on wet and slippery roads, the ESP will not
be able to prevent instances of vehicle sliding in all
instances.
9. Overly loud ESP noises can be due to the following

(a) Loosening of ESP assembly within bracket.
(b) Loosening of ESP bracket within vehicle body.
(c) ESP bracket plastic gasket missing or damaged.
07-66 Brake System
DIAGNOSIS FLOWCHART
1 Vehicle to be sent to manufacturer for repair
2 Analyse the issue
3 Obtain DTC
DTC present Move on to step 4
No DTC found Move on to step 6
4 Record DTC, then delete code.
Confirm and recreate fault: Accelerate vehicle to a speed above 40 km/h in order to
5
simulate the fault environment and to obtain DTC
DTC present Current DTC. Move on to step 7
DTC has arisen before. Move on to

No DTC found
step 8
6 Deal with no-code fault, then move on to step 9
7 Conduct troubleshooting according to DTC Checklist, then move on to step 9
8 Conduct troubleshooting according to fault symptoms, then move on to step 9
9 Confirm that the fault has been remedied, conduct post-repair test
10 Prevent fault from re-occurring
End
Brake System 07-67
DEALING WITH NO-CODE FAULTS

If there is a fault with the brake system but no DTCs have been saved in the ESP, the fault is known
as a no-code fault. No-code faults are typically caused by faults in the basic brake system. For in-
stance:
• Brake fluid leak (may lead to 'softer' brakes, overly long brake pedal travel, and even total loss of
brake performance in severe cases)
• Use of poor-quality brake fluid (use of poor-quality brake fluid can lead to corrosion of the brake pipe-
line and ESP hydraulic pressure regulator components and even total loss of brake performance in
severe cases)
• Air present inside brake pipeline (may lead to 'softer' brakes or even loss of brake performance en-
tirely)
• Blockage in brake pipeline (may lead to 'stiffer' brakes, brake deviation or even loss of brake perfor-
mance entirely)
• Excessive brake disc wear (may lead to 'softer' brakes, overly-long brake pedal travel)
• Booster fault (may lead to 'softer' or 'stiffer' brakes, overly long brake pedal travel, and even total loss
of brake performance in severe cases)
• Incorrect brake pipeline connections (may lead to compromised ESP performance, drifting, long brak-
ing distances, etc.) For the correct installation method, please refer to the markings close to the oil
apertures on the ESP hydraulic pressure regulating module: MC1 indicates master cylinder pipeline
1; MC2 indicates master cylinder pipeline No. 2; FL stands for front left wheel cylinder pipeline; FR
stands for front right wheel cylinder pipeline; RL stands for rear left wheel cylinder pipeline; RR stands
for rear right wheel cylinder pipeline)
Attention:
• Lack of power or abnormal cutting off of power supply to ESP will cause the ABS and
ESP indicators to light up without a DTC recorded.
Suggestion for fault elimination: Check the corresponding parts based on fault symptoms and elimi-
nate faults using the vehicle repair and maintenance manual.
07-68 Brake System
DEALING WITH INTERMITTENT FAULTS

Within the electrical system, spontaneous contact issues may arise in the electric circuit and input/
output signal transmission points to cause intermittent faults. Sometimes, the cause for the fault may
go away on its own, which is why identifying the cause may be somewhat of a challenge. When you
encounter an intermittent fault, take the following steps to try and simulate the fault.
Possible causes Fault simulation Remark

Shake the ESP electronic controller unit Replace parts if the cabling has been
connector gently on the ground from left twisted broken or has broken due to ten-
to right and from top to bottom sion.
Shake the ESP cabling connector gently When the vehicle is moving, the wheel
When vibrations
on the ground from left to right and from speed sensor cabling may cause momen-
may be the chief
top to bottom tary open circuits/short circuits as it moves
cause
Shake the sensor gently on the ground up and down together with the suspension
from left to right and from top to bottom system. Therefore, you must conduct a
Shake other components (including the drive test of the vehicle when checking
wheel bearing) gently sensor cabling.
Use a blower to warm up the part you
When temperature
suspect to be at fault
may be the chief —
Use a cold spray to check for signs of
cause
cold welding
When an overly Turn on all appliance switches, including
high power load the A/C, headlamp, audio system, wiper
—
may be the chief switches, etc., to have the vehicle work
cause on high load.
If the fault does not appear at this juncture, you will have to wait for the next time it occurs in order to
conduct another round of diagnostics and repair. Generally speaking, intermittent faults will become
eventually become reproducible faults that will not disappear on their own.
Brake System 07-69
DTC CHECKLIST
DTC Fault description
C190004 Power supply voltage too high or too low
C190104 Power supply voltage too low
C100004 ESP controller malfunction
C101008 ESP software error
C006B06 ABS/ESP not working normally
Front left wheel speed sensor fault: outside of expected range, lost, noise, intermittent
C003108
disconnection
Front left wheel speed sensor wiring fault: signal line shorted to ground or open circuit;
C003200
open power circuit
C00A000 Front left wheel speed sensor wiring fault: power supply shorted to ground
C00A100 Front left wheel speed sensor wiring fault: signal line shorted to power supply
C00A900 Front left wheel speed sensor fault: cause unknown
Front right wheel speed sensor fault: outside of expected range, lost, noise, intermittent
C003408
disconnection, etc.
Front right wheel speed sensor wiring fault: signal line shorted to ground or open circuit;
C003500
open power circuit
C00A200 Front right wheel speed sensor wiring fault: power supply shorted to ground
C00A300 Front right wheel speed sensor wiring fault: signal line shorted to power supply
C00AA00 Front right wheel speed sensor fault: cause unknown
Rear left wheel speed sensor fault: outside of expected range, lost, noise, intermittent
C003708
disconnection, etc.
Rear left wheel speed sensor wiring fault: signal line shorted to power supply, or open
C003800
circuit
C00A400 Rear left wheel speed sensor wiring fault: power supply shorted to ground
C00A500 Rear left wheel speed sensor wiring fault: signal line shorted to power supply
C00AB00 Rear left wheel speed sensor fault: cause unknown
Rear right wheel speed sensor fault: outside of expected range, lost, noise, intermittent
C003A08
disconnection
C003B00 Rear right wheel speed sensor wiring fault: signal line shorted to power supply
C00A600 Rear right wheel speed sensor wiring fault: power supply shorted to ground
C00A700 Rear right wheel speed sensor wiring fault: signal line shorted to power supply
C00AC00 Rear right wheel speed sensor fault: cause unknown
Wheel speed sensor assembly fault (interchanging of wheel speed sensors, wheel
C109904
speed differentials too high, faults with multiple sensors)
C004460 Pressure transducer signaling fault
C004510 Pressure transducer circuitry fault
C004008 Brake lamp switch signal abnormal
07-70 Brake System
U160108 Brake lamp switch CAN signal invalid

C006108 Lateral acceleration sensor signal error
C006208 Longitudinal acceleration sensor signal error
C006308 Yaw velocity sensor signal error
C019604 Yaw velocity sensor fault
C00A800 Yaw velocity sensor not calibrated, or calibration failure
U000500 CAN bus voltage too high
U000700 CAN bus voltage too low
C100104 CAN bus hardware fault
U000104 CAN bus shut fault
U100104 External CAN bus fault
U010004 EMS CAN packet timeout
U010008 EMS data cut off or signal invalid
C106600 Steering angle sensor calibration error
C046008 Steering angle sensor fault (signal)
U012604 Steering angle sensor packet timeout
U012608 Steering angle sensor data cut off or signal invalid
U010104 TCU CAN packet timeout
U010108 TCU data cut off or signal invalid
C001004 Valve fault: front left fluid intake valve
C001104 Valve fault: front left fluid outlet valve
C001404 Valve fault: front right fluid intake valve
C001504 Valve fault: front right fluid outlet valve
C001804 Valve fault: rear left fluid intake valve
C001904 Valve fault: rear left fluid outlet valve
C001C04 Valve fault: rear right fluid intake valve
C001D04 Valve fault: rear right fluid outlet valve
C000104 Valve fault: guide valve No. 1
C000204 Valve fault: guide valve No. 2
C000304 Valve fault: high-pressure valve No. 1
C000404 Valve fault: high-pressure valve No. 2
C109504 Valve relay fault
C002004 Reflux pump fault
C007208 Conventional valve fault (overheating protection, invalid signal, damaged hardware)
Brake System 07-71
C104C04 ESP switch fault

C121208 Configuration code error
U160208 Handbrake signal invalid (CAN signal)
C100300 Clutch switch fault
U160308 Clutch signal invalid (CAN signal)
U160408 Reverse switch signal invalid (CAN signal)
C108C08 Reverse switch signal power level persistently high/low
U012308 Communications with yaw velocity sensor lost
U051308 Yaw velocity sensor data invalid
C006102 Lateral acceleration sensor signal error
C006202 Longitudinal acceleration sensor signal error
C006302 Yaw velocity sensor signal error
U014004 BCM CAN communications timeout
U014008 BCM data cut off
U014604 CAN bus gateway timeout
U014608 CAN bus gateway data cut off
U120204 TOD CAN bus data timeout
U120208 TOD data cut off
U016504 AMT CAN bus data timeout
U016508 AMT data cut off
07-72 Brake System
FAULT DIAGNOSIS
ECU POWER SUPPLY MALFUNCTION
1. DTCs: C1900; C1901
2. Possible causes
(a) Battery voltage too high or too low;
(b) Vehicle body not grounded properly.
3. Diagnostic and repair method
(a) Test battery voltage, and recharge battery when necessary (standard voltage value 9 V-16 V);
(b) Check the two ESP grounding points, including the ESP electronic controller and reflux pump motor
grounding points;
(c) Turn on all vehicle appliances that consume significant amounts of power and measure ESP voltage
(power supply may be insufficient at high load);
(d) Measure the voltage change that occurs when the vehicle is being started up and when all high-power
appliances are being turned on. Existing power faults can cause significant voltage changes in the
power circuit.
ECU faults
1. DTC: C100004
2. Possible causes
(a) ECU damaged.
(a) Replace ESP assembly and discharge air from brake pipeline.
BRAKE SYSTEM ABNORMALITY (ABS/ESP WORKED FOR TOO LONG A PERIOD)
1. DTC: C006B06
2. Possible causes
(a) Sustained hard driving or braking for long periods of time;
(b) Inaccurate wheel speed sensor signals;
(c) Abnormal steering wheel turn sensor, yaw velocity sensor signals.
(a) Obtain wheel speed sensor data stream using the diagnostic tester and observe to see if any wheel in
particular is spinning at a higher or lower speed consistently;
(b) Start the vehicle and drive in an 8-figure loop. During the test, the steering wheel must be turned to
full lock both left and right. Then, read the DTC again;
(c) If there is no DTC related to the steering angle sensor or yaw velocity sensor present, you would need
to check that the ESP is installed along the correct plane and is secured. The ESP bracket must not
be used with other equipment.
WHEEL SPEED SENSOR WIRING FAULTS
1. DTCs: C003200; C00A000; C00A100; C003500; C00A200; C00A300; C003800; C00A400;
C00A500; C003B00; C00A600; C00A700
2. Possible causes
(b) Wheel speed sensor signal and power cords connected the wrong way round.
(c) Signal line shorted to earth.
(a) Check for signs of open circuits/short circuits with the wheel speed sensor cabling;
(b) Check for loose or broken wheel speed sensor cabling connectors;
(c) Check to see if the wheel speed sensor power and signal lines are connected to the right terminals;
(d) Accelerate vehicle to speed of 40 km/h and above to activate ESP dynamic self-check;
(e) If fault is not eliminated following dynamic self-check, replace wheel speed sensor.
Brake System 07-73
WHEEL SPEED SENSOR SIGNALING FAULTS

1. DTCs: C003108; C00A900; C003408; C00AA00; C003708; C00AB00; C003A08; C00AC00;
C109904
2. Possible causes
(a) Wheel speed sensor cabling twisted, or connectors loose/broken;
(b) Wheel speed sensor signal line shorted to power supply;
(c) Wheel speed sensor power cord shorted to ground;
(d) Gear ring not installed, missing teeth, foreign matter in gear ring, gear ring de-magnetized, gear ring
off-center;
(e) Sensor and gear ring clearance too large;
(f) Wheel speed sensor under magnetic interference from external sources; (wheel or shaft not de-mag-
netized)
(g) Wheel speed sensor fault;
(h) Gear teeth count error;
(i) Tire size incorrect.
(a) Check for twisting of wheel speed sensor cabling;
(b) Check for loose or broken wheel speed sensor cabling connectors;
(c) Check for signs of wheel speed sensor cabling shorted to either power supply or earth;
(d) Check that the wheel speed sensor has been secured correctly;
(e) Obtain wheel speed sensor data stream using the diagnostic tester. Then record all various wheel
speeds during travel and make sure that they are consistent with the speed indicator, check that the
speed indicator is accurate;
(f) If the wheel speed taken is inconsistent with the indicator speed, check that the wheel speed sensor
signal gear ring is not missing any teeth, dirty, contain foreign matter, de-magnetized, or off-center;
(g) Following replacement/repair/maintenance of wheel speed sensor, you must bring the vehicle to a
speed of 40 km/h and above to activate ESP dynamic self-check.
PRESSURE TRANSDUCER FAULTS
1. DTCs: C004460; C004510
2. Possible causes
(a) Brake lamp switch or switch circuitry fault;
(b) Pressure transducer malfunction.
(a) Check that the brake lamp switch and circuitry are functioning normally;
(b) Replace ESP assembly and discharge air from brake pipeline.
BRAKE LAMP SWITCH (BLS) FAULTS
1. DTCs: C004008; U160108
2. Possible causes
(a) Open brake lamp switch circuit or short circuit;
(b) Brake lamp switch installed incorrectly;
(c) Brake lamp switch damaged.
(a) Check brake lamp switch and cabling;
(b) Replace brake lamp switch.
07-74 Brake System
YAW RATE SENSOR FAULT

The yaw rate sensor covers three types of signals: lateral acceleration, longitudinal acceleration, and
yaw rate.
1. DTCs: C006108; C006208; C006308; C019604; C00A800
2. Possible causes
(a) Yaw rate sensor installation position incorrect; (make sure that the sensor is on the correct plane with-
in the vehicle body)
(b) Yaw rate sensor calibrated incorrectly;
(c) Yaw rate sensor damaged.
(a) Adjust yaw rate sensor installation position, and check position for signs of twisting and wear-and-
tear;
(b) Re-calibrate yaw rate sensor;
(c) Replace yaw rate sensor.
CAN BUS FAULT
1. DTCs: U000500; U000700; C100104; U000104; U100104
2. Possible causes
(a) Battery voltage too high or too low (standard range: 9.3 V-16.8 V);
(b) CAN bus gateway fault;
(c) ECU damaged.
(a) Test battery voltage, and recharge battery when necessary;
(b) Check CAN bus and various bus connections;
(c) Replace ESP assembly and discharge air from brake pipeline.
STEERING WHEEL TURN SENSOR FAULT
1. DTCs: C106600; C046008; U012604; U012608
2. Possible causes
(a) Steering angle sensor calibrated incorrectly;
(b) Steering angle sensor wiring fault;
(c) Steering angle sensor connector loose or broken;
(d) Steering angle sensor damaged.
(a) Cancel steering angle sensor calibration and re-calibrate;
(b) Check steering angle sensor cabling;
(c) Check and re-connect steering angle sensor connector;
(d) Replace steering angle sensor.
CAN BUS NODE FAULT
1. DTCs: U012604; U012608; U010104; U010108; U014008; U014004; U014608; U014604; U012308;
U051308; U120204; U120208
2. Possible causes
(a) CAN bus communication cut off;
(b) CAN bus node power supply fault;
(c) CAN bus node fault (disconnected from CAN bus or ECU fault).
Brake System 07-75

(a) Check that CAN bus communications are normal;
(b) Turn off ignition switch, and test the resistance of CAN-H and CAN-L from various CAN bus nodes to
ESP; (standard value: less than 5 Ω)
(c) Test CAN-H and CAN-L resistance from various CAN bus node connectors (with connectors in place);
(standard value: 60 Ω)
(d) Check power supply of various CAN bus nodes;
(e) Obtain CAN bus node DTCs and check based on specific codes obtained.
SOLENOID VALVE FAULTS
1. DTCs: C001004; C001104; C001404; C001504; C001804; C001904; C001C04; C001D04; C000104;
C000204; C000304; C000404; C007208
2. Possible causes
(a) System overheating protection;
(b) ESP controller unit damaged.
(a) Cool vehicle for 10 minutes and then obtain DTC again;
(b) Replace ESP assembly and discharge air from brake pipeline.
SOLENOID VALVE RELAY FAULTS
1. DTC: C109504
2. Possible causes
(a) Poor power supply to solenoid valve (low voltage, blown fuse or poor contacts);
(b) ESP controller unit not properly grounded;
(c) ESP controller unit damaged.
(a) Check valve relay circuitry, fuse and power source voltage;
(b) Use a 21 W test light to test the voltage decrease between the ESP connector valve relay pin and bat-
tery cathode; (test value: less than 0.2 V)
(c) Use a 21 W test light to test the voltage decrease between the ESP electronic control unit ground pin
on the ESP connector and vehicle body grounding point; (test value: less than 0.2 V)
(d) Accelerate vehicle to speed of 40 km/h and above to activate ESP dynamic self-check;
(e) If the fault is still present following dynamic self-check, replace the ESP assembly and discharge air
from the brake pipelines.
REFLUX PUMP MOTOR FAULTS
1. DTC: C002004
2. Possible causes
(a) System overheating protection;
(b) Poor power supply to pump motor (low voltage, blown fuse or poor contacts);
(c) Pump motor not grounded properly;
(d) Pump motor damaged.
(a) Cool vehicle for 10 minutes and then obtain DTC again;
(b) Check pump motor circuitry, fuse and power source voltage;
(c) Use a 21 W test light to test the voltage decrease between the ESP connector pump motor power pin
and battery cathode; (test value: less than 0.2 V)
(d) Use a 21 W test light to test the voltage decrease between the ESP connector pump motor ground pin
and vehicle body grounding point; (test value: less than 0.2 V)
(e) Accelerate vehicle to speed of 40 km/h and above to activate ESP dynamic self-check;
(f) If the fault is still present following dynamic self-check, replace the ESP assembly and discharge air
from the brake pipelines.
07-76 Brake System
ESP OFF SWITCH FAULTS

1. DTC: CC104C04
2. Possible causes
(a) ESP OFF switch depressed by another object;
(b) ESP OFF switch or circuitry damaged.
(a) Turn off ESP OFF switch manually, then restart ESP function;
(b) Check ESP OFF switch.
ESP SETTINGS FAULT
1. DTC: C121208
2. Possible causes
(a) Settings not established;
(b) Incompatible settings.
(a) Write in the correct settings using the diagnostic tester.
CAN BUS NODE CONTROLLER SIGNALS ABNORMAL
1. DTCs: U010104; U010108; U160208; C100300; U160308; U160408; C108C08; U014004; U014008;
U014604; U014608; U120204; U120208; U016504; U015608
2. Possible causes
(a) Abnormal hand brake signals;
(b) Clutch switch malfunction;
(c) Abnormal clutch signals;
(d) Clutch signal line short-circuited or circuit open;
(e) Abnormal reverse gear signals;
(f) Reverse gear signal line short-circuited or circuit open;
(g) Abnormal BCM system signals;
(h) CAN gateway fault;
(i) Abnormal TCU system signals;
(j) Abnormal TOD system signals;
(k) Abnormal AMT system signals.
(a) Check each relevant part according to DTC instructions;
(b) Check the handbrake signal line/clutch switch/clutch signal line/reverse gear signal line;
(c) Check BCM system controller;
(d) Check CAN bus gateway;
(e) Check TCU system controller;
(f) Check TOD system controller;
(g) Check AMT system controller.
Brake System 07-77
SYSTEM AIR DISCHARGE

ABOUT THE AIR DISCHARGE PROCEDURE
You must discharge air from the brake system after replacing system components (such as brake
fluid, brake pipeline, hydraulic unit) or when the brake pedal feels 'soft'.
The new hydraulic unit to be installed must be an ESP hydraulic regulator with electronic controller
which has been topped up with oil.
When discharging air, you must make sure that the brake system is structurally complete and that all
hydraulic units have been properly connected.
The hand brake must be engaged prior to air discharge.
Brake fluid is corrosive; therefore, wash off immediately if it comes into contact with skin.
DISCHARGING USING THE EXHAUST/FILLING UNIT (DISCHARGE PRESSURE 2BAR)
A is sufficient brake fluid to turn on the switch, set pressure at 2bar

C

D

E
HYBRID MANUAL AND 2BAR DISCHARGE METHOD

A is sufficient brake fluid to turn on the switch, set pressure at 2bar

B1

C

D

E
07-78 Brake System
MANUAL DISCHARGE
Top up reservoir (to neck of filter)
A
Discharge air from each wheel cylinder via the steps below
Open air bleed screw

C

D
Close air bleed screw

E
Release brake pedal

F

G
If unsuccessful, conduct discharge procedure again

H
Check brake fluid level and ensure that it lies

I
Remark:
• Recommended X-loop sequence: rear left, front left, front right, rear right.
• The reservoir brake fluid level must not fall below the MIN level marked through the entire dis-
charge process.
CROSS-VALIDATION
1. Remove ESP and install on another working vehicle
of similar make
2. Calibrate and adjust ESP as necessary (for spe-
cific instructions on calibrations and adjustments,
please refer to the vehicle repair and maintenance
manual).
3. Drive the vehicle, making sure that vehicle speed
does not go lower than 40 km/h; allow the ESP to
perform a dynamic self-test and then obtain DTC
again.
Brake System 07-79

ESP ASSEMBLY
REMOVAL
1. With the ignition switch in the OFF position, discon-
nect negative terminal of the battery.
2. Remove cabling from ESP assembly.
3. Depress brake pedal fully and secure using the
brake pedal bracket to prevent brake fluid from spill-
ing after the brake pipeline has been disconnected
from the brake main cylinder.
4. Disconnect brake pipeline, and stop up the ESP as-
sembly threaded hole and the oil aperture on the
brake pipeline using a plug to prevent debris from
entering the system.
5. Remove ESP from fixing bracket.
Installation
1. Install ESP assembly onto bracket, with tightening
torque at (8±2) N•m.
2. Remove plugs from the ESP threaded hole and
brake pipeline oil aperture, connect brake pipe-
line to ESP assembly with tightening torque at
(16±2) N•m.
3. Top up brake fluid to MAX level marked on reservoir
and discharge air using methods specified.
4. Calibrate and adjust ESP as needed
ESP SWITCH
REMOVAL
1. Remove the two panels that make up the console
panel switch assembly;
2. Disconnect switch connector;
Dog:
3. Remove switch from the rear with the aid of a Phil-

lips screwdriver.
Memorandum
地址：河北省保定市朝阳南大街2266号
邮编：071000
长城汽车客户热线：400-666-1990
销售传真：0312-2197600 服务传真：0312-2192936
网址：http://www.haval.com.cn 版号：01-14.06-01SM1 Z
哈弗H1
维修手册
第二册
(共两册)
INTRODUCTION
THIS MANUAL IS THE SECOND VOLUME OF THE HAVAL H1 REPAIR AND MAINTE-
NANCE MANUAL (2 VOLUMES IN TOTAL).
Volume 1 Volume 2
01-Overview 08-Vehicle Body
02-Engine Accessories 09-Vehicle Interior/Vehicle Exterior
03-Transmission 10-HVAC (Heater, Ventilation and Air Conditioning)
04-Transmission System System
05-Suspension System 11-Safety and Protective Equipment
06-Steering System 12-Electrical Accessories
07-Brake System 13-Vehicle Body Control System
APPLICABLE MODELS:
4G15+5MT/6AMT (2WD), Left-hand Drive, China V/Euro V
THE FOLLOWING IS ONE OF THE MANUALS CONCERNING THIS VEHICLE. PLEASE

REFER TO IT.
Manual Name Edition Number
Haval H1 Circuit Diagram 01-14.06-01EM
ALTHOUGH THIS MANUAL HAS BEEN COMPILED WITH THE UTMOST DILIGENCE, WE
CANNOT GUARANTEE THAT ITS CONTENTS ARE COMPLETELY FREE FROM ERROR.
AS THE VEHICLE MODELS ARE CONSTANTLY BEING UPDATED, WE CANNOT GUAR-
ANTEE THAT THE LATEST INFORMATION WILL BE DELIVERED TO YOU IN A TIMELY
AND ACCURATE MANNER.
AS THE EDITOR'S SKILL IS LIMITED, THIS MANUAL INEVITABLY WILL BE DEFICIENT

IN SOME PLACES. WE ASK THE READERS TO BE GENEROUS WITH THEIR CRITI-
CISMS AND CORRECTIONS.
IF YOU HAVE ANY SUGGESTIONS REGARDING THE CONTENTS OR PRESENTATION

OF THIS MANUAL, PLEASE SEND THEM TO CYWX@GWM.CN. YOU WILL BE EX-
TREMELY GRATEFUL.
IF YOU ENCOUNTER OTHER TECHNICAL PROBLEMS DURING REPAIR, PLEASE CON-

TACT OUR CUSTOMER-SUPPORT TECHNICIANS AT: 0312-2192613.
THE FINAL RIGHTS OF INTERPRETATION FOR THIS MANUAL ARE RESERVED BY THE
GREAT WALL MOTOR CO., LTD.

All rights reserved
Information cut-off date: June 2014
Without the permission of the Great Wall Motor Co., Ltd, this manual, in part or in whole, may not
be reprinted, copied, stored, or transmitted.
Total Contents
Overview
Engine Accessories
Transmission
Transmission System
Suspension System
Steering System
Brake System
Vehicle Body
Vehicle Interior/Vehicle Exterior
HVAC (Heater, Ventilation and Air Conditioning) System
Safety and Protective Equipment
Electrical Accessories
Vehicle Body Control System
Vehicle Body 08-1
VEHICLE BODY
ENGINE HOOD
Engine Hood................................................................08-3
Engine Hood Lock........................................................08-8
Engine Hood Lock Cable.............................................08-9
Engine Hood Hinge......................................................08-11
VEHICLE DOORS
Schematics.....................................................................08-12
Front Door....................................................................08-12
Back Door....................................................................08-13
Front Door....................................................................08-14
Back Door....................................................................08-17
FENDER
Fender Assembly.........................................................08-22
FUEL FILLER CAP
Fuel Filler Cap..............................................................08-25
Fuel Filler Cable...........................................................08-27
VEHICLE BODY REFERENCE DIMENSIONS
Subframe.........................................................................08-30
Engine Bay......................................................................08-31
Left Side Wall..................................................................08-32
Right Side (of body).......................................................08-33
Back Door Frame...........................................................08-34
STANDARD CLEARANCE
Engine Hood...................................................................08-35
Front Door.......................................................................08-36
Rear Door........................................................................08-37
Back Door.......................................................................08-38
08-2 Vehicle Body
ENGINE HOOD
LOCATION DIAGRAM
1. Engine Hood 3. Engine Hood Lock Cable

2. Engine Hood Lock
Vehicle Body 08-3

ENGINE HOOD
Removal
Attention:
• Place the protective cushion on top of the
fender and front windshield to avoid damage
to the paint, glass, and molded pieces during
removal and installation of the engine hood.
1. Pull the opening handgrip for the engine hood
2. Raise and support the engine hood
3. Remove the front washer water tubing assembly
4. Mark the location of the hinge on the engine hood to

facilitate positioning during reinstallation
08-4 Vehicle Body
5. Remove the 2 hinge bolts securing the engine hood

on each side
6. With assistance, remove the engine hood

Vehicle Body 08-5
Installation
1. With assistance, align the engine hood at the posi-
tion marked during removal
Attention:
• Putting different metals in direct contact with
each other will accelerate corrosion. You must
use the correct fasteners to prevent premature
corrosion.
2. Install the 2 hinge bolts securing the engine hood
on each side
Tightening torque: 22 to 29 N•m
3. Install the front washer water tubing assembly
4. Check whether the engine hood position is accurate

08-6 Vehicle Body
ADJUSTMENT
Remark:
• A centering bolt is used to install the engine hood
hinge and engine hood lock.
• While installing the centering bolt, you cannot ad-
just the engine hood and engine hood lock. When
performing the adjustment, you can use a stan-
dard bolt (and washer) to replace the centering
bolt.
Centering Standard
bolt bolt
1. Check the clearance of the engine hood

2. Adjust the horizontal and vertical clearance
(a) Loosen the 4 hinge bolts on each side of the engine
hood.
(b) Move the engine hood to adjust its clearance to within

the standard range.
Standard range (A): 3.5±1 mm
(c) After the adjustment, tighten the hinge bolts on both
sides of the engine hood.
3. Front height adjustment

(a) Turn the setting piece so that the engine hood and fend-
er are aligned.
Remark:
• Move the setting piece by turning it.
(b) Adjust the engine hood lock.
(c) Remove the clip and grill.
Vehicle Body 08-7
(d) Adjust the engine hood lock so that the latch can
smoothly enter.
(e) After adjustment, tighten the bolts for the engine hood
lock.
08-8 Vehicle Body
ENGINE HOOD LOCK

Removal
1. Open the engine hood and support it
2. Remove the trim plate on the front bumper
3. Remove the 3 bolts securing the engine hood lock
and then disconnect the opening cable for the en-
gine hood lock
Installation
Vehicle Body 08-9
ENGINE HOOD LOCK CABLE

Removal
1. Remove the engine hood lock cable
(a) Open the engine hood.
(b) Remove the opening handgrip for the engine hood from
the dashboard.
(c) Remove the cable from the opening handgrip for the en-
gine hood.
(d) Remove the 3 bolts securing the engine hood lock.
(e) Separate the 2 snaps and then remove the cable from
the engine hood lock assembly.
08-10 Vehicle Body
Installation
1. Install the engine hood lock cable
Remark:
• Putting different metals in direct contact with each
other will accelerate corrosion. You must use the
correct fasteners to prevent premature corrosion.
(a) Install the 2 snaps and then install the cable on the en-
gine hood lock assembly.
(b) Install the 3 bolts securing the engine hood lock.

(c) Install the cable to the opening handgrip for the engine
hood.
(d) Install the opening handgrip for the engine hood on the
dashboard.
(e) Close the engine hood.

Vehicle Body 08-11
ENGINE HOOD HINGE

Removal
1. Remove the engine hood
2. Remove the fender
3. Remove the bolts and hinges
Installation
08-12 Vehicle Body
VEHICLE DOORS
SCHEMATICS
FRONT DOOR
Vehicle Body 08-13
BACK DOOR
22~29

08-14 Vehicle Body

FRONT DOOR
Adjustment
Remark:
• Handle the rear doors in the same way as the front
doors.
• The procedure for the right side is the same as
that for the left side.
• A centering bolt is used to secure the door hinge
to the vehicle body and door. While installing the
centering bolt, you cannot adjust the vehicle doors.
When performing an adjustment, you can use a
standard bolt (and washer) in place of the center-
ing bolt.
Centering Standard
bolt bolt 1. Check the front left door panel sub-assembly
Check the clearance and confirm that it is within the
standard range.
2. Adjust the front left door panel sub-assembly
(a) Use the SST to loosen the hinge bolts at the top and
bottom of the door in order to adjust the door horizon-
tally and vertically.
(b) After the adjustment, tighten the door-hinge bolts.
(c) Slightly loosen the screws securing the latch and lightly
strike the latch with a plastic hammer to adjust its posi-
tion.
(d) After the adjustment, tighten the screws securing the
latch.
Vehicle Body 08-15
Removal
Remark:
• Handle the rear doors in the same way as the front
doors.
• During the removal and installation of the vehicle
doors, two people are required to carry out the
procedure.
• During the disassembly and installation of the
vehicle door assembly, be sure to perform the
mounting adjustment.
• Check whether the moving parts of the hinge are
poorly lubricated, and if necessary apply vehicle-
body grease.
• After installation, perform a check.
1. Remove the front fender
3. Remove the dust boot of the front-door electrical-
equipment wiring and disconnect the wiring
4. Remove the front-door retainer
(a) Remove the 3 bolts and retainers.
Remark:
• Remove the retainers through the maintenance
opening.
5. Using a cloth, clean the door-hinge mounting sur-

face and mark the location of the hinge on the ve-
hicle body to facilitate positioning during reinstalla-
tion
6. Remove the front-door hinge
7. Remove the front-door assembly

08-16 Vehicle Body
Installation
1. Install the front-door retainer
(a) Coat the retainer's sliding location with general-purpose
grease.
(b) Install the retainer on the door panel with 2 bolts.
Tightening torque: 7±1 N•m
(c) Coat the threads of the bolts with an adhesive material.
(d) Install the retainer on the vehicle body panel with the
bolts.
Door parameters
Front-door Engine hood opening
36°/60° 75°
opening angle angle
Rear-door open- Back-door maximum
36°/63° 85°
ing angle opening angle
2. Install the front-door hinge
3. Connect the front-door wiring and install the dust

boot for the door electronics
4. Install the front fender
Vehicle Body 08-17
BACK DOOR
ADJUSTMENT
Remark:
• The procedure for the left side is the same as that
for the right side.
• While installing the centering bolt for the back
door, you cannot adjust the back door. When per-
forming an adjustment, you can use a standard
bolt (and washer) in place of the centering bolt.
Centering Standard
bolt bolt
1. Check the back-door-panel sub-assembly

Check the clearance and confirm that it is within the
standard range.
2. Adjust the back-door sheet-metal sub-assembly
(a) Remove the protective surface inside the top cover.
(b) As illustrated, loosen the vehicle-body side hinge nuts
to horizontally and vertically adjust the back door.
(c) After the adjustment, tighten the vehicle-body side hinge
nuts.
(d) Loosen the back-door latch bolt to horizontally and verti-

cally adjust the back-door latch.
(e) After the adjustment, tighten the back-door latch bolts.
08-18 Vehicle Body
Removal
Remark:
• Two people are required to carry out the disas-
sembly and installation of the back door.
• When disassembling and installing the back-door
assembly, make sure to perform the mounting ad-
justment.
• Check whether the moving parts of the hinge are
poorly lubricated, and if necessary apply vehicle-
body grease.
• After installation, you must perform a check.
1. Open the back door
3. Disconnect the back-door wiring
4. Remove the rear washer water tubing assembly
5. Remove the back-door brace strut

(a) Remove the 2 bolts securing the back-door gas-spring
mounting bracket.
(b) Remove the single gas-spring ball bolt securing the
back-door brace strut.
(c) Remove the back-door brace strut.
Vehicle Body 08-19
6. Remove the back-door hinge

(a) Remove the 2 bolts.
7. With assistance, remove the back door

08-20 Vehicle Body
Installation
1. Install the back-door hinge
2. Install the back-door strut

(a) Use 2 bolts to secure the back-door gas-spring mount-
ing bracket.
(b) Use the gas-spring ball bolt to secure the back-door
brace strut.
3. Install the rear washer water tubing assembly

4. Connect the back-door wiring
6. Close the back door
Vehicle Body 08-21
FENDER
LOCATION DIAGRAM
1. Left Fender Assembly

08-22 Vehicle Body

FENDER ASSEMBLY
Removal
1. Remove the engine bay front protective cover
2. Raise and support the vehicle
3. Remove the front wheel
4. Remove the splash guard
5. Remove the front bumper and front-bumper mount-
ing bracket
6. Remove the left headlamp assembly
7. Remove the front-left vehicle-body trim plate
8. Remove the left fender
(a) Remove the 3 bolts from the top of the left fender.
(b) Remove the 2 bolts from the bumper side of the left
fender.
(c) Remove the 2 bolts from the left-fender side wall.
(d) Remove 1 bolt from the trim-plate location on the left
fender.
(e) Remove 1 bolt from the bottom of the left fender.
(f) Take off the left fender.
Vehicle Body 08-23
Installation
1. Install the left fender
(a) Install 3 bolts on the top of the left fender.
(b) Install 2 bolts on the bumper side of the left fender.
(c) Install 2 bolts on the left-fender side wall.
(d) Install 1 bolt on the trim-plate location on the left fender.
(e) Install 1 bolt on the bottom of the left fender.
2. Install the front-left vehicle-body trim plate
3. Install the left headlamp assembly
4. Install the front bumper and front-bumper mounting
bracket
5. Install the splash guard
6. Install the front wheel
7. Lower the vehicle
8. Install the engine bay front protective cover
08-24 Vehicle Body
FUEL FILLER CAP

LOCATION DIAGRAM
1. Fuel Filler Cable Spiker 3. Fuel Filler Cap Assembly

2. Fuel Filler Cable
Vehicle Body 08-25

FUEL FILLER CAP
Removal
1. Pull the opening handgrip for the fuel-tank door and
open the fuel filler cap
2. Disconnect the spacing cable from the fuel filler cap
3. Remove the 2 bolts securing the fuel filler cap

4. Take off the fuel filler cap
08-26 Vehicle Body
Installation
Attention:
corrosion.
1. Install the 2 screws securing the fuel filler cap
2. Connect the spacing cable to the fuel filler cap
3. Close the fuel filler cap

Vehicle Body 08-27
FUEL FILLER CABLE

Removal
2. Remove the vehicle-body trim plate
3. Disconnect the cable from the fuel filler cap
4. Remove the seat belt bolts and fastening device

from under the B column
5. Separate the snap securing the fuel filler cable
6. Remove the signal screw securing the fuel filler
cable spiker
7. Separate the cable from the fuel filler cable spiker
8. Remove the main driver seat

9. Remove the front-left and back-left door cover
plates as well as the trim plate under the left B col-
umn
10. Move aside the carpet on the left side
11. Remove the cable
08-28 Vehicle Body
Installation
1. Pass the cable into the passenger compartment
2. Restore the carpet on the left side to its original po-
sition
3. Install the front-left and back-left door cover plates
and the trim plate under the left B column
4. Install the main driver seat
5. Connect the cable to the handgrip
Attention:
corrosion.
6. Install the signal bolt on the fuel filler cable spiker
7. Install the snap on the fuel filler cable
8. Use a bolt to install seat belt fastening device under
the B column and then tighten the bolt securing the
aforementioned
9. Connect the cable to the fuel filler cap
10. Install the vehicle-body trim plate
11. Close the back door
Vehicle Body 08-29
VEHICLE BODY REFERENCE DIMENSIONS

This section provides the reference dimensions for the entire vehicle. Please refer to it during mainte-
nance.
• All numerical dimensions are actual size.
• Measurement points are taken from the center of the mounting hole.
• When using a gauge, adjust both measuring pins to an equal length and then check the measur-
ing pins and the gauge itself to ensure there is no gap when using it.
• When using a tape measure, you must ensure that there is no stretching, twisting, or bending.
• An asterisk (*) following the numerical value of a measurement point indicates that the measure-
ment point symmetrically on the other side has the same value.
• The coordinates of the measurement points indicate the measured distance from the standard
"X," "Y," and "Z" lines.
• The left and right symmetry points for the measurement coordinates indicate that the left side
point coordinates and the right side ones are symmetrical.
08-30 Vehicle Body
SUBFRAME
49.6
164.5
65
5.5
689.3±1
872±1.5
271.5±1
219±0.8
834±1.5 106.7±0.8
Units: mm
Vehicle Body 08-31
ENGINE BAY
1121.049
Units: mm
08-32 Vehicle Body
LEFT SIDE WALL
B
C 845 F
1047 1133
G
907
D E
Units: mm
Aperture Aperture
Symbol Name Symbol Name
(mm) (mm)
Front door top hinge installa- Rear door top hinge installa-
A 15 B 15
tion opening tion opening
Front door top hinge installa- Rear door bottom hinge in-
C 15 D 15
tion opening stallation opening
Rear door bottom hinge in- Rear door latch installation
E 15 F 15
stallation opening opening
Rear door latch installation
G 15 — — —
opening
Vehicle Body 08-33
RIGHT SIDE (OF BODY)
B
G 845
1047
F 1133
C
907
E D
A
Units: mm
Aperture Aperture
(mm) (mm)
Front door top hinge installa- Rear door top hinge installa-
A 15 B 15
tion opening tion opening
Front door top hinge installa- Rear door bottom hinge in-
C 15 D 15
tion opening stallation opening
Rear door bottom hinge in- Rear door latch installation
E 15 F 15
stallation opening opening
Rear door latch installation
G 15 — — —
opening
08-34 Vehicle Body
BACK DOOR FRAME
A B
891.1 891.1
1425.4
1425.4
C D
Units mm
Aperture Aperture
(mm) (mm)
Back door assisted strut in- Back door assisted strut in-
A 7 B 7
stallation opening stallation opening
Rear bumper installation Rear bumper installation
C 7 D 7
opening opening
Vehicle Body 08-35
STANDARD CLEARANCE
ENGINE HOOD
A
B
Part Measured value mm

A 3.5±1
B -1±0.5
C 6.5±1
D 6±1
08-36 Vehicle Body
FRONT DOOR
D
F
E G
A
B
H
I

A 3.5±0.5
B 0±0.5
C 5.5±1.0
D 4±0.5
E -3.6±0.5
F 3.5±0.5
G 0±1.0
H 3.5±0.5
I 0±1.0
Vehicle Body 08-37
REAR DOOR
F
G D
I
J
B
K
L
C

A 5.5±1.0
B 3.5±0.5
C 0±1.0
D 3.5±0.5
E 4.0±0.5
F —
G 4
H —
I 3.5±0.5
J 0±1.0
K 3.5±0.5
L 0±1.0
08-38 Vehicle Body
BACK DOOR
I
-
+
J
B
A
D
-
+
C H
- -
F
+
+
E

A 5±0.5
B -1~0
C 5.5±1
D -1~0
E 5±1
F —
G (5~6) ±1
H —
J 5±0.5
I (-11.65~-4.3) ±1
Memorandum
Memorandum
Vehicle Interior/Vehicle Exterior 09-1
VEHICLE INTERIOR/VEHICLE
EXTERIOR
DASHBOARD
Schematics.....................................................................09-3
Main Dashboard...........................................................09-3
Auxiliary Dashboard.....................................................09-5
Main Dashboard...........................................................09-6
Auxiliary Dashboard.....................................................09-10
BUMPER
Schematics.....................................................................09-12
Front Bumper...............................................................09-12
Rear Bumper................................................................09-13
Front Bumper...............................................................09-14
Rear Bumper................................................................09-16
SEATS
Schematics.....................................................................09-17
Driver's Seat Assembly................................................09-17
Front Seat Assembly....................................................09-18
Rear Seat Assembly....................................................09-19
Driver's Seat/Front Seat...............................................09-22
Rear Seat.....................................................................09-25
CARPET
Schematics.....................................................................09-28
Carpet Assembly..........................................................09-29
CEILING
Schematics.....................................................................09-30
Ceiling..........................................................................09-32
GLASS
Schematics.....................................................................09-35
Front Windshield..........................................................09-35
Front Windshield..........................................................09-36
Back-Door Glass..........................................................09-40
09-2 Vehicle Interior/Vehicle Exterior
VEHICLE INTERIOR TRIM

Schematics.....................................................................09-43
Protective Surface Inside Front Door...........................09-43
Protective Surface Inside Rear Door...........................09-44
Back-Door Inside Protective Surface...........................09-45
Side Wall Trim Plate.....................................................09-46
Front-Door Inner Fender..............................................09-47
Rear Door Inner Fender...............................................09-50
Back Door Inner Fender...............................................09-52
A-Column Guard..........................................................09-53
B-Column Guard..........................................................09-55
C-Column Guard..........................................................09-57
VEHICLE EXTERIOR TRIM
License Plate Light Decorative Panel..........................09-60
Deflector.......................................................................09-61
Decorative Labels........................................................09-62
Lower Body Deflector...................................................09-63
Schematics.....................................................................09-64
Luggage Rack..............................................................09-64
Ventilation Cover Plate.................................................09-65
Radiator Deflector........................................................09-66
Wheel Cover Trim........................................................09-67
Luggage Rack..............................................................09-68
Ventilation Cover Plate.................................................09-69
License Plate Light Decorative Panel..........................09-70
Deflector.......................................................................09-71
Decorative Labels........................................................09-72
Lower Body Deflector...................................................09-73
Radiator Deflector........................................................09-74
Wheel Cover Trim........................................................09-75
DASHBOARD
SCHEMATICS
MAIN DASHBOARD
UPPER DASHBOARD ASSEMBLY
2 3
1 4
12 11
10
9
1. Combination Instrument Cover Assembly 7. Central Vent Assembly

2. Dashboard Central Storage Box Assembly 8. Dashboard Upper Body Central Connecting
(5MT + Central Storage Box) Frame
3. Multimedia Display Base Stand (6AT + Mul- 9. Dashboard Right Decorative Plate Assembly
timedia Display Base Stand) 10. Dashboard Left Decorative Plate Assembly
4. Display Bracket (6AT + Display Base) 11. Dashboard Upper Body Left Connecting
5. Upper Dashboard Body Frame, Welded
6. Right-Side Vent Assembly 12. Left-Side Vent Assembly
LOWER DASHBOARD ASSEMBLY
3 2
7
8
1. Lower Dashboard Body 5. Combination Switch Bottom Shield

2. Glove Box Assembly 6. Lower Left Dashboard Guard Assembly
3. Combination Dashboard Cover 7. Left-Side Storage Box
4. Combination Switch Top Shield 8. Engine Hood Handle Assembly
AUXILIARY DASHBOARD
3 4
2
8
7
1. Auxiliary Dashboard Body Assembly 5. Upper Auxiliary Dashboard Cover Body

2. Cigarette Lighter Mount 6. Auxiliary Dashboard Rear-End Rubber Pad
3. Auxiliary Dashboard Front-End Rubber Pad 7. Auxiliary Dashboard Rear Cover Plate
4. Gear Selector Lever Handle Cover Assembly 8. Auxiliary Dashboard Support Bracket

MAIN DASHBOARD
Removal
Attention:
• When using a flathead screwdriver to pry off
the auxiliary dashboard, you should wrap the
flathead screwdriver and the corresponding
parts in a protective film to avoid damage.
• You should wear gloves to avoid injuring your
hands.
• Be careful not to damage the trim and other
parts.
1. Face the wheels forwards
Attention:
• Place the ignition switch in the "LOCK" posi-
tion and disconnect the negative terminal of
the battery for at least 90 seconds before be-
ginning work.
2. Remove the auxiliary dashboard
3. Remove the front door side seal
4. Remove the strut A upper guard
5. Remove th combination switch shield
(a) Remove the 3 screws.
(b) Remove the top shield for the combination switch.
(c) Remove the bottom shield for the combination switch.
6. Remove the cobination dashboard cover

7. Remove the combination instrument

8. Remove the CD player panel
(a) Separate the 4 snaps.
MAP
1 3 5
2 4 R
12 V 120 W
Snap:
9. Remove the large glove box

(a) Open the large-glove-box assembly.
(b) Disconnect the damping cylinder and the large-glove-
box connector.
(c) Pull the large-glove-box assembly upwards, separating

the 2 bottom grooves and shafts.
(d) Take out the large-glove-box assembly.

10. Remove the central air vent
11. Remove the upper dashboard body
(b) Separate the 6 snaps.
(c) Take off the upper dashboard body.
12. Remove the lower dashboard body

(a) Remove the bolts.
(b) Take off the lower dashboard body.
13. Remove the left trim plate

(a) Remove the 5 screws from behind it.
14. Remove the right trim plate

(a) Remove the 15 screws from behind it.
15. Remove the central glove box

Snap:
16. Remove the left-side glove box

(a) Open the small glove box and directly pull it out.
17. Remove the handle for the engine-compartment

cover
(a) Directly pull it out.
18. Remove the left lower guard

Snap:
Installation
AUXILIARY DASHBOARD
Removal
Attention:
• When using a flathead screwdriver to pry off
the auxiliary dashboard, you should wrap the
flathead screwdriver and the corresponding
parts in a protective film to avoid damage.
• You should wear gloves to avoid injuring your
hands.
• Be careful not to damage the trim and other
parts.
Attention:
ginning work.
2. Remove the snap fasteners on the front of the auxil-
iary dashboard
3. Remove the upper auxiliary dashboard cover

(b) Disconnect the USB wiring connector.
Snap:
4. Remove the gear selector lever handle cover as-

sembly
(a) Disconnect the wiring connector for the AMT indicator.
5. Take off the auxiliary dashboard's front and rear

rubber mats
6. Remove the auxiliary dashboard assembly

Installation
BUMPER
SCHEMATICS
FRONT BUMPER
4
3
8
2 7
10
13
11
14
12
15
1. Front Bumper Tow Hook Plug 9. Front Bumper Wheel Arch Decorative (Left)
2. Front Fog Lamp Decorative Ring (Right) 10. Front Left Fog Lamp Decorative Panel Body
3. Front Fog Lamp Decorative Strip (Right) 11. Front Fog Lamp Decorative Strip (Left)
4. Front Right Fog Lamp Decorative Panel Body 12. Front Fog Lamp Decorative Ring (Left)
5. Front Bumper Right Bracket 13. Ventilation Grille
6. Front Bumper Wheel Arch Decorative (Right) 14. Ventilation Grille Decorative Strip
7. Front Bumper Body 15. Front Bumper Lower Decorative Panel
8. Front Bumper Left Bracket
REAR BUMPER
7
3
2
1
8
10
1. Rear Bumper Wheel Arch Decorative Panel 6. Rear Bumper Wheel Arch Decorative Panel
(Left) (Right)
2. Rear Bumper Left Bracket 7. Rear Bumper Tow Hook Plug
3. Rear Bumper Body 8. Front Bumper Lower Decorative Panel
4. Rear Step Bumper Body 9. Right Exhaust Pipe Decorative Cover Assembly
5. Rear Bumper Left Bracket Assembly 10. Left Exhaust Pipe Decorative Cover Assembly

FRONT BUMPER
Attention:
• Carry out the disassembly and installation of
the front bumper with assistance.
• Do not scratch the front bumper and vehicle
body.
• Wear gloves to protect your hands.
Removal
1. Open the engine bay cover and appropriately sup-
port it
2. Remove the ventilation grille assembly
(a) Remove the 4 bolts from the top of the ventilation grille.
3. Remove the front bumper

(a) Remove the bolt connecting the bumper and the end of
the support.
(b) Remove the 2 snap fasteners connecting the bumper

and lower-body deflector.
(c) Remove the self-tapping screw connecting the bumper

and splash guard.
(d) Remove the 2 bolts and 2 self-tapping screws connect-

ing the bumper to the sheet metal of the vehicle body.
(e) Disconnect the fog lamp connector.

(f) Remove the front bumper.
Installation
Attention:
• Confirm that the bracket and headlamp are
clamped in place.
• Adjust the bumper support and relative fender
position.
REAR BUMPER
Attention:
• Carry out the disassembly and installation of
the rear bumper with assistance.
• Do not scratch the rear bumper and vehicle
body.
Removal
2. Remove the rear bumper
(a) Remove the 2 nuts and 2 bolts from the top of the bum-
per.
(b) Remove the 2 bolts connecting the bumper and the

sheet metal.
(c) Remove the 4 snap fasteners connecting the bumper

and mud flaps.
(d) Disconnect the tail lamp connector.

(e) Remove the rear bumper.
Installation
Attention:
• Confirm that the bracket and rear headlamp
are clamped in place.
• Adjust the bumper support and relative fender
position.
SEATS
SCHEMATICS
DRIVER'S SEAT ASSEMBLY
15
14
3
4
45±5
45±5
13
12 7
8
45±5
9
45±5
11
10
1. Driver Seat Backrest and Cushion 8. Driver Seat Tilt Adjuster Lever
Assembly 9. Height Adjuster Handle Cover
2. Driver Seat Headrest Assembly 10. Driver Seat Height Adjuster Lever
3. Slave Headrest Cannula 11. Driver Seat Frame Assembly
4. Master Headrest Cannula 12. Driver Seat Cushion Assembly
5. Left-Side Airbag 13. Electronic Belt Buckle
6. Driver Seat Left Rear Guard 14. Driver Seat Right-Side Guard
7. Driver Seat Left-Side Guard 15. Driver Seat Right Rear Guard
FRONT SEAT ASSEMBLY

2
1
11
3
10
4
45±5
45±5
6
45±5
45±5 7
1. Front Passenger Seat Backrest and 6. Front Passenger Seat Left-Side Guard
Cushion Assembly 7. Electronic Belt Buckle
2. Front Passenger Seat Headrest Assembly 8. Front Passenger Seat Cushion Assembly
3. Slave Headrest Cannula 9. Front Passenger Seat Right-Side Guard
4. Master Headrest Cannula 10. Front Passenger Seat Tilt Adjuster Lever
5. Front Passenger Seat Frame Assembly 11. Right-Side Airbag Assembly
REAR SEAT ASSEMBLY

INTEGRATED TYPE
2
3
2
45±5 3
4 5
9 8
45±5
45±5
6
10
7
45±5
11
1. Rear Seat One-Piece Seat Headrest As- 6. Rear Seat One-Piece Inner Fender (Left)
sembly 7. Rear Seat One-Piece Guard (Left)
2. Master Headrest Cannula 8. Rear Seat One-Piece Inner Fender (Right)
3. Slave Headrest Cannula 9. Rear Seat One-Piece Guard (Right)
4. Rear Seat One-Piece Backrest Cable Box 10. Rear Seat Backrest and Cushion Assembly
Assembly 11. Rear Seat One-Piece Cushion Assembly
5. Rear Seat Backrest Frame Assembly
REAR 40% SEAT ASSEMBLY
13
14
2
45±5
12 11
45±5 5
6
45±5
9
10 45±5
1. Rear Seat Headrest Assembly 9. Rear Seat Individual Guard (Right)

2. Slave Headrest Cannula 10. Rear Seat Individual Seat Cushion As-
3. Rear Seat Individual Backrest Frame sembly
Assembly 11. Rear Seat Individual Tilt Adjuster Guard
4. Rear Seat Individual Rear Guard 12. Rear Seat Side Upper Guard (Outside)
5. Rear Seat Individual Guard (Left) 13. Rear Seat Individual Backrest Cushion
6. Rear Seat Individual Outside Guard Assembly
(Left) 14. Master Headrest Cannula
7. Rear Seat Inner Fender
8. Rear Seat Individual Seat Cushion
Frame Assembly
REAR 60% SEAT ASSEMBLY
3
4
45±5
8 5
6
9 45±5
45±5
45±5
10
13
11
12
1. Rear Seat Twin Backrest Cushion Assembly 8. Rear Seat Twin Guard (Right)
2. Rear Seat Headrest Assembly 9. Rear Seat Twin Side Guard (Right)
3. Slave Headrest Cannula 10. Rear Seat Twin Guard (Left)
4. Master Headrest Cannula 11. Rear Seat Twin Tilt Adjuster Guard
5. Rear Seat Twin Rear Guard 12. Rear Seat Twin Seat Cushion Frame As-
6. Rear Seat Twin Backrest Frame Assembly sembly
7. Rear Seat Side Upper Guard (Outside) 13. Rear Seat Twin Seat Cushion Assembly

DRIVER'S SEAT/FRONT SEAT
Removal
Attention:
ginning work.
• Touch the door-lock screw to discharge static
electricity.
• Before repair or maintenance, please consult
the airbag's position and precautions as well
as its operating procedures.
• Do not damage, wrinkle, or warp the carpet.
• Do not damage the dashboard or other interior
trim.
2. Disconnect the seat-bottom connector
3. Remove the driver's seat
(a) Remove the rear-foot bolts.
(b) Remove the front-foot bolts.
(c) Take out the driver's seat.
Installation
Disassembly
Attention:
• Before using a screwdriver, please wrap its
head in tape.
1. Remove the height adjuster
(a) Remove the 2 decorative covers.
(b) Remove the screw for the fixed height adjuster.
2. Remove the side panel

(a) Remove the single screw.
(b) Separate the 4 snaps.

3. Remove the seat belt latch

(a) Remove the single bolt.
(b) Disconnect the seat-bottom connector.
Assembly
Assemble by performing the disassembly procedure in
reverse.
REAR SEAT
Attention:
• During the removal, transport, and installation
of the seat, pay attention to safety to avoid be-
ing scratched or bruised by it.
• Pay attention to the vehicle's interior trim dur-
ing installation and transport to avoid scratch-
ing the side panels.
• After installation is completed, you should
check the tightening torque of the mounting
bolts.
INTEGRATED TYPE
Removal
1. Remove the cushion
(a) Lift the front part of the cushion up and remove it from
the cushion's fixing supports.
Remark:
• The seat and bracket are connected by a snap.
(b) Press the cushion's hook down and take if off the
beam's hook.
2. Remove the backrest

(a) Remove the 4 bolts securing the backrest.
(b) Take off the backrest.
3. Remove the seat frame

(b) Remove the seat frame.
Installation
4/6 TYPE LEFT SEATS

Removal
1. Remove the trunk cover
2. Remove the base plate's on-board tool kit (left side)
(a) Turn the 2 switches.
3. Remove the foot cover

(a) Separate the 6 dogs.
4. Remove the seat assembly

(a) Remove the 3 bolts securing the foot bracket.
(b) Remove the 4 bolts securing the seat.

(c) Remove the seat.
Installation
4/6 TYPE RIGHT SEATS

Removal
2. Remove the base plate's on-board tool kit (right
side)
(a) Turn the 2 switches.
3. Remove the foot cover

4. Remove the seat assembly

(a) Remove the 3 bolts securing the foot bracket.
(b) Remove the 4 bolts securing the seat.

(c) Remove the seat.
Installation
CARPET
SCHEMATICS
2 3
14
13 4
7
12
8
10 6
11
9 7
1. Front Right Carpet Insulation Mat 10. Driver-Side Floor Mat (Right)
2. Rear Right Carpet Insulation Mat 11. Driver Foot Rest Bracket Assembly
3. Carpet Assembly (Right)
4. Rear Left Carpet Insulation Mat 12. Front Passenger Foot Rest Bracket As-
5. Front Left Carpet Insulation Mat sembly (Left)
6. Driver-Side Floor Mat (Left) 13. Front Passenger Foot Rest Bracket As-
7. Front Floor Plug sembly (Right)
8. Front Floor Plug Seal 14. Front Passenger Side Floor Mat
9. Driver Foot Rest Bracket Assembly (Left)

CARPET ASSEMBLY
Attention:
ginning work.
• Touch the door-lock screw to discharge static
electricity.
• Before repair or maintenance, please consult
the airbag's position and precautions as well
as its operating procedures.
• Do not damage, wrinkle, or warp the carpet.
trim.
Removal
1. Remove the front seat
2. Remove the rear seat
3. Remove the front door sill guard
4. Remove the rear door sill guard
5. Remove the back door sill
6. Remove the strut A lower guard
7. Remove the strut B lower guard
8. Remove the strut C lower guard
9. Remove the auxiliary dashboard
10. Remove the carpet
(a) Remove the 2 back-row snaps.
(b) Pull the seat cabling out through the hole in the carpet.
(c) Remove the carpet.
Installation
Attention:
• Ensure that the seat cabling and parking-
brake-cable cabling is correct.
• Check whether the snaps are damaged. If they
are, immediately replace them.
• Ensure that the fasteners and snaps are fixed
in place.
• Ensure that the accelerator pedal hook is fixed
in place and does not come off.
CEILING
SCHEMATICS
WITHOUT SUNROOF
2
3
4
3
1. Rear Center Seatbelt Base Bracket 4. Ceiling Body

2. Rear Center Seatbelt Base Shield 5. Ceiling Foam Piece No. 1
3. Ceiling Support Block No. 1
WITH SUNROOF
2
3
4
3
1. Rear Center Seatbelt Base Bracket 4. Ceiling Body

2. Rear Center Seatbelt Base Shield 5. Ceiling Foam Piece No. 1
3. Ceiling Support Block No. 1

CEILING
Attention:
ginning work.
trim.
Removal
1. Remove the rear shelf
(a) Separate the pull rope and back door.
(b) Separate the rear shelf's 2 dogs and remove the rear-
shelf assembly.

(a) Turn the trunk-cover's switch and remove the trunk cover.
3. Remove the base plate's on-board tool kit (right

side)
(a) Turn the 2 switches and remove the on-board tool kit.
Remark:
• The removal procedure is the same as with the
right side.
5. Remove the right-rear seat

6. Remove the left-rear seat
7. Remove the front door side seal stripe
8. Remove the rear-door side seal stripe
9. Remove the front door sill
10. Remove the rear door sill
12. Remove the A-column guard
13. Remove the B-column guard

14. Remove the C-column guard
15. Remove the ceiling handle
(a) Pry open the decorative covers fixed over the bolts
(b) Remove the 2 screws.
16. Remove the right-side sun visor

(a) Separate the sun visor and sun visor bracket.
(b) Remove the 2 screws.
17. Remove the left-side sun visor
Remark:
right side.
18. Remove the right-side sun visor bracket

(a) Rotate the sun visor bracket from 60 to 120 degrees
counterclockwise to separate its 2 dogs. Then remove
60 – 120°
the sun visor bracket.
19. Remove the left-side sun visor bracket
Remark:
right side.
20. Remove the ceiling lamp assembly

21. Remove the reading lamp assembly
22. Remove the ceiling

(a) Remove the 2 snaps.
(b) Take the ceiling out through the back door.
Installation
Attention:
• Ensure that the seat cabling is correct.
• Check whether the snaps are damaged. If they
are, immediately replace them.
• Ensure that the fasteners and snaps are fixed
in place.
GLASS
SCHEMATICS
FRONT WINDSHIELD
1. Front Windshield Decorative Block As- 3. Front Windshield Decorative Block As-
sembly (Lower Right) sembly (Lower Left)
2. Front Windshield Glass Assembly

FRONT WINDSHIELD
Removal
1. Remove the protective surface inside the top cover
2. Remove the rearview mirror assembly
3. Remove the ventilation cover body
4. Remove the windshield
(a) Insert a piano wire (A) between the vehicle body and
glass.
(b) Tie a knot between the two ends of the piano wire to act
B as a lever (like a wood block) (B).
Attention:
B
• To prevent the exterior of the vehicle body
from being scratched, affix a layer of protec-
tive tape (A) to it.
• When separating the glass from the vehicle, be
careful not to damage the vehicle's paint or its
interior or exterior trim.
• To avoid scratching the dashboard safety
A
cushion, place a plastic sheet (B) between the
piano wire and safety cushion.
(c) Pull the piano wire along the edge of the glass to cut it.
(d) Separate the positioning block.
(e) Use a suction disc to remove the glass.
5. Clean the windshield
(a) Use a scratcher to remove damaged stoppers, seal
stripes, and adhesive material stuck to the glass.
(b) Use white gas to clean the perimeter of the glass.
Attention:
• Do not touch the surface of the glass after
cleaning.
• Do not damage the glass.
• If you are using new glass, also use white gas
to clean it.
Installation
1. Clean and recondition the vehicle body's contact
surfaces.
A
(a) Use a knife to remove any leftover or unnecessary ad-
hesive material from the contact surface.
A (b) Use a cloth seeped in a cleaning solution to clean the
vehicle body's contact surfaces.
Attention:
• If all of the adhesive material has already been
removed, you must continue on to clean the
vehicle body.
2. Position the glass.

(a) Use a suction disc to place the glass in the correct posi-
tion.
A (b) Check all of the contact surfaces on the edge of the
glass and confirm that they are sufficiently level and
smooth.
(c) Make a reference mark (A) between the glass and the
vehicle body.
Attention:
• Check the positioning block and ensure that it
is correctly affixed to the vehicle body.
• When reusing glass, check and correct the po-
sition of the reference mark.
(d) Remove the glass.
3. Coat the side contact surfaces of the vehicle body
A with primer M (A) using a brush.
Attention:
• The primer should dry for at least 3 minutes.
A
• Do not coat adhesive material (B) with primer M.
B
• Discard the remaining primer M.
A
˖
A 4. Using a brush or sponge, coat the edges of the back

A of the glass and contact surfaces with primer (C).
A A Specification:
B
Part Specified state
B
A-A a a 7.0 mm
b 23.5 mm
B-B b Attention:
• If you carelessly coat other parts of the vehicle
C with primer, use a clean cloth to wipe it off be-
fore it dries.
• Do not coat adhesive material with primer.
• Discard the remaining primer.
A 5. Coat the back edges of the glass with adhesive ma-

A terial
(a) Cut off the nozzle end of the tube of adhesive material.
A A
B Remark:
B • After cutting off the end, use all of the adhesive
A-A a
material before the time listed in the table below.
b
Useful lifespan
b a a B-B Temperature Useful lifespan
b
35 ºC 15 min
20 ºC 1 h 40 min
5 ºC 8h
(b) Place the tube of adhesive material in a glue gun.
(c) Coat the glass with the adhesive material.
Specification:
Part Measured value
a 8.0 mm
b 12.0 mm
6. Install the glass

(a) Use a suction disc to place the glass and align it with
the reference mark. Gently press down along the edges.
Attention:
• Check the stopper and confirm that it is prop-
erly affixed to the vehicle body.
• Check the clearance between the vehicle body
and glass.
(b) Gently press on the front of the glass to ensure that it
fits tightly.
(c) Use a scratcher to remove excess or protruding adhe-
sive material (A).
Remark:
A • Coat the edges of the windshield (A) with adhesive
material (B).
B
Attention:
• Be careful not to drive the vehicle within the
times listed in the table below.
Minimum period:
Temperature Minimum period before driving
35 ºC 1 h 30 min
20 ºC 5h
5 ºC 24 h
7. Check whether there are leaks
(a) Perform a leak test before the adhesive material com-
pletely hardens.
(b) Use vehicle-glass sealant to seal any leaks.
BACK-DOOR GLASS
Removal
1. Remove the back-door glass
(a) Insert a piano wire (A) between the vehicle body and
A
glass.
(b) Tie a knot between the two ends of the piano wire to act
as a lever (like a wood block).
Attention:
• To prevent the exterior of the vehicle body
from being scratched, affix a layer of protec-
tive tape (A) to it.
• When separating the glass from the vehicle, be
careful not to damage the vehicle's paint or its
A
interior or exterior trim.
(c) Pull the piano wire along the edge of the glass to cut it.
Attention:
• If you will reuse the back-door glass, do not
damage the snaps installed on the glass while
removing the adhesive material.
(d) Use a suction disc to remove the glass.
2. Clean the back-door glass
(a) Use white gas to clean the perimeter of the glass.
Attention:
• Do not touch the surface of the glass after
cleaning.
• Do not damage the glass.
Installation
1. Clean and recondition the contact surfaces of the
vehicle body
(a) Using a knife, chip off any rough, uneven adhesive ma-
terial (A) on the contact surfaces of the vehicle body,
A A ensuring that the surfaces are in good shape.
(b) Use a cloth seeped in a cleaning solution to clean the
vehicle body's contact surfaces.
Attention:
• If all of the adhesive material has already been
removed, you must clean the vehicle body.
2. Coat the exposed parts of the vehicle body with

A
primer M (A) using a brush
Attention:
A • The primer should dry for at least 3 minutes.
B • Do not coat adhesive material (B) with primer M.
• Discard the remaining primer M.
A
˖
A 3. From the rear, use a brush or sponge to coat the

C
A C edges of the glass and contact surfaces with primer
B D D Attention:
B • If you carelessly coat other parts of the vehicle
A-A B-B
a a with primer, use a clean cloth to wipe it off be-
fore it dries.
b c
D-D
C-C a e
• Discard the remaining primer.
• Do not put on too much primer.
d f
Specification:
Part Measured value
a 14.0 mm
b 10.0 mm
c 12.8 mm
d 30.0 mm
e 22.0 mm
f 38.0 mm
A 4. Apply the adhesive material from the back side

C
A C
(a) Cut off the nozzle end of the tube of adhesive material.
B D D Attention:
B • After cutting off the end, use all of the adhe-
A-A B-B
a a sive material before the time listed in the table
b b below.
C-C
c d
D-D
Useful lifespan:
b a a a
Temperature Useful lifespan
b b
e f
35 ºC (95°F) 15 min
20 ºC (68°F) 1 h 40 min
5 ºC (41°F) 8h
(b) Place the tube of adhesive material in a glue gun.
(c) Coat the glass with the adhesive material.
Specification:
Part Measured value
a 8.0 mm
b 12.5 mm
c 10.0 mm
d 12.8 mm
e 30.0 mm
f 30.0 mm
5. Install the glass on the vehicle body
(a) Use tape or a similar product to secure the back-window
glass to the vehicle body until the adhesive material
hardens.
Attention:
• Check the snaps and confirm that they are cor-
rectly installed on the vehicle body.
• Check the clearance between the vehicle body
and glass.
(b) Gently press on the front of the glass to ensure that it
fits tightly.
(c) Use a scratcher to remove excess or protruding adhe-
sive material (A).
Attention:
• Coat the exterior edges of the glass with the
adhesive material.
• Do not drive the vehicle within the times listed
in the table below.
Minimum period:
A
Temperature Minimum period before driving
35  ºC 1 h 30 min
20  ºC 5h
5  ºC 24 h
6. Check whether there are leaks
(a) Perform a leak test before the adhesive material com-
pletely hardens.
(b) Use vehicle-glass sealant to seal any leaks.
VEHICLE INTERIOR TRIM

SCHEMATICS
PROTECTIVE SURFACE INSIDE FRONT DOOR
4
1
1. Front Left Door Waterproof Membrane 4. Front Left Door Inner Protective Plate As-
2. Front Left Door Power Window Switch sembly
Panel Screw Cover 5. Front Left Door Buckle Base
3. Front Left Door Power Window Switch 6. Front Left Door Main Handle Frame
Panel 7. Front Left Door Main Handle Cover
PROTECTIVE SURFACE INSIDE REAR DOOR
1. Rear Left Door Waterproof Membrane 3. Rear Left Door Power Window Switch Panel
2. Rear Left Door Power Window Switch Panel 4. Rear Left Door Inner Protective Plate As-
Screw Cover sembly
BACK-DOOR INSIDE PROTECTIVE SURFACE
1. Back Door Inner Fender Assembly 4. Back Door Guard Plug Cover
2. Back Door Guard Handle 5. Back Door Guard Tail-Lamp Maintenance
3. Back Door Guard Tail-Lamp Maintenance Opening Cover, Right
Opening Cover, Left
SIDE WALL TRIM PLATE
10
1. Strut A Upper Left Guard 7. Rear Left Door Sill Guard

2. Strut A Lower Left Guard 8. Strut C Lower Left Guard
3. Front Left Door Sill Guard 9. Strut C Upper Left Guard
4. Strut B Upper Left Guard 10. Rear Left Shock Absorber Maintenance
5. Strut B Lower Left Guard Cover
6. Front Left Seat Belt Height Adjuster Slider

FRONT-DOOR INNER FENDER
Remark:
• The removal procedure for the front-right and
front-left door fender is the same.
Removal
1. Lower the window
3. Remove the door buckle base
4. Remove the front door inner handle

(a) Remove the cover plate for the front door inner handle.
(b) Remove the screw for the front door inner handle.
5. Remove the front-door power-window switch panel

(a) Remove the screw cover for front door armrest box.
(b) Remove the screw securing the power-window switch,

take out the power-window switch, and disconnect the
cable connectors.
6. Remove the front-door main handle

(a) Remove the cover plate for the front-door main-handle.
(b) Remove the main handle's 2 screws.
7. Remove the front-door inner fender

(a) Insert a screwdriver into the snap securing the door in-
ner fender and pry it loose.
(b) Remove the 7 snaps securing the front door inner fend-
er surface.
Attention:
• Before using the screwdriver, you must encase
its head in tape.
Snap:
(c) Take off the front-door inner fender.

Caution
• When taking off the the front-door inner fender,
avoid bending it as much as possible to pre-
vent creating wrinkles and fractures. You can
place it flat on a piece of cardboard.
Installation
Attention:
• Check whether the snaps are damaged or have
been broken by weight, and replace them when
necessary.
• Confirm that the power-window switch connec-
tor is inserted normally and that the connec-
tion is secure.
• Confirm that the vehicle window and power
door lock function normally.
REAR DOOR INNER FENDER

Remark:
• The cover plate for the rear-left and rear-right door
panels is the same.
Removal
1. Lower the vehicle window
3. Remove the rear door inner handle
(a) Remove the cover plate for the rear door inner handle.
(b) Remove the rear door inner handle screw.
4. Remove the rear-door power-window switch panel

(a) Remove the screw cover for the rear-door armrest box.
(b) Remove the screw securing the power-window switch,

take out the power-window switch, and disconnect the
cable connectors.
5. Remove the rear door inner fender

(a) Insert a screwdriver into the snap securing the door in-
ner guard and pry it loose.
(b) Remove the 7 snaps securing the front door inside pro-
tective surface.
Attention:
• Before using the screwdriver, you must encase
its head in tape.
Snap:
(c) Take off the rear door inner fender.

Caution
• When taking off the the rear door inner fender,
avoid bending it as much as possible to pre-
vent creating wrinkles and fractures.
Installation
Attention:
necessary.
• Confirm that the power-window switch connec-
tor is inserted normally and that the connec-
tion is secure.
• Confirm that the vehicle window and power
door lock function normally.
BACK DOOR INNER FENDER

Removal
2. Remove the back door inner fender
Snap:
Installation
Attention:
necessary.
A-COLUMN GUARD
Removal
Attention:
• Be careful not to scratch the trim or trim plate.
Remark:
• Remove the right side in the same order as the left
side.
1. Remove the door frame seal
2. Remove the front left door sill guard
(a) Separate the 8 dogs for the front left door sill guard.
3. Remove the strut A lower left guard

4. Remove the strut A upper left guard
Snap:
Installation
Attention:
necessary.
• If the side curtain airbag is triggered, replace
the snap on top of the A-column guard.
• When cracks, deformations, or other damage
appear on the A-column guard, it must be re-
placed.
• Push the snaps and hooks so that they are
firmly in place.
B-COLUMN GUARD
Removal
Attention:
Remark:
side.
2. Remove the front left door sill guard
(a) Separate the 8 dogs for the front left door sill guard.
3. Remove the rear left door sill guard

(a) Separate the 6 dogs for the rear left door sill guard.
4. Remove the regulator cover

Remark:
• The removal procedure for the left and right regu-
lator covers is the same.
(a) Pull outwards in a vertical direction, disconnect the dog,
and then you can remove the regulator cover.
5. Remove the bolt securing the front-left seat belt

6. Remove the strut B guard

(a) Separate the 2 snaps and 2 dogs.
Snap:
7. Remove the strut B upper guard

(a) Separate the 3 snaps and 2 dogs.
Snap:
Installation
Attention:
necessary.
the snap on top of the B-column guard.
appear on the B-column guard, it must be re-
placed.
firmly in place.
C-COLUMN GUARD
Removal
Attention:
Remark:
side.
2. Remove the back door sill guard
(b) Separate the 8 dogs.
Snap:
3. Remove the rear left door sill guard

(a) Separate the 6 dogs for the rear left door sill guard.
4. Remove the rear shelf

(a) Separate the pull rope and back-door connector.
(b) Separate the rear shelf's 2 dogs and remove the rear-
shelf assembly.

(a) Turn the trunk-cover's switch and remove the trunk cover.

(a) Turn the 2 switches and remove the on-board tool kit.
7. Dislodge the seat belt from the seat belt clip
8. Remove the fixing bolt securing the rear-left seat

belt

(a) Remove the 3 screws.
(b) Separate the 3 snaps and 6 dogs.
Snap:
Remark:
• You must disconnect the trunk-light connector from
the right side.
Snap:
10. Remove the C-column upper guard

(b) Take out the seat belt through the slit in the C-column
and take off the C-column upper guard,
Snap:
Installation
Attention:
necessary.
the snap on top of the C-column guard.
appear on the C-column guard, it must be re-
placed.
firmly in place.
VEHICLE EXTERIOR TRIM

LOCATION DIAGRAM
LICENSE PLATE LIGHT DECORATIVE PANEL
1. License Plate Light Decorative Panel

DEFLECTOR
1. Deflector
DECORATIVE LABELS
1
2
1. Rear Logo 3. Great Wall Motors Logo

2. "Haval H1" Logo 4. Front Logo
LOWER BODY DEFLECTOR
1. Lower Right Deflector 2. Lower Left Deflector

SCHEMATICS
LUGGAGE RACK
4
6
3
5
1. Right Luggage Rack Rear Cover Assembly 4. Right Luggage Rack Assembly
2. Left Luggage Rack Rear Cover Assembly 5. Left Luggage Rack Front Cover Assembly
3. Left Luggage Rack Assembly 6. Right Luggage Rack Front Cover Assembly
VENTILATION COVER PLATE
4 3
1. Right Vent Cover Assembly 3. Brake Fluid Fuel Filler Cap Assembly
2. Left Vent Cover Assembly 4. Vent Cover Seal
RADIATOR DEFLECTOR
1. Radiator Upper Deflector Body 3. Radiator Lower Left Deflector Body

2. Radiator Lower Right Deflector Body
WHEEL COVER TRIM
2
3
11
12 10
18
4 5
19 6
9 8
23 17
20
24 7
15 13
16
14
22 21
1. Rear Wheel Fender (Rear Right) 11. Rear Right Door Decorative Panel Body
2. Rear Wheel Fender (Rear Left) 12. Front Right Door Decorative Panel Body
3. Rear Right Wheel Arch Decorative Panel Body 13. Left Door Sill Outer Decorative Panel Body
4. Rear Right Wheel Arch Decorative Panel Rein- 14. Front Left Wheel Arch Decorative Panel Body
forcing Bracket 15. Strut A Outer Decorator Plate Assembly (Left)
5. Rear Left Door Decorative Panel Body 16. Engine Cover Side Decorative Piece (Left)
6. Rear Left Wheel Arch Decorative Panel Rein- 17. Right Door Sill Outer Decorative Panel Body
forcing Bracket 18. Strut A Outer Decorator Plate Assembly (Right)
7. Rear Left Wheel Arch Decorative Panel Body 19. Engine Cover Side Decorative Piece (Right)
8. Left Door Sill Decorative Panel Reinforcing 20. Front Right Wheel Arch Decorative Panel Body
Bracket 21. Front Left Wing and Blocking Plate Assembly
9. Front Left Door Decorative Panel Body 22. Front Left Splash Guard
10. Right Door Sill Decorative Panel Reinforcing 23. Right Wing and Blocking Plate Assembly
Bracket 24. Front Right Splash Guard

LUGGAGE RACK
Removal
1. Remove the front and back installed cover-plate as-
semblies
2. Remove the 8 mounting bolts for the luggage rack
3. Take off the luggage rack

Installation
VENTILATION COVER PLATE

Removal
1. Remove the wiper arm
2. Remove the seal for the front-vent cover plate
3. Remove the brake fluid fuel filler cap

4. Remove the ventilation cover plate for the front-
right wall
(a) Remove the single snap fastener.
(c) Remove the ventilation cover plate for the front-right
wall.
5. Remove the ventilation cover plate for the front-left

wall
(a) Remove the 2 snap fasteners.
(c) Remove the ventilation cover plate for the front-left wall.
Installation
LICENSE PLATE LIGHT DECORATIVE

PANEL
Removal
1. Remove the rear wiper
2. Remove the back door inner fender
3. Remove the license plate light decorative panel
(a) Remove the 6 nuts.
(b) Remove the 7 snaps.
Snap:
(c) Take off the license plate light decorative panel.

Installation
DEFLECTOR
Removal
1. Remove the back-door maintenance plug
2. Remove the deflector

(a) Remove the 3 nuts.
(b) Disconnect the high-mount brake lamp connector.

(c) Take off the deflector.
Installation
DECORATIVE LABELS
Removal
1. Take directly off
2. Use a cleaning agent to clean the surface of the ve-
hicle body
Installation
1. Tear off the outer packaging
2. Take out the decorative label
3. Tear off the label strip's one-sided 3M glue tape
4. Place in the correct position and affix it there
LOWER BODY DEFLECTOR

Removal
1. Remove the tires
3. Remove the lower body deflector
(b) Remove the 5 snap fasteners.
(c) Remove the 2 snaps.
Snap:
(d) Remove the 4 screws.
(e) Take off the lower body deflector.

Installation
RADIATOR DEFLECTOR
Removal
2. Remove the radiator deflector
(a) Remove the 5 snaps from the radiator upper deflector.
(b) Remove the 2 nuts from the radiator upper deflector.
(c) Remove the 2 snaps from the radiator lower left deflec-
tor.
(d) Remove the 2 snaps from the radiator lower right de-
flector.
Installation
WHEEL COVER TRIM

Removal
1. Remove the door inner guard
2. Remove the front and back decorative panels for
the wheel arches
Snap:
3. Remove the screw for the door sill decorative pan-

el's front section
4. Remove the big snaps connecting the bottom of the

door sill decorative panel and the sheet metal
Snap:
5. Remove the tire

6. Remove the bumper
7. Remove the lower body deflector
8. Remove the front splash guard
(a) Remove the 7 snap fasteners.
(b) Remove the 3 fasteners for the rear bumper decorative

panel.
(c) Remove the single plastic nut.
9. Remove the rear fender

(a) Remove the single snap.
Snap:
(b) Remove the 2 snap fasteners.
Installation
Memorandum
Memorandum
Hvac (Heater, Ventilation and Air Conditioning) System 10-1
HVAC (HEATER, VENTILATION

AND AIR CONDITIONING) SYSTEM
AIR-CONDITIONING SYSTEM
Air-Conditioning System..............................................10-2
Air-Conditioning Regulation Control.............................10-3
A/C Pipeline.................................................................10-4
Schematics.....................................................................10-5
A/C Duct Assembly......................................................10-5
Air Regulation Device..................................................10-6
Pin Definitions..............................................................10-9
Commonly Used Test Instruments...............................10-19
On-Board Inspection....................................................10-27
Precautions..................................................................10-36
Procedures Related to Refrigerant..............................10-43
A/C Controller Panel....................................................10-47
Compressor Assembly.................................................10-48
Condenser Assembly...................................................10-50
A/C Assembly...............................................................10-51
Blower..........................................................................10-52
Cooling Pipe.................................................................10-53
Evaporator Temperature Sensor..................................10-54
Cabin Temperature Sensor..........................................10-56
Outside Temperature Sensor.......................................10-58
Air-Conditioning Filter Cartridge...................................10-60
10-2 Hvac (Heater, Ventilation and Air Conditioning) System
LOCATION DIAGRAM
2 5
1. A/C Duct Assembly 4. A/C Pipeline

2. Interior A/C Assembly 5. Cooling Condenser Assembly
3. Sight Glass 6. Compressor Assembly
AIR-CONDITIONING REGULATION CONTROL
1. Outside Temperature Sensor 3. Air-conditioning Controller with Panel

2. Cabin Temperature Sensor Assembly
A/C PIPELINE
6 4
5
3
1. A/C and Heater Water Outlet Pipe 5. Cooler Outflow Assembly

2. A/C and Heater Water Inlet Pipe 6. HVAC Inlet/Outlet Pipe with Pressure
3. Compressor Exhaust Pipe Assembly Switch Assembly
4. Compressor Intake Pipe Assembly
SCHEMATICS
A/C DUCT ASSEMBLY
1. Central Defroster Duct Assembly 3. Central Ventilation Duct Assembly

2. Right Vent Duct with Right Defroster 4. Left Vent Duct with Left Defroster Duct
Duct Assembly Assembly
AIR REGULATION DEVICE
3
2
4
7
6
8
1. Expansion Valve Element 6. Speed Regulator Module

2. Evaporator Core Assembly 7. Interior A/C Assembly
3. External Circulation Duct Component 8. Heater Core Assembly
4. Filtration Screen Component 9. Evaporator Temperature Sensor
5. Blower Fan Component
SPECIFIED TORQUE
Tightening
Standard parts Fastening parts Quantity
torque (N•m)
Nut HVAC & front wall assembly 15 1
Bolt HVAC & front wall assembly 15 2
Screw HVAC & dashboard reinforcing beam 15 3
HVAC & dashboard reinforcing beam-cen-

Self-tapping screw force in 1
tral passage bracket
Bolt Compressor & engine 32±2 4
Bolt Condenser & vehicle body 23 2
Bolt Upper condenser suspension assembly 10 2
Bolt Outlet pipe bracket assembly 10 1
Bolt Compressor exhaust pipe & compressor 10±2 1
Bolt Air suction pipe & compressor 10±2 1
HVAC inlet/outlet pipe and pressure switch

Bolt 10±2 1
assembly & expansion valve
Bolt Cooler outflow assembly & condenser 10±2 1
Suction pipe bracket assembly & vehicle

Nut 10 1
body
Compressor air suction pipe & HVAC cool-
Bolt 10±2 1
ing pipe
Screw Left duct & upper dashboard body force in 2
Screw Right duct & upper dashboard body force in 2
Bolt Compressor exhaust pipe & condenser 10±2 1
HVAC inlet/outlet pipe and pressure switch

—— 13.5±1.5 1
assembly & cooler outflow assembly

SYSTEM PARAMETERS
Item Structures and parameters

Refrigeration capacity 4600 W±5%
Heating capacity 5000 W±5%
Refrigerant R134a: 510±10 g
Oil cooling capacity 130-140 mL
Reservoir 0.269 L (including desiccant)
Motor rated power 325 W/DC13 V
Expansion valve R134a H-shape expansion valve
COMPRESSOR SPECIFICATIONS
Item Parameters
Permissible continuous revolution speed (r/min) 800-7800
Maximum permissible angle of inclination when installed (°) ±35
Compressor Applicable refrigerant R134a
Lubricating oil brand 300001202 (SP10)
Oil quantity (ml) 130~140
PIN DEFINITIONS
MANUAL A/C PANEL CONNECTOR PORTS AND ASSIGNMENTS
A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6
A9 A10 A11 A12 A13 A14 A15 A16 B7 B8 B9 B10 B11 B12
Pin Pin Voltage

Pin function Orientation Amperage Remark
number assignment range (V)
A1 BATT+ Battery anode Input 12 <100 mA

A2 IG2 Ignition voltage Input 12 <1500 mA
A3
Active high
A4 BLOWER_ON Blower "start" signal Input 0/12 <10 mA
power level
A5 FET-G Blower motor drive Output 0~8 <50 mA
A6 FET-D Blower feedback voltage Input 0~12 <5 mA
A7 HI-DRIVER Blower hi-speed drive Output 0/12 <200 mA
A8 INTAKE+ Circulation motor pin #5 Output 12/0 <800 mA

Active high
A9 A/C SIGNAL A/C signal Output 12/0 <30 mA
power level
A10 MODE-F/B Mode motor feedback Input 0.1~4.9
Temperature motor feed-
A11 TEMP-F/B Input 0.1~4.9
back
Potentiometer positive
A12 VREF(5 V) Output 5
power supply
A13
A14
A15
A16
Pin Pin Voltage

B1 GND Power supply GND Input

B2 S-GND Signal ground Input <5 mA
PRDEF-DRIV- Active low
B3 Rear defroster drive Output 12/0 <200 mA
ER power level
B4
B5 VENT Mode motor pin #5 Output 12/0 <800 mA
B6 HEAT Mode motor pin #4 Output 12/0 <800 mA
B7 ILL- Backlight, negative pole Input 0 <500 mA
B8 ILL+ Backlight, positive pole Input 12 <500 mA
Temperature motor pin
B9 HOT Output 12/0 <800 mA
#5
Temperature motor pin
B10 COOL Output 12/0 <800 mA
#4
B11 INTAKE- Circulation motor pin #1 Output 12/0 <800 mA
B12
AUTOMATIC A/C PANEL CONNECTOR PORTS AND ASSIGNMENTS
A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6
A9 A10 A11 A12 A13 A14 A15 A16 B7 B8 B9 B10 B11 B12
Pin Pin Voltage

A1 BATT+ Battery anode 12 <500 mA

A2 IG2 Ignition voltage 12 <1500 mA
A3 CAR-SPEED Vehicle speed signal Input XX <X mA
Active high
A4 BLOWER_ON Blower "Start" signal Input 0/12 <2 mA
power level
Active high
A5 FET-G Blower drive (G-pole) Output 0~8 <50 mA
power level
Blower feedback volt-
A6 FET-D Input 0~12 <5 mA
age
Active low
A7 HI-DRIVER Blower hi-speed drive Output 0/12 <150 mA
power level
Internal/external circu-
A8 REC Output 12/0 <500 mA
lation actuator pin #1
Active high
A9 A/C SIGNAL A/C signal Output 12/0 <30 mA
power level
Mode actuator feed- Active high
A10 MODE-F/B Input 0.1~4.9 <5 mA
back power level
Heat/cooling actuator Active high
A11 TEMP-FB Input 0.1~4.9 <5 mA
feedback power level
Potentiometer positive
A12 VREF(5 V) 5
power supply
Outside temperature
A13 AMBIENT-
sensor -
Cabin temperature
A14 IN_CAR-
sensor -
Cabin temperature
A15 IN-SENSOR Input 0.1~4.9 <5 mA
sensor
A M B I E N T Outside temperature
A16 Input 0.1~4.9 <5 mA
SENSOR sensor
Pin Pin Voltage

B1 GND Power supply GND

B2 S-GND Signal ground <5 mA
PRDEF-DRIV- Active low
B3 Rear defroster drive output 12/0 <150 mA
ER power level
Wa te r te m p e r a t ure
B4 TEMP-WATER input 0.1~4.9 <5 mA
sensor
B5 VENT Mode actuator pin P1 output 12/0 <500 mA
B6 HEAT Mode actuator pin P2 output 12/0 <500 mA
Backlight, negative
B7 ILL- 12/0 <500 mA
pole
Backlight, positive
B8 ILL+ 12/0 <500 mA
pole
Heat/cooling actuator
B9 HOT output 12/0 <500 mA
pin P1
Heat/cooling actuator
B10 COOL output 12/0 <500 mA
pin P2
Internal/external circu-
B11 PRE output 12/0 <500 mA
lation actuator pin #2
B12 LIN LIN message output 0-12
COOLER/HEATER ACTUATOR CONNECTOR PORTS AND ASSIGNMENTS
TEMP+ TEMP- Temp F/B VDD_T GND
5 4 3 2 1
Pin number Pin definitions
1 Ground
2 Feedback power source

3 Feedback
4 Drive -
5 Drive +
MODE ACTUATOR CONNECTOR PORTS AND ASSIGNMENTS
MODE+ MODE- Mode F/B VDD_M GND
5 4 3 2 1
1 Ground
2 Feedback power source
3 Feedback
4 Drive -
5 Drive +
INTERNAL/EXTERNAL CIRCULATION ACTUATOR CONNECTOR PORTS AND ASSIGN-

MENTS
INTAKE+ INTAKE-
5 1
1 Drive -
2 —
3 —
4 —
5 Drive +
SPEED MODULE PORTS AND ASSIGNMENTS
4 3 2 1
1 Output
2 Control terminal
3 Feedback
4 Ground
BLOWER INTERFACE AND ASSIGNMENTS
1
2
1 Cathode
2 Anode
The below table lists fault descriptions and an analysis of their causes as a basic troubleshooting ref-
erence. When diagnosing specific faults, troubleshooting based on the apparent symptoms must be
confirmed with the appropriate instruments.
Remark:
• Before replacing or repairing parts, first check whether the fault is due to the refrigeration sys-
tem, air circulation device, or compressor pins.
Fault Symptoms Analysis of Causes

The fuse is burnt out, and the compressor relay is damaged
The pressure switch contact is disconnected and, the circuit has shorted
or is open
The compressor's electromagnetic clutch coil circuit is open
The switch is burnt out
The main relay is burnt out
The compressor is The clutch is slipping
not pulling in air The compressor belt is broken or too loose
The compressor has broken down
The cooling medium is insufficient; the pressure in the system is lower
than 0.196 MPa
The air- The pressure in the system is in excess of 3.14 MPa
conditioning The engine water temperature is too high
system is The clutch voltage is less than 7 V
not cooling The compressor relay's normally-open contact is stuck, and the system
The compressor is
the air is seriously leaking its cooling medium or has no cooling medium
pulling in air
The blower is not working
The fuse is burnt out
The blower's motor brush is damaged
The blower switch is broken
The connector for the blower is been disconnected or there is an open
The blower is not circuit
putting out air The speed regulator module is damaged
The blower does not put out air at high speed; the high-speed relay is
damaged
Note: when the blower is not working, the resistance is close to 0, but
when there is an open circuit, the resistance is ∝
The cool- The cooling system is blocked by ice
ing system The compressor is The thermal resistor or thermo bulb has malfunctioned
s o m e t i m e s operating normally The A/C switch contact is poor
cools the air The condenser fan is damaged
a n d s o m e - The compressor is
times does operating abnor- The clutch is slipping, the clutch coil has come loose, and the clutch coil
not ground is bad
mally

The blower fan is normal: the air-supply duct is damaged
The blower fan is abnormal:
(1) The blower switch is abnormal
There is low air flow
(2) The power from the power supply is low
(3) The speed regulator module is damaged
The air-conditioning filter cartridge or evaporator is plugged
The compressor is operating normally
(1) The high-pressure and low-pressure sides are equally low pressured
(a) The expansion valve is plugged
(b) The expansion valve is not opening sufficiently
(2) The high-pressure and low-pressure sides are equally high pres-
sured
(a) The high-pressure duct has broken down, and the flow is impeded
(b) The thermal resistor has become ineffective
(c) The expansion valve is opening too much
(d) There is too much refrigerating machine oil
(e) There is too much refrigerant
(f) The condenser is dissipating heat poorly
Note: When the rpm is 2000 r/min, the cooling fan is in top gear, and
the air temperature is 30 °C to 35 °C, the pressure within the system on
the low-pressure side should be within 0.147 MPa to 0.25 MPa, and the
high-pressure side should be within 1.37 MPa to 1.67 MPa
The cooling The compressor is operating normally
is insufficient (3) The pressure on the high-pressure side is too low
(a) The low-pressure pipeline is damaged
(b) The low-pressure pipeline is plugged
The air flow is nor- (4) The pressure on the low-pressure side is too low
mal (a) The evaporator is frosted over
(b) The expansion valve is plugged
(c) The low-pressure pipeline is impeded
(d) The temperature-sensitive speed regulator resistor has become inef-
fective
(5) The pressure on the low-pressure side sometimes normal and
sometimes under negative pressure, and there are signs of water and
ice blockage within the cooling system
(6) The low-pressure side is under negative pressure, the pressure
on the high-pressure side is too low, and the cooling system has been
clogged internally
(7) The pressure on the low-pressure side is too low, and the pressure
on the high-pressure side is too high
(a) The condenser is clogged internally
(b) The high-pressure duct is clogged
(8) The pressure on the low-pressure side is too high, and the pressure
on the high-pressure side is too low
(a) The compressor is leaking
(b) The compressor valve is damaged
(9) The condenser fan has low air flow, leading the condenser to dissi-
pate heat poorly

The compressor is operating abnormally
(1) The compressor has broken down internally
(2) The compressor belt is loose and slipping
(3) The magnetic clutch has broken down
(a) The power supply is providing too little power
(b) The stator is interfering with the rotor
The cooling The air flow is nor- (c) The idling stability amplifier has broken down
is insufficient mal (d) The circuit has been disconnected, and the connected parts are de-
tached
(e) The switch and relay are working poorly
(f) The circuit has shorted and is open
(g) The grounding is poor
Other causes
The cabin seals are poor
The belt is too loose or excessively worn
The compressor mounting bracket screw is loose
The compressor mounting bracket is damaged
The cool- An internal part or parts of the compressor are damaged
ing system The refrigerating machine oil is insufficient or absent
The noise levels
is making The clutch is slipping and making noise
are excessive
substantial The clutch bearings are insufficiently oiled or damaged
noise The blower motor bearings are damaged
The blower bracket is loose or broken off
The blower blade is loose or broken off
The blower blade is rubbing against other parts
The air-conditioner blower has broken down
The blower relay is damaged
Not providing warm
The heating air duct is plugged
air or providing too
The cooling water pipe is plugged
little warm air
The cooling/heating air damper actuator is damaged
There is insufficient coolant
The fuse has burnt out or the switch's contact is poor
The blower motor has been burnt
The blower is not
The high-speed blower relay circuit is open
Heating sys- rotating
The speed regulator resistor is damaged
tem
The circuit is open
Water is leaking The warm air and water pipes have aged, and the joints are not firm
The fan speed regulator resistor is damaged
Over heating
The cooling/heating air damper actuator is damaged
The air-valve position is not ideal
The defroster does The air outlet is clogged
not have enough Not enough warm air is being provided
hot air The air-duct installation is not seated
The circuit is open
COMMONLY USED TEST INSTRUMENTS

USING A MANIFOLD PRESSURE GAUGE ASSEMBLY FOR DIAGNOSIS
Description:
• Using a manifold pressure gauge assembly is one way to determine that a part is broken.
• For details on how to use a manifold pressure gauge assembly and the relevant precau-
tions, please consult the description provided by the device manufacturer.
After satisfying the test conditions below, read the pressure on the manifold pressure gauge as re-
quired.
Test conditions:
• When putting the switch in the internal cycle position, the temperature of the inlet port is
30 °C to 35 °C.
• The engine is running at 1500 rpm.
• The blower's speed control switch is at its highest speed position.
• The temperature regulator knob is set to "coldest."
• The air-conditioner switch is on.
• The car doors are completely open.
• The high-pressure end of the guage is connected to the HVAC cooling pipeline's high-
pressure port, and the low-pressure end of the guage is connected to the compressor's
air suction pipe.
1. The cooling function is relatively good
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
R134a
Instrument readings:
Low-pressure side: 0.147 MPa to 0.25 MPa
High-pressure side: 1.37 MPa to 1.67 MPa
2. Moisture appears from the refrigeration system
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
8 3
0
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
Symptoms Possible causes Diagnosis Corrective measures

Moisture in the refrigera- • Please clean the drying
When the drying chamber
tion system is freezing in chamber or replace the
is overfull and moisture in
During operation, the pres- the expansion valve throt- condenser
the refrigeration system
sure at the low-pressure tle, leading the circulation • Remove the moisture in
has frozen in the expan-
side alternates between to be temporarily stopped. circulation by repeatedly
sion valve throttle, the
normal and a vacuum When it melts, however, evacuating the air
circulation of refrigerant is
normal operation is re- • Fill with an appropriate
temporarily stopped
stored amount of new refrigerant
3. The refrigerant circulates poorly
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa

• The pressure is low on
both the low-pressure and
high-pressure sides The flow of refrigerant Please clean the drying
The drying chamber is
• The pipe connecting the has been plugged by dust chamber or replace the
plugged
condenser to the refrig- within the drying chamber condenser
eration system is covered
in frost
4. The refrigerant does not circulate
Condition: the refrigeration system cannot refrigerate (sometimes it can refrigerate)
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa

• Check the expansion
• The low-pressure side
valve
indicates a vacuum, and
• The flow of refrigerant • Clean out any dust in
the high-pressure side in-
has been plugged by the expansion valve by
dicates an extremely low
moisture or dust in the re- The refrigerant does not blowing air into it
pressure
frigeration system circulate • Replace the condenser
• There are signs of frost-
• Air leaks in the expan- • Evacuate it and then
ing or condensation on
sion valve are hindering fill it with an appropriate
pipes on both sides of the
the flow of refrigerant amount of new refrigerant
reservoir/dryer or expan-
• If the expansion valve
sion valve
has gas leaks, replace it
5. The refrigerant has been overfilled or the condenser is cooling poorly
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa

• The pressure is too high • There is too much refrig- • Clean the condenser
on both the low-pressure • Overuse of the refrigera- erant in circulation (the • Check the cooling fan
and high-pressure sides tion system leads to it be- refrigerant has been over- while the cooling fan mo-
• Even if the rotational ing unable to function at filled) tor is running
speed of the engine is its full capacity • The condenser cools • If 1 and 2 are normal,
reduced, air bubbles can • The condenser cools poorly (the condenser then test the quantity of
be seen through the sight poorly fin of the cooling fan is refrigerant and supply the
glass plugged) appropriate amount
6. There is air within the refrigeration system
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01
35
MPa MPa
Remark:
• If you turn on the refrigeration system and add refrigerant when it is not creating a vacu-
um, the meter will read as illustrated.

• The pressure is too high
on both the low-pressure
• Check whether the en-
and high-pressure sides
There is air within the re- gine oil for the compres-
• The low-pressure pipe-
There is air in the system frigeration system sor is dirty or insufficient
line is overheated and
Purification is poor • Evacuate it and add new
cannot be touched
refrigerant
• Air bubbles can be seen
through the sight glass
7. The expansion valve has broken down
Condition: insufficient refrigeration
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01
35
MPa MPa

on both the low-pressure • There is too much re-
and high-pressure sides frigerant within the low-
The expansion valve has Check the expansion
• There is frost or a large pressure pipeline
broken down valve
amount of condensation • The expansion valve is
on pipe for the low-pres- opening too much
sure side
8. The compressor is compressing poorly
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1 5
01 07 30
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 - 01 35
MPa MPa

• The compressor has
on both the low-pressure
broken down
and high-pressure sides The compressor is leak- Repair or replace the
• Leaks have appeared
• The pressure on the ing internally compressor
from a damaged valve or
high-pressure side is too
fractured sliding parts
low
9. The cooling is insufficient
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01 35
MPa MPa

• Check for air leaks and
make repairs if necessary
• The pressure is low on
• Fill with an appropriate
both the low-pressure and
amount of new refrigerant
high-pressure sides • The refrigerant is circu-
• When connecting the
• Air bubbles can be seen The refrigeration system lating insufficiently
instrument, the indicated
continuously through the has leaks • The refrigerant is leak-
pressure should be close
sight glass ing
to 0. After checking for
• Refrigeration perfor-
leaking parts and making
mance is insufficient
repairs, a vacuum should
be produced
Meter readings (reference)
Low-pressure
side pressure
MPa (kgf/cm2)
0.5 (5.0)
Blower HI area
0.4 (4.0)
1.06 (10.9)
0.3 (3.0) 0.27 (2.85)
1.2 (12.3)
0.22 (2.25)
0.2 (2.1) Blower LO area
0.2 (2.0)
1.25 (12.8)
0.14 (1.5)
1.32 (13.5) High-pressure
side pressure
MPa (kgf/cm2)
0.5 (5.0) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0)
ON-BOARD INSPECTION
AIR-CONDITIONER FUNCTION CHECK
1. Install the meter on the high-pressure side
2. Put the vehicle in the following state
Item Condition
Vehicle The vehicle is parked in a cool, shady spot
Vehicle doors All open
Air-conditioner switch On
Engine revolving speed 2,000 rpm
Inlet-mode-selector air-valve position External circulation
Air-outlet air-valve position Face
Temperature setting Coldest
Blower speed HI
Air-conditioner inlet temperature *1 25 °C-30 °C
Condenser pressure (high-pressure side meter) *2 1.5 MPa
Tips:
• *1 A correct judgment can only be made when maintaining the inlet temperature between
25 °C and 35 °C. If the temperature is lower than 25 °C, then the test should be postponed.
• *2 While the condenser pressure (at the high-pressure side meter) is greater than 1.5
MPa, spray or drench the condenser with water to lower the pressure. While the condens-
er pressure is too low, cover the front of the condenser to increase the pressure.
3. Place a dry and wet bulb thermometer in the middle of the air-inlet port, and place a dry bulb
thermometer in the middle of the air-outlet port
4. When operating the air-conditioner after step [*1], keep the air-outlet port temperature stable (for
around 5 to 6 minutes)
5. Measure the wet-bulb temperature at the air-inlet port and the dry-bulb temperature at the air-
outlet port
6. Use the humidity table below to determine the relative humidity based on the dry and wet bulb
thermometer measurements at the air-inlet port
6. Use the humidity table below to determine the relative humidity based on the dry and wet bulb
thermometer measurements at the air-inlet port
30
Relative humidity
0%
10
25
90
80
70
60
Wet bulb temperature 20 50
40
15
30
Relative humidity
10 20
0
10
90
5 80
70
60 10
0 50
40
30
20
10
-5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1819 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Dry bulb temperature (ć)
Example For example, if the dry-bulb temperature is 25 °C and

Wet bulb
the wet-bulb temperature is 19.5 °C, the relative humid-
temperature 20
60
ity is 60%, as that is the intersection between the two
15 dotted lines in the table.
22 23 24 25 26 27
Dry bulb temperature
(g) Use the standard-performance chart below to lookup the intersection between the difference between
the temperature measured at the air-inlet and air-outlet ports and the relative humidity.
Standard: The intersection is within the diagonals on the chart.
26
24
22
20
18
Air intake and air outlet
temperature difference (°C)
16
14
12
10
8
30 40 50 60 70
Relative humidity %
Air intake and air outlet Cross-over For example, if the air-inlet and air-outlet ports have a
temperature difference (°C) point temperature difference of 17 °C and the relative humid-
22
20
ity is 60%, the intersection lies within the diagonals.
18 Thus, this air-conditioner is operating normally.
16
14
12
10
50 60 70
Relative humidity %
PRESSURE SWITCH CHECK

1 1. Magnetic clutch control:
Check the operating condition of the pressure switch.
2 3 (a) Secure the manifold pressure gauge.
(b) Connect the two leads of the ohmmeter to terminals 4
and 1.
Low-pressure side 4 High-pressure side
(c) As the illustration indicates, check the breakover be-
tween the terminals when the refrigerant pressure
196 kPa 3,140 kPa changes.
OFF (no flow) OFF (no flow) Remark:
• If the operating condition does not meet the speci-
fication, replace the HVAC inlet/outlet pipe and
pressure switch assembly.
1 2. Cooling fan control:
Check the operating condition of the pressure switch.
2 3 (a) Connect the two leads of the ohmmeter to terminals 2
and 3.
4 (b) As the illustration indicates, check the breakover be-
tween the terminals when the refrigerant pressure
1,770 kPa
changes.
OFF (no flow) ON (flow) • If the operating condition does not meet the speci-
1,370 kPa fication, replace the HVAC inlet/outlet pipe and
pressure switch assembly.
COMPRESSOR ASSEMBLY CHECK

1. Check the compressor assembly.
(a) Disconnect the connector.
(b) Measure the resistance based on the table below.
Standard:
Tester connector Specified state
Terminal-Compressor 4.5 ± 0.5 Ω
2. Test the operating condition.

(a) Start the engine.
(b) Check the compressor belt pulley.
Standard: The compressor can pull in air and disconnect normally.
Remark:
• When you cannot use the sight glass to determine the amount of refrigerant, you can use the
connected pressure meter to see whether the system's pressure is normal when the compressor
is operating. You can check whether the air outlet is emitting cold air to see if the compressor re-
lay or pressure switch has a short.
A/C CONTROLLER CHECK

1. Electrical A/C controller check
(a) Control functions check
A/C
6 8 A7 A10 B1 B4
1 5 A1 A6 B5 B8
A/C, defroster Internal and external circulation Fan switch
Switch-function
Tested terminals Satisfactory state
condition
Air-flow setting 0 B1-B2-B3-B4-B5-B6-B7-B8 10 kΩ or greater
Air-flow setting 1 B3-B6-B7 Less than 1 Ω
Air-flow switch Air-flow setting 2 B3-B5-B7 Less than 1 Ω
OFF 1-2 10 kΩ or greater
A/C
A/C Switch/ ON 1-2 Less than 1 Ω
Rear-defroster switch Rear OFF 3-4 10 kΩ or greater
Defroster ON 3-4 Less than 1 Ω
Internal and external Internal circulation A3-A4, A5-A6 Less than 1 Ω
circulation switch External circulation A2-A3, A4-A5 Less than 1 Ω
Nighttime illumination and indication light check

Switch Tested state Satisfactory state
Air-flow switch controller module Battery cathode-B4 and battery anode-B8 Lit
A/C and rear defroster module Battery cathode-7 and battery anode-B8 Lit
Interior/exterior circulation control Battery cathode-A1 and battery anode-A7 Lit
module
(b) blower speed resistor

(1) Check whether the blower speed resistor is brokenover.
Measure the resistance based on the table below.
Standard:
2 1 1-2
Tester connector Specified state
1.09 ± 10% W
4 3 1-3 0.39 ± 10% W
1-4 1.27 ± 10% W
If the value does not meet the specification, replace the
blower speed resistor.
1 (2) Check the blower assembly.
2
Connect the battery anode (+) lead to terminal 2 and
connect the cathode (-) to terminal 1. Then, check the
electric motor and confirm that it operates stably.
If the the operating condition does not meet the specifi-
cation, replace the blower's electric motor.
(3) Check whether the relay is brokenover.

Measure the resistance based on the table below.
Standard:
30 87 85 Condition Tester connector Specified state
30 87 Normal 87-30 10 Ω or greater
86 85 86 Apply B+ between
87-30 Less than 1 Ω
terminal 85 and 86
If the value does not meet the specification, replace the
relay.
2. Automatic A/C controller check

With the ignition key in the ON position, the automatic
A/C controller can perform its air-conditioning system
self-diagnostic function. The details of the operation are
as follows:
(a) Press the OFF button and then press the rear-defroster
button; the system will then begin troubleshooting. The
set temperature will then be an integer.
(b) After beginning the diagnosis, if there are no faults, the
code displayed will be 00. After 4 seconds, the display
will automatically return to being shutdown.
(c) Diagnostic trouble code: Each fault code will be dis-
played for 4 seconds and will be displayed in order from
1 to 9. After the display is finished, it will automatically
exit and return to being shutdown.
01: The cabin temperature sensor is shorted or open.
02: The external temperature sensor is shorted or open.
03: The circulation motor drive module is overheated or
suffering from overcurrent.
04: The mode motor drive module is overheated or suf-
fering from overcurrent.
05: The temperature-control motor drive module is over-
heated or suffering from overcurrent.
06: The mode motor feedback potentiometer has a fault.
07: The temperature-control motor feedback potentiom-
eter has a fault.
08: The mode motor has a fault.
09: The temperature-control motor has a fault.
REFRIGERANT QUANTITY CHECK

Check the sight glass for the cooler outflow pipe.
Test conditions:
• The engine is running at 1,500 rpm.
• The blower control switch is in the "HI" position.
• The air-conditioner switch is on.
• The temperature regulator knob is set to "coldest."
• The car doors are completely open.
Refrigerant
Item Symptoms Corrective measures
quantity
1. Check for air leaks and make re-
pairs if necessary
1 Air bubbles are present Not enough *
2. Fill with refrigerant until the air bub-
bles disappear
Empty, not enough,

2 There are no air bubbles See 3 and 4
or excess
1. Use an air-leak tester to determine

There is no temperature difference whether there are air leaks. If neces-
3 between the compressor's air-inlet Empty or very little sary, perform repairs
and air-outlet ports 2. Fill with refrigerant until the air bub-
bles disappear
The temperature difference be-
Appropriate amount
4 tween the compressor's air-inlet and See 5 and 6
or excess
air-outlet ports is too great
1. Recover the refrigerant
After the air-conditioner is shut off, 2. Bleed off the refrigerant and then
5 Excess
the refrigerant is immediately clear add an appropriate amount of pure re-
frigerant
After the air-conditioner is shut off,
6 the refrigerant immediately bubbles Appropriate amount —
and then becomes clear
• *: If the refrigerant is full and the ambient temperature is greater than normal, the air bub-
bles within the sight glass will appear normal.
Tips:
• When you cannot use the sight glass to determine the amount of refrigerant, you can use
the connected pressure meter to see whether the system's pressure is normal when the
compressor is operating. You can check whether the air outlet is emitting cold air to see
if the compressor relay or pressure switch has a short.

PRECAUTIONS
PRECAUTIONS FOR DURING THE PROCEDURE
1. Carry out the procedure outside or indoors in a well-ventilated area (with the exception of re-
covering coolant when you have a filling machine)
2. To prevent fires, open flames and smoking are prohibited.
3. Wear overalls when working and confirm that the protective devices are in good condition,
without damage or fractures.
4. To prevent electric shocks, fires, or other accidents, laypeople should not perform removal or
repair.
5. Before starting the engine, confirm that the tools, measuring instruments, and other parts have
not been forgotten on moving, revolving, or electrified parts.
6. Before starting the engine, a warning should be sounded for the workers and their safety con-
firmed.
7. When checking electrical circuits, be careful not to touch the terminals or other electrified
parts. A short may be caused by the body or other parts.
8. Use rated fuses to prevent burning out relays and other electrical components and starting
fires.
9. Be careful when using hoses and pipes to prevent gas from leaking out.
10. All dust within hoses, pipes, and their connectors should be cleaned out to prevent gas leaks
and abnormal operation.
11. Avoid bringing water, oil, or other liquids into contact with the fan and fan motor or the V-shaped
belt to avoid damage and fires.
12. Before working, confirm that the air-conditioner has stopped. And, to prevent injury, do not
touch the belt or fan.
13. When replacing air-conditioning (A/C) system parts, you must disconnect the negative battery
cable.
14. The compressor is a high-speed moving part, and any foreign matter, no matter how small, in-
side the air-conditioning system will damage the compressor. Thus, you must clean the entire
air-conditioning system. Do not allow moisture or dust to enter the system. When removing
conduits, you must immediately plug or cap the pipe nozzle. And, before reconnecting them,
you must remove the plug or cap.
15. Do not open the high-pressure valve of the manifold vacuum meter while the engine is run-
ning. This is because the high-pressure gas backflow will create an unnecessary danger.
16. When tightening or loosening any connector, you must use another wrench to secure its mat-
ed component.
17. If any of the following conditions are satisfied, let the engine idle for at least 2 minutes when
turning on the air-conditioner switch.
(a) The refrigerant gas has been newly replaced or parts of the air-conditioning system have been re-
placed.
(b) The engine has not been started for a long time.
18. It is forbidden to perform welding or steam cleaning when the A/C pipeline or other parts are
installed in the car or near it.
19. It is forbidden to use water, a corrosive solution, or a flammable/combustible solution to clean
the air-conditioning system.
PRECAUTIONS FOR WHEN REPLACING THE

AIR-CONDITIONING SYSTEM COMPONENTS
1. After the system has been discharged, you must
disconnect or loosen the connectors
2. You should quickly plug or cap open ports to pre-
Moisture
vent moisture or dust from getting in
Dust
Plug
3. It is forbidden to remove seal covers before replac-

ing parts
4. Before connecting to open ports, you must install
a seal ring. Before connecting, you must coat the
open ports and seals with lubricating oil
PRECAUTIONS FOR WHEN INSTALLING THE

CONNECTORS
1. When installing a new O-ring (using the specified
part), coat it in compressor lubricating oil
2. Tighten the nuts with the specified torque
Bolt pin
Positioning pin
Indentation
Conduit
Nut
PRECAUTIONS FOR WHEN DEALING WITH

PIPES AND OPEN PORTS
1. Use pure, moisture-free refrigerant and lubricat-
ing oil to keep the internal parts of the refrigeration
system in a stable chemical condition. An abnor-
mal amount of dust, moisture, or air will affect the
chemical stability, leading to serious breakdowns
and damage
2. When you must open the refrigeration system, it is
forbidden to unplug or uncap the pipes before the
preliminary repair work is complete
3. When opening pipes or ports, you should quickly
plug or cap them to prevent moisture or dust from
getting in
4. Before use, all the pipes from the parts storeroom
should be plugged or sealed
5. You cannot attempt to use bundle-formed pipes for
the convenience of assembly. Install suitable pipes
when making repairs
6. All tools, including those such as the manifold pres-
sure gauge, ought to be kept clean and dry
PRECAUTIONS CONCERNING REFRIGERANT

1. Do not put the refrigerant tank on top of the engine
or radiator to avoid serious accidents
2. Place the refrigerant tank out of the reach of chil-
dren and in a place where it will not be stuck by
hard objects to avoid serious accidents
3. Do not place the refrigerant in a sealed location or
near an open flame
4. The boiling point of the refrigerant is roughly -30 °C.
When handling refrigerant, you must wear protec-
tive gloves and goggles. If refrigerant comes into
contact with your skin, you will suffer frostbite. You
must wear goggles
5. If the liquid coolant comes into contact with eyes

or skin, use a large quantity of water to wash the
affected parts. Do not rub the skin or eyes; apply
Vaseline and immediately receive professional treat-
ment from a hospital
6. Do not heat the refrigerant tank or place it near open
flames
7. Be careful not to drop the refrigerant tank or allow it

to be struck by other objects to prevent the refriger-
ant from escaping into the air
8. If the system is unexpectedly discharged, you must

ventilate the work area before continuing repairs
9. When discharging the system, do not discharge the
refrigerant quickly. If you do, the oil for the system's
A/C compressor will be sucked out
10. Do not overfill the system with refrigerant. If you
do overfill with refrigerant, it will cool insufficiently,
fuel economy will be reduced, and the engine will
breakdown from overheating
11. Do not operate engines or refrigerating compressor
assemblies without refrigerant. This may damage
the internal parts of the refrigerating compressor
assembly
12. When cleaning R-134a from within the air-condition-
ing system, you should use service equipment that
has been certified to fulfill the requirements (R-134a
recycling facility)
13. You cannot mix refrigerants, for example R-134a
(tetrafluoroethane) and R12 (dichlorodifluorometh-
ane)
14. You cannot allow refrigerant to be exposed to frost
and snow
15. Use an electronic leak detector to test the system
and confirm whether it is leaking refrigerant. R-134a
and the tester's spark point will create toxic gases.
Thus, you should be cautious when testing for leaks
16. Only use lubricating oil recommended for use with
the R-134a system. Choosing another lubricating oil
will result in the system breaking down
PRECAUTIONS CONCERNING O-RINGS

1. Use new O-rings
2. To avoid looseness in the O-rings and to prevent
the refrigerant from leaking, do not wear gloves or
use a rag when manipulating them
3. Coat the O-rings with compressor oil to prevent
them from sticking before installing them
4. Use a torque wrench to tighten the O-ring joint. Over
tightening will deform the O-ring and pipe end
5. If work on the connecting pipe is interrupted mid-
way, you should seal the pipes again and shut them
with a plug or tape to prevent contaminants from
entering
6. Visually check the O-ring, the threads and their con-

nected surfaces, and the joint surface. If there is a
problem, replace the parts
7. Install the O-rings in the grooves of the pipe at the

appropriate angle
8. Use the specified lubricating oil and O-rings. Coat
the surface and sides of the O-ring with oil before
installing it. Coat the top of the O-ring and pipe
groove with compressor oil
9. After tightening, use a clean rag to wipe off excess

oil on the connection and other places to prevent
contaminating the vehicle body or other parts
10. If you suspect that there are leaks after tightening,
do not continue to tighten the connector. Instead,
disconnect the connector, remove the O-ring, and
check the O-ring, threads, and connector
11. The O-ring is a single-use part
PRECAUTIONS CONCERNING COMPRESSOR OIL

1. If replacing any of the following parts, you must fill up with the recommended amount of com-
pressor oil
(a) the condenser (including the drying chamber/desiccant)
(b) the evaporator
(c) the pipes or hoses
(d) the compressor
2. Do not return used oil to the container to avoid contamination
3. Different kinds and brands of oils should not be mixed. Otherwise, the compressor will be
damaged
4. Compressor oil is extremely absorbent. Make sure that it is exposed to the air for as little time
as possible
5. Do not allow the compressor oil to splatter within the vehicle or the paint will be damaged. If
compressor oil does splatter on the paint, clean it off immediately
6. Do not bring lubricating oil in contact with moisture, dust, metal dust, or other such items
7. When lubricating oil comes into contact with the air, it increases the moisture within it. Be-
cause of this, immediately seal the lubricating-oil tank after use to shield it from the air
8. You must store the compressor's lubricating oil in a steel container. Do not store it in a plastic
container
PROCEDURES RELATED TO REFRIGER-

ANT
Attention:
• Only use R-134a refrigerant service equipment.
During actual operation, please consult the
manual and precautions provided by the manu-
facturer of the device for the specific operating
procedure
• If the system discharges unexpectedly, venti-
late the working area before continuing repairs
• For further information about health and safety,
you can consult the manuals provided by the
manufacturers of the refrigerant and lubricat-
ing oil
• Vapors from air-conditioning refrigerant or
lubricating oil will irritate your eyes, nose, or
throat
• Be careful when continuously repairing equip-
ment
• Inhaling vapors from air-conditioning refriger-
ant or lubricating oil is forbidden
RECOVERY OF REFRIGERANT
1. As indicated in the illustration, connect the R-134a
A refrigerant recovery/recirculation/filling device (A),
or other equipment with the same function, to the
high-pressure maintenance port (B) and low-pres-
sure maintenance port (C) according to the instruc-
tions of the equipment manufacturer
2. After completing the recovery process, measure

the amount of compressor oil discharged from the
air-conditioning (A/C) system. Before filling, ensure
that the same amount of new compressor oil will be
put back into the air-conditioning (A/C) system
SYSTEM VACUUM PUMPING

Attention:
• When exposing the air-conditioning (A/C)
system to the atmosphere (such as during in-
stallation or repair), you must use an R-134a
recovery/recirculation/filling device to create a
vacuum. If the system is disassembled for sev-
eral days, you must replace the reservoir and
desiccant, and you must evacuate the system
for several hours.
A 1. Connect the R-134a refrigerant recovery/recircula-
tion/filling device (A) to the high-pressure mainte-
nance port (B) and low-pressure maintenance port
(C), and then evacuate the system
2. After twenty 20 minutes, shut the high-pressure and
low-pressure valves and turn off the vacuum pump
C when the low pressure reaches or exceeds 0.1 MPa.
If the low pressure does not reach 0.1 MPa, the sys-
B
tem may have leaks. Fill the parts of the system and
check them for leaks
REFRIGERANT FILLING
A 1. As indicated in the illustration, connect the R-134a
refrigerant recovery/recirculation/filling device (A)
to the high-pressure maintenance port (B) and low-
pressure maintenance port (C) according to the in-
structions of the equipment manufacturer
2. Evacuate the system

3. Fill the system with the specified amount of refriger-
ant. Only use R-134a refrigerant
4. Use the specified amount of R-134a refrigerant to fill
the system. Do not overfill it, or the compressor will
be damaged
5. Check whether the refrigerant is leaking
6. Check the performance of the system
Attention:
• Do not operate the cooling compressor before
filling with refrigerant because it cannot oper-
ate normally without refrigerant and will over-
heat.
• Check the amount of refrigerant by measuring
it, and not through the sight glass.
• To prevent damage to the compressor from
hydraulic shock, fill with refrigerant liquid from
the high-pressure side when the car is stopped
and fill with refrigerant gas from the low-pres-
sure side when the compressor is operating.
WARMING THE ENGINE

1. After filling with refrigerant, allow the engine to
warm up for at least 2 minutes
Attention:
• After removing and installing the refrigerant
pipes for the cooler (including the compres-
sor), you must allow the compressor to warm
up before turning on the air-conditioner switch
to prevent damage.
CHECK FOR AIRTIGHTNESS

A 1. As indicated in the illustration, connect the R-134a
refrigerant recovery/recirculation/filling device (A)
to the high-pressure maintenance port (B) and low-
pressure maintenance port (C) according to the in-
structions of the equipment manufacturer
2. Open the high-pressure valve and fill the system

with the specified quantity of refrigerant. Then,
close the filler valve and disconnect the filling sys-
tem fitting
Remark:
• Select a measuring device that suits the refriger-
ant-filling device.
3. At least once a year, check the system for leaks us-
ing an R-134a refrigerant leakage detector with a
precision of 10 g
4. If leaks are detected and you must disassemble the
system (to repair or replace pipes, connectors, or
other parts), you should recover all the refrigerant
within the system
5. After checking for leaks and making repairs, you
must evacuate the system
A/C CONTROLLER PANEL

Removal
1. Remove the A/C controller panel
(a) Separate the 5 clips and remove the A/C controller panel.
MAP
Snap:
2. Disconnect the rear connector and take off the panel
Installation
COMPRESSOR ASSEMBLY
Removal
1. Recover the refrigerant in the refrigeration system
2. Remove the engine's lower left and right spoiler as-
semblies
3. Remove the fan and generator drive belt
4. Disconnect the compressor exhaust pipe assembly
(a) Remove the bolt and disconnect the compressor ex-
haust pipe assembly.
(b) Remove the O-ring from the compressor exhaust pipe
assembly.
Attention:
• Use polyvinyl-chloride insulating tape to seal
any openings left by disconnected parts to
prevent moisture and foreign matter from en-
tering.
5. Disconnect the compressor intake pipe assembly

(a) Remove the bolt and disconnect the compressor intake
pipe assembly.
(b) Remove the O-ring from the compressor intake pipe as-
sembly.
Attention:
tering.
6. Remove the compressor assembly

(a) Disconnect the connector.
(b) Remove the 4 bolts and the compressor assembly.
7. Check the compressor engine oil

Attention:
• When checking the level of the compressor en-
gine oil, be sure to observe the precautions for
the removal and installation of the compressor.
• Because remnants of compressor engine oil
may still be within the vehicle pipes, if you
install a new compressor without discharg-
ing the remaining engine oil, there will be too
much oil, hindering the heat exchange during
coolant circulation and leading to refrigerant
failure.
• If there are too few oil remnants during the re-
moval of the compressor, check whether there
are leaks.
• Ensure that the type of engine oil used match-
es that indicated by the label on the compres-
sor itself.
Installation
CONDENSER ASSEMBLY
Removal
2. Remove the grill on the front bumper
3. Remove the front bumper body
4. Disconnect the compressor exhaust pipe assembly
and the cooler outflow pipe
(a) Remove the bolt and disconnect the compressor ex-
haust pipe assembly. Remove the O-ring from the com-
pressor exhaust pipe assembly.
(b) Remove the cooler outflow pipe and remove the O-ring
from the cooler outflow pipe.
Attention:
tering.
(c) Disconnect the outlet pipe.
5. Remove the cooling condenser assembly
(a) Remove the 2 bolts and the cooling condenser assem-
bly.
6. Remove the upper condenser suspension assem-

blies
(a) Remove the 2 bolts and 2 upper condenser suspension
assemblies.
Installation
A/C ASSEMBLY
Removal
1. Remove the front engine-compartment-connecting
framework parts.
(a) Remove the bolt connecting the HVAC cooling pipeline
and the air-conditioner.
(b) Disconnect the warm air and water pipes.
2. Disconnect the drip pipe and the air-conditioner
3. Disconnect the vehicle body's ground wire and wir-

ing connectors from the dashboard
4. Remove the dashboard
5. Remove the 6 bolts and single nut from the air-con-
ditioner assembly and vehicle-body front wall
6. Take off the A/C assembly

Installation
BLOWER
Removal
1. Remove the bottom right foot block
2. Disconnect the blower power supply
3. Remove the 3 screws
4. Take off the blower
Installation
COOLING PIPE
Removal
2. Remove the broken pipe or hose
Attention:
• After removing the cooling pipe, immediately
plug any opening to prevent moisture and for-
eign matter from entering.
Installation
1. Install the broken pipe or hose
2. Tighten the bolts or nuts with the specified torque
Attention:
• When tightening, do not use more than the
specified torque.
3. Evacuate the refrigerant system and then fill it with
refrigerant
4. Check whether the refrigerant is leaking
5. Check the operation of the air-conditioner
EVAPORATOR TEMPERATURE SENSOR

Removal
1. Remove the evaporator from the interior A/C assem-
bly
2. Remove the clamps/clips and evaporator tempera-
ture sensor from the evaporator
Attention:
• Do not bend the evaporator core or plates.
Installation
Check
1. Remove the evaporator core and the evaporator
temperature sensor
2. Immerse the sensor in ice water and measure the
resistance of each of its terminals
3. Pour hot water on the sensor and check how the re-
1 2 sistance changes
Ω
Relationship between temperature and resistance
Temperature (ºC) Minimum (kΩ) Standard (kΩ) Maximum (kΩ)

-20 12.73 13.062 13.40
-15 9.691 9.917 10.146
-10 7.419 7.572 7.725
-5 5.716 5.817 5.92
0 4.433 4.50 4.568
5 3.444 3.505 3.567
10 2.696 2.75 2.805
15 2.125 2.173 2.222
20 1.687 1.729 1.772
25 1.349 1.385 1.423
30 1.086 1.118 1.15
35 0.88 0.907 0.936
40 0.717 0.741 0.766
45 0.588 0.609 0.631
50 0.485 0.504 0.523
55 0.403 0.419 0.435
60 0.336 0.35 0.364
65 0.282 0.294 0.307
70 0.237 0.248 0.259
75 0.201 0.21 0.22
80 0.171 0.179 0.188
CABIN TEMPERATURE SENSOR

Removal
1. Pry out the cabin temperature sensor from the dash-
board
2. Remove the air hose for the cabin temperature sen-
sor and disconnect the plug
Installation
Attention:
• Ensure that the connector for the air hose is
solid and reliable.
CHECK
1. Remove the cabin temperature sensor
2. Take the cabin temperature sensor and test it
• Adjust the system to Max Cool and measure
the resistance.
1 2
• Adjust the system to Max Hot and measure the
resistance.
3. Compare the measured reading of the resistance
between terminals 1 and 2 of the interior tempera-
ture sensor to the standard value. The resistance
Ω should fall within the specified range
4. If the resistance is not within the specified range,
replace the cabin temperature sensor

-20 14.68 15.13 15.58
-15 11.52 11.88 12.24
-10 9.11 9.392 9.674
-5 7.257 7.481 7.705
0 5.82 6 6.18
5 4.699 4.844 4.989
10 3.817 3.935 4.053
15 3.12 3.217 3.314
20 2.565 2.644 2.723
25 2.12 2.186 2.252
30 1.762 1.817 1.872
35 1.472 1.518 1.564
40 1.236 1.274 1.312
45 1.043 1.075 1.107
50 0.8788 0.906 0.9332
55 0.7517 0.7749 0.7981
60 0.6423 0.6622 0.6821
65 0.5513 0.5683 0.5853
OUTSIDE TEMPERATURE SENSOR

Removal
2. Separate the connector clip and take the outside
temperature sensor off of the radiator's right deflec-
tor
Installation
CHECK
1. Remove the outside temperature sensor
2. Immerse the sensor in ice water and measure the
resistance of each of its terminals
3. Pour hot water on the sensor and check how the re-
1 2 sistance changes
Ω

-40 322.39 337.31 352.88
-35 233.21 243.2 253.6
-30 170.66 177.41 184.41
-25 126.21 130.8 135.55
-20 94.247 97.391 100.63
-15 71.045 73.206 75.425
-10 54.024 55.513 57.037
-5 41.429 42.457 43.506
0 32.031 32.741 33.462
5 24.957 25.446 25.942
10 19.595 19.93 20.269
15 15.498 15.955 15.726
20 12.345 12.497 12.65
25 9.9 10 10.1
30 7.957 8.055 8.153
35 6.436 6.529 6.622
40 5.238 5.324 5.412
45 4.288 4.367 4.447
50 3.53 3.602 3.675
55 2.921 2.986 3.053
60 2.429 2.488 2.548
AIR-CONDITIONING FILTER CARTRIDGE

Replacement
1. Remove the glove box
2. Remove the air-conditioner filter cartridge
3. Remove the filter core from its housing
Installation
Attention:
• Confirm that there are no leaks in the blower
installation.
Memorandum
Memorandum
Safety and Protective Equipment 11-1
SAFETY AND PROTECTIVE

EQUIPMENT
SEAT BELT
Schematics.....................................................................11-4
Front Seat Seat Belt.....................................................11-4
Rear Seat Seat Belt.....................................................11-5
Rear Seat Middle Seat Belt..........................................11-6
Electronic Belt Buckle..................................................11-7
Rear Buckle Assembly.................................................11-8
Overview.........................................................................11-9
Check...........................................................................11-9
Car Trial.......................................................................11-10
Front Seat Seat Belt.....................................................11-11
Rear Seat Seat Belt (Both Sides)................................11-13
Rear Seat Seat Belt (Center).......................................11-14
Rear Buckle Assembly.................................................11-15
Electronic Belt Buckle..................................................11-16
Precautions..................................................................11-17
SRS SYSTEM
Driver Airbag and Passenger Airbag............................11-18
Side Curtain Airbag......................................................11-19
Seat-Side Airbags........................................................11-20
Overview.........................................................................11-21
Diagnosis and inspection..............................................11-22
External Diagnosis Flowchart......................................11-22
Airbag Warning Indicator Check..................................11-22
System Diagnosis Flowchart........................................11-22
Precautions..................................................................11-23
The X-431PAD Diagnostic Tool....................................11-28
Airbag ECU Connector Diagram..................................11-30
11-2 Safety and Protective Equipment
ECU Pin Definitions.....................................................11-30

ECU Wiring Diagram....................................................11-32
Diagnostics for Vehicles Involved in a Collision...........11-33
Airbag Module Disposal...............................................11-34
Precautions..................................................................11-36
Airbag ECU..................................................................11-37
Clock Spring.................................................................11-38
Driver Airbag................................................................11-40
Passenger Airbag.........................................................11-42
Side Airbag...................................................................11-44
Side Curtain Airbag......................................................11-45
SEAT BELT
LOCATION DIAGRAM
4
2
8
9
1. Front Passenger Seat Belt Assembly 6. Rear Left Double Lock

2. Rear Seat Belt Assembly (Right) 7. Driver Seat Assembly
3. Rear Seat Belt Assembly (Center) 8. Driver Seat Belt Buckle
4. Rear Right Double Lock 9. Front Passenger Seat Belt Buckle
5. Rear Seat Belt Assembly (Left)
SCHEMATICS
FRONT SEAT SEAT BELT
1
45±5
45±5
45±5
4
45±5
1. Height Adjuster 4. Webbing

2. Guide Ring 5. Retractor
3. Lock Tongue
REAR SEAT SEAT BELT
45±5
45±5
3
45±5
1. Webbing 3. Retractor
2. Guide Ring 4. Lock Tongue
REAR SEAT MIDDLE SEAT BELT

TRIPLE-POINT TYPE
Compared to an ordinary seat belt, the triple-point type seat belt has an additional guide (secondary
guide), and the upper guide ring is installed on the ceiling.
45±5
1
2
3
45±5
4
45±5
6
5
1. Guide Ring 4. Lock Tongue

2. Webbing 5. Lock Tongue
3. Secondary Guide Ring 6. Retractor
ELECTRONIC BELT BUCKLE
1. Driver Seat Belt Buckle 3. ECU Cabling

2. Sensor Cabling
REAR BUCKLE ASSEMBLY
2
1
3 4
1. Rear Seat Belt Buckle (Right) 3. Rear Seat Belt Buckle (Center)
2. Rear Seat Belt Buckle (Center) 4. Rear Seat Belt Buckle (Left)
OVERVIEW
Seat belts are the principal means for protecting the driver and passengers. When the vehicle is in a
collision or rolls over, the seat belt can keep the occupants within their seats and reduce the likelihood
of injury. Please wear your seat belt correctly while driving.
The front seats of this vehicle have three-point fixed retracting-type seat belts, the two exterior rear
seats have three-point fixed seat belts, and the center rear seat has a triple-point type seat belt.
The unfastened seat belt warning indicators for the driver's and front passenger's seats are located
on the combination instrument and front air-conditioner panel, respectively. Their purpose is to remind
the passengers to fasten their seat belts.
Symptoms Parts involved in the fault
1. instrument fuse
The driver's seat belt unfastening indicator 2. combination instrument
does not light 3. main driver seat latch assembly
4. wiring
1. combination instrument
The driver's seat belt unfastening indicator
2. main driver seat latch assembly
does not turn off
3. wiring
1. instrument fuse
2. console panel body
The passenger's seat belt unfastening indi-
3. passenger seat latch assembly
cator does not light
4. combination instrument
5. wiring
1. console panel body
The passenger's seat belt unfastening indi- 2. passenger seat latch assembly
cator does not turn off 3. combination instrument
4. wiring
CHECK
1. Check the passenger seat latch assembly
Check the anchor switch.
A
(a) Fasten the seat belt (the anchor switch is ON).
(b) Check the resistance between the terminals.
Standard:
Tester connect Specified state
1 2
A-1 and A-2 Less than 1 Ω
(c) Release the seat belt (the anchor switch is OFF).
(d) Check the resistance between the terminals.
Standard:
A-1 and A-2 10 kΩ or greater
If it does not meet the standard, replace the seat latch
assembly.
2. Check the main driver seat latch assembly

Check the anchor switch.
A
(a) Fasten the seat belt (the anchor switch is ON).
(b) Check the resistance between the terminals.
Standard:
1 2
A-1 and A-2 Less than 1 Ω
(c) Release the seat belt (the anchor switch is OFF).
(d) Check the resistance between the terminals.
Standard:
A-1 and A-2 10 kΩ or greater
If it does not meet the standard, replace the seat latch
assembly.
Attention:
• Replace broken parts in the seat and seat belt
system (the external seat belt, the seat latch
assembly, bolts, nuts, the seat belt height ad-
juster, tie-anchor parts, the winding shaft, and
other items).
• Seat and seat belt systems not used in an ac-
cident should still be checked and replaced if
damage is discovered or if they operate abnor-
mally.
CAR TRIAL
1. Fasten the front-seat seat belt.
2. Accelerate the car to 16 km/h and then forcefully
step on the brake pedal. Check the seat belt and
confirm that it is locked at this time and cannot be
extended.
Attention:
• Perform the test in a safe area. If the seat belt
does not lock, remove the seat belt assembly
and check it. Additionally, no matter when the
new seat belt assembly is being installed, con-
firm that it works normally first.

FRONT SEAT SEAT BELT
Removal
1. Disconnect negative terminal of the battery and wait
90 seconds before continuing
2. Remove the bolt securing the front seat seat belt
from below
3. Remove the strut B lower guard

(a) Remove the seal stripe.
(b) Remove the door sill.
(c) Remove the strut B lower guard.
4. Remove the height adjuster cover
5. Remove the bolt securing the front seat seat belt
from above
6. Disconnect the pre-fastening connector

7. Remove the bolt securing the retractor
8. Remove the strut B upper guard

9. Remove the height adjuster
Installation
REAR SEAT SEAT BELT (BOTH SIDES)

Removal
1. Remove the partition
2. Remove the tool box (both left and right sides have
one)
3. Remove the seat
4. Remove the bolt securing the rear seat seat belt
from below
5. Remove the back-door seal stripe

8. Remove the strut C upper guard
9. Remove the bolt securing the rear seat belt from
above
10. Remove the bolt for the rear seat seat belt retractor
Installation
REAR SEAT SEAT BELT (CENTER)

TRIPLE-POINT TYPE
Removal
Remove the center-rear-seat triple-point type seat belt
as follows only after removing the left and right rear seat
seat belts.
1. Unlock the two lock tongues of the seat belt from
the lock (latch)
2. Take off the rear center seatbelt base shield
3. Take off the cover for the upper guide ring and re-
move the bolt for the upper guide ring
4. Remove the bolt securing the guide bracket

5. Remove the bolt securing the seat belt retractor
Installation
REAR BUCKLE ASSEMBLY

Removal
1. Rear fixed-seat triple-point type
After removing the rear seat, remove the two latches in-
dividually securing it to the vehicle body.
2. Rear 40% sliding seat double lock
(a) Take off the plastic protective cover for the seat.
(b) Release the 40% seat latch fixing bolt.
3. Rear 60% sliding seat double lock
(a) Remove the seat.
(b) Release the 60% seat latch fixing bolt.
Installation
ELECTRONIC BELT BUCKLE

Removal
1. Remove the Front Seat
2. Remove the electronic belt buckle
Installation
PRECAUTIONS
• Prevent sharp objects and damaging sub-
stances from coming into contact with the seat
belt.
• Avoid twisting or damaging the retaining ring
or locking plate.
• Bleaching or dying the seat belts is forbidden.
You can only use neutral liquid soap and water
to clean the seat belts.
• When installing the screws and bolts securing
the seat belt, first tighten the screws and bolts
by hand to avoid incorrectly threading them.
• Repairing the retractor mechanism or cover
plate is forbidden. Replace a damaged assem-
bly.
• Replace a cracking or damaged seat belt.
Remark:
After completing the installation, check it according to
the following steps:
• Check whether all the bolts and screws securing
the seat belt are tight.
• Check the seat belt's retaining ring. The retaining
ring should easily lock and unlock.
• After the locking plate has been inserted into the
retaining ring, forcefully pull the seat belt. The re-
taining ring cannot release.
• Completely pull out the shoulder belt. The seat
belt should not kink or tear.
• Let the shoulder belt retract completely. It should
retract quickly.
SRS SYSTEM
LOCATION DIAGRAM
DRIVER AIRBAG AND PASSENGER AIRBAG
1. Front Passenger Airbag Assembly

2. Driver Airbag Assembly
SIDE CURTAIN AIRBAG
1. Right-Side Curtain Airbag Assembly

2. Left-Side Curtain Airbag Assembly
SEAT-SIDE AIRBAGS
1. Right-Side Airbag Assembly

2. Left-Side Airbag Assembly
OVERVIEW
The Supplemental Restraint System (SRS) is an auxiliary safety device that can reduce the danger of
injury, and mitigate the severity of injuries, by inflating the main and supplementary airbags, the air-
bags on the sides of the front seats, and the airbag curtains when the vehicle sustains a front or side
impact of a certain severity.
The Supplemental Restraint System (SRS) cannot replace seat belts. If you are not wearing your seat
belt when the airbags go off, you may be seriously injured. You must wear your seat belt when driving
or riding in a car. The Supplemental Restraint System (SRS) provides its best auxiliary protection dur-
ing a collision when the occupants are properly wearing their seat belts.
The Supplemental Restraint System (SRS) includes the driver airbag, the passenger airbag, the left
and right airbag curtains, the airbags on the side of the front seats, the front collision sensor, and the
side collision sensor.
If repairs are not carried out according to the correct procedures, the SRS may unexpectedly deploy
during repairs, leading to serious injuries.
If mistakes are made while repairing parts of the SRS, the SRS may not operate normally. Thus, be-
fore inspecting and repairing the Supplemental Restraint System (SRS) (including the removal, instal-
lation, checking, and replacement of parts), you must read the precautions concerning repair, and
please must work carefully.

EXTERNAL DIAGNOSIS FLOWCHART
Faults in the SRS-ECU can be divided into two types based on when they occur into: current faults
and history faults. Additionally, they can also be divided by their nature into external and internal
faults.
Codes for current faults and history faults may be present at the same time. Fault codes for external
faults can be cleared by the diagnostic tool, but those for internal faults cannot be so cleared and can
only be cleared by replacing the SRS-ECU.
Attention:
• After installing a new electronic control unit for the airbag system, the airbag system warning
indicator will flash continuously for 6 to 7 seconds and then go out after the ignition switch has
been placed in the ON condition. This indicates that the the airbag system is operating normally.
If so, the system does not need inspection or repair. Otherwise, you must perform a diagnosis,
inspection, and repair.
Warning indicator Use a diagnostic tester and K- Discover the Handle Clear the diagnos-
constantly lit line connector to scan the ECU. fault location the fault tic trouble code
AIRBAG WARNING INDICATOR CHECK

1. When the ignition switch is put in the ON position, check whether the SRS warning indicator
flashes continuously for 6 to 7 seconds.
2. If after 6 to 7 seconds the warning indicator turns off, then it is operating normally.
3. If it does not perform as described above, then you must perform a diagnostic check.
603 418 SYSTEM DIAGNOSIS FLOWCHART

0r-B1 W-P
The SRS-ECU will perform a series of circulating diag-
0.5 0.5
nostic tests to check whether the airbag system is ready.
9 16 This test will prevent the airbag system from activating
in error and, at the same time, will ensure that it will
1 905 905A 7 8 activate when necessary in a collision. If a fault is dis-
B B
covered, the SRS-ECU will store the appropriate trouble
0.5 0.5
code and activate the warning indicator to indicate that
a fault has occurred and to facilitate maintenance.
PRECAUTIONS
1. When the SRS indicator light indicates a fault, you
can diagnose it using the X-431PAD diagnostic tes-
ter. Do not disconnect the battery during diagnosis,
or the diagnostic tester will not function.
2. To avoid serious injury, you may only conduct re-
pairs on the SRS only after satisfying the following
conditions for 90 seconds.
• The ignition switch is in the "LOCK" position.
• The negative terminal of the battery is disconnect-
ed. (The SRS has backup power. Thus, if work
starts within 90 seconds of disconnecting negative
terminal of the battery, the SRS may still deploy.)
• Disconnect negative terminal of the battery and
pre-install the audio system.
• Before disconnecting the cable, record travel data
as necessary. Do not used a spare power supply
to avoid clearing saved settings
3. If the SRS has suffered a slight impact, but has not
deployed, you should check the driver airbag as-
sembly, the front passenger airbag assembly, and
the pretensioner seat belt before continuing to use
the car.
4. Do not use parts for the SRS of other vehicles.
When replacing SRS parts, you should use new re-
placement parts.
5. If it is possible that the airbag ECU assembly will be
struck during repair, you should remove the airbag
ECU assembly before repair.
6. Do not disassemble or repair the ECU assembly,
driver airbag assembly, front passenger airbag as-
sembly, or pretensioner seat belt.
7. If the following situations occur, replace the airbag
ECU assembly, driver airbag assembly, or front pas-
senger airbag assembly.
• When damage has been caused by a fall.
• When cracks, pitting, or other defects have ap-
peared on the housing, bracket, or connector.
8. It is forbidden to directly expose the airbag assem-
bly, ECU assembly, driver airbag assembly, front
passenger airbag assembly, or seat belt pretension-
er to hot air or flames.
9. It is forbidden to use a multimeter to measure the
driver airbag assembly or font passenger airbag as-
sembly. Otherwise, the airbag may deploy, leading
to injuries.
10. The SRS parts are affixed with an informational la-
bel; you should follow the precautionary directions
on it.
11. After finishing work on the SRS, check the SRS
warning indicator.
After the ECU confirms a fault through a circulating diagnostic test, the SRS-ECU will store the cor-
responding fault code, the first time it was detected, the latest time it was detected, and the number of
times it has occurred in its EEPROM.
The SRS-ECU can store a maximum of 16 faults.
DTC DTC DTC

Error Name Description
MSB LSB Code
ERR_BAT_VOLTAGE_HIGH 90H 12H B1012 The battery voltage is too high.
ERR_BAT_VOLTAGE_LOW 90H 11H B1011 The battery voltage is too low.
The driver's font airbag is shorted to the
ERR_SQUIB_LEAK_GRND 1 90H 21H B1021
ground.
The passenger's font airbag is shorted to
2 90H 26H B1026
the ground.
The driver's pretensioner is shorted to the
3 90H 31H B1031
ground.
The passenger's pretensioner is shorted
4 90H 36H B1036
to the ground.
The driver's side airbag is shorted to the
5 90H 41H B1041
ground.
The passenger's side airbag is shorted to
6 90H 46H B1046
the ground.
The driver's side curtain airbag is shorted
7 90H 51H B1051
to the ground.
The passenger's side curtain airbag is
8 90H 56H B1056
shorted to the ground.
The driver's font airbag is shorted to the
ERR_SQUIB_LEAK_PLUS 1 90H 22H B1022
power supply.
The passenger's font airbag is shorted to
2 90H 27H B1027
the power supply.
The driver's pretensioner is shorted to the
3 90H 32H B1032
power supply.
The passenger's pretensioner is shorted
4 90H 37H B1037
to the power supply.
The driver's side airbag is shorted to the
5 90H 42H B1042
power supply.
The passenger's side airbag is shorted to
6 90H 47H B1047
the power supply.
The driver's side curtain airbag is shorted
7 90H 52H B1052
to the power supply.
8 90H 57H B1057
shorted to the power supply.
ERR_SQUIB_RES_LOW 1 90H 23H B1023 The driver's font airbag is shorted.
2 90H 28H B1028 The passenger's font airbag is shorted.
3 90H 33H B1033 The driver's pretensioner is shorted.

4 90H 38H B1038 The passenger's pretensioner is shorted.
5 90H 43H B1043 The driver's side airbag is shorted.
6 90H 48H B1048 The passenger's side airbag is shorted.
7 90H 53H B1053 The driver's side curtain airbag is shorted.
8 90H 58H B1058
shorted.
The driver's font airbag has an open cir-
ERR_SQUIB_RES_HIGH 1 90H 24H B1024
cuit.
The passenger's font airbag has an open
2 90H 29H B1029
circuit.
The driver's pretensioner has an open cir-
3 90H 34H B1034
cuit.
The passenger's pretensioner has an
4 90H 39H B1039
open circuit.
The driver's side airbag has an open cir-
5 90H 44H B1044
cuit.
The passenger's side airbag has an open
6 90H 49H B1049
circuit.
The driver's side curtain airbag has an
7 90H 54H B1054
open circuit.
The passenger's side curtain airbag has
8 90H 59H B1059
an open circuit.
ERR_SQUIB_CONFIGURA- The driver's font airbag has a configura-
1 90H 25H B1025
TION tion error.
The passenger's font airbag has a con-
2 90H 2AH B102A
figuration error.
The driver's pretensioner has a configura-
3 90H 35H B1035
tion error.
The passenger's pretensioner has a con-
4 90H 3AH B103A
figuration error.
The driver's font side airbag has a con-
5 90H 45H B1045
figuration error.
The passenger's font side airbag has a
6 90H 4AH B104A
configuration error.
The driver's side curtain airbag has a con-
7 90H 55H B1055
figuration error.
The passenger's side curtain airbag has a
8 90H 5AH B105A
configuration error.
The driver's side sensor has a voltage er-
ERR_SAT_VOLTAGE_1 90H 81H B1081
ror.
The passenger's side sensor has a volt-
ERR_SAT_VOLTAGE_2 90H 86H B1086
age error.
The driver's side sensor has an open cir-

ERR_SAT_OC_1 90H 82H B1082
cuit or is shorted to the power supply.
The passenger's side sensor has an open
ERR_SAT_OC_2 90H 87H B1087
circuit or is shorted to the power supply.
The driver's side sensor does not have a
ERR_SAT_SAMPLING_1 90H 84H B1084
synchronizing signal.
The passenger's side sensor does not
ERR_SAT_SAMPLING_2 90H 89H B1089
have a synchronizing signal.
ERR_WLAMP_OC 90H 93H B1093 The warning indicator has an open circuit.
The warning indicator is shorted to the
ERR_WLAMP_LEAK_PLUS 90H 92H B1092
power supply.
The warning indicator is shorted to the
ERR_WLAMP_LEAK_GRND 90H 91H B1091
ground.
The collision output has an open circuit or
ERR_COP_LEAK_GRND 90H A1H B10A1
is shorted to the ground.
The collision output is shorted to the pow-
ERR_COP_LEAK_PLUS 90H A2H B10A2
er supply.
The driver's side sensor has a saturation
ERR_SAT_SATURATION_1 90H 85H B1085
error.
The passenger's side sensor has a satu-
ERR_SAT_SATURATION_2 90H 8AH B108A
ration error.
The driver's side sensor has a signal er-
ERR_SAT_SENSOR_1 90H 85H B1085
ror.
The passenger's side sensor has a signal
ERR_SAT_SENSOR_2 90H 8AH B108A
error.
The driver's side sensor has a communi-
ERR_SAT_BAD_COM_1 90H 83H B1083
cation error.
The passenger's side sensor has a com-
ERR_SAT_BAD_COM_2 90H 88H B1088
munication error.
ERR_CRASH_ INHIBIT 90H 01H B1001 Factory Mode
The driver's font airbag has been de-
ERR_CRASH_DRV_FRONT 90H 02H B1002
ployed.
The passenger's font airbag has been de-
ERR_CRASH_PAS_FRONT 90H 03H B1003
ployed.
The driver's pretensioner has been de-
ERR_CRASH_DRV_PRETEN 90H 04H B1004
ployed.
The passenger's pretensioner has been
ERR_CRASH_PAS_PRETEN 90H 05H B1005
deployed.
The driver's side airbag has been de-
ERR_CRASH_DRV_SIDE 90H 06H B1006
ployed.
The passenger's side airbag has been
ERR_CRASH_PAS_SIDE 90H 07H B1007
deployed.
The driver's side curtain airbag has been

ERR_CRASH_DRV_CURTAIN 90H 08H B1008
deployed.
The passenger's side curtain airbag has
ERR_CRASH_PAS_CURTAIN 90H 09H B1009
been deployed.
90H 13H B1013 There is an error within the ACU.
THE X-431PAD DIAGNOSTIC TOOL

Check the SRS airbag system's system fault and clear
the ECU trouble code.
INTERNAL FAULTS
The microcontroller may also test the below items outside of the startup test and circulating diagnostic
test.
1. Ignition circuit trigger transistor: a high-end transistor, which is also tested outside the startup
test and circulating diagnostic test. But it may be opened when a low-end transistor is shorted
to the power supply. Thus, the low-end transistors can only be tested during the startup test to
prevent activation in error.
2. The ignition voltage is supplied by the boost converter.
3. The acceleration sensor performs a self-check during the startup test.
4. During a circulating diagnostic test, the acceleration sensor is permitted to deviate within a
certain range.
5. The controller, including (AD converter, ROM, RAM, and other such parts)
6. The safety sensor condition
Attention:
• The expander circuit connector contains a short-circuiting rod that shorts its positive ter-
minal to its negative terminal when it is not connected to prevent static electricity or other
items from deploying it in error. When the connector is poor and the short-circuiting rod
is connected, the fault description may be unable to be cleared.
CLEARING THE DIAGNOSTIC TROUBLE CODE
When the ECU received the "Clear Diagnostic Trouble Code" order from the X-431PAD Diagnostic
Tool over the serial interface, the ECU will clear its diagnostic trouble codes. But, if an internal diag-
nostic trouble code or collision has been recorded, it will not carry out the order for clearing.
1. Fault condition display
After the operating voltage has been supplied to the SRS-ECU by the battery, the SRS-ECU will light
the warning indicator to test the bulb. During the initialization period, the light will flash continuously
for 6 to 7 seconds. To notify the driver that there is a fault, the warning indicator will remain lit continu-
ously after the operating voltage has been supplied. If the number of history trouble codes is less than
16, the warning indicator will turn itself off after being lit for 6 to 7 seconds after there is power (ignition
on). If there are 16 history trouble codes and a current fault appears, the current fault will be recorded
and the earliest history fault will be cleared automatically.
2. Fault indications
When a fault has appeared in the system, the warning indicator will remain lit for a long time.
An indicated or history fault can only be reset by a professional. An internal fault or a "collision re-
corded" fault in the SRS-ECU cannot be reset, and in such circumstances the SRS-ECU must be re-
placed.
3. Microcontroller - independent warning indicator
The controller can perform a diagnostic test on itself, and if there is a fault within the controller, the
warning indicator will remain lit for a long time.
If an airbag warning indicator remains lit, please perform a check according to the following steps.
• The first step for all faults is to use a scanner to check which part the fault has appeared in.
• Then, carry out a check using the method corresponding to that location.
• If the results of the scan are that there is an internal fault or that the airbag has already been de-
ployed, then replace the SRS-ECU.
• Remove the fault.
FAULT TESTING AND REMOVAL
When the ignition key in the "ON" position and the airbag alarm indicator remains lit, you can perform
a simple test according to the following procedure.
This test uses the resistance of the circuit to determine the fault location by individually replacing the
driver airbag assembly, the front passenger airbag assembly, the driver's seat belt, and the front pas-
senger's seat belt to determine which part has a fault.
1. Airbag test for the dual-airbag configuration
(a) Disconnect negative terminal of the battery for 90 seconds and then remove the driver airbag, unplug
the airbag connector, and then use a resistor with a resistance of about 2.5 Ω to replace the driver air-
bag's receiving wiring terminal.
(b) Place the key in the ignition switch and turn it to the "ON" position. At the same time, see whether the
airbag alarm indicator is flashing. If the indicator lights for 6 seconds and then goes off, it indicates
that this part has the fault and must be replaced. If, however, the indicator remains lit, then the fault is
not in this part and you should proceed to the next step of the check.
(c) Disconnect negative terminal of the battery for 90 seconds and then disconnect the replacement re-
sistor, reinstall the driver-side airbag, disconnect the passenger airbag's wiring connector, and in the
same way replace it with the resistor.
(d) Repeat step (b).
(e) Disconnect negative terminal of the battery for 90 seconds and then disconnect the replacement re-
sistor, reinstall the passenger airbag, remove the driver-side strut B lower guard, remove the seat belt
pre-fastening connector, and in the same way use a resistor to replace the seat belt detonator.
(f) Repeat step (b).
(g) Disconnect negative terminal of the battery for 90 seconds and then disconnect the replacement
resistor, reconnect the driver-side seat belt wiring, remove the passenger-side strut B lower guard,
remove the seat belt pre-fastening connector, and in the same way use a resistor to replace the seat
belt detonator.
(h) Repeat step (b).
(i) If at this point you still haven't found the fault, it means that there is a short or open circuit in the wir-
ing. Please check the the circuit for a fault.
(j) If there is no fault in the circuit, then you must replace the airbag ECU.
This method for testing the airbag system for faults is a relatively simple one and generally should be
used only when a tester is unavailable. After a fault has appeared in the airbag system, you must re-
place it, and not repair it.
2. Airbag test for the single-airbag configuration
The test method is as that provided above, except that the single-airbag configuration only has two
main-airbag circuits, and so the test is simpler. If there is no problem with the airbag module or wiring,
then please check the airbag ECU at a specialized manufacturer.
AIRBAG ECU CONNECTOR DIAGRAM
13 24 16 1
B A
1 12 32 17
ECU PIN DEFINITIONS

PIN Symbol Description Wiring
A1 Left Front A/B Feed Driver's airbag (+) Twisted pair
A2 Left Front A/B Retrun Driver's airbag (-) Twisted pair
A3 Right Front A/B Retrun Passenger's airbag (-) Twisted pair
A4 Right Front A/B Feed Passenger's airbag (+) Twisted pair
A5 Left PT A/B Feed Driver's pretensioner seat belt (+) Twisted pair
A6 Left PT A/B Retrun Driver's pretensioner seat belt (-) Twisted pair
A7 Right PT A/B Retrun Passenger's pretensioner seat belt (-) Twisted pair
A8 Right PT A/B Feed Passenger's pretensioner seat belt (+) Twisted pair
A9 Left Side A/B Feed Left-side airbag (+) Twisted pair
A10 Left Side A/B Retrun Left-side airbag (-) Twisted pair
A11 Right Side A/B Retrun Right-side airbag (-) Twisted pair
A12 Right Side A/B Feed Right-side airbag (+) Twisted pair
A13 Left Curtain A/B Feed Left-side curtain airbag (+) Twisted pair
A14 Left Curtain A/B Retrun Left-side curtain airbag (-) Twisted pair
A15 Right Curtain A/B Retrun Right-side curtain airbag (-) Twisted pair
A16 Right Curtain A/B Feed Right-side curtain airbag (+) Twisted pair
A17 Warning Lamp Airbag warning indicator
A18 — —
A19 Crash Output Knock signal output
A20 — —
A21 — —
A22 — —
A23 Left S-RSU Retrun Side-collision sensor, driver's side (-) Twisted pair
A24 Left S-RSU Feed Side-collision sensor, driver's side (+) Twisted pair
PIN Symbol Description Wiring

A25 Right S-RSU Feed Side-collision sensor, passenger's side (+) Twisted pair
A26 Right S-RSU Retrun Side-collision sensor, passenger's side (-) Twisted pair
A27 K-Line K-line diagnostic cable
A28 — —
A29 — —
A30 GND Ground wire
A31 — —
A32 IG Ignition
ECU WIRING DIAGRAM
Front passenger air-bag
K-line
diagnostic cable
Right airbag
Airbag warning
indicator
Knock signal
Driver pretensioner seat belt output
Passenger pretensioner seat belt
Left-side airbag
Right-side airbag Gnd
Ignition
signal
Left-side curtain airbag
Right-side curtain airbag
Left-side collision sensor
Right-side collision sensor

DIAGNOSTICS FOR VEHICLES INVOLVED IN A COLLISION

Regardless of whether the airbags have deployed, the inspection and maintenance of a vehicle in-
volved in a collision should be performed as described below.
1. Check the SRS-ECU diagnostic signal
(a) Connect the (X-431PAD diagnostic Tool) diagnostic interface.
(b) Use it (the X-431PAD diagnostic Tool) to read the diagnostic results.
2. Repair procedure
(a) When the airbags have been deployed, the following parts should be replaced with new ones.
Passenger's Side Airbag Module
SRS-ECU
Driver-side airbag module
Driver and passenger front pretensioner seat belts
(b) Check the following parts and replace them with new ones if they are abnormal.
Clock spring
Steering wheel, steering column, and lower steering axle sub-assembly
(c) The installed condition of the driver side airbag module on the steering wheel.
Check whether the steering wheel is making abnormal noises, the action is good, and the clearance
is normal.
Check whether the wiring connector is damaged and whether the terminals are deformed.
3. SRS-ECU
(a) Check whether the SRS-ECU housing and bracket is dented, cracked, or deformed.
(b) Check whether the connector is damaged and whether the terminals are deformed.
(c) Check the installation condition of the SRS-ECU bracket.
Check whether the cover is dented, cracked, or deformed.
Check whether the connects is damaged, whether the terminals are deformed, and whether the wiring
is notched.
Check whether the gas generator housing is dented, cracked, or deformed.
Check whether the direction of the arrows is the direction of the vehicle.
(d) Check the installation condition of the airbag module.
4. Driver Side Airbag Module
5. Clock spring
(a) Check whether the connector or protective tube are damaged, and check whether the terminals are
deformed.
(b) Check whether the housing is deformed.
6. Steering wheel, steering column, and lower axle sub-assembly
(a) Check safety of the driver side airbag module.
(b) Check whether the steering wheel is making abnormal noises and whether the clearance is normal.
7. Check the wiring connector (dashboard cabling).
Check whether the wiring is installed securely, whether the connector is damaged, and whether the
terminals are deformed.
8. Warning labels
The driver side airbag, clock spring, SRS-ECU, and passenger side airbag all have warning labels
that use illustrations. When using airbags or performing maintenance on them, carry out work accord-
ing to the noted indications. Additionally, if the labels are damaged or dirty, replace them with new
ones.
AIRBAG MODULE DISPOSAL

Attention:
• When disposing of the SRS airbags, first de-
ploy them.
• When replacing the airbag module, you should
deploy the airbag outside the vehicle.
• When deploying an airbag, fires may appear,
so carry out the operation near a smoke detec-
tor.
• When deploying an airbag, there will be a loud
sound, so those nearby should plug their ears,
and the operation should not be carried out
near residences whenever possible.
AIRBAG DEPLOYMENT
1. Park the car in a level location
2. Remove the negative and positive terminals of the
battery, and remove the battery from the vehicle
Attention:
• The person doing this must not wear clothes
that will create static electricity from friction.
• Begin the procedure after having removed the
positive and negative terminals of the battery
for 90 seconds.
3. Remove the driver side airbag module according to
the correct procedure
4. Remove deployment wiring the from the number 2

connector of the clock spring
Prepare two 6 m or longer wirings for deployment and
connect the ends to each other (short them).
Attention:
• Deployment of an airbag should be performed
6 m or greater away from people or obstruc-
6 m or greater tions, and should be carried out in a broad, flat
space. When deploying an airbag module out-
side, you should avoid strong winds, and dur-
ing a light breeze, you should ignite it against
the wind.
5. Insert the airbag deployment wiring into the airbag

detonation device
6. Secure the bolts on the inner side of the driver side
airbag module, that is, those not used to to install it,
to the rim using a relatively thick metal wire
7. Connect the deployment wiring connected to the
driver side airbag module to the underside of the
old tire installed on the rim. And then secure the
driver side airbag module above using the metal
wire connected to the bolts (as illustrated)
8. Fix the driver side airbag module on top of the tire,

and then place three old, hub-less tires on top of it
(as illustrated)
9. As far away from the vehicle as possible, sever the

deployment wiring connector for the driver side
airbag module, and then connect it to the two termi-
nals of the battery removed from the car to deploy it
(as illustrated)
Attention:
• Ensure that there is no one near the driver side
airbag module before deploying it. After de-
ploying the driver side airbag module, the gas
generator will be hot. Wait for it to cool for 30
minutes before use.
10. After deploying the driver side airbag module, dis-
pose of it as specified

PRECAUTIONS
For safety, please read the following precautions con-
cerning maintenance before beginning work.
1. When carrying out airbag maintenance, you should
perform the work in sequence according to the
items indicated in this chapter.
2. You must use the test apparatus and dedicated
tools specified in this chapter.
3. When performing maintenance on the following
parts, if a problem appears with the part, you must
replace it with a new one.
• Airbag control element (SRS-ECU)
• Clock spring
• Driver front airbag module
• Passenger front airbag module
• Driver front pre-tensioning seat belt
• Passenger front pre-tensioning seat belt
• Airbag wiring
4. When beginning maintenance, you should take off
the battery's cathode connector and wait 90 sec-
onds before continuing. Additionally, after removing
the cathode, wrap it with insulated adhesive tape to
insulate it.
In order to be able to deploy the airbag for a certain
time after battery power has been cut off, the SRS-ECU
internal capacitor will retain a certain amount of electri-
cal energy. Thus, if work is carried out without waiting a
certain time, it is possible that the airbag will deploy in
error, leading to serious injury.
5. While spray painting, the SRS-ECU, airbag modules,
clock spring, and other such parts should be re-
moved and put away because they may be affected
by high temperatures (93 °C or greater).
After maintenance on the airbag system has been com-
pleted, you must use a diagnostic scanner to clear the
trouble codes in order to allow the warning indicator to
operate normally.
AIRBAG ECU
Attention:
• You cannot take apart or repair the SRS-ECU
for any reason. If it has a fault, please replace
it with a new one.
• Do not allow the SRS-ECU to be struck or shak-
en. If you discover that it is dented, cracked, or
deformed, you must replace the SRS-ECU with
a new one.
• Every time the airbags are deployed, you must
replace the SRS-ECU with a new one after-
wards.
• While removing or repairing parts in the vicin-
ity of the SRS-ECU, be careful not to strike it.
Removal
1. Place the ignition switch in the OFF position
2. Disconnect the battery (-) cathode, and place it in
an appropriate location or wrap it with tape. Wait 90
seconds before continuing the procedure
3. Remove the dashboard base
4. Dismount the connector for the airbag ECU
5. Dismount the SRS-ECU
AUTOLIV ELECTRONIC
XY 21610232-8
Installation
Remark:
• Check whether the SRS-ECU housing is dented,
cracked, or deformed.
• Check whether the connectors are damaged or
deformed. If they are dented, cracked, or de-
formed, the SRS-ECU should be replaced with a
new one.
• Install the SRS-ECU. If you cannot install the SRS-
ECU accurately and without errors, the airbags will
not function normally.
CLOCK SPRING
Attention:
• Remove the battery (-) cathode and then wait
90 seconds before continuing. After removing
the (-) cathode, wrap it with tape to insulate it.
• The clock spring may not be taken apart or
repaired for any reason. If there is a fault, you
must replace it with a new one.
• The clock spring must not fall on the ground
or into water or oil. If it is dented, cracked, or
deformed, please replace it with a new one.
• Place a removed clock spring in a clean, dry
place.
Removal
1. Insert screwdrivers into the openings on the left
and right sides of the bottom cover of the steering
wheel. Using an appropriate amount of force, push
until the airbag module pops up
2. Gently grab the airbag module
3. Disconnect the cable connector on top of the the

airbag module and remove the driver front airbag
module
4. Remove the steering wheel locknut on top of the
steering column
5. Remove the steering wheel
Remark:
• When the spline and column grip each other too
tightly, the steering wheel may be difficult to sepa-
rate from the column. Be careful not to force the
removal of the steering wheel. You should give the
screw on top of the column several turns and then
lift up the steering wheel again to avoid damaging
the clock spring through forceful removal.
6. Open the guards on the top and bottom of the com-
bination switch
7. Disconnect the lower-end instrument cable connec-

tor
8. Remove the clock spring
Remark:
Check each of the following items, and if any of them
are in poor condition, you must replace the clock spring
with a new one.
• Check whether the connector or protecting pipe is
damaged and whether the terminals are deformed.
• Check whether the housing is damaged.
• Check whether the top connector and the corre-
sponding lower connector of the clock spring are
brokenover.
Installation
Remark:
• Before performing this procedure check whether
the front wheels are pointing straight ahead. If not,
put them into position.
• If the clock spring to be installed is not new, you
must re-compress the center of the clock spring.
Twist the clock spring completely in the clockwise
direction. Then, turn it 3.5 revolutions in the op-
posite direction, until the clip's protrusion and it's
recess are aligned (as illustrated). Additionally, the
yellow roller can be seen through the peephole.
Warning:
• If you cannot re-compress the center of the
clock spring, the steering wheel will not be
able to rotate midway or the clock-spring cir-
cuit will become poor, preventing the SRS air-
bag from operating normally.
DRIVER AIRBAG
Removal
1. Return the front wheels to the center and turn off
the ignition switch
Attention:
• After turning off the ignition switch and dis-
connecting negative terminal of the battery,
wait 90 seconds before continuing.
Warning:
• In order to be able to deploy the airbag for a
certain time after battery power has been cut
off, the SRS-ECU internal capacitor will retain
a certain amount of electrical energy. Thus, if
work is carried out without waiting a certain
time, it is possible that the airbag will deploy
in error, leading to serious injury.
3. Insert screwdrivers into the openings on the left
and right sides of the bottom cover of the steering
wheel. Using an appropriate amount of force, push
until the airbag module pops up
4. Gently take the driver-side airbag module and dis-

connect all the connectors between the driver air-
bag assembly and the clock spring
Attention:
• A removed driver-side airbag module should
be placed face up in a clean, dry location.
Installation
1. Check the following items, and if any are in poor
condition, you must replace the airbag module with
a new one, disposing of the old part after following
the specified deployment procedure
(a) Check whether the cover is dented, cracked or de-
formed.
(b) Check whether the wiring connector is damaged or the
terminals are deformed.
(c) Check whether the gas-generator housing is dented,
cracked, or deformed.
(d) Check whether the airbag module is installed poorly.
Attention:
• Use an electrical inspection instrument to di-
agnose the circuits of the airbag module. Do
not take it apart.
• The resistance of the airbag module (squib) cir-
cuit cannot be tested, even with the specified
tester. If a test instrument is applied to test the
resistance, current will flow within the squib,
and sometimes static electricity will cause the
it to deploy in error, leading to serious injuries.
2. Individually connect the clock spring to the corre-
sponding connectors of the driver airbag assembly
3. Correctly place the driver-side airbag module in its
installation position on the steering wheel. Ensure
that the airbag module is clamped firmly in place. (Do
not strike the airbag module with force when putting
it in position.)
Attention:
• When installing the steering wheel and airbag
module assemblies, do not catch the clock
spring wiring.
4. Reconnect the negative terminal of the battery
5. Post-installation check
(a) Gently turn the steering wheel to the left and right to
check whether there are any abnormalities or noise.
(b) Place the ignition switch in the ON position.
(c) The warning indicator should light for 6 seconds and
then go off.
(d) If the warning indicator remains lit after 6 seconds (or
remains lit the entire time), you must remove the fault.
PASSENGER AIRBAG
Removal
Attention:
connecting the negative terminal of the battery,
Warning:
• In order to be able to deploy the airbag for a
certain time after battery power has been cut
off, the SRS-ECU internal capacitor will retain
a certain amount of electrical energy. Thus, if
work is carried out without waiting a certain
time, it is possible that the airbag will deploy
in error, leading to serious injury.
2. Remove interior trim parts such as the console
panel, the left and right trim plates, and the left-side
and right-side cover plates
Remark:
• See the chapter on interior and exterior trim for
the removal procedure for such parts.
3. Disconnect the passenger airbag wiring connector
4. Remove the 2 bolts securing the passenger airbag
5. Remove the upper dashboard body and take it out

along with the passenger airbag module
Remark:
• See the chapter on interior and exterior trim for the
removal procedure for these parts.
6. Remove the 2 screws securing the passenger air-

bag
7. Release the clip structure and remove the passen-

ger airbag module
Remark:
• The sides of the airbag cover have pawls that se-
cure it to the dashboard bracket.
Installation
Remark:
• After installing the airbag, confirm that the system
is operating normally. Put the ignition switch in
the ON position. Normally, the SRS indicator light
should turn on for about 6 seconds and then go
off.
SIDE AIRBAG
Remark:
• Before repair or maintenance, put on a pair of
gloves to protect your hands, and see the section
on seats in the chapter on interior and exterior trim
for the removal procedure for seats.
Removal
Attention:
2. Disconnect the side-airbag wiring connector
3. Remove the seat assembly and seat back assembly
4. Remove the assembly nut and side airbag
Installation
Attention:
• Use new mounting bolts.
• When replacing the side airbag, ensure that
the seat back is installed correctly. Incorrect
installation can lead to abnormal deployment.
• Ensure that the wiring wire is installed and that
it will not press tightly against or interfere with
other parts.
SIDE CURTAIN AIRBAG

Remark:
• Before repair or maintenance, put on a pair of
gloves to protect your hands. Please consult the
replacement procedure for internal trim, and be
careful not to damage the trim parts or plates.
Removal
Attention:
2. Remove the A, B, and C column guards, the C-

column mounting bracket, the roof handrail, the sun
visor, the reading lamp, the ceiling, the ceiling hand-
rail bracket and other such parts that are involved
with the side curtain airbags (For the procedure and
instructions, please consult the guides for the re-
moval of the specific items)
3. Pull out the cable connector for the side curtain air-
bag
4. Remove the 2 illustrated mounting bolts for the
side-curtain-airbag generator
5. In order, remove the 4 snaps holding the side cur-
tain airbag and the front drawstring. Then, take off
the side curtain airbag
Installation
Attention:
• Use new mounting bolts.
• Attentively install the front column trim and
be careful of items such as wirings and pipes
around the curtain airbag. They should pass
above the curtain airbag and be fixed securely
there. They must not entangle the airbag.
• The front drawstring should pass below the A
column's interior trim plate secondary retain-
ing fastener (be careful when installing the A
column's interior trim plate), Otherwise, the
side curtain airbag will not deploy normally, re-
sulting in serious injuries.
Memorandum
Electrical Accessories 12-1
ELECTRICAL ACCESSORIES
LIGHTING SYSTEM
Pin Definitions..............................................................12-7
Beam-Focusing Adjustment.........................................12-15
Combination Headlamp Assembly...............................12-22
Front Fog Lamp Assembly...........................................12-22
Daytime Running Lamp Assembly...............................12-23
Reading Lamp Assembly.............................................12-23
Ceiling Lamp Assembly................................................12-24
Trunk Lamp Assembly..................................................12-24
High-Mount Brake Lamp Assembly..............................12-25
Combination Tail Lamp Assembly................................12-25
Back Door Combination Lamp Assembly.....................12-26
License Plate Light Assembly......................................12-26
Rear Fog Lamp Assembly............................................12-27
Combination Switch Assembly.....................................12-27
Console Panel Switch Assembly .................................12-28
Warning Light Switch Assembly...................................12-28
Door Switch Assembly.................................................12-29
Brake Lamp Switch Assembly......................................12-29
WIPER/WASHER
Schematics.....................................................................12-31
Front Wiper Assembly..................................................12-31
Rear Wiper Assembly..................................................12-32
12-2 Electrical Accessories

Front Wiper Assembly..................................................12-38
Rear Wiper Assembly..................................................12-39
Washer Fluid Tank Assembly.......................................12-40
Cleaning Solution Pump Assembly..............................12-40
Front Windshield Washer Nozzle Assembly................12-41
Rear Nozzle Assembly.................................................12-41
HORN
Electric Horn Assembly................................................12-44
INSTRUMENT/DISPLAY
Liquid Crystal Display..................................................12-46
Rules Regulating LCD Screen Information Display.....12-47
Factory Reset...............................................................12-47
Standard Display Information.......................................12-47
Alarm Information.........................................................12-51
Primary Alarm Information...........................................12-52
Secondary Alarm Information.......................................12-54
Buzzer Alarms..............................................................12-55
Rule Regulating Sound Alerts......................................12-57
Pin Definitions..............................................................12-58
Procedures For Repair..................................................12-59
Combination Instrument Assembly..............................12-59
REARVIEW MIRRORS
Pin Definitions..............................................................12-61

Power Side Mirror Switch Assembly............................12-63
Exterior Rearview Mirror Assembly..............................12-64
Interior Rearview Mirror Assembly...............................12-64
AUDIO SYSTEM
Pin Definitions..............................................................12-66
CD/Multimedia Player Assembly..................................12-67
Multimedia Player Display Assembly...........................12-68
Front Tweeter Assembly..............................................12-68
Door Speaker Assembly..............................................12-69
Antenna Assembly.......................................................12-69
USB and Audio Input Panel Assembly.........................12-70
CONSOLE LOCK SYSTEM
Pin Definitions..............................................................12-72
Door Lock Assembly....................................................12-74
Front Door Outside Handle Assembly..........................12-75
Rear Door Outside Handle Assembly..........................12-77
Back Door Lock............................................................12-78
Back Door Outside Handle Assembly..........................12-78
Door Lock Interior Clamp Assembly.............................12-79
Console Panel Switch Assembly .................................12-79
IMMOBILIZER SYSTEM
Immobilizer ECU Assembly..........................................12-81
Immobilizer Coil Assembly...........................................12-81
Ignition Lock Assembly................................................12-82
WINDOW LIFT
Pin Definitions..............................................................12-84
Front Window Lift Assembly.........................................12-86
Rear Window Lift Assembly.........................................12-87
Front Left Window Switch Assembly............................12-88
Power Window Switch Assembly.................................12-89
SUNROOF
Sunroof Assembly........................................................12-91
REVERSE RADAR
Pin Definitions..............................................................12-93
Collision Avoidance Radar Probe Assembly................12-95
Collision Avoidance Radar ECU Assembly..................12-95
ON-BOARD MONITORING SYSTEM
Reverse Camera Assembly.........................................12-97
NAVIGATION SYSTEM
Overview.........................................................................12-98
Important Information for the User...............................12-98
Common Faults............................................................12-99
ENGINE ECU
ECU Assembly.............................................................12-102
BATTERY
Battery assembly.........................................................12-104
ON-BOARD POWER SOURCE
Spare Battery Assembly...............................................12-106
MULTI-FUNCTION STEERING WHEEL SWITCH
Multi-function Steering Wheel Switch..........................12-107
LIGHTING SYSTEM
LOCATION DIAGRAM
4 8
3
2
9
10
11
12
13
14
15
16
1. Combination Headlamp Assembly 9. Back Door Combination Lamp Assembly

2. Warning Light Switch Assembly 10. Rear Fog Lamp Assembly
3. Door Switch Assembly 11. Combination Tail Lamp Assembly
4. Reading Lamp Assembly 12. Console Panel Switch Assembly
5. Ceiling Lamp Assembly 13. Combination Switch Assembly
6. Trunk Lamp Assembly 14. Brake Lamp Switch Assembly
7. High-Mount Brake Lamp Assembly 15. Front Fog Lamp Assembly
8. License Plate Light Assembly 16. Daytime Running Light Assembly

PIN DEFINITIONS
CEILING LAMP ASSEMBLY
1 2 3
Pin No. Function

1 Cathode
2 Anode
3 Cathode
HIGH-MOUNT BRAKE LAMP ASSEMBLY
1 2
Pin No. Function

1 Cathode
2 Anode
BACK DOOR COMBINATION LAMP ASSEMBLY
1 2
4 3
Pin No. Function

1 Reverse lamp
2 GND
3 —
4 Position lamp
BRAKE LAMP SWITCH
4 3 2 1
Pin No. Function

1 Brake lamp anode
2 GND
3 Contact signal
4 Brake lamps
CONSOLE PANEL SWITCH ASSEMBLY
8 1
16 9
Pin No. Function

1 GND
2 Unlock function output
3 Lock function output
4 12 V
5 GND
6 Headlight height adjust output
7 Page Up functional output
8 Page Down functional output
9 SET functional output
10 Backlight input
11 Backlight output
12 LIM/RET functional output
13 —
14 —
15 —
16 —
COMBINATION SWITCH ASSEMBLY (12-PIN)
1 2 3
4 5 6 7 8 9 10 11 12
Terminal 1 2 3 4 5 6 7 8 9 10 11 12
Function
Main light switch
While the Low beam

main light
High beam
switch is
Dimmer turned off Overtake
switch While the Low beam
main light
High beam
switch is
turned on Overtake
L
Steering switch Central
R
Front fog lamp
Fog lamp switch
Front and rear
fog lamp
Pin No. Function Rated current (A)

1 GND —
2 Rear fog lamp 0.01
3 Front fog lamp 0.01
4 GND —
5 — —
6 GND —
7 Clearance lamp 0.01
8 High beam while overtaking 0.01
9 Low beam headlamp 0.01
10 GND —
11 Right turn 0.01
12 Left turn 0.01
WARNING INDICATOR SWITCH ASSEMBLY
1 6
1
HAZARD SW1
2 R1 LED1 5
4 R2 LED2
Pin No. Function

1 HAZARD signal input
2 Indicator signal input
3 —
4 Backlight power source input
5 Ground wire
6 —
READING LAMP ASSEMBLY (3-PIN)
1 2 3 L1 K1
+
L2 K2
U=12V
Pin No. Function

1 Anode
2 Cathode
3 Cathode
READING LAMP ASSEMBLY (10-PIN)
10 9 8 7 6
5 1
Function Pin 1 5 6 7 8 9 10
Gear position
Door lamp OFF

switch
DOOR
Upwards
(White)
Sunroof Intermediate
switch position
Downwards
COMBINATION HEADLAMP ASSEMBLY (2-PIN)
1 2
Pin No. Function

1 GND
2 Live wire
1 2 3
4 5 6
Pin No. Function

1 Front position lamp +
2 High beam+
3 Low beam-
4 Front position lamp -
5 High beam-
6 Low beam+
3 2 1
Pin No. Function

1 Anode
2 CDE
3 Cathode
COMBINATION TAIL LAMP ASSEMBLY
1 2
3 4
Pin No. Function

1 Position lamps
2 Steering lamps
3 Brake lamps
4 GND
BEAM-FOCUSING ADJUSTMENT
Note:
• Use front high beam lamp for beam focusing.
• Adjust the low beam lamp using the same method.
1. Prepare the vehicle as follows.
(a) Check and make sure that there are no signs of dam-
age or deformation in the area around the headlights.
(b) The vehicle should be on a full fuel tank.
(c) Tire pressure levels are within specifications.
(d) Vehicle is parked on a flat horizontal surface.
(e) Personnel weighing 75 kg is seated in the driver's seat.
(f) Move the vehicle from top to bottom to stabilize suspen-
sion at normal position.
2. Prepare a thick sheet of white paper (for the draw-
Left V-line V-line Right V-line
ing of baseline).
Note:
• Lean the piece of paper against the wall, vertically.
H-line • The baselines used for inspecting the low beam
lamp and inspecting the high beam lamp are not
the same.
(a) V-line (center of vehicle)
Ground
Draw a straight line down the center of the sheet and
align the line with the center of the vehicle.
(b) H-line (headlight height)
Draw a horizontal line equidistant between the high
beam lamp and vehicle height as measured from the
ground on the sheet of paper.
(c) Left V-line, right V-line (mark center between left and
right headlight)
Left and right vertical lines are along where the high
beam lamp center markings are.
Note:
• Repeat the procedure to adjust the low beam
lamp.
3. Check high beam lamp focusing.
(a) Align sheet against vehicle.
Right V-line (1) Place the sheet of paper 3 m from headlamp,
against the wall, and with H-line at the same height as
90° V-line the center marking.
3m
(2) Align V-line on the sheet with the center of the ve-
hicle, and make sure that the sheet forms a 90° angle
Left V-line
against the V-line.
(b) Start the engine.
(c) Turn on headlight; check and make sure that the beam
is within specified range of values.
Note:
• When checking high beam lamp focusing, turn off
the low beam lamp or disconnect low beam con-
nector.
4. Adjust beam focus in the vertical direction

Low beam Left V-line
Right V-line
Turn beam focusing screw using a screwdriver to adjust
40 mm high beam focus to within specified range.
Attention:
H-line • Tighten the screw in order to adjust low beam
focus.
40 mm • When the screw has been overly tightened,
40 mm 40 mm loosen the connector and then tighten again to
adjust high beam focus.
Note:
• Prior to adjusting beam focus in the vertical direc-
High beam Left V-line tion, turn the light height regulator switch to the 0
Right V-line position.
40 mm
• Turn the screwdriver in the clockwise direction to
shift the beam downwards and in the anti-clock-
H-line
wise direction to shift the beam upwards.
40 mm
40 mm 40 mm
Horizontal
direction
Vertical direction

LOW BEAM LAMP

1. Bulb
2. Fuse
Low beam lamp does not turn on (on one side)
3. Cabling
4. Grounding
1. Fuse
2. Low beam relay
3. Combination switch assembly
Low beam lamp does not turn on (all)
4. Bulb
5. Cabling
6. Grounding
1. Bulb
2. Cabling
Low beam lamp dim 3. Low beam relay
4. BCM controller
5. Grounding
1. Bulb
2. Cabling
Low beam lamp bulb flashing
3. Low beam relay
4. Grounding
HIGH BEAM LAMP

1. Bulb
High beam lamp does not turn on (on one side) 2. Cabling
3. Grounding
1. High beam fuse
2. High beam relay
High beam lamp does not turn on (all)
4. Bulb
5. Cabling
6. Grounding
1. Bulb
2. Cabling
High beam lamp dim
3. BCM controller
4. Grounding
1. Bulb
High beam lamp bulb flashing 2. Cabling
3. Grounding
POSITION LAMP

1. Bulb
Front left position lamp does not light up 2. Cabling
3. Grounding
1. Bulb
Front right position lamp does not light up 2. Cabling
3. Grounding
1. Bulb
Rear left position lamp does not light up 2. Cabling
3. Grounding
1. Bulb
Rear right position lamp does not light up 2. Cabling
3. Grounding
1. BCM controller
2. Cabling
All position lights do not light up
4. Grounding
FRONT FOG LAMP

1. Front left fog lamp fuse
2. Front left fog lamp relay
Front left fog lamp does not light up 4. Bulb
5. Cabling
6. BCM controller
7. Grounding
1. Front right fog lamp fuse
2. Front right fog lamp relay
Front right fog lamp does not light up 4. Bulb
5. Cabling
6. BCM controller
7. Grounding
1. Fog lamp switch assembly
2. Bulb
All fog lamps do not light up 3. Cabling
4. BCM controller
5. Grounding
Fog lamp cannot be switched off 2. Cabling
3. BCM controller
REAR FOG LAMP

2. Bulb
All fog lamps do not light up 3. Cabling
4. BCM controller
5. Grounding
Fog lamp cannot be switched off 2. Cabling
3. BCM controller
1. Bulb
Fog lamp does not light up (on one side) 2. Cabling
3. Grounding
STEERING LAMPS

1. Cabling
2. BCM controller
Steering lamp does not light up 3. Bulb
5. Grounding
2. Bulb
Steering lamps on one side do not light up
3. Cabling
4. Grounding
BRAKE LAMPS

1. Brake lamp switch assembly
2. Cabling
Both brake lamps do not light up (high-mount
3. Bulb
brake lamp lights up at the same time)
4. BCM controller
5. Grounding
Brake lamp cannot be switched off 2. Cabling
3. BCM controller
1. Bulb
2. Cabling
Brake lamp does not turn on (on one side)
3. BCM controller
4. Grounding
HIGH-MOUNT BRAKE LAMP

2. Cabling
High-mount brake lamp does not light up (brake
3. Bulb
lamps light up at the same time)
4. BCM controller
5. Grounding
High-mount brake lamp does not light up (brake 2. Cabling
lamps also do not light up) 3. BCM controller
4. Grounding
High-mount brake lamp cannot be switched off 2. Cabling
3. BCM controller
REVERSE LAMP

1. Bulb
2. Fuse
Reverse lamp does not light up 3. Reverse lamp switch assembly
4. Cabling
5. Grounding
1. Reverse lamp switch assembly
Reverse lamp cannot be switched off
2. Cabling
READING LAMP

1. Reading lamp assembly
2. Cabling or connector
3. BCM controller
Reading lamp does not light up
4. Economizer relay
5. Economizer relay fuse
6. Grounding
1. Reading lamp assembly
Reading lamp does not light up when door
3. Door lamp switch
opens and in DOOR position
4. BCM controller
5. Grounding
DAYTIME RUNNING LIGHT

2. BCM controller
Daytime running light does not light up
3. Daytime running light assembly
4. Grounding
CEILING LAMP

1. Ceiling lamp assembly
3. BCM controller
Ceiling lamp does not light up
4. Economizer relay
5. Economizer relay fuse
6. Grounding
1. Ceiling lamp assembly
Ceiling lamp does not light up when door opens
3. Door lamp switch
and in DOOR position
4. BCM controller
5. Grounding
POWER LAMP HEIGHT ADJUSTMENT SYSTEM

1. Light height regulator switch assembly
2. Right low beam fuse
Power lamp height adjustment system does not
3. Cabling
work
4. Light height regulator motor
5. Grounding
HAZARD WARNING INDICATOR

1. Hazard warning indicator switch assembly
2. Cabling
Hazard warning indicator does not work
3. BCM controller
4. Grounding

COMBINATION HEADLAMP ASSEMBLY
Removal
3. Remove combination headlamp assembly
(a) Disconnect combination headlamp assembly cable con-
nector.
(b) Remove the 4 combination headlamp assembly fixing
bolts.
(c) Remove combination headlamp assembly.
Installation
FRONT FOG LAMP ASSEMBLY

Removal
2. Remove front fog lamp trim plate assembly
3. Remove front fog lamp assembly

(a) Disconnect front fog lamp assembly cable connector.
(b) Remove front fog lamp assembly screw.
(c) Remove front fog lamp assembly.
Installation
DAYTIME RUNNING LAMP ASSEMBLY

Removal
3. Remove daytime running light assembly
(a) Disconnect daytime running light assembly cable con-
nector.
(b) Remove daytime running light assembly screw
(c) Remove daytime running light assembly.
Installation
READING LAMP ASSEMBLY

Removal
2. Remove reading lamp assembly
(a) Pry open the left and right reading lamp shields.
(b) Remove reading lamp assembly screw.
(c) Remove reading lamp assembly.
(d) Disconnect reading lamp assembly cable connector.
Installation
CEILING LAMP ASSEMBLY

Removal
2. Remove ceiling lamp assembly
(a) Pry open the ceiling light cover.
(b) Remove screw.

(c) Remove ceiling lamp assembly.
(d) Disconnect ceiling light assembly cable connector.
Installation
TRUNK LAMP ASSEMBLY

Removal
2. Remove trunk lamp assembly
(a) Pry to remove trunk lamp assembly.
(b) Disconnect trunk lamp assembly cable connector.
Dog:
Installation
HIGH-MOUNT BRAKE LAMP ASSEMBLY

Removal
2. Remove deflector assembly
3. Remove high-mount brake lamp assembly
(a) Disconnect high-mount brake lamp assembly cable con-
nector.
(b) Remove high-mount brake lamp assembly screw.
(c) Remove high-mount brake lamp assembly.
Installation
COMBINATION TAIL LAMP ASSEMBLY

Removal
2. Remove tail-lamp assembly maintenance cover
3. Remove right tail-lamp assembly
(a) Disconnect combination tail lamp assembly cable con-
nector.
(b) Remove the 2 combination tail lamp assembly fixing
bolts.
(c) Remove combination tail lamp assembly.
Installation
BACK DOOR COMBINATION LAMP AS-

SEMBLY
REMOVAL
2. Remove back door lamp assembly maintenance
cover
3. Remove back door combination lamp assembly
(a) Remove back door combination lamp assembly nut.
(b) Remove back door combination lamp assembly.
(c) Disconnect back door lamp assembly cable connector.
Installation
LICENSE PLATE LIGHT ASSEMBLY

Removal
2. Remove license plate light assembly
(a) Pry to remove license plate light assembly.
(b) Disconnect license plate light assembly cable connec-
tor.
Dog:
Installation
REAR FOG LAMP ASSEMBLY

Removal
2. Remove rear bumper assembly
3. Remove rear fog lamp assembly
(a) Disconnect rear fog lamp assembly cable connector.
(b) Remove rear fog lamp assembly screw.
(c) Remove rear fog lamp assembly.
Installation
COMBINATION SWITCH ASSEMBLY

Removal
4. Remove clock spring
5. Remove combination switch assembly
(a) Remove combination switch steel hoop.
(b) Disconnect combination switch assembly cable connec-
tor.
(c) Remove combination switch assembly.
Installation

Removal
2. Remove lower left guard plate assembly
3. Remove console panel switch assembly
(a) Disconnect console panel switch assembly cable con-
nector.
(b) Push out console panel switch assembly.
Dog:
Installation
WARNING LIGHT SWITCH ASSEMBLY

Removal
2. Remove central vent assembly
3. Remove warning light switch assembly
(a) Disconnect warning light switch assembly cable connec-
tor.
(b) Push out warning light switch assembly.
Dog:
Installation
DOOR SWITCH ASSEMBLY

Removal
1. Open vehicle door
3. Remove door switch assembly
(a) Remove door switch assembly bolt.
(b) Disconnect door switch assembly cable connector.
Installation
BRAKE LAMP SWITCH ASSEMBLY

Removal
2. Remove brake switch
Depress brake pedal as much as possible to push the
piston upwards until it no longer moves, then turn the
switch in the clockwise direction 45°and upwards to re-
move.
Installation
1. Install brake switch
Insert the brake lamp switch into the installation hole.
Then, turn anti-clockwise 45° until you hear a "click"
sound. This means that it has been installed into posi-
tion.
WIPER/WASHER
LOCATION DIAGRAM
2 3
4
8 5
7
6
1. Cleaning Solution Pump Assembly 6. Front Wiper Assembly

2. Rear Washer Pipe Assembly 7. Front Windshield Washer Nozzle Assembly
3. Rear Nozzle Assembly 8. Front Washer Pipe Assembly
4. Rear Wiper Assembly 9. Washer Fluid Tank Assembly
5. Combination Switch Assembly
SCHEMATICS
FRONT WIPER ASSEMBLY
2
3
2× 24
2× 24 4
1. Front Wiper Blade 3. Front Wiper Arm Bolt Cover

2. Front Wiper Arm Assembly 4. Front Wiper, Rod and Motor Assembly
REAR WIPER ASSEMBLY
1
2
3× 9
1. Rear Wiper Blade 4. Rear Wiper Sealant/Sealing

2. Rear Wiper Arm 5. Rear Wiper Motor Assembly
3. Rear Wiper Decorative Cover

Front wiper does not work WIPER fuse
Windshield wiper switch assembly
Windshield wiper motor assembly
Cabling or grounding
Front wiper does not work in LO or HI position Windshield wiper switch assembly
Front wiper does not work in INT position Windshield wiper switch assembly
Front washer motor does not work WIPER fuse
Windshield wiper switch assembly
Washer motor
Rear wiper does not work in INT position WIPER fuse

Rear wiper switch
Rear wiper motor
Rear washer motor does not work WIPER fuse
Rear wiper switch
Rear washer motor
Rear wiper does not work when washer switch is in ON posi- Rear wiper switch
tion
Rear wiper motor
Cleaning fluid does not flow Washer hose and nozzle
With the wiper switch in the OFF position, the wiper blade
Windshield wiper motor assembly (wiper
cannot be retracted or placed in the wrong position.
arm and blade component position)
Wiper blade is in contact with vehicle body.
ON-BOARD INSPECTION
WIPER POSITION
1. Check windshield wiper motor assembly
(a)
Operate windshield wiper motor assembly.
(b)
Stop windshield wiper motor assembly operations.
(c)
Identify the location where the wiper has stopped auto-
matically.
Note:
• After the front wiper motor stops operating, raise
the wiper blade 2 times and then identify the loca-
tion where it has stopped.
Normal:
The front wiper stop position is as shown in the illustra-
tion.
Note:
• If the result does not meet specified requirements,
remove and re-install front wiper arm and wiper
blade assembly, then perform the aforementioned
check in order to re-test the front wiper motor and
connecting rod assembly. If the result still does
not meet specified requirements, then check the
front wiper motor and connecting rod assembly re-
moved from the vehicle body.
REAR WIPER ASSEMBLY
Switch
condition Power Power Black White Red
Operating supply+ supply- wire wire wire
1 condition
Normal scraping
brush
3 2
Automatic stop
Pin No. Wire color

1 White
2 Red
3 Black
1 2 3 4 5
1 4 5 High speed (+)
Low speed (+) (-)

2 3
Automatic
(+)
stop
Pin No. Function

1 High speed
2 Low speed
3 Ground-
4 Return to original position
5 Power supply+
COMBINATION SWITCH ASSEMBLY (10-PIN)
1 2 3 4 5 6 7 8 9 10
Terminal 1 2 3 4 6 7 8 9 10
Function
MIST Auto return to position
OFF
Front INT
wiper
LO
switch
HI
Wash Auto return to position
INT adjustment
Wash Auto return to position
Rear OFF
wiper
ON
switch
Wipe and wash Auto return to position
Pin No. Function Rated current (A)

1 — —
2 High speed 0.01
3 GND —
4 Low speed 0.01
5 — —
6 GND —
7 Front wipe and wash 0.01
8 Rear wipe and wash 0.2
9 Rear wipe 0.2
10 Front wiper interval adjustment 0.01
CLEANING SOLUTION PUMP ASSEMBLY
1 2
Pin No. Function

1 Cathode
2 Anode

Removal
2. Remove left and right front wiper arm assemblies
(a) Remove front wiper arm bolt cover.
(b) Remove left and right front wiper arm assembly nut.
(c) Remove left and right front wiper arm assemblies.
3. Remove front ventilator cover body

4. Remove front wiper, rod and motor assembly
(a) Remove bolt that secures the front wiper, rod and motor
assembly.
(b) Disconnect front wiper, rod and motor assembly cable
connector.
Installation
REAR WIPER ASSEMBLY

Removal
2. Remove back door inner fender assembly
4. Remove rear wiper arm assembly
(a) Remove rear wiper arm bolt cover.
(b) Remove nut.
5. Apply sealant on rear wiper
6. Remove rear wiper motor assembly

(a) Disconnect rear wiper motor cable connector.
(b) Remove 3 bolts.
Installation
WASHER FLUID TANK ASSEMBLY

Removal
1. Drain windshield cleaning fluid
4. Remove washer fluid tank assembly
Front (a) Disconnect washer fluid tank assembly cable connector.
(b) Disconnect washer fluid tank assembly washer liquid
pipe.
(c) Remove washer fluid tank assembly fixing bolt.
(d) Remove washer fluid tank assembly.
Installation
CLEANING SOLUTION PUMP ASSEMBLY

Removal
1. Drain windshield cleaning fluid
4. Remove cleaning solution pump assembly
(a) Disconnect cleaning solution pump assembly cable con-
nector.
(b) Disconnect cleaning solution pump assembly washer
liquid pipe.
(c) Remove cleaning solution pump assembly.
Installation
FRONT WINDSHIELD WASHER NOZZLE

ASSEMBLY
Removal
1. Remove engine bay cover inner plate
2. Remove washer nozzle
(a) Disconnect washer hose connector.
(b) Remove 2 clips and front washer nozzle.
Attention:
• Do not reuse the washer nozzle.
Installation
REAR NOZZLE ASSEMBLY

Removal
1. Remove rear washer nozzle decorative cover
2. Remove washer nozzle
(a) Disconnect washer hose connector.
(b) Remove two clips and front washer nozzle.
Attention:
• Do not reuse the washer nozzle.
Installation
HORN
LOCATION DIAGRAM
1. Tweeter Assembly
2. Woofer Assembly

Horn button assembly
Tweeter assembly
Woofer assembly
Horn does not sound Fuse
Horn relay
Clock spring
Cabling
ON-BOARD INSPECTION
1. Check tweeter assembly
(a) Apply battery voltage to electric horn and check horn
operations.
Standard:
Measurement standards Function

Battery anode (+) → Terminal 1 Electric horn
Battery cathode (-) → Terminal 2 sounding
If the result does not meet specifications, replace tweet-

er assembly.
2. Check woofer assembly
(a) Apply battery voltage to electric horn and check horn
operations.
Standard:
Measurement standards Function

Battery anode (+) → Terminal 1 Electric horn
Battery cathode (-) → Terminal 2 sounding
If the result does not meet specifications, replace woof-

er assembly.
3. Check electric horn relay assembly
1 2 (a) Remove electric horn relay from fuse box inside the front
engine compartment.
3 5 (b) Check electric horn relay resistance.
Standard:
5
2 1 Diagnostic
Specifications
tester connection
3
Open-circuit
3-5 Breakover
(When applying battery voltage to
terminals 1 and 2)
If the result does not meet specifications, replace relay
assembly.

ELECTRIC HORN ASSEMBLY
Removal
3. Remove electric horn assembly
(a) Disconnect electric horn assembly connector.
(b) Remove electric horn assembly bolt.
(c) Remove electric horn assembly.
Installation
INSTRUMENT/DISPLAY
LOCATION DIAGRAM
1. Combination Instrument Assembly


LIQUID CRYSTAL DISPLAY
KEY PARAMETERS
Screen is a monochrome dot-matrix LCD black screen with blue lettering
Resolution: 124*170
Pitch: 0.015 mm*0.015 mm
Screen area: 56.56 mm*40.69 mm
External dimensions: 53.39 mm*76.30 mm
Backlight color: white + blue halo
Viewing angle: 12 o' clock direction
INSTRUMENT CONTROL BUTTONS

Up button: Up
Long press on Up button: Continue Menu Up and Down
Continue Down- Auto return mode Upwards commands
1
wards button Down button: Down Increase, Decrease
Long press on Down button: OK Backlight Intensity
(Continue Downwards)
Up button:
• Enter menu interface
• OK
OK, Back, Speed Auto return mode • Reset Trip Computer Menu return com-
2
Limit key button Down button: mand
• Up one level
Long press on normal display screen:
• Enter Speed Limit interface
RULES REGULATING LCD SCREEN INFORMATION DISPLAY

1. Start-up animation: When the key moves from the OFF to ON position, the instruments receive
power. At this point the Start animation sequence with the Haval logo and text "Great Wall Mo-
tor" will show for 3 s.
2. All Trip Computer screens can be hidden, following which only the form of the vehicle (doors-
closed state) and four wheels will be shown.
3. Primary alarm information and secondary alarm information must be shown for 3 s; the latter
will be canceled after the 3-second display. Once an alarm has been triggered an alarm mes-
sage will be shown in the center of the display. If there are several important alarm messages
to be read, they will be rotated every 3 s. To prevent the display from flashing, each alarm mes-
sage will be shown for at least 3 s.
4. When ignition memory is closed, only Trip Computer information and not the settings interface
will be saved. Buttons can only be operated under KL15 and not KL30.
5. In Trip Computer interfaces that can be cleared, press the OK button for 2 s to reset the Trip
Computer. If the press lasts longer than 2 s, the current interface will be retained and you will
only be able to continue to operate it after taking your finger off the button. The subtotal mile-
age meter can only be reset via the "Subtotal Mileage" interface. After resetting the Trip Com-
puter, if you continue to press on the OK button any increase in the meter value will not be re-
flected. Trip Computers that can be reset include: Subtotal mileage, Driving time, and Average
Speed. The reset Subtotal Mileage meter reads as follows: "0.0"; Driving time, "00:00"; Average
speed, "---".
6. Alarm information will not appear when buttons are being operated; they will only appear if
there have been no button operations for at least 60 seconds.
7. In the Settings interface, if there have been no button operations for 10 seconds, the display
will automatically return to the Trip Computer interface; if there are button operations within 10
seconds, commands will be executed accordingly. You will be allowed to return to the previous
menu (level) in each interface. If alarm information appear in this 10-second period, they will
not pop up until you have returned to the Trip Computer interface.
8. Alarm informations may contain only text and may not be displayed in graphical form. Once an
alarm has been triggered the corresponding alarm message will be shown immediately in the
center of the display and disappear after 3 s. After it disappears, an exclamation mark inside
a triangle at the upper left corner of the LCD indicates that there is an important alarm mes-
sage to be read; for secondary alarms, you may locate the corresponding alarm messages via
"Check Alarm Information" in the menu.
FACTORY RESET
1) Conducting a Factory Reset will affect the following counts: Subtotal Mileage, Average Fuel
Consumption, Driving Time and Average Speed;
2) Reset Trip Computer Settings: all Trip Computers selected by default;
3) Speed alarm: closed by default (cannot be closed if configuration does not allow);
4) Language: Chinese;
5) Units: Metric (if meters use Imperial units then all units will follow the Imperial system).
STANDARD DISPLAY INFORMATION

MILEAGE INFORMATION
Input signal
Instrument receives CAN signal VehicleSpd information and displays Total Mileage and Subtotal Mile-
age.
Range of values shown for Total Mileage is 0-999999 while the range for Subtotal Mileage is
0-999.9 km.
TRIP COMPUTER INFORMATION

• All Trip Computer information can be accessed or closed using the menu.
• When several Trip Computers are being shown, use the Upwards and Downwards command to
toggle between different Trip Computer displays.
• You can reset Subtotal Mileage, Average Speed, Driving Time, Mileage, etc., meters one at a time
via the menu; alternatively, a long press of the OK button within the Trip Computer display in ques-
tion will also reset the Trip Computer.
S/N Name Relevant ECU

1 Subtotal mileage ESP
2 Instantaneous fuel consumption ECM
3 Continuing mileage ECM
4 Driving time ECM
5 Average vehicle speed ESP
6 Tire pressure monitoring BCM
SUBTOTAL MILEAGE
Overview
• LCD shows Subtotal Mileage with range of 0-999.9 km and granularity at 0.1 km.
• Subtotal Mileage value shown can be reset with a long press of the OK button for at least 2 s.
• The instrument needs to automatically record Subtotal Mileage values. Turning off the ignition does
not reset the count, which is however automatically reset when battery power is disconnected.
Input
Power status: at ignition on
Hard line input: Steering wheel button signal
Mileage recorded by the instrument
Output
Subtotal Mileage: ---.- km
INSTANTANEOUS FUEL CONSUMPTION
Overview
Current fuel consumption levels are calculated based on oil consumption data from ECM as well as
current mileage information. A numerical value is shown on the LCD screen.
Input
Power status: KL15
CAN information: VehicleSpd, FuelConsumptionInst
Output
Instantaneous fuel consumption level: --.- L/100 km
CONTINUING MILEAGE
Overview
The Continuing Mileage counter shows the mileage possible with current fuel tank levels and is based
on the Average Fuel Consumption value calculated as well as current fuel levels; mileage possible is
then shown;
As drive conditions evolve constantly and future developments can be unpredictable, meter values
shown are based on the assumption that current drive conditions (oil consumption, speed, etc.) re-
main unchanged.
Input
Power status: at ignition on
ECM CAN info.
Fuel sensor signal from within the instrument
Output
Continuing mileage: - - - (units)
DRIVING TIME
Overview
The Driving Time counter shows a tally of how long you have driven since the last time the Subtotal
Mileage was reset.
Input
Power status: KL15
Engine speed signal: ENG_SPEED_ECM
Output
Driving time: -- hours -- minutes
AVERAGE VEHICLE SPEED
Overview
The Average Speed counter shows the average vehicle speed since the last time the counter was re-
set.
Input
Power status: KL15
CAN signal from ABS: VehicleSpd
Engine speed signal: ENG_SPEED_ECM
Output
Average speed: --- km/h
TIRE PRESSURE MONITORING
Overview
Tire pressure and temperature values from BCM are shown on the instrument display, which must
show an illustration of the vehicle form and its tires.
Input
Power status: KL15
CAN info
NEXT MAINTENANCE
Overview
Shows the distance to be traveled till the next maintenance session for the vehicle is due.
Input
Power status: KL15
Output
"Next Maintenance due in ---- km"
CRUISE CONTROL
Overview
Provides reminder to driver via the display when instrument receives Cruise Control signal.
Input
Power status: KL15
Signal: CruiseControlStatus
Output
"Cruise Control --- km/h"
ALARM INFORMATION
ALARM INFORMATION LIST
Classification: Classification:
Secondary Alarm
Primary Alarm Primary Alarm Information Secondary Alarm
Information
Information Information
"Rainfall and Light Sensor Fault"
1 "Tire Pressure Too High" IGN ON 1
CAN IGN ON
"Tire Temperature Too High" IGN "Please Perform Maintenance
2 2
ON on a Timely Basis" IGN ON
3 "Brake System Fault" IGN ON 3
"Overspeeding Detected, Please
4 — —
Drive Safely" IGN
"Please Fasten Seat Belt" IGN
5 — —
ON
6 "Lights Not Turned Off" IGN ON — —
"Door(s) Not Closed" IGN ON/IGN
7 — —
OFF
8 "Hand Brake On" IGN ON — —
"Engine Oil Pressure Low" IGN
9 — —
ON
"Low Fuel Levels, Please Top Up
10 — —
Tank" IGN ON
11 "Tire Pressure Too Low" IGN ON — —
12 "Key Not Removed" IGN OFF — —
The classification determines the order of the message to be shown when the ignition switch is started
if there are multiple messages to be shown. At every IGN ON, secondary alarms and prompts will be
shown once in rotation (with each alarm shown for 3 s) followed by primary alarms. If there are no
alarm messages to be shown then the main interface will be displayed.
PRIMARY ALARM INFORMATION

KEY NOT REMOVED
Overview
Instrument will show this alarm message when the driver-side door is opened when the ignition switch
has been moved to OFF or when it is in the ACC position.
Input
Power status: KL30
Signal: KeyInsertionSts=1
Output
"Key Not Removed"
DOOR(S) NOT CLOSED
Overview
The corresponding prompt will be provided if any of the four doors are open.
Input
Power status: KL15 or KL30
Signal: DriverDoorSts=1, LRDoorSts=1, PassengerDoorSts=1, RRDoorSts=1
Output
"Door(s) Not Closed"
LOW FUEL LEVELS, PLEASE TOP UP TANK
Overview
The alarm information will show when the instrument receives low fuel level signal as well as the "Fuel
warning indicator ON" signal.
Input
Power status: KL15
Signal: Resistor signal
Output
“Low Fuel Levels, Please Top Up Tank”
PLEASE FASTEN SEAT BELT
Overview
The alarm message will appear when vehicle speed is greater than 20 km/h and one or more seat
belts have not been fastened.
Input
Power status: KL15
Signal: DrvSeatbeltCmd, VehicleSpeed
Output
"Please Fasten Seat Belt"
HAND BRAKE ON
Overview
This alarm message will appear when vehicle speed is greater than 6 km/h and hand brake is still en-
gaged.
Input
Power status: KL15
Signal: Hard line low power level
Output
"Hand Brake On"
BRAKE SYSTEM FAULT

Overview
This alarm message will appear when EBD and brake fluid levels are low and the corresponding sig-
nal has been received by the instrument.
Input
Power status: KL15
Signal: Hard line low power level; EBDFailSts=1
Output
"Brake System Fault"
ENGINE OIL PRESSURE LOW
Overview
The LCD screen will show the message "Engine Oil Pressure Low" when engine oil levels are low and
when instrument receives a low power signal.
Input
Power status: KL15
Signal: Hard line low power level
Output
"Engine Oil Pressure Low"
OVERSPEEDING DETECTED, PLEASE DRIVE SAFELY
Overview
The LCD screen will show the message "Overspeed Pls. Drive Safely" when vehicle traveling speed
exceeds alarm value set.
Input
Power status: KL15
Signal: VehicleSpeed
Output
"Overspeeding Detected, Please Drive Safely"
LIGHTS ON
Overview
The LCD screen will show the message "Lights on" when the position light/master light switch indica-
tor is still on.
Input
Power status: KL15
Signal: PosLmpSts
Output
"Lights On"
TIRE PRESSURE TOO LOW
Overview
The alarm information will appear when tire pressure values are lower than specified values.
Input
Power status: KL15
Signal: LFTirePressure, RFTirePressure, LRTirPressure, RRTirPressure
Output
"Tire Pressure Too Low"
TIRE PRESSURE TOO HIGH

Overview
The alarm information will appear when tire pressure values are higher than specified values.
Input
Power status: KL15
Signal: LFTirePressure, RFTirePressure, LRTirPressure, RRTirPressure
Output
"Tire Pressure Too High"
TIRE TEMPERATURE TOO HIGH
Overview
The alarm information will appear when tire temperature values exceed specified values.
Input
Power status: KL15
Signal: LeftFrontTireTemp, RightFrontTireTemp, LeftRearTireTemp, RightRearTireTemp
Output
"Tire Temperature Too High"
SECONDARY ALARM INFORMATION

RAINFALL AND LIGHT SENSOR FAULT
Overview
This alarm message will appear when the rainfall and light sensor is damaged.
Input
Power status: KL15
Signal: RLSFailSts=1
Output
"Rainfall and Light Sensor Fault"
PLEASE PERFORM MAINTENANCE ON A REGULAR AND TIMELY BASIS
Overview
This alarm message will appear when Next Maintenance value is less than 500 km.
Input
Power status: KL30
Output
"Please perform maintenance on a regular and timely basis"
BUZZER ALARMS
BUZZER ALARM INFORMATION DESCRIPTION
S/N Name Trigger method (within a single ignition cycle)

1 Reverse radar (IGN ON) —
2 120 km/h Alarm (IGN ON) —
3 Cruise Control (IGN ON) When CruiseControlStatus = 1, 1x sound alert
4 Rainfall and Light Sensor Fault (IGN ON) When RLSFailSts = 1, 1x sound alert
5 Key Battery Low (IGN ON) When WarningKeyLowBattery = 1, 1x sound alert
Please perform maintenance on a timely ba- 1x sound alert when Maintenance Due value is less
6
sis (IGN ON) than 500 km
7 ESCL System Fault (IGN ON/OFF) When WarningEsclFailed = 1, 1x sound alert
Tire Pressure Monitoring System Fault (IGN
8 When TPMSFailureInd = 1, 5x sound alert
ON)
9 Tire Pressure Too High (IGN ON) 1x sound alert when alarm is triggered
10 Tire Temperature Too High (IGN ON) 1x sound alert when alarm is triggered
1x sound alert when low level signal received from
11 Brake System Fault (IGN ON)
brake fluid level hard line
1x sound alert when vehicle speed is higher than
12 Over speed alarm (IGN ON)
user-set limit
13 Please Fasten Seat Belt (IGN ON) —
60x sound alerts when PosLmpSts=1 signal has
14 Lights On (IGN OFF)
been received and when driver-side door is opened
15 Please Take Key (IGN OFF) 1x sound alert when WarningKeyInCarWhenExit=1
16 Door(s) Not Closed (IGN ON/OFF) —
17 Valid Key Not Found (IGN ON/OFF) 1x sound alert when WarningValidKeyNotFound=1
1x sound alert when SSSWError=1 or PEPSPDM-
18 One-key Start Switch fault (IGN ON/OFF)
DriverErrorInd=1
19 PEPS Power Source Fault (IGN ON/OFF) 1x sound alert when PEPS_PRDErr=1
20 Power Source Relay Fault (IGN ON/OFF) 1x sound alert when PowerRelayFault=1
21 Please Move Steering Wheel (IGN OFF) 1x sound alert when WarningESCLUnlockFailed=1
Step Gently on Clutch (Brake) + Press Start
22 1x sound alert when WarnEngStartNotMet=1
Button (IGN ON/OFF)
Alert at 1 Hz frequency when vehicle speed ≥6 km/h
23 Hand Brake On (IGN ON) and when low signal is received from hand brake hard
line
1x sound alert when engine speed >500 rpm, en-
24 Engine Oil Pressure Low (IGN ON) gine oil low signal and hard line low signal received
for more than 5 s
25 Insufficient Fuel Levels (IGN ON) 1x sound alert
26 Tire Pressure Too Low (IGN ON) 1x sound alert when alarm is triggered
S/N Name Trigger method (within a single ignition cycle)

27 BCM Power Source Fault (IGN ON/OFF) 1x sound alert when BCM_PRDErr=1
1x sound alerts when KeyInsertionSts=1 signal has
28 Key Not Removed (IGN OFF)
been received and when driver-side door is opened
Please Turn Off Power Source (IGN ON/ 1x sound alert when WarningPowerNotInOffPosi-
29
OFF) tion=1
Steering Lamps and Hazard Light (IGN ON/
30 Synchronized with left/right steering lamp frequency
OFF)
1x sound alert when there is a change in EspFun-
31 ESP ON/OFF (IGN ON)
cOffSts
RULE REGULATING SOUND ALERTS

SEAT BELT NOT FASTENED ALARM
The front passenger seat comes in two variants, one equipped with a sensor and one without. You
can verify which variant is fitted to your vehicle through CAN signal settings. When there is no sensor
equipped with the front passenger seat, the instrument determines if an alarm is required by detecting
seat belt status; when the seat is equipped with a sensor, whether an alarm is issued based on both
seat belt status and if someone is detected to be sitting in the front passenger seat.
WHEN FRONT PASSENGER SEAT IS EQUIPPED WITH SENSOR
Driver seat belt
1) When vehicle speed is <20 km/h and the driver's seat belt has not been fastened, the alarm indica-
tor will come on; the indicator will turn off when seat belt has been fastened.
2) When vehicle speed is ≥20 km/h and the driver's seat belt has not been fastened, the Seat Belt Not
Fastened indicator will light up and flash at the frequency of 1 Hz. At the same time, the instrument
will issue an audio alarm also timed at 1 Hz frequency. Both the light and sound alert will go on for
100 s. During this 100-second period, if the seat belt is fastened the audio alarm will cease and the
indicator will go off; if vehicle speed goes below 18 km/h the audio alarm will cease while the indica-
tor stays lit; at this point, if vehicle speed goes above 20 km/h the 100-second count for the audio and
indicator alerts will be re-started. After 100 seconds, the audio alarm will cease while the indicator will
stop flashing but stay lit.
Front passenger seat belt
1) When vehicle speed is <20 km/h and the front passenger's seat belt has not been fastened with a
low power level output from the instrument, the Front Passenger Seat Belt Not Fastened indicator will
come on; when the front passenger seat is not occupied and the corresponding seat belt is not fas-
tened, the instrument will have a high power level output.
2) When vehicle speed is ≥20 km/h and the front passenger's seat belt has not been fastened, the
seat belt indicator will light up and flash at the frequency of 1 Hz. At the same time, the instrument will
issue an audio alarm also timed at 1 Hz frequency. Both the light and sound alert will go on for 100 s.
During this 100-second period, if the seat belt is fastened the audio alarm will cease and power level
output is high; if vehicle speed goes below 18 km/h the audio alarm will cease while the instrument
continues to issue a low power level output; at this point, if vehicle speed goes above 20 km/h the
100-second count for the audio and indicator alerts will be re-started. The buzzer alert will stop after
100 s while the low power level output will continue.
The audio alarm timers for the driver's and front passenger seat belt alerts are independent of each
other.
WHEN FRONT PASSENGER SEAT IS NOT EQUIPPED WITH SENSOR
1) The rules regulating the driver's seat belt are the same as when the seat is equipped with a sensor.
2) No matter if there is someone in the front passenger's seat, as long as the seat belt has not been
fastened there will be a low power level output that will in turn light up the Seat Belt Not Fastened indi-
cator.
SPEED ALARM
1) When vehicle speed is ≥120 km/h the 120 km/h alarm indicator will flash (lit for 0.5 s, then dim for
0.5 s) with an audio alarm triggered at the same time.
2) If vehicle speed stays consistently at 120 km/h or above, the instrument will cease its speed alarm
after 10 times while the speed indicator will continue to flash until vehicle speed has been reduced to
115 km/h or lower.
3) Once the 120 km/h alarm has been triggered, when vehicle speed continues above 115 km/h the
audio alarm will cease after 10 seconds.
4) When vehicle speed goes below 115 km/h both audio and indicator alerts will cease.
REVERSE RADAR SOUND ALARM
Radar probe alert priority levels and audio frequencies are determined by the radar control module.
The instrument is only responsible for issuing audio alarms based on signals received.
PIN DEFINITIONS
COMBINATION INSTRUMENT ASSEMBLY
20 1
40 21
Pin No. Function Pin No. Function

1 K15 ignition 2 KL30 battery
3 Body ground 4 —
5 Anti-vehicle body theft (system) 6 Low brake fluid levels indicator
7 Reserved output low effect 8 —
9 Engine immobilizer indicator 10 High power output (OC)
11 Fuel sensor ground 12 Fuel sensor input
13 — 14 —
15 — 16 —
17 Airbag indicator 18 —
19 Release handbrake (low effect) 20 Pulse output (OC)
21 + (hard line low input) 22 - (hard line low input)
23 SET (hard line low input) 24 LIM (hard line low input)
25 Front passenger seat belt 26 Front passenger weight sensor
27 Body ground 28 CAN_HS_High
29 CAN_HS_Low 30 —
31 — 32 —
33 Reverse gear signal input (high effect) 34 —
35 Driver seat belt unfastened 36 Front passenger seat belt signal output
37 Engine oil pressure alarm indicator 38 —
39 — 40 Electrical charge indicator

COMBINATION INSTRUMENT ASSEMBLY
Removal
2. Combination instrument cover
3. Remove combination instrument assembly
(a) Remove combination instrument assembly bolt.
(b) Remove combination instrument assembly.
(c) Disconnect combination instrument assembly cable
connector.
Installation
REARVIEW MIRRORS
LOCATION DIAGRAM
3
2
1. Power Side Mirror Switch Assembly

2. Exterior Rearview Mirror Assembly
3. Interior Rearview Mirror Assembly

PIN DEFINITIONS
EXTERIOR REARVIEW MIRROR ASSEMBLY
1 2 3 4 5 6
7 8 9 10 11 12
Pin No. Function

1 Steering lamp cathode
2 Heating plate cathode
3 Power stowing device cathode
4 Power stowing device anode
5 Steering lamp anode
6 Heating plate anode
7 —
8 —
9 —
10 Adjust motor vertically
11 Common motor adjustment terminal
12 Adjust motor horizontally
POWER SIDE MIRROR SWITCH ASSEMBLY (POWER STOW)
1 2 3 4 5
6 7 8 9 10
Pin No. 1 2 3 4 5 6 7 8 9 10
Adjust right side mirror towards
+ -
the left (Y2)
Adjust right side mirror towards
- +
the right (Y1)
Raise right side mirror (X1) + -
Lower right side mirror (X2) - +
Adjust left side mirror towards
+ -
the left (Y2)
Adjust left side mirror towards
- +
the right (Y1)
Raise left side mirror (X1) - +
Lower left side mirror (X2) + -
Input 31 58d 15
Stow (rearview/side) mirror OUT

POWER SIDE MIRROR SWITCH ASSEMBLY
Removal
2. Remove rearview mirror switch panel
Dog:
3. Remove power side mirror switch assembly

(a) Disconnect power side mirror switch assembly cable
connector.
(b) Remove power side mirror switch assembly.
Dog:
Installation
EXTERIOR REARVIEW MIRROR ASSEMBLY

Removal
2. Remove front door guard assembly
3. Remove exterior rearview mirror assembly
(a) Remove exterior rearview mirror assembly.
(b) Disconnect exterior rear mirror assembly cable connec-
tor.
Installation
INTERIOR REARVIEW MIRROR ASSEMBLY

Removal
1. Remove interior rearview mirror assembly
Push interior rearview mirror assembly upwards while
pressing on its base to remove.
Installation
AUDIO SYSTEM
LOCATION DIAGRAM
3
2
1. Antenna Assembly 4. Door Speaker Assembly

2. Front Tweeter Assembly 5. CD/Multimedia Player Assembly
3. Multimedia Player Display Assembly 6. USB and Audio Input Panel Assembly

PIN DEFINITIONS
USB AND AUDIO INPUT PANEL ASSEMBLY
9 7 5 3 1
10 8 6 4 2
Pin No. Function

1 Auxiliary audio input, left
2 Auxiliary sound ground
3 Auxiliary sound ground
4 Auxiliary audio input, right
5 Auxiliary video input detector
6 USB 5 V power source
7 USB signal -
8 USB Ground
9 USB housing ground
10 USB signal +
DOOR SPEAKER ASSEMBLY
1 2
Pin No. Function

1 Cathode
2 Anode

CD/MULTIMEDIA PLAYER ASSEMBLY
Removal
2. Remove CD/multimedia player panel assembly
(a) Remove CD/multimedia player panel assembly.
(b) Disconnect CD/multimedia player panel assembly cable
connector.
Snap:
3. Remove CD/multimedia player assembly

(a) Remove CD/multimedia player assembly fixing bolt.
(b) Remove CD/multimedia player assembly.
(c) Disconnect CD/multimedia player assembly cable con-
nector.
Installation
MULTIMEDIA PLAYER DISPLAY ASSEM-

BLY
Removal
2. Remove multimedia player display assembly
(a) Remove multimedia player display assembly and multi-
media display base stand.
(b) Disconnect multimedia player display assembly cable
connector.
(c) Remove multimedia player display assembly.
Snap:
Installation
FRONT TWEETER ASSEMBLY

Removal
2. Remove strut A upper guard assembly
3. Remove front tweeter assembly
(a) Disconnect front tweeter assembly cable connector.
(b) Remove front tweeter assembly screw.
(c) Remove front tweeter assembly.
Installation
DOOR SPEAKER ASSEMBLY

Removal
2. Remove door guard assembly
3. Remove door speaker assembly
(a) Remove 3 door speaker assembly screws.
(b) Remove door speaker assembly.
(c) Disconnect door speaker assembly cable connector.
Installation
ANTENNA ASSEMBLY
Removal
2. Remove top cover assembly
3. Remove antenna assembly
(a) Disconnect antenna assembly cable connector.
(b) Remove antenna assembly.
Installation
USB AND AUDIO INPUT PANEL ASSEMBLY

Removal
2. Remove USB and audio input panel assembly
(a) Pry USB and audio input panel assembly to remove.
(b) Disconnect USB and audio input panel assembly cable
connector.
Dog:
Installation
CONSOLE LOCK SYSTEM

LOCATION DIAGRAM
7
6
5
4
3
8
9
10
11
12
13
15
14
1. Rear Left Door Lock Assembly 9. Front Right Door Outside Handle Assembly
2. Rear Left Door Outside Handle Assembly 10. Front Right Door Lock Assembly
3. Rear Left Door Lock Handle Assembly 11. Rear Right Door Lock Handle Assembly
4. Front Left Door Lock Assembly 12. Rear Right Door Outside Handle Assembly
5. Front Left Door Outside Handle Assembly 13. Rear Right Door Lock Assembly
6. Front Left Door Lock Handle Assembly 14. Back Door Micro-Switch
7. Console Panel Switch Assembly 15. Back Door Lock Assembly
8. Front Right Door Lock Handle Assembly

PIN DEFINITIONS
IMMOBILIZER ECU ASSEMBLY (3 PINS)
1 2 3
Pin No. Function

1 Coil side A
2 Coil side B
3 GND
IMMOBILIZER ECU ASSEMBLY (8 PINS)
2 4 6 8
1 3 5 7
Pin No. Function

1 B+
2 GND
3 LED
4 ON side
5 R-LINE
6 —
7 K-Line
8 W-Line
IMMOBILIZER COIL ASSEMBLY
1 2 3
Pin No. Function

1 Coil side A
2 Coil side B
3 GND

DOOR LOCK ASSEMBLY
Removal
2. Remove door guard assembly
3. Remove door waterproof membrane
4. Remove door lock assembly
(a) Disconnect lock core and lock cylinder connector rod.
(b) Disconnect door outside handle assembly cable and
door lock assembly.
Note:
• For the lock assembly on the driver's side, you
need to perform step (a) to dismantle; other locks
do not have the lock cylinder connector rod com-
ponent.
(c) Remove 3 door lock assembly screws.
(d) Remove door lock assembly via the maintenance open-
ing.
Installation
FRONT DOOR OUTSIDE HANDLE ASSEMBLY

Removal
2. Remove front door fender assembly
3. Remove front door waterproof membrane
4. Remove front door outside handle assembly
(a) Disconnect lock core and lock cylinder connector rod.
(b) Disconnect door outside handle assembly cable and
door lock assembly.
Note:
• For the lock assembly on the driver's side, you
need to perform step (a) to dismantle; the lock cyl-
inder connector rod component is not present on
the front passenger's side.
(c) Remove maintenance opening blanking cap.
(e) Remove front door lock core and decorative cover

Note:
• There is no lock core on the front passenger's
side.
(f) Remove front door outside handle.

(g) Remove door outside handle frame screw, pry door out-
side handle frame to remove.
Installation
REAR DOOR OUTSIDE HANDLE ASSEM-

BLY
Removal
2. Remove rear door guard assembly
3. Remove rear door waterproof membrane
4. Remove rear door outside handle assembly
(a) Disconnect outside handle frame and outward-opening
lever.
(b) Remove door lock decorative cover.
(c) Remove rear door outside handle.
(d) Remove rear door outside handle frame screw, pry rear
door outside handle frame to remove.
Installation
BACK DOOR LOCK

Removal
3. Remove back door lock
(a) Break off connector.
(b) Remove 3 screws.
(c) Remove lock via the maintenance opening.
Installation
BACK DOOR OUTSIDE HANDLE ASSEMBLY

Removal
3. Remove license plate light decorative plate assem-
bly
(a) Remove license plate light decorative plate assembly
bolt.
(b) Remove back door outside handle assembly bolt.
(c) Remove license plate light decorative plate assembly.
4. Remove back door outside handle assembly
(a) Disconnect back door outside handle assembly cable
connector.
(b) Remove back door outside handle assembly.
Dog:
Installation
DOOR LOCK INTERIOR CLAMP ASSEMBLY

Removal
2. Remove door lock handle assembly
(a) Pry door lock inside handle assembly bolt cover to re-
move
(b) Remove door lock inside handle assembly screw
(c) Disconnect door lock insider handle assembly cabling.
(d) Pry door lock handle assembly to separate.
Dog:
Installation

Removal
2. Remove lower left guard assembly
3. Remove console panel switch assembly
(a) Disconnect console panel switch assembly cable con-
nector.
(b) Remove console panel switch assembly.
Dog:
Installation
IMMOBILIZER SYSTEM
LOCATION DIAGRAM
1
2
1. Ignition Lock Assembly

2. Immobilizer Coil Assembly
3. Immobilizer ECU Assembly

IMMOBILIZER ECU ASSEMBLY
Removal
3. Remove steering column lower guard plate
4. Remove immobilizer ECU assembly
(a) Remove immobilizer ECU assembly screw.
(b) Disconnect immobilizer ECU assembly cable connector.
(c) Remove immobilizer ECU assembly.
Installation
IMMOBILIZER COIL ASSEMBLY

Removal
3. Remove immobilizer coil assembly
(a) Remove immobilizer coil assembly.
(b) Disconnect immobilizer coil assembly cable connector.
Dog:
Installation
IGNITION LOCK ASSEMBLY

Removal
3. Remove immobilizer coil assembly
(a) Remove immobilizer coil assembly.
(b) Disconnect immobilizer coil assembly cable connector.
Dog:
4. Remove ignition lock assembly

(a) Remove ignition lock assembly screw.
(b) Remove ignition lock assembly.
(c) Remove ignition lock assembly cable connector.
Installation
WINDOW LIFT
LOCATION DIAGRAM
1
2
1. Power Window Switch Assembly 3. Rear Window Lift Assembly

2. Front Left Window Switch Assembly 4. Front Window Lift Assembly

PIN DEFINITIONS
REAR WINDOW LIFT ASSEMBLY
1 2
Pin No. Function State

1 Anode
Raise
2 Cathode
POWER WINDOW SWITCH ASSEMBLY
3 1
6 4
Pin No. Function

1 GND
2 Ignition gear
3 GND
4 Manual downshift output
5 Backlight power source
6 Manual raise output
FRONT LEFT WINDOW SWITCH ASSEMBLY
12 7
6 1
Pin No. Function

1 Lower front passenger window using power window system
2 Raise front passenger window using power window system
3 Child safety lock
4 Backlight power
5 Raise driver window using power window system
6 Lower driver window using power window system
7 Lower rear right window using power window system
8 Raise rear right window using power window system
9 GND
10 Ignition power supply
11 Raise rear left window using power window system
12 Lower rear left window using power window system

FRONT WINDOW LIFT ASSEMBLY
Removal
1. Lower front door window glass to appropriate level
Note:
• Lower window glass until it is flushed with the door
exterior weather strip.
3. Remove front door inner fender assembly
4. Remove front door waterproof membrane
5. Remove front door window glass assembly
6. Remove front window lift assembly
(a) Disconnect front window lift assembly cable connector.
(b) Remove front window lift assembly bolt.
(c) Remove front window lift assembly.
Installation
REAR WINDOW LIFT ASSEMBLY

Removal
1. Lower rear door window glass to appropriate level
Note:
• Lower window glass until it is flushed with the door
exterior weather strip.
3. Remove rear door inner fender assembly
4. Remove rear door waterproof membrane
5. Remove rear door window glass assembly
6. Remove rear window lift assembly
(a) Disconnect rear window lift assembly cable connector.
(b) Remove rear window lift assembly bolt.
(c) Remove rear window lift assembly.
Installation
FRONT LEFT WINDOW SWITCH ASSEMBLY

Removal
2. Remove front left window switch panel
Dog:
3. Remove front left window switch assembly

(a) Disconnect front left window switch assembly cable con-
nector.
(b) Remove front left window switch assembly.
Installation
POWER WINDOW SWITCH ASSEMBLY

Removal
2. Remove window lift switch panel.
Dog:
3. Remove power window switch assembly

(a) Disconnect power window switch assembly cable con-
nector.
(b) Remove power window switch assembly.
Installation
SUNROOF
LOCATION DIAGRAM
1. Front Sunroof Drip Tube

2. Power Window Assembly
3. Rear Sunroof Drip Tube

SUNROOF ASSEMBLY
Removal
2. Remove top cover assembly
3. Remove sunroof assembly
(a) Disconnect sunroof assembly cable connector.
(b) Disconnect 4 drip pipes from the sunroof assembly.
(c) Remove 12 sunroof assembly fixing bolts.
(d) Remove sunroof assembly.
Installation
REVERSE RADAR
LOCATION DIAGRAM
1. Collision Avoidance Radar ECU Assembly

2. Collision Avoidance Radar Probe Assembly

ACTIVATING THE SYSTEM
With the ignition switch is in the ON position, the reverse radar will automatically be activated when R
gear is engaged. There will be no audio prompt when the system has been automatically activated.
This indicates that everything is normal.
SHUTTING DOWN THE SYSTEM
The reverse radar system will be shut off when the gear selector lever is shifted out of R gear.
EFFECTIVE OPERATING ZONE
Distance from obstacle
Side Center Center Side Alarm sound

sensor (left) sensor (left) sensor (right) sensor (right)
— 100 cm-150 cm 100 cm-150 cm — Long interval
40 cm-80 cm 40 cm-100 cm 40 cm-100 cm 40 cm-80 cm Short interval
0-40 cm 0-40 cm 0-40 cm 0-40 cm Long horn
PIN DEFINITIONS
COLLISION AVOIDANCE RADAR PROBE ASSEMBLY
1 2
Pin No. Function

1 Cathode
2 Anode
COLLISION AVOIDANCE RADAR ECU ASSEMBLY
1 2 3 4 5 6 7 8
16 15 14 13 12 11 10 9
Pin No. Function

1 Radar probe signal, left center
2 Radar probe signal, left side
3 —
4 —
5 Radar probe signal, right center
6 —
7 —
8 Reverse gear signal
9 —
10 —
11 —
12 —
13 —
14 —
15 Radar probe signal, right side
16 GND

COLLISION AVOIDANCE RADAR PROBE
ASSEMBLY
Removal
2. Remove rear bumper assembly
3. Remove collision avoidance radar probe assembly
(a) Disconnect reverse radar probe assembly cable con-
nector.
(b) Remove collision avoidance radar probe assembly.
Installation
COLLISION AVOIDANCE RADAR ECU AS-

SEMBLY
Removal
2. Remove upper dashboard body assembly
3. Remove collision avoidance radar ECU assembly
(a) Remove collision avoidance radar ECU assembly bolt.
(b) Disconnect collision avoidance radar ECU assembly
cable connector.
(c) Remove collision avoidance radar ECU assembly.
Installation
ON-BOARD MONITORING SYSTEM

LOCATION DIAGRAM
1. Reverse Camera Assembly


REVERSE CAMERA ASSEMBLY
Removal
2. Remove back door inner protective plate assembly
3. Remove license plate light decorative plate assem-
bly
(a) Remove license plate light decorative plate assembly
bolt.
(b) Remove license plate light decorative plate assembly.
4. Remove reverse camera assembly
(a) Disconnect reverse camera assembly cable connector.
(b) Remove back door outside handle assembly and re-
verse camera assembly.
Dog:
(c) Remove reverse camera assembly.
Installation
NAVIGATION SYSTEM
OVERVIEW
MAIN MAP INTERFACE
The interface will come up each time the user selects the navigator function. Please read the following
carefully.
GPS INFORMATION
Satellite modes: a total of three available, which are Search, 2D and 3D.
Satellite count: number of satellites connected/found.
Level of precision: Reflects positioning margin of error. The smaller the value, the more accurate the
GPS positioning. A value below 13 is desirable.
IMPORTANT INFORMATION FOR THE USER
1. As there are differences from vehicle to vehicle, at start-up the navigation system needs some
time to re-acquire GPS positioning for greater precision in vehicle positioning. During the
drive, the system will automatically calibrate itself on a dynamic basis.
2. If vehicle ignition has been turned off for some time, upon re-start the navigation system would
require a longer time to acquire GPS signals and positioning. Generally speaking, in locations
where reception is good the process will complete within 3 minutes.
3. Locations where GPS signal reception may be compromised include: on roads surrounded by
high-rises on both sides, on roads surrounded by tall trees, under overpasses, in underground
parking lots, and inside tunnels. In such locations, the navigation system will not be able to re-
ceive GPS signals and positioning may be less accurate as a result.
4. Sometimes, the system will not be able to tell if the vehicle is on an elevated road or traveling at
ground level. The system will refresh vehicle positioning after some time when the two roads diverge.
5. If the vehicle is traveling on a road parallel with, and close to, another road (such as on a ser-
vice road), the navigation system may mis-identify vehicle positioning. The system will refresh
vehicle positioning after some time when the two roads diverge.
6. When the vehicle is at a bend, if it is traveling at a relatively high speed or does not travel
along the center of the road, system vehicle positioning may lag slightly or 'jump ahead'. If
there is a service road after the bend, vehicle positioning may end up on the service road as a
result. The system will refresh vehicle positioning after some time when the two roads diverge.
Traveling slowly at a turn can help prevent the occurrence of this issue.
7. To avoid overwhelming the driver with meaningless noise, voice prompts have been disabled
for certain turns, for instance where there is no fork at said turn or if the turn-off is at a height
significantly different from the road the vehicle is currently traveling on.
8. At bends, if there are other roads parallel to the road you are turning into, a voice prompt
along the lines of "Now, please turn towards Y at the X intersection" will be issued to help the
driver select the correct turn-in. A common occurrence is the existence of service roads. At
this point, any service road will also be considered as a turn-off for voice prompt purposes.
9. When performing route determination, and when handling address inputs, language switch-
overs, day/night mode switchovers and POI searches, more system resources are required
and some processing time is needed. We recommend that users do not perform operations
such as turning on the ignition, switch interfaces or remove the SD at such moments to avoid
undermining system stability, which in severe instances can cause the system to reboot.
10. To prevent damage to, or the loss of, map data stored on the SD and the subsequent failure of
the system to acquire map data required for navigation, never remove the SD card when the
system is powered.
11. Users should refrain from applying stickers on the windshield glass as these may also affect
GPS reception; without GPS signals, the system will not be able to determine vehicle position-
ing and will only show an arrow to indicate the vehicle against a white (blank) background.
Map data will appear once positioning has been determined.

COMMON FAULTS
NAVIGATION
1. Navigator unable to receive satellite signals
(a) When vehicle is parked indoors, inside a tunnel, among high-rises (park vehicle outdoors, in an open
area, for around 30 minutes);
(b) When windshield sticker contains metallic content (Shake the windshield glass free to get satellite sig-
nals);
(c) When the vehicle is located close to a high voltage cable or other equipment capable of putting out
interference;
(d) When an new or modified appliance is in the vehicle, or when a MP3 transmitter capable of interfering
with the navigation system has been installed;
(e) Remove the navigator and check that the GPS antenna is not detached, loose or damaged (replace
GPS antenna to confirm);
(f) Check that the antenna jack thimble is not damaged.
2. Vehicle symbol does not move when vehicle has begun to move off (system has been turned
on)
(a) Make sure that the unit is able to receive GPS signals;
(b) Check that vehicle speed signal is being fed to the navigator device.
3. Unable to obtain map data
(c) Check map storage card for signs of damage (re-format card and then load map data again, or switch
to another map storage card);
(d) Check card slot for signs of damage (insert a map storage card that has been determined to work nor-
mally into the navigator device to see if it can be read);
(e) Check that map storage card contains other documents or software (and check that document size is
within normal range);
(f) Check that map data has not been deleted or if other map data is being used;
(g) Check that the map storage card is an original card.
4. Unable to find destination
(a) Check that the map is not out-of-date;
(b) Check that the destination is relatively new (in general, new locations are added to maps six months
or longer after they have been confirmed).
RADIO
1. Unable to receive radio signals
(a) Make sure that antenna is secured and that antenna jack thimble is not damaged;
(b) Check antenna for signs of damage (try using another antenna).
2. Signal interference (noise in signals)
(a) Check for poor antenna contacts;
(b) Make sure that your vehicle is not located close to high voltage cables or among high-rise buildings.
3. Radio station located, but no sound heard
(a) Check that the device has not been muted;
(b) Check for sound output from other sources.
USB
1. Unable to read USB
(a) Check the USB drive for signs of damage (connect to computer to see if drive data can be read and
written to determine if drive is damaged);
(b) Check USB drive cable for signs of loose (remove USB cable and re-connect);
(c) Check USB cable for signs of damage (use another cable to determine if cable is damaged);
(d) Check if USB drive capacity is supported by the navigator (maximum capacity supported is 16 G);
(e) Check USB drive content to make sure that file types are supported by navigator.
FUNCTIONAL ISSUES
1. No response when panel buttons are pressed
(a) Check panel buttons for signs of jamming;
(b) Check for signs of seepage into the panel (e.g., perfume, air freshener, water);
(c) Check for signs of knocks to the panel or deformation.
2. Panel buttons not lit
(a) Remove device and check light voltage (normal voltage being 12 V).
3. Zero audio output
(a) Check the unit and make sure that it has not be muted;
(b) Remove the unit and check for short circuiting in horn cables one by one;
(c) Lay out horn cabling and check if any of the power output pins have short-circuited.
4. No output from single horn
(a) Enter Settings menu, check that horn front/back and left/right output is centered;
(b) Check horn for signs of burnout;
(c) Check horn cabling for signs of short-circuiting or open circuits.
5. No or incorrect response from touchscreen
(a) Check for signs of damage to touchscreen surface;
(b) Check screen protector to make sure that it is not pressed down by the device outer frame (tear off
protector to see if the touchscreen works);
(c) Enter Settings menu to re-calibrate.
6. Unable to start up device
(a) Remove navigator device, measure power and ignition voltage on power cord and compare to normal
levels;
(b) Check that the fuse has not burned out.
7. Bluetooth incompatible, or cannot be found
(a) Check that the device Bluetooth switch has been switched on;
(b) Check that Bluetooth has been activated on your mobile device;
(c) Bluetooth turned on, but unable to connect (try connecting with another mobile device);
(d) Clear the mobile and navigator connections list and then try to pair devices again.
8. Volume too low with Bluetooth
(a) Check mobile volume level;
(b) Check unit mobile level.
9. "Fatal errors" (black screen, hung device, etc.)
(a) Did you remove the USB drive while playing media?
(b) Did you update unit software?
10. No response from reverse video or reverse gear
(a) If a black screen appears when reverse gear has been engaged, it may mean that there is no signal
output from the camera (replace camera to see if it is working properly);
(b) If the vehicle does not respond when reverse gear is engaged, measure reverse signal to check if it
has been sent to the host (check that voltage is 12 V using multimeter).
ENGINE ECU
LOCATION DIAGRAM
1. ECU Assembly

ECU ASSEMBLY
Removal
2. Glove box assembly
3. Remove ECU assembly
(a) Remove ECU assembly pressure plate nut.
(b) Disconnect ECU assembly cable connector.
(c) Remove ECU assembly.
Installation
BATTERY
LOCATION DIAGRAM
1. Battery Assembly

BATTERY ASSEMBLY
Removal
1. Disconnect battery anode and cathode wiring
2. Remove battery assembly
(a) Remove battery pressure plate.
(b) Remove battery assembly.
Installation
ON-BOARD POWER SOURCE

LOCATION DIAGRAM
1. Spare Battery Assembly


SPARE BATTERY ASSEMBLY
Removal
2. Remove spare battery assembly
(a) Pry spare battery assembly to remove.
(b) Disconnect spare power source assembly cable con-
nector.
Installation
MULTI-FUNCTION
STEERING WHEEL SWITCH
MULTI-FUNCTION STEERING WHEEL
SWITCH
Removal
2. Remove airbag assembly
Attention:
• Secure clock spring to prevent it from moving.
4. Remove multi-function switch
(a) Disconnect multi-function switch cable connector.
(b) Remove multi-function switch.
Installation
Memorandum
Vehicle Body Controller 13-1
VEHICLE BODY CONTROL

SYSTEM
BCM
Overview.........................................................................13-2
Door Lock System........................................................13-2
Lighting System...........................................................13-3
Wiper and Washer System..........................................13-7
Power Saving Function................................................13-7
Power Side Mirror........................................................13-8
System Block Diagram.................................................13-10
Pin Definition................................................................13-14
List of Diagnostic Trouble Code...................................13-19
BCM.............................................................................13-23
13-2 Vehicle Body Controller
BCM
OVERVIEW
DOOR LOCK SYSTEM
1. To lock
With the power in OFF mode and all vehicle doors closed, once the remote LOCK command has
been received BCM will implement lock. At the same time, the left and right steering lamps will light
up. If the interior lamps are lit at the time of locking, they will dim gradually. If the interior lamps have
not been lit they will stay dim.
2. To unlock
With the power in OFF mode and all vehicle doors closed, once the remote UNLOCK command has
been received BCM will implement unlock. At the same time, the left and right steering lamps will flash
twice at 1.5 Hz frequency and interior lamps will light up for 30 s.
3. Search for vehicle
With the power source in OFF mode and vehicle locked, a long press of the Lock button will lead
the BCM to light up the left and right steering lamps at 1.5 Hz frequency for 11 times and sound the
rear drive horn to sound out 3 short horns. To cancel the Search function, press the Unlock, Lock or
Search buttons on the remote control.
4. Console unlock
With the power source in OFF, ACC or ON mode, press the console switch and the BCM will execute
console unlock.
5. Back door unlock
When the front left lock is unlocked, pressing the release switch on the back door will unlock the back
door instantly.
6. Console lock
With the power source in OFF, ACC or ON mode, press the console switch and the BCM will execute
console lock.
7. Vehicle speed lock
With power source in ON mode, driver-side door unlocked and all vehicle doors closed, when vehicle
speed increases from less than 12 km/h (can be changed in settings) to a speed higher than 15 km/h
the BCM will implement lock.
8. Auto arm
After a successful remote unlock, if all five doors remain closed and their status, changed, within 30 s,
BCM will implement lock.
9. Anti-error lock
When closing vehicle doors, if the right doors are closed and when closing the last door (including the
back door), the BCM will initiate four-door unlock.
10. Key-remove unlock
With power source in ON or ACC mode, switch to OFF mode and pull out key from ignition. Once
completed, BCM will unlock four doors.
11. Unlock upon collision
After the BCM fails to detect a false knock signal, unlock will be delayed by 3 s for 5 consecutive un-
lock actions.
After the BCM detects a valid knock signal, it will implement unlock immediately for 5 consecutive un-
lock actions. The BCM will also light up the high-mount brake lamp and the hazard indicator as well as
the center ceiling lamp for an extended period.
To cancel knock indicator: Ignition must be moved from OFF to ON position again, with the brake ped-
al switch turned off. Press the hazard indicator button and it will turn off after two flashes.
LIGHTING SYSTEM
LOW BEAM LAMP
1. About the function
BCM on or when low beam lamp has been turned off.
2. Prerequisites
All of the following conditions must be satisfied:
(a) System power source is in IGN ON mode;
(b) Automatic light switch is disconnected;
(c) Battery voltage is greater than 10.5 V;
3. Basic process
(a) When the aforesaid conditions have been satisfied, after the low beam lamp switch has been con-
nected, the BCM lights up the low beam lamp;
(b) When the low beam lamp is lit, the disconnection of the low beam lamp switch will lead the BCM to
turn off the low beam lamp;
(c) When the low beam lamp is lit, when system power switches from IGN ON mode to another mode,
the BCM turns off the low beam lamp;
(b) When the low beam lamp is lit, the connection of the automatic light switch will lead the BCM to turn
off the low beam lamp;
(e) When the low beam lamp is lit, if battery voltage is lower than 10 V and the engine is not working, the
BCM turns off the low beam lamp; the BCM will light up the low beam lamp when battery voltage re-
turns to the 10.5 V level;
HIGH BEAM LAMP

BCM turns on or turns off the high beam lamp (including the overtaking lamp).
2. Prerequisites
Battery voltage greater than 10.5 V.
3. Basic process
(a) With system power in OFF mode, after the high beam lamp switch has been turned on BCM will light
up the high beam lamp. At the same time, BCM will also send CAN information (HighBeamSts) to light
up the high beam indicator light on the dashboard. If there is no change to the status of all five doors,
after 30 s BCM will send CAN information (HighBeamSts) to turn off the dashboard high beam indica-
tor light and the bus will go into sleep mode; BCM will turn off high beam lamp after the power saving
delay period is over. If there is any change in status to any of the five doors, the 30 s period and the
power saving delay period will be reset and start from 0;
(b) With system power in ACC mode, after the high beam lamp switch has been turned on BCM will light
up the high beam lamp. At the same time, BCM will also send CAN information (HighBeamSts) to light
up the high beam indicator light on the dashboard;
(c) With system power in IGN ON mode and when battery voltage is greater than 10 V (can be changed
in settings), after the high beam lamp switch has been turned on BCM will light up the high beam
lamp. At the same time, BCM will also send CAN information (HighBeamSts) to light up the high beam
indicator light on the dashboard.
(d) After the high beam lamp switch has been turned off BCM will turn off the high beam lamp. At the
same time, BCM will also send CAN information (HighBeamSts) to turn off the high beam indicator
light on the dashboard;
(e) With the high beam lamp switch turned on and where system power has been switched from a non-
START mode to START mode, BCM will turn off the high beam lamp. At the same time, BCM will also
send CAN information (HighBeamSts) to turn off the high beam indicator light on the dashboard;
(f) When the high beam lamp has been turned on and when system power is in IGN ON mode, if battery
voltage is lower than 10 V and the engine is not working, BCM will turn off the high beam lamp. At the
same time, BCM will also send CAN information (HighBeamSts) to turn off the high beam indicator
light on the dashboard; if battery voltage returns to 10.5 V, BCM will light up the high beam lamp and
also send CAN information (HighBeamSts) to light up the dashboard high beam indicator light;
4. Others
(a) When the low beam lamp switch has been disconnected, it is a transient-type switch and the high
beam lamp becomes an overtaking lamp; when the low beam lamp switch has been turned on, the
high beam lamp switch becomes a lock-type switch. This is determined by the organizational proper-
ties of the combination switch;
(b) When the synchronization tolerance of the high beam lamp and lighting/dimming of the dashboard
high beam indicator light is 100 ms, the delay is not perceptible to the casual observer;
(c) When the high beam lamp lights up the low beam lamp must be turned on as well. This is because
both the high beam and low beam lamps use the same bulb, and the high beam lamp relay controls
the directionality of the solenoid valve to alternately light up the high beam and low beam lamps.
FRONT FOG LAMP

1. Prerequisites
(b) Position lamp has been activated;
(c) License plate lamp has been activated;
(d) Battery voltage is greater than 10.5 V.
2. Basic process
(a) When the necessary conditions have been fulfilled and after the front fog lamp switch has been con-
nected, BCM will light up the front fog lamp and send CAN information (FrontFogLmpSts) at the same
time to light up the dashboard front fog lamp indicator light;
(b) When the front fog lamp has been turned on, if battery voltage is lower than 10 V and the engine is
not working, BCM will turn off the front fog lamp. At the same time, BCM will also send CAN informa-
tion (FrontFogLmpSts) to turn off the front fog lamp indicator light on the dashboard; if battery voltage
returns to 10.5 V, BCM will light up the front fog lamp and also send CAN information (FrontFogLmpSts)
to light up the dashboard front fog lamp indicator light;
REAR FOG LAMP

BCM lights up and turns off the rear fog lamp.
2. Prerequisites
(b) Position lamp has been activated;
(c) Low beam, high beam lamp or front fog lamp has been activated;
(d) Battery voltage is greater than 10.5 V.
3. Basic process
(a) When the necessary conditions have been fulfilled and after the rear fog lamp switch has been con-
nected, BCM will light up the rear fog lamp and send CAN information (RearFogLmpSts) at the same
time to light up the dashboard rear fog lamp indicator light;
(b) When the rear fog lamp has been turned on, if battery voltage is lower than 10 V and the engine is not
working, BCM will turn off the rear fog lamp. At the same time, BCM will also send CAN information
(RearFogLmpSts) to turn off the rear fog lamp indicator light on the dashboard; (if battery voltage re-
turns to 10.5 V, BCM will light up the rear fog lamp and also send CAN information (FrontFogLmpSts)
to light up the dashboard rear fog lamp indicator light);
(c) When there is a rear fog lamp failure, when system power is in IGN ON mode the BCM will send a
rear fog lamp malfunction signal for indication on the dashboard;
INTERIOR LAMPS
1. Function
(a) When system power is in OFF, ACC, or IGN ON mode, once any one of the five doors is opened BCM
will turn on interior lamps immediately as well as implement the following:
After interior lamps have been turned on for 8 min (can be changed in settings), they will be dimmed
within 1.4 s at 100 Hz frequency from 100% to 0%;
During the 8-min (can be changed in settings) interior light delay period, if any one of the five doors
has been opened again the interior light delay period will be reset and start from 0;
When system power is in IGN ON mode, within the 8-min (can be changed in settings) interior light
delay period, after all five doors have been closed the BCM will immediately dim interior light bright-
ness from 100% to 0% at 100 Hz frequency within 1.4 s;
When system power is in IGN OFF or ACC mode, within the 8-min (can be changed in settings) inte-
rior light delay period, after all five doors have been closed the BCM will dim interior light brightness
after a 30-second delay from 100% to 0% at 100 Hz frequency within 1.4 s;
(b) When all five doors have been closed and system power mode is switched from IGN ON to ACC or
OFF, the BCM will immediately dim interior lamp brightness from 100% to 0% at 100 Hz frequency
within 1.4 s;
(c) For details on interior lamp control with the Unlock Upon Collision function, please refer to the section
on the function;
2. Others
When the front/rear ceiling lamp and rear reading lamp switches are connected in DOOR mode, the
MCU controls the front/rear ceiling lamp and rear reading lamp;
When the front/rear ceiling lamp and rear reading lamp switches are connected in ON/OFF mode, the
front/rear ceiling lamp and rear reading lamp are controlled directly by the switch;
BRAKE LAMP
When the brake switch is connected, the BCM lights up the brake lamp
BCM detects brake lamp fuse short-circuited, turns on brake lamp
After the brake lamp switch has been connected, should any of the brake lamp (left brake lamp, right
brake lamp, high-mount brake lamp) switches are short-circuited or if the drive chip is damaged, the
BCM lights up the other lights determined to be working properly. At the same time, the left/right steer-
ing lamps, dashboard left/right steering indicators, and hazard indicator backlight will flash at 1.5 Hz
frequency until the brake switch has been disconnected.
EMERGENCY BRAKE LIGHT

When the power source is in ON mode with vehicle speed greater than 30 km/h and acceleration at
least at 3 m/s2, with reception of the ABS brake signal the BCM will initiate flashing of the left and right
steering lamps at frequency of 3 Hz for at least 3 times each time they are activated.
DAYTIME RUNNING LIGHT

When the position lamps have not been turned on when the power source is in ON mode and the en-
gine is running, the daytime running light will turn on.
STEERING LAMPS
With power source in ON mode and the left steering lamp switch connected, the left steering lamp will
turn on. The right steering lamp will turn on when the right steering lamp switch is connected.
HAZARD INDICATOR
When the hazard indicator switch has been connected, the left and right steering lamps will turn on at
the same time and flash at the frequency of 1.5 Hz.
LANE CHANGE LIGHT

When the left steering lamp switch has been connected for less than 500 ms, the left steering lamp
will light up and flash at the frequency of 1.5 Hz for 3 times. If any of the front or rear lamps are dam-
aged, the other lamp in the pair will flash more quickly.
When the right steering lamp switch has been connected for less than 500 ms, the right steering lamp
will light up and flash at the frequency of 1.5 Hz for 3 times. If any of the front or rear lamps are dam-
aged, the other lamp in the pair will flash more quickly.
FRONT FOG LAMP AUXILIARY LIGHTING

1. Prerequisites
When vehicle speed is lower than 40 km/h, power is ON, when position lamp is activated, and when
low beam lamp is activated.
(a) Steering wheel angle greater than 60 degrees, left turn, front left fog lamp lights up;
(b) Steering wheel angle greater than 60 degrees, right turn, front right fog lamp lights up;
(c) Left steering lamp switch connected for longer than 500 ms, front left fog lamp lights up;
(d) Right steering lamp switch connected for longer than 500 ms, front right fog lamp lights up;
(e) BCM receives R gear signal, steering wheel turn angle greater than 60 degrees, both front fog lamps
light up.
POSITION LAMP AND LICENSE PLATE LIGHT

Position lamp switch connected, position lamp and license plate light are turned on.
FOLLOW-ME-HOME
With the power source in OFF mode and the low beam lamp switch connected, successful locking of
the vehicle doors will lead the position lamp and low beam lamp to light up for 30 s.
WELCOME LIGHT
With the power source in OFF mode and the low beam lamp switch connected, once the unlock com-
mand is received the position lamp and low beam lamp will light up for 30 s.
CONSOLE BACKLIGHT AND AMBIENT LAMP

1. Prerequisites
(a) Power supply is in OFF, ACC, IGN ON or START modes;
2. Basic process
(a) With the aforementioned conditions satisfied and the vehicle not in armed status, once the position
light output condition has been met the BCM will brighten the console backlight and atmosphere lamp
in a linear fashion within 0.7 s at the frequency of 100 Hz from 0% to 100% and then keep the console
backlight and ambient lamp lit. The BCM then dims the console backlight and ambient lamp when
power saving kicks in;
(b) With the aforementioned conditions satisfied, once the console backlight and ambient lamp have been
activated and there is no position lamp output, the BCM will dim the console backlight and ambient
light in a linear fashion at the frequency of 100 Hz from 100% to 0% within 1.4 s;
(c) With the aforementioned conditions satisfied, once the console backlight and ambient lamp have been
activated and the vehicle is armed, the BCM will dim the console backlight and ambient lamp in a lin-
ear fashion at the frequency of 100 Hz from 100% to 0% within 1.4 s;
WIPER AND WASHER SYSTEM

FRONT WIPER
Front wiper modes available are: Lo-speed, Hi-speed, Auto, Auto/Intermittent and Off;
With power source in ON mode and the lo-speed switch connected, the wiper will operate at low
speed; when the hi-speed switch is connected, the wiper will operate at high speed (all vehicles must
be closed);
When the electrical switch has been connected: BCM will implement one wiper cycle at low speed;
The wiper has 5 grades of intensity, with the interval between wipes set at: 2 s, 3 s, 4 s, 5 s and 6 s;
FRONT WASHER
When the front washer switch is connected, BCM will send a water spray command. The BCM will
also initiate front wiper operation at low speed after a 1-second delay;
The front washer should be shut off after the front washer switch has been connected continuously for
15 s.
ANTI-VEHICLE BODY THEFT SYSTEM

1. Indicator light
Once the vehicle is armed, the immobilizer indicator will light up for 50 ms, dim for 2 s and then flash;
in Pre-armed status, the indicator light will turn on for 1 second and dim for 1 second.
2. Disarm
Unprotected state following authentication using remote control, key or engine anti-theft system.
3. Pre-arm
Following lock command via remote control or PEPS, the vehicle will go into Armed mode after a
15-second delay. In this state, even if an input signal is detected the alarm will not be triggered. Fur-
ther, the vehicle will also switch from Pre-armed status to Disarmed status.
4. Fullarmed status
After an armed vehicle (armed via various console lock means) receives an Unlock command from
the remote control or after successful authentication by the engine anti-theft system, the vehicle will
switch to Disarmed status. In Fullarmed status, when any vehicle door has been opened or when the
ignition switch is switched from other states to ON/START, the alarm will be triggered and the horn will
go off; the lights will turn on for 200 ms and then off 200 ms for a total of 27 flashes. A total of 6 alarm
cycles, lasting 27 seconds each and with an interval of 3 seconds between each interval, will be ex-
ecuted. If, during this period, the situation that has triggered the alarm is remedied the alarm will be
de-activated. Otherwise, the alarm will go off after the 6 cycles have been completed and the cause of
alarm, hidden.
POWER WINDOW DELAY

1. Basic process
(a) When the system power mode is switched from another mode to IGN ON, the BCM will connect the
power window delay relay;
(b) When the system power mode is switched from IGN ON to another, the BCM will start its 30-second
timer. Within this 30-second period, should any door (apart from the back door) open, the BCM will re-
set the 30-second timer and disconnect the power window delay relay at the same time;at the end of
the 30-second period, the BCM disconnect the power window delay relay;
POWER SAVING FUNCTION

If BCM is in Fullarmed status, the delay timer is set at 2.5 min; if BCM is in Unarmed status, the power
saving timer is set at 10 min.
POWER SIDE MIRROR

1. Basic process
(a) With system power in OFF mode, if BCM successfully executes the remote unlock function, after 10
seconds it will also connect the rearview mirror unfold relay to open the side mirrors; if BCM success-
fully executes the Auto Arm or remote lock function, after 10 seconds it will also connect the rearview
mirror fold relay to stow the mirrors;
(b) With system power in IGN ON mode and when the rearview mirror open/stow switch switched to open
mode, after 10 seconds the BCM will turn on the rearview mirrors unfold relay to open up the side mir-
rors; when the rearview mirror open/stow switch has ben switched to stow mode, after 10 seconds the
BCM will start the rearview mirror stow relay in order to stow side mirrors;
(c) In the 10 seconds that the BCM needs to start the side mirror opening/stowing process, if power mode
is switched to Crank mode, the BCM will continue to implement side mirror open/stow;
2. Others
In the 10 seconds that the BCM needs to start the side mirror opening/stowing process, if a mirror
open/stow switch command or remote command is received, current relay output will be halted and
the new command, implemented after a 200 ms delay.
LOCATION DIAGRAM
1. Vehicle Body Controller


SYSTEM BLOCK DIAGRAM
BCM_GND J2-B4
BCM_GND J2-B3
BCM_GND J1-B4 BCM_GND
Console lock_GND J2-B6
Console lock_GND
VBATT
25 A KL30_interior lamp power source J1-B1
20 A
KL30_external lamp power source J1-B8
TPMS-FSK J2-A43
RKE-ASK RF
VBATT
Brake pedal switch J2-A35
Open rearview mirrors/stowing switch J2-A14
Lane deviation switch J1-A42
Key insert switch driver J2-A8
Unlocking connection Door lock status switch J2-A30
Front wiper regulating switch J1-A47

430±10%
990±10%
1610±10%
2360±10%
0 ohm
Left steering-lamp switch J2-A19

Right steering-lamp switch J2-A20
Front wiper shutdown switch, wet current 40 mA J2-A39
Hand brake switch J2-A16

Door opening connection Front left door status switch J2-A2
Door opening connection Front right door status switch J2-A3
Door opening connection Rear left door status switch J2-A4
Door opening connection Rear right door status switch J2-A5
Door opening connection Engine hood status switch J2-A6
Door opening connection Backup door status switch J2-A1

VBATT
3W
Console lock switch J2-A32
Console unlock switch J2-A33
Backup door unlock switch J2-A7

Lighting OFF
Automatic light switch J2-A23
Position lamp switch J2-A9
Low beam lamp switch J2-A22
High beam lamp switch J2-A21

Overtaking lamp
switch
Hazard indicator switch J1-A48
Rear fog lamp switch J2-A24
Front fog lamp switch J2-A34
Front washer switch J2-A10
OFF
HIGH Front wiper hi-speed switch J2-A12
MIST Front wiper low-speed switch
LOW J2-A13
VBATT
Acc feedback switch J2-A26
Ign1 feedback switch J2-A27
Start feedback switch J2-A25
Ign2 feedback switch J2-A 29
Reverse gear switch J2-A 38

21 W
21 W
ABM Knock signal J2-A 31

airbag
CAN_L_2 J2-A 42
CAN_H_2 J2-A 41
CAN_H_1 J1-A 39
CAN1 CAN
CAN_H_1 J1-A 45
J1-A2 Hazard indicator backlight MAX 30 mA
J1-A19 Ignition lock backlight MAX 30 mA
VBATT
J1-A38 Immobilizer indicator MAX 30 mA
J1-A4 Console backlight and ambient lamp MAX 3 A
21 W
J1-B5 Rear fog lamp
21 W
J1-A6 Right brake lamp 21 W
J1-A5 Left brake lamp 21 W
5W
J1-B3 Daytime running light
5W
J1-B2 High-mount brake lamp 3W
21 W 21 W 5W
J1-B7 Left steering lamp
J1-B6 Right steering lamp
21 W 21 W 5W
J2-B7 Position lamp & license plate light 28 W
V_BAT_D_RELAY VBATT
20 A
J2-B2 KL30_console lock power source
J2-B5 Door lock motor MAX 15 A
M M M M
Console lock_GND Console lock_GND J2-B1 Door unlock motor MAX 15 A
J2-B8 Interior lamp 10 W

Door Off On Ceiling lamp
VBATT
10W 2*5 W
Door Off
Trunk light Reading lamp
On
J1-A32 Economizer relay fuse

VBATT
On
VBATT
J1-A33 Rearview mirror fold relay

M M
VBATT
J1-A25 Rearview mirror unfold relay
J1-A13 Backup door unlock relay

M
VBATT
VBATT
J1-A36 Front right fog lamp relay 55 W
J1-A8 Front left fog lamp relay 55 W
VBATT
J1-A16 Power window delay relay
VBATT
65 W
J1-A7 High beam lamp relay 65 W

VBATT
65 W
J1-A15 Low beam lamp relay 65 W
VBATT
J1-A10 Horn relay
VBATT
J1-A17 Front washer relay

M
KL 30
H
M
L
J1-A20 Front wiper power source relay
J1-A11 Front wiper speed relay

PIN DEFINITION
J1 BLACK
B5 B8
B1 B4 B8 B4 A48 A43
A6 A48
A1 A43
B5 B1 A6 A1
J2 GRAY
BCM pin Function names Input/output type

J1-B1 Interior lamp power source Power
J1-B2 High-mount brake lamp O-H-P
J1-B3 Daytime running light O-H-P
J1-B4 BCM GND GND
J1-B5 Rear fog lamp O-H-P
J1-B6 Right steering lamp O-H-P
J1-B7 Left steering lamp O-H-P
J1-B8 Exterior lamp power source Power
J1-A1 N/A N/A
J1-A2 Hazard indicator backlight O-H
J1-A3 N/A N/A
J1-A4 Console backlight and ambient lamp O-H-P
J1-A5 Left brake lamp O-H-P
J1-A6 Right brake lamp O-H-P
J1-A7 High beam lamp relay O-L
J1-A8 Front left fog lamp relay O-L
J1-A9 N/A N/A
J1-A10 Horn relay O-L
J1-A11 Front wiper speed relay O-L
J1-A12 N/A N/A
J1-A13 Back door unlock relay O-L
J1-A14 N/A N/A
J1-A15 Low beam lamp relay O-L
J1-A16 Power window delay relay O-L
J1-A17 Front washer relay O-L
J1-A18 N/A N/A
J1-A19 Ignition lock backlight O-H
J1-A20 Front wiper power source relay O-L
J1-A21 N/A N/A
J1-A22 N/A N/A
J1-A23 N/A N/A
J1-A24 N/A N/A
J1-A25 Rearview mirror unfold relay O-L
J1-A26 N/A N/A
J1-A27 N/A N/A
J1-A28 N/A N/A

J1-A29 N/A N/A
J1-A30 N/A N/A
J1-A31 N/A N/A
J1-A32 Economizer relay O-L
J1-A33 Rearview mirror fold relay O-L
J1-A34 N/A N/A
J1-A35 N/A N/A
J1-A36 Front right fog lamp relay O-L
J1-A37 N/A N/A
J1-A38 Immobilizer indicator O-L
J1-A39 HS_CAN_1 (H) Comm-WU
J1-A40 N/A N/A
J1-A41 N/A N/A
J1-A42 Lane deviation switch I-D-L
J1-A43 N/A N/A
J1-A44 N/A N/A
J1-A45 HS_CAN_1 (L) Comm-WU
J1-A46 N/A N/A
J1-A47 Front wiper regulating switch I-A
J1-A48 Hazard indicator switch I-D-L-WU

J2-B1 Door unlock motor Relay
J2-B2 Console lock power source Power
J2-B3 BCM GND GND
J2-B4 BCM GND GND
J2-B5 Door lock motor Relay
J2-B6 Console lock GND GND
J2-B7 Position lamp and license plate light O-H-P
J2-B8 Interior lamp O-L-P
J2-A1 Back door status switch I-D-L-WU
J2-A2 Front left door status switch I-D-L-WU
J2-A3 Front right door status switch I-D-L-WU
J2-A4 Rear left door status switch I-D-L-WU
J2-A5 Rear right door status switch I-D-L-WU
J2-A6 Engine hood status switch I-D-L-WU
J2-A7 Back door unlock switch I-D-L-WU
J2-A8 Key insert switch I-D-L-WU
J2-A9 Position lamp switch I-D-L-WU
J2-A10 Front washer switch I-D-L
J2-A11 N/A N/A
J2-A12 Front wiper high-speed switch I-D-L
J2-A13 Front wiper low-speed switch I-D-L
J2-A14 Side mirror open/stow switch I-D-L
J2-A15 N/A N/A
J2-A16 Hand brake switch I-D-L
J2-A17 N/A N/A
J2-A18 N/A N/A
J2-A19 Left steering lamp switch I-D-L
J2-A20 Right steering lamp switch I-D-L
J2-A21 High beam lamp switch I-D-L
J2-A22 Low beam lamp switch I-D-L
J2-A23 Automatic light switch I-D-L
J2-A24 Rear fog lamp switch I-D-L
J2-A25 Start feedback switch I-D-H-WU
J2-A26 ACC feedback switch I-D-H-WU
J2-A27 IGN1 feedback switch I-D-H-WU
J2-A28 N/A N/A

J2-A29 IGN2 feedback switch I-D-H-WU
J2-A30 Driver-side door lock status switch I-D-L-WU
J2-A31 Knock signal I-D-H/L
J2-A32 Console lock switch I-D-L-WU
J2-A33 Console unlock switch I-D-L-WU
J2-A34 Front fog lamp switch I-D-L
J2-A35 Brake pedal switch I-D-H-WU
J2-A36 N/A N/A
J2-A37 N/A N/A
J2-A38 Reverse gear switch I-D-H
J2-A39 Front wiper stop position switch I-D-L
J2-A40 N/A N/A
J2-A43 RF antenna Comm-WU
J2-A44 N/A N/A
J2-A45 N/A N/A
J2-A46 N/A N/A
J2-A47 N/A N/A
J2-A48 N/A N/A
LIST OF DIAGNOSTIC TROUBLE CODE

Diagnostic Trouble Code Code definition (English)
B10E114 Window Active Delay Relay output short to ground or open
B10E112 Window Active Delay Relay output short to battery
B10E215 Hazard LED output short to battery or Hazard LED output open
B10E211 Hazard LED output short to ground
B104213 Left Brake Light short to battery or open load
B104212 Left Brake Light short to battery
B104211 Left Brake Light short to ground
B104313 Right Brake Light short to battery or open load
B104312 Right Brake Light short to battery
B104311 Right Brake Light short to ground
B104913 High Brake Light short to battery or open load
B104912 High Brake Light short to battery
B104911 High Brake Light short to ground
B12AA14 Front Washer Relay output short to ground or open
B12AA12 Front Washer Relay output short to battery
B124414 Front wiper Power Relay output short to ground or open
B124412 Front wiper Power Relay output short to battery
B12A714 Horn Control Relay output short to ground or open
B12A712 Horn Control Relay output short to battery
B105114 Low Beam Relay output short to ground or open
B105112 Low Beam Relay output short to battery
B107514 Trunk Unlock Relay output short to ground or open
B107512 Trunk Unlock Relay output short to battery
B105214 High beam Relay output short to ground or open
B105212 High beam Relay output short to battery
B124314 Front wiper Speed Relay output short to ground or open
B124312 Front wiper Speed Relay output short to battery
B106614 Rearview Mirror Close Relay output short to ground or open
B106612 Rearview Mirror Close Relay output short to battery
B10A514 Rearview Mirror Open Relay output short to ground or open
B10A512 Rearview Mirror Open Relay output short to battery
B100114 Battery Saver Relay output short to ground or open
B100112 Battery Saver Relay output short to battery
B104114 Left Front Fog Relay output short to ground or open
B104112 Left Front Fog Relay output short to battery

B104014 Right Front Fog Relay output short to ground or open
B104012 Right Front Fog Relay output short to battery
B125177 2WD/4WD motor not in request position
B10E315 ESCL Lock Enable output short to battery or open
B10E311 ESCL Lock Enable output short to ground
B10E415 Start/Stop Switch Backlight output short to battery or open
B10E411 Start/Stop Switch Backlight output short to ground
B100016 BCM Inter Power (battery) under voltage
B100017 BCM Inter Power (battery) over voltage
B104813 Position Light short to battery or open load
B104812 Position Light short to battery
B104811 Position Light short to ground
B104413 Rear defog output short to ground or open load
B104412 Rear defog output short to battery
B106011 Rear defog output short to ground
B103518 Right turn Lights One bulb is outage
B103513 Right turn light open load
B103511 Right turn light Over temperature/Short to Ground
B103418 Left turn Lights One bulb is outage
B103413 Left turn light open load
B103411 Left turn light Over temperature/Short to Ground
B12D011 LIN I short to ground
B12D111 LIN 2 short to ground
B100216 BCM Exter Power (battery) under voltage
B100217 BCM Exter Power (battery) over voltage
B100A13 CenterContol_PWR open or relay fail
Switch panel illumination short to battery or Switch panel illumination
B10A013
open load
B10A012 Switch panel illumination short to battery
B10A011 Switch panel illumination short to ground
B12A813 Interior light PWM open or short to ground
B12A812 Interior light PWM short to battery or over temperature
B102514 ACC Relay output short to ground or open
B102512 ACC Relay output short to battery
B102614 IGN1 Relay output short to ground or open
B102612 IGN1 Relay output short to battery
B102714 IGN2 Relay output short to ground or open

B102712 IGN2 Relay output short to battery
B124577 Front wiper motor stall
B125325 Post Crash Input signal shape/waveform failure
B102814 2/4WD Transfer A Relay output short to ground or open
B102812 2/4WD Transfer A Relay output short to battery
B102914 2/4WD Transfer B Relay Relay output short to ground or open
B102912 2/4WD Transfer B Relay output short to battery
B125325 Limphome Input signal shape/waveform failure
U010188 HS-CAN bus off
B105013 Day running lamp open load
B105012 Day running lamp short to battery
B105011 Day running lamp short to ground
U030487 ATA5781 Communication Error
U020151 FL TPS not learnt
U020251 FR TPS not learnt
U020351 RL TPS not learnt
U020451 RR TPS not learnt
U000687 Master Switch frame response time out
U000187 RL Antipinch Module frame response time out
U000287 RR Antipinch Module frame response time out
U000387 FL Antipinch Module frame response time out
U000487 FR Antipinch Module frame response time out
U000587 Rain Light Sensor Module frame response time out
U000787 CAN Node ECM time out (CAN BCM)
U010187 CAN Node IP time out (CAN BCM)
U010287 CAN Node SAS time out (CAN BCM)
U010387 CAN Node ABS time out (CAN BCM)
U010487 CAN Node ABM time out (CAN BCM)
U010587 CAN Node PEPS time out (CAN BCM)
U010687 CAN Node AC time out (CAN BCM)
U020187 FL Tire Sensor Missing
U020287 FR Tire Sensor Missing
U020387 RL Tire Sensor Missing
U020487 RR Tire Sensor Missing
U020152 FL Tire low pressure
U020252 FR Tire low pressure

U020352 RL Tire low pressure
U020452 RR Tire low pressure
U020153 FL Tire high pressure
U020253 FR Tire high pressure
U020353 RL Tire high pressure
U020453 RR Tire high pressure
U020154 FL Tire fast leakage
U020254 FR Tire fast leakage
U020354 RL Tire fast leakage
U020454 RR Tire fast leakage
U020155 FL Tire high temperature
U020255 FR Tire high temperature
U020355 RL Tire high temperature
U020455 RR Tire high temperature
U020156 FL Tire Pressure Sensor Low Battery
U020256 FR Tire Pressure Sensor Low Battery
U020356 RL Tire Pressure Sensor Low Battery
U020456 RR Tire Pressure Sensor Low Battery

BCM
Removal
2. Remove the large glove box
3. Disconnect wiring connector
4. Remove 3 bolts
5. Remove BCM module assembly

Installation
Memorandum
地址：河北省保定市朝阳南大街2266号
邮编：071000
长城汽车客户热线：400-666-1990
销售传真：0312-2197600 服务传真：0312-2192936
网址：http://www.haval.com.cn 版号：01-14.06-01SM2 Z
տ‫ڗ‬.
ऄ૨֣
FOREWORD
THIS MANUAL (HAVAL H1 CIRCUIT DIAGRAMS) COVERS THE FOLLOWING SUB-
JECTS: INFORMATION ABOUT THE FUSE BOXES, GROUNDING POINTS, CIRCUIT DIA-
GRAMS, CONNECTOR DIAGRAMS, AND SYSTEM PRINCIPLES.
APPLICABLE MODEL(S): HAVAL H1 SERIES.
THE MANUAL CONTENT BELOW IS APPLICABLE FOR THIS SPECIFIC VEHICLE MOD-
EL FOR YOUR REFERENCE.
Manual name Version No.

Haval H1 Repair and Maintenance Manual 01-14.06-01SM
ALTHOUGH WE HAVE COMPILED THIS MANUAL TO THE BEST OF OUR ABILITY, WE

CANNOT GUARANTEE THAT THE CONTENT OF THIS MANUAL TO BE COMPLETELY
ERROR-FREE. FURTHER, WE CANNOT GUARANTEE THE CONTENT IN THIS MANU-
AL TO BE THE MOST UP-TO-DATE AS OUR MODELS ARE CONSTANTLY BEING IM-
PROVED.
SHOULD YOU COME ACROSS ANY ERRORS OR OMISSIONS IN THE MANUAL CON-
TENT, WE WOULD BE VERY GRATEFUL IF YOU COULD POINT THEM OUT.
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Circuit Diagram 1
CIRCUIT DIAGRAM
INTRODUCTION
Diagram Descriptions....................................................4
Repairing Circuitry Faults.............................................7
Abbreviations.................................................................12
KEY ELECTRICAL MODULES
Location Diagram...........................................................13
ABOUT THE FUSE BOXES
Fuse Box No. 1 (Inside Cab) Layout.............................14
Fuse Box No. 2 (Inside Engine Compartment) Layout 16
Battery Positive Fuse.....................................................18
ABOUT GROUNDING AND SHUNT
Engine Cabling Grounding............................................19
Front Cabling Grounding and Shunts..........................20
Instrument Cabling Grounding and Shunts................22
Body Cabling Grounding...............................................23
Rear Cabling Grounding................................................24
CABLING DIAGRAM
Engine Cabling...............................................................25
Front Cabin Cabling.......................................................28
Instrument Cabling........................................................30
Body Cabling..................................................................32
Door Cabling...................................................................33
Ceiling Cabling...............................................................35
Rear Cabling...................................................................36
CONNECTOR DIAGRAM
Engine Cabling Connector FZ.......................................38
Engine Bay Cabling Connector QZ..............................41
Dashboard Cabling Connector YZ................................44
Vehicle Body Cabling Connector CZ............................49
Door Cabling Connector ZQ, YQ, ZH, YH.....................51
Rear Cabling Connector BZ..........................................53
Ceiling Wiring Connector DZ........................................54
2 Circuit Diagram
SYSTEM SCHEMATIC
Power, Startup, Charge System....................................55
Power Steering System.................................................57
Engine Control Unit (ECU)............................................58
Transmission Control System......................................63
Airbag Control System..................................................64
Vehicle Stabilization System.........................................66
Anti-Lock Braking Control System...............................67
Anti-Theft Control System.............................................68
Reverse Lamp and Reverse Radar Control System....69
Audio Control System...................................................70
Combination Instrument System..................................72
A/C Control System.......................................................74
Electric Rearview Mirror Control System....................76
Rear Wiper and Washer System...................................77
Vehicle Body Control System.......................................78
Window Control System................................................86
Cigarette Lighter, On-Board Power Source,
Sunroof Control System................................................88
Circuit Diagram 3
INTRODUCTION
Tips:
• The content in this circuit diagram manual is applicable to all Haval H1 vehicles.
• Please study the descriptions and illustrations in this manual carefully to aid your understanding.
4 Circuit Diagram
DIAGRAM DESCRIPTIONS
1. About the fuse boxes and power supply
There are a total of three fuse boxes on this vehicle, and they are: the battery positive fuse (inside the
engine compartment), the front cabin fuse box (inside the engine compartment), and the driver's cab
fuse box (under the left side of the dashboard).
• 30a is a regular power cord that leads from the battery positive fuse MAIN with capacity 60 A.
• 30b is a regular power cord that leads from the battery positive fuse ABS with capacity 40 A.
• 30c is a regular power cord that leads from the battery positive fuse ALT with capacity 120 A.
• 30d is a regular power cord that leads from the battery positive fuse ALT with capacity 120 A.
• 15a is an IG power cord that leads from the driver's cab fuse box, IG1 relay.
• 15b is an IG power cord that leads from the ignition switch IG2 pin.
• X1 is an ACC power cord that leads from the driver's cab fuse box, ACC relay.
• X2 is an ACC power cord that leads from the driver's cab fuse box, ACC relay.
2. Cabling codes
• FZ stands for engine cabling
• QZ stands for engine bay cabling
• YZ stands for meter cabling
• CZ stands for body cabling
• BZ stands for rear cabling
• ZQ stands for front left door cabling
• YQ stands for front right door cabling
• ZH stands for rear left door cabling
• YH stands for rear right door cabling
• DZ stands for ceiling cabling
• GF stands for engine cabling grounding
• GQ stands for front cabling grounding
• GY stands for instrument cabling grounding
• GC stands for body cabling grounding
• GB stands for rear cabling grounding
• GX stands for battery negative terminal of the battery grounding
3. Description of text below wiring diagrams
A: Connections between circuits.
A 1. Connected to the front-bumper cabling B: Connections between circuit and power appliance.
and engine bay cabling qz01-qc30
Note:
B 2. Connected to the front left radar probe qz01
3. Connected to the front right radar probe qz07 • The illustration on the left is a sample and does
4. Connected to the front right fog lamp qz10 not serve as reference for the model at hand.
5. Connected to the front right radar probe qz09
6. Connected to the right-side daytime
running light qz08
Circuit Diagram 5
4. Description of schematic codes

Note:
• The illustration on the left is a sample and does
not serve as reference for the model at hand.
(a) Connections for broken lines between two facing pages.
85 87 87 a
Unlock relay
970
B
1.25
30
86
286 287
BlGr YB
0.35 1.25
87 a
970
B
1.25
(b) Indicates that parts of the system in question are not

rear ceiling lamp
ground-illumination light
Left rearview-mirror
ground-illumination light
Right rearview-mirror
8 8
1 3 shown here.
9 9
908
B
0.5
85 88
BlR WGr
0.5 0.5
J1-A35
J1-A36
(c) Indicates that connections lead to other systems.

30
Connected to the
BCM J1-A4 pin
Headlight-adjuster switch
351 79
OBl lg 717
0.35 0.5 GR
Door lamp relay
b e 0.5
86 30 86
(d) Indicates upwards power supply.
30 30a 30b 30c

6 Circuit Diagram
5. Connectors
Example:
(a) Pin hole No. for female connector.
The holes are numbered from the upper left corner to
the lower right corner.
(b) Pin hole No. for male connector.
The holes are numbered from the upper right corner to
the lower left corner.
Female connector Male connector
(c) The difference between male and female connectors.

Example: You can differentiate a male connector from a female
connector from the shape of the internal pins.
• All connectors are indicated by their open ends and
are secured at the top.
• When separating connectors, pull on the body of the
connector and not the connecting cable.
Attention:
Female connector Male connector • Before separating connectors, first check the
type of connector that you are preparing to
disconnect.
6. Cable color and cross-sectional area (mm2)
Light
Cable color Black White Red Green Yellow Brown Blue Gray Purple Orange Pink
green
Code B W R G Lg Y Br Bl Gr V Or P
For monochromatic conductor, the color indication is based on the alphabet found in the table; for
double-colored conductor, the first alphabet indicates the primary color and the second alphabet, the
secondary color.
E.g.:
monochromatic conductor: The red wire is indicated as R.
double-colored conductor: Main color being red and secondary color, blue, indicated as RBl.
0.5BrGr indicates brown cable with thin gray line of cross-sectional area 0.5 mm2.
Circuit Diagram 7
REPAIRING CIRCUITRY FAULTS

MATTERS TO NOTE WHEN CONDUCTING
CIRCUIT REPAIRS
1. Please adhere to the following rules before embark-
ing on the repair of electrical appliances:
(a) You must disconnect negative terminal of the battery
prior to starting the repair of any electrical appliance.
Attention:
• Prior to starting the repair of any electric com-
ponent, make sure that the ignition key is in
the OFF or LOCK positions, and that all power
loading appliances have been turned OFF un-
less otherwise stated in the repair instructions.
If repair tools or equipment are likely to touch
electrically-charged and exposed electrical
terminals, you must also disconnect the bat-
tery negative terminal line. Failure to adhere to
these safety precautions will lead to bodily in-
jury and/or damage to vehicle or vehicle com-
ponents.
(b) If you are required to disconnect the battery for a check
or repair procedure, make sure to disconnect negative
terminal of the battery.
(c) To prevent damage to the battery terminal, loosen the
nut that secures the cable, and pull cabling upwards.
Make sure not to twist the cabling or pry off the cabling
with force.
(d) When cleaning battery and cable terminals or connec-
tors, use a piece of cloth specially designed for the pro-
cedure. Do not scrape at the terminals or connectors
using a file or other abrasive material.
(e) When connecting the cable with the battery terminal,
loosen the securing nut. Tighten again when installation
is complete. Do not knock the cable connector onto the
battery terminal using a hammer.
(f) Do not conduct fast charging of the battery if the battery
ground wire has not been disconnected. Failure to ad-
here to this advisory will damage the alternator diode.
(g) Do not attempt to start the engine when the battery
ground wire connection is loose to avoid severe dam-
age to the wire.
(h) It is mandatory to keep the battery positive (+) terminal
well-covered.
8 Circuit Diagram
2. Check the corresponding fuse/relay box fuse. Check

The same amperage rating for damage to the battery, battery charge status and
make sure that it is clean. Make sure connectors are
well-secured.
10 10 When replacing a fuse, you must make sure that the
new fuse is rated to specifications. Do not use a fuse
that exceeds specifications or does not meet specifica-
tions.
3. Dismantling cable connectors.

(a) When disconnecting connectors, first pinch the two
ends of the connector, open up latch, then press on the
lock jaws to free the connector.
(b) When disconnecting connectors, do not pull on wiring.
Hold on to the connector body during the procedure.
(c) When connecting connectors, check for signs of defor-
mation, damaged or lost pins in the connector.
(d) A clicking sound during connector connection indicates
that the connector is now properly in place.
4. Checking cable connectors.

Joint loosen
(a) Check when connecting.
Pinch the two ends of the connector, make sure that it
Core wire has been fully inserted, then secure.
(b) Check when disconnecting.
Terminal Conduct check by pulling gently at the wiring from the
deformation
back of the connector. Look for pins that are poorly con-
nected, lost pins, loose clips and damaged cables.
Pull gently
Conduct visual inspection for signs of corrosion, broken
bits of metal, foreign matter, water and for signs of twist-
ing, rust, overheating, contamination or terminal/pin de-
formation, etc.
Circuit Diagram 9
(c) Check terminal contact pressure.

Prepare a connector plug that is compatible with a con-
nector terminal, then insert into mount. Check for good
contact and strong tension.
Terminal identical
to the positive terminal
5. Repair method for cable connector terminals.

(a) If there is dust on the pins/terminal, clean contact sur-
face using compressed air or a clean piece of cloth. Do
not clean using sandpaper as doing so may damage the
electro-plated surface.
(b) If there is insufficient contact pressure, replace mount
with a new one of the same type.
(c) Replace damaged, deformed or corroded terminals. If
the terminal does not lock into the outer housing, re-
place outer housing as well.
6. Handling of cables
Error (a) If you need to remove cabling, begin by checking con-
nections and clamp positions for easy re-installation.
(b) Do not twist, pull at, or loosen cabling with great force.
(c) Do not allow cabling to get in contact with high-temper-
ature, rotating, moving, vibrating or sharp components.
Avoid panel edges, the sharp ends of screws and other
sharp objects.
(d) Never squeeze or press on cabling when installing com-
ponents.
(e) Scratching or otherwise damaging cable insulation is
strictly prohibited. If cable insulation has been scratched
or shows cracks, replace cabling or repair using polyvi-
nyl chloride (PVC) insulating tape.
CHECK FOR OPEN CIRCUITS

1. For the open circuit shown in Figure 1, check resis-
Figure 1 tance (step 2) or voltage (step 3).
ECU
Open-
C B A
Sensor circuit
1 1 1 1
2 2 2 2
10 Circuit Diagram
2. Check resistance.
Figure 2 (a) Disconnect connectors A and C and measure resistance
between the two.
ECU Resistance: 1 Ω or less
Note:
Sensor 1 1 1 • Measure resistance when swaying cabling verti-
2 2 2 cally and horizontally gently.
C B A Figure 2:
Between connector A terminal 1 and connector C termi-
nal 1 → 10 kΩ or greater
Between connector A terminal 2 and connector C ter-
minal 2 → less than 1 Ω At this time, there is an open
circuit between connector A terminal 1 and connector C
terminal 1.
Figure 3
(b) Disconnect connector B and measure resistance be-
tween connectors.
ECU Figure 3:
Between connector A terminal 1 and connector B1 ter-
Sensor
minal 1 → less than 1 Ω
Between connector B2 terminal 1 and connector C ter-
1 1 1 1 minal 1 → 10 kΩ or greater
2 2 2 2 There is an open circuit between connector B2 terminal
C B2 B1 A
1 and connector C terminal 1.
3. Check voltage.
Figure 4
(a) You can also check for open circuits by checking volt-
age in the circuit that leads to the ECU connector termi-
5V nal.
Figure 4:
Sensor 0 V 5V 1
1 1 With various connectors still connected, measure the
2 2 2 voltage between vehicle body ground and ECU 5V out-
C B A put connector A terminal 1, connector B terminal 1, and
connector C terminal 1, in this order.
(b) Example values:
5 V: Between connector A terminal 1 and vehicle body
ground
5 V: Between connector B terminal 1 and vehicle body
ground
0 V: Between connector C terminal 1 and vehicle body
ground
In the example above, there is an open circuit between
connector B terminal 1 and connector C terminal 1 ca-
bling.
Circuit Diagram 11
CHECK FOR SHORT CIRCUITS

1. If the cabling is short-circuited to ground (Figure 5),
Figure 5
check resistance with reference to vehicle body
Short- ground to locate the short circuit.
C circuited B A
1 1 1
2 2 2
2. Check resistance with reference to vehicle body

Figure 6
ground.
(a) Disconnect connectors A and C, and measure the re-
sistance between connector A terminals 1/2 and vehicle
ECU
body ground.
Sensor Resistance: 10 kΩ or greater
1 1 1
2 2 2 Note:
C B A • Measure resistance when swaying cabling verti-
cally and horizontally gently.
As shown in Figure 6:
Between connector A terminal 1 and vehicle body
ground → less than 1 Ω
Between connector A terminal 2 and vehicle body
ground → 10 kΩ or greater
At this point, there is an open circuit between connector
A terminal 1 and connector C terminal 1.
(b) Disconnect connector B and measure the resistance be-
Figure 7
tween connector A terminal 1 and vehicle body ground,
as well as the resistance between connector B2 termi-
nal 1 and vehicle body ground.
ECU Figure 7:
Sensor
1 1 1 1 Between connector A terminal 1 and vehicle body
2 2 2 2 ground → 10 kΩ or greater
C B2 B1 A Between connector B2 terminal 1 and vehicle body
ground → less than 1 Ω
At this point, there is an open circuit between connector
B2 terminal 1 and connector C terminal 1.
12 Circuit Diagram
ABBREVIATIONS
THE ABBREVIATIONS USED IN THIS CHAPTER ARE LISTED BELOW.
Abbreviations Definition in English
A/C Air-conditioner
ABS Anti-lock braking system
ALS Automatic headlamp leveling system
BCM Vehicle body control system
CAN Controller area network
DRS Yaw angle sensor
ECU Electronic control unit
EGR Exhaust gas recirculation
EPS Power steering
ESP Electronic vehicle stabilization system
ESCL Electronic steering column lock control unit
FCP Front A/C control panel
HCM Automatic air-conditioning
HAVC Hybrid automatic voltage control (HAVC)
HID Xenon headlamp
MCU Micro-program controller
PEPS Passive entry/passive start system
RCP Rear A/C control panel
RMI Rollover prevention
SRS Supplemental restraint system
TCU Automatic transmission control unit
TOD Sub-actuator control module
TPMS Tire pressure monitoring system
VVT Variable valve timing
Circuit Diagram 13
KEY ELECTRICAL MODULES

LOCATION DIAGRAM
4
3
7 6 1
1. Tire Pressure Monitoring System 5. Collision Avoidance Radar ECU

2. BCM 6. Anti-Lock Braking System (ABS)
3. Airbag ECU 7. Engine ECU
4. EPS Controller ECU
14 Circuit Diagram
ABOUT THE FUSE BOXES

FUSE BOX NO. 1 (INSIDE CAB) LAYOUT
F25
F24
F23
F22
F21
F20
F19
F18
F17
F16
F15
B+
J01 J02 J03 J04
F26
S/B1
F27
J05 J06 J07 F28
S/B2
F29
F30
S/B3
F31
F32 S/B4
J08 J09 J10 J11
F33
F34 S/B5
F35
F36 S/B6
J12 J13 J14 J15 F37
F38 S/B7
F39
F40 F44
F41 F45
J16 J17 J18
F42 F46
F43 F47
Circuit Diagram 15
Fusing S/B2 Reserved —

S/N Name
current S/B3 Reserved —
J1 Turn on relay — S/B4 Door and window relay 30 A
J2 Stow relay — S/B5 Blower 40 A
J3 Front wiper hi-speed relay — S/B6 Reserved —
J4 Front wiper relay — S/B7 Transport 40 A
J5 High-speed blower relay —
J6 ACC relay —
J7 IG1 relay —
J8 Back door unlock relay —
J9 Economizer relay fuse —
J10 Front left fog lamp relay —
J11 Front right fog lamp relay —
J12 Front washer relay —
J13 Window relay —
J14 Reverse lamp relay (AMT) —
J15 Defroster relay —
J16 Blower relay —
J17 Rear wiper relay —
J18 Rear washer relay —
F15 Airbag 15 A
F16 ABS/ESP 5 A
F17 Combination instrument 10 A
F18 BCM 25 A
F19 Rear wiper 10 A
F20 Cassette player 15 A
F21 Combination instrument 10 A
F22 Front wiper 15 A
F23 Reverse 10 A
F24 Cigarette lighter 25 A
F25 ACC 15 A
F26 Reserved —
F27 BCM 25 A
F28 BCM 20 A
F29 IG1 25 A
F30 ACC 25 A
F31 Reserved —
F32 Front right fog lamp 10 A
F33 Brake lamp 10 A
F34 Front left fog lamp 10 A
F35 Economizer relay fuse 10 A
F36 Back door lock 15 A
F37 Defroster 25 A
F38 Reserved —
F39 Reserved —
F40 Trunk light 5 A
F41 Reserved —
F42 AM1 15 A
F43 Sunroof 25 A
F44 Reserved —
F45 Reserved —
F46 Reserved —
F47 Reserved —
S/B1 Reserved —
16 Circuit Diagram
FUSE BOX NO. 2 (INSIDE ENGINE COMPARTMENT) LAYOUT
J02 J03
J01
F45 F46 F47
J04
F08 F09 F10 F11 F12 F13 F14
J10
F01 F02 F03 F04 F05 F06 F07
J05
J06 J07 J08 J09
QT3
Circuit Diagram 17
MT MODEL
Fusing Fusing
S/N Name S/N Name
current current
J01 Main relay — F07 Engine ECU 10 A
J02 Oil pump relay — F08 Oil pump 15 A
J03 Horn relay — F09 Horn 15 A
J04 Fan low-speed relay — F10 ABS/ESP 25 A
J05 Reserved — F11 Compressor 10 A
J06 Starter relay — F12 Reserved —
J07 High beam relay — F13 Fan relay-low 30 A
J08 Low beam relay — F14 Fan relay-high 40 A
J09 Compressor relay — F15 Spare 10 A
J10 Fan hi-speed relay — F16 Spare 15 A
F01 Starter relay 30 A F17 Spare 25 A
F02 Reserved —
F03 AM2 15 A
F04 Main relay 25 A
F05 High beam 15 A
F06 Low beam 15 A
AMT MODEL
Fusing Fusing
S/N Name S/N Name
current current
J01 Fan hi-speed relay — F07 Engine ECU 10 A
J02 Oil pump relay — F08 Oil pump 15 A
J03 Horn relay — F09 Horn 15 A
J04 Fan low-speed relay — F10 ABS/ESP 25 A
J05 Main relay — F11 Compressor 10 A
J06 Starter relay — F12 Reserved —
J07 High beam relay — F13 Fan relay-low 30 A
J08 Low beam relay — F14 Fan relay-high 40 A
J09 Compressor relay — F15 Spare 10 A
J10 TCU relay — F16 Spare 15 A
F01 Starter relay 30 A F17 Spare 25 A
F02 ESP 40 A
F03 AM2 15 A
F04 Main relay 25 A
F05 High beam 15 A
F06 Low beam 15 A
18 Circuit Diagram
BATTERY POSITIVE FUSE
S/B1 S/B2 S/B3 S/B4
1 3 5 7
L2 L1 L3 L4
MT vehicle model
S/N Circuit Amperage

S/B1 EPS 80 A
S/B2 ALT 120 A

S/B3 ABS/ESP 40 A
S/B4 MAIN 60 A
AMT vehicle model
S/N Circuit Amperage
S/B1 EPS 80 A
S/B2 ALT 120 A

S/B3 TCU 60 A
S/B4 MAIN 80 A
Circuit Diagram 19
ABOUT GROUNDING AND SHUNT

ENGINE CABLING GROUNDING
1 2
1. GF01 Ground Wire No.: 930

2. GF02 Ground Wire No.: 910 922
3. GF03 Ground Wire No.: 910
20 Circuit Diagram
FRONT CABLING GROUNDING AND SHUNTS
2
3
1. GQ01 Ground Wire No.: 902 903

2. GQ02 Ground Wire No.: 925
3. QZ60 Shunt
4. GX01 Ground Wire No.: 900
6. GQ04 Ground Wire No.: 904 906 907
7. GX02 Ground Wire No.: 900
Circuit Diagram 21
AMT MODEL

22 Circuit Diagram
INSTRUMENT CABLING GROUNDING AND SHUNTS
6 5
1. YZ81 Shunt
2. GY01 Ground Wire No.: 911 912 914 920 921
3. YZ80 Shunt
4. GY02 Ground Wire No.: 908 913
5. GY03 Ground Wire No.: 933
6. GY04 Ground Wire No.: 909
Circuit Diagram 23
BODY CABLING GROUNDING
1. GC01 Ground Wire No.: 918 920

2. GC02 Ground Wire No.: 919 920 923
24 Circuit Diagram
REAR CABLING GROUNDING
1. GB01 Ground Wire No.: 907 920 921

2. GB02 Ground Wire No.: 909
Circuit Diagram 25
CABLING DIAGRAM
ENGINE CABLING
3 4 5
2
6
1
15
7 8
9
14 10
13
12
11
1. Connect to A/C Pressure Switch FZ10 9. Connect to Knock Sensor FZ14

2. Connect to Dashboard Cabling A FZ3 10. Connect to Starter FZ16
3. Connect to Ground 11. Connect to Electronic Throttle FZ13
4. Connect to Ground 12. Connect to Starter Generator Magnet
5. Connect to Engine ECU FZ1 FZ15
6. Connect to Dashboard Cabling B FZ2 13. Connect to Compressor FZ4
7. Connect to Generator FZ6 14. Connect to Generator Output FZ7
8. Connect to Oil Pressure Switch FZ5 15. Connect to VVT Valve FZ25
26 Circuit Diagram
2
3
4
5
1 6
7
8
9
19
18
17
16
15
14 13 12
11
10
1. Connect to Front Oxygen Sensor FZ22 11. Connect to Reverse Switch FZ19
2. Connect to Cylinder 1 Ignition Coil FZ20 12. Connect to Engine Speed Sensor FZ24
3. Connect to Cylinder 2 Ignition Coil FZ29 13. Connect to Coolant Temperature Sensor
4. Connect to Cylinder 3 Ignition Coil FZ31 FZ21
5. Connect to Cylinder 4 Ignition Coil FZ32 14. Connect to Air Intake Temperature and
6. Connect to Phase Sensor FZ11 Pressure Sensor FZ12
7. Connect to Canister Control Valve FZ30 15. Connect to Ground
8. Connect to Battery Positive (Starter) 16. Connect to Nozzle No. 4 FZ8
FZ27 17. Connect to Nozzle No. 3 FZ17
9. Connect to Front Cabin Cabling FZ28 18. Connect to Nozzle No. 2 FZ18
10. Connect to Battery Positive Fuse FZ26 19. Connect to Nozzle No. 1 FZ9
Circuit Diagram 27
AMT MODEL
1. Connect to Shift Motor Controller 1 3. Connect to Shift Motor Controller 2

FZ35 FZ36
2. Connect to Engine Bay Cabling A FZ34 4. Connect to Transmission Oil Tempera-
ture Sensor FZ33
Note:
• The insertion piece shown in the illustration is for the AMT model; for other parts, please refer to
the basic vehicle model
28 Circuit Diagram
FRONT CABIN CABLING
22
21
20
32 33 1
31
30 2
19 29
28
24 3
18 23
26 4
25
17 5
27
6
16 7
8
9
10
15
14
11
13
12
1. Connect to Driver's Cab Fuse Box QZ27 18. Connect to Washer Liquid Motor QZ25
2. Connect to Ground 19. Connect to Front Right Headlamp Assembly QZ9
3. Connect to Instrument Cabling A QZ1 20. Connect to Front Right Steering Lamp QZ30
4. Connect to Instrument Cabling B QZ2 21. Connect to Front Right Headlamp Assembly Reg-
5. Connect to Body Cabling QZ4 ulator Motor QZ28
6. Connect to Front Left Wheel Speed Sensor QZ24 22. Connect to Front Right Wheel Speed Sensor QZ23
7. Connect to Clutch Switch QZ5 23. Connect to Horn 2 QZ16
8. Connect to Ground 24. Connect to Radiator Fan Motor QZ20
9. Connect to Ground 25. Connect to Radiator Fan Motor QZ20
10. Connect to Front Left Headlamp Assembly Regu- 26. Connect to Front Left Headlamp Assembly QZ14
lator Motor QZ29 27. Connect to Front Left Steering Lamp QZ17
11. Connect to Front Left Fog Lamp QZ18 28. Connect to Battery Positive Cable QZ12
12. Connect to Left Daytime Running Light QZ32 29. Connect to ESP/ABS ECU QZ13
13. Connect to Ground 30. Connect to Brake Fluid Level Warning Switch QZ7
14. Connect to Horn QZ15 31. Connect to Wiper Motor QZ21
15. Connect to Outside Temperature Sensor QZ26 32. Connect to ESP Controller QZ34
16. Connect to Right Daytime Running Light QZ33 33. Connect to Brake Lamp Switch QZ6
17. Connect to Front Right Fog Lamp QZ19
Circuit Diagram 29
AMT MODEL
5 4
1. Connect to ESP Controller QZ34 4. Connect to Clutch Motor Controller QZ8

2. Connect to TCU QZ35 5. Connect to Input Shaft Speed Sensor QZ10
3. Connect to Ground 6. Connect to Engine Wire Wiring A QZ11
Note:
• The insertion piece shown in the illustration is for the AMT model; for other parts, please refer to
the basic vehicle model
30 Circuit Diagram
INSTRUMENT CABLING
1 2 3 4
27
26
25
5
6
24 7
8
9
23
22
21
20 10
19
18
12 11
17
13
14
15
16
1. Connect to Engine Wire Wiring A YZ40 14. Connect to Console Panel Switch YZ51
2. Connect to Circulation Throttle Actuator 15. Connect to Diagnostic Interface YZ3
YZ58 16. Connect to Ground
3. Connect to BCM-J2 YZ71 17. Connect to Vehicle Body Cabling A YZ6
4. Connect to Front Right Tweeter YZ16 18. Connect to Front Left Door B (White) YZ1
5. Connect to BCM-J1 YZ70 19. Connect to Front Left Door A (White) YZ2
6. Connect to Engine Wire Wiring B YZ41 20. Connect to Front Cabin Cabling A YZ8
7. Connect to Front Right Door Cabling A 21. Connect to Ceiling Cabling A YZ5, B YZ9
YZ45 22. Connect to Front Cabin Cabling B YZ4
8. Connect to Front Right Door Cabling B 23. Connect to Reverse Radar Controller
YZ46 YZ34
9. Connect to Ground 24. Connect to Front Left Tweeter YZ12
10. Connect to Vehicle Body Cabling B YZ7 25. Connect to Accelerator Pedal Module
11. Connect to Turn Angle Sensor YZ52 YZ61
12. Connect to Air-Conditioner Temperature 26. Connect to EPS Controller C YZ66
Sensor YZ42 27. Connect to Combination Instrument
13. Connect to Ground (White) YZ39
Circuit Diagram 31
9
8
7
6
5
4
3
2
1
10
11
12
13
26 14
25 15
24 16
23
22
21
20
19
18
17
1. Connect to Sensor Connector Plug YZ67 15. Connect to Cigarette Lighter (White) YZ28
2. Connect to Immobilizer ECU 1 YZ24 16. Connect to Back-Up Power Supply (White)
3. Connect to Ignition Switch (White) YZ10 YZ72
4. Connect to Speed Regulator Resistor YZ44 17. Connect to Body Cabling D YZ90
5. Connect to MP5 YZ37 18. Connect to Central Control Panel Switch II
6. Connect to Temperature Damper Actuator YZ73
YZ53 19. Connect to Gear Shift Control Assembly
7. Connect to Mode Damper Actuator YZ54 (AMT Model) YZ62
8. Connect to Hazard Indicator Switch YZ91 20. Connect to Ground
9. Connect to Passenger Airbag YZ50 21. Connect to Airbag ECU (Yellow) YZ32
10. Connect to Blower YZ60 22. Connect to Rear Oxygen Sensor YZ91
11. Connect to A/C Controller A YZ56 23. Connect to Clock Spring Connector 1 YZ43
12. Connect to A/C Controller B YZ57 24. Connect to Clock Spring Connector 2 YZ11
13. Connect to Key Detector Switch YZ47 25. Connect to Clock Spring Connector 3 YZ19
14. Connect to Right Combination Switch (Wiper) 26. Connect to Left Combination Switch (Lights)
YZ13 YZ14
32 Circuit Diagram
BODY CABLING
6 9
8
7
10
4 11
3
2 12
1 13
27
26 25 24
14
23
15
16
17
18
19
20
21
22
1. Connect to Dashboard Cabling B CZ31 14. Connect to Rear Left Door Lamp Switch CZ20
2. Connect to Front Passenger Side Seat Belt 15. Connect to Rear Left Wheel Speed Sensor
Retractor CZ9 CZ19
3. Connect to Front Right Door Lamp Switch 16. Connect to Oil Pump Sensor CZ15
CZ10 17. Connect to Rear Left Door Cabling CZ13
4. Connect to Rear Right Door Cabling CZ11 18. Connect to Front Left Door Lamp Switch CZ12
5. Connect to Rear Right Wheel Speed Sensor 19. Connect to Driver-Side Seat Belt Retractor
CZ17 20. Connect to Left-Side Airbag CZ62
6. Connect to Rear Right Door Lamp Switch 21. Connect to Meter Cabling A CZ30
CZ18 22. Connect to Front Cabin Cabling CZ5
7. Connect to Ground 23. Connect to Driver Seat Belt Switch CZ7
8. Connect to Trunk Light CZ32 24. Connect to Parking Brake Switch CZ36
9. Connect to Rear Right Lamp Assembly CZ28 25. Connect to Dashboard Cabling D CZ52
10. Connect to Back Door Cabling II A, B CZ1,2 26. Connect to Front Passenger Seat Belt Switch
11. Connect to Ground CZ8
12. Connect to Rear Left Lamp Assembly CZ22 27. Connect to Right-Side Airbag CZ63
13. Connect to Rear Body Cabling CZ16
Circuit Diagram 33
DOOR CABLING
4 7
3
2
8
1 9
10
11
12
13
1. Connect to Instrument Cabling A ZQ1 7. Connect to Rear Left Door Lock Motor ZH5
2. Connect to Left Side Mirror ZQ12 8. Connect to Power Window Motor ZH2
3. Connect to Left Power Side Mirror Regula- 9. Connect Rear Left Door Subwoofer ZH4
tor Switch (White) ZQ10 10. Connect to Front Left Door Lock Motor ZQ8
4. Connect to Power Window Main Controller 11. Connect to Front Left Power Window Motor
Switch ZQ6 ZQ7
5. Connect to Body Cabling ZH1 12. Connect to Front Left Bass Speaker ZQ4
6. Connect to Rear Left Door Power Window 13. Connect to Instrument Cabling B ZQ2
Switch ZH3
34 Circuit Diagram
5
4
1
7 6
8
9
10
11
1. Connect to Instrument Cabling A ZQ1 6. Connect Rear Right Door Subwoofer YH4
2. Connect to Right Side Mirror ZQ10 7. Connect to Body Cabling ZH1
3. Connect to Front Right Door Lock Motor 8. Connect to Front Right Door Power Win-
ZQ8 dow Switch YQ6
4. Connect to Rear Right Power Window Mo- 9. Connect to Front Right Power Window Mo-
tor YH2 tor YQ7
5. Connect to Rear Right Door Power Window 10. Connect to Front Right Bass Speaker YQ4
Switch YH3 11. Connect to Instrument Cabling B YQ2
Circuit Diagram 35
CEILING CABLING
2
1
1. Connect to Reading Lamp DZ2 4. Connect to Left-Side Curtain Airbag DZ4

2. Connect to Sunroof Switch DZ2 5. Connect to Dashboard Cabling DZ1
3. Connect to Right-Side Curtain Airbag
DZ5
36 Circuit Diagram
REAR CABLING
7
6
2
5
1. Connect to Body Cabling BZ21 5. Connect to Center-Left Probe BZ24

2. Connect to Rear Right Fog Lamp BZ22 6. Connect to Left Probe BZ23
3. Connect to Right Probe BZ26 7. Connect to Rear Left Fog Lamp BZ27
4. Connect to Center-Right Probe BZ25
Circuit Diagram 37
17
16
18
15
1
2
3
4
5
14
13 6
12
11
10
9
1. Connection Between Back Door Cabling A1 11. Connect to Back Door Start Switch BZ15
and Back Door Cabling B1 BZ6 and BZ11 12. Connection Between Back Door Cabling A2
2. Connect to Back Door Lock Motor BZ13 and Back Door Cabling B2 BZ5 and BZ12
3. Connection Between Back Door Cabling B 13. Connect to Left License Plate Light BZ18
and Back Door Cabling C BZ32 and BZ33 14. Connect to Left Back Door Lamp BZ5
4. Connect to Ground 15. Connect to Rear Defroster "+" BZ4
5. Connect to Rear Wiper Motor BZ14 16. Connection Between Back Door Cabling A1
6. Connect to Rear Defroster "-" BZ31 and Back Door Cabling A BZ1 and CZ1
7. Connect to Ground 17. Connection Between Back Door Cabling A2
8. Connect to Right Back Door Lamp BZ16 and Back Door Cabling A BZ2 and CZ2
9. Connect to Right License Plate Light BZ17 18. Connect to High-Mount Brake Lamp BZ3
10. Connect to Reverse Camera BZ19
38 Circuit Diagram
CONNECTOR DIAGRAM
ENGINE CABLING CONNECTOR FZ
404 405 464 7B 461 450 440 435 432 448 449 67D 206
6 BlW BlP R W BrBl BlG BrY GrR Gr GrY BlY GV PG 24
5 4
0.75 0.75 0.75 0.85 0.5 0.75 0.5 0.75 0.5 0.5 0.5 0.5 0.5
480 483
433 403 431 422 434 442 451 430 439 436 444 438 441 437 692 RBl RG
25 WR BlG WBl VB GrBl RY P Y BR BrW BlW BlV V VW RY 43 2.0 2.0
0.75 0.75 0.75 0.5 0.75 0.75 0.75 0.75 0.75 0.5 0.5 0.5 0.5 0.5 0.5 930A
B 3
2.0
401L 401M 407 406 479 427 910A 12 910B 443 429 15C 211 66 930B 503A
482 481
44 RW RW PY BlB GR YG B WBl B PB GrW BW BlR RBl B R 62 RW RB
0.75 0.75 0.75 0.75 0.75 0.5 0.75 0.5 0.75 0.5 0.5 0.5 0.5 0.5 0.75 0.5 2.0 2.0
401N 446 446A 447 447A 426 212 412 466 434B 14 A 208 13 445 411 930C 502A 2 1
63 RW BlR BlR GrB GrB OrBl GB WBl BlOr GrBl WV RB WG BY BlB B W 81
0.75 0.75 0.75 0.75 0.75 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.75 0.5 0.75 0.5
FZ1 connected to the engine ECU
16 692 429 7B 466 206 435B 61 60B 207 422

9 PG GrR RW R RY VB 1
10 WB RY GrW W BlOr 1
0.5 0.5 0.5 0.85 0.5 0.5 0.5 0.85 0.85 0.5 0.5
434A 442A 439A 440 430 441 431 401J 356 502A 503A
11 18 YV W R 10
20 GrBl RY BR BrY Y V WBl RW
0.5 0.5 0.5
0.75 0.75 0.5 0.5 0.75 0.5 0.75 0.85
FZ2 dashboard cabling B FZ3 dashboard cabling A
214
WBl 356 16
0.85 YV WB
0.5 0.5
FZ4 connected to FZ5 Oil pressure switch FZ6 connected to

the compressor the generator
2 401A 403
401D 406
R RW BlB 1 RW BlG 2
1 2 0.85 0.75
16.0 0.85 0.75
FZ7 connected to FZ8 connected to FZ9 connected to

the engine output the number 4 nozzle the number 1 nozzle
208 1
RB
0.5
922E 211
439D 411 434C 435A 437 442B 436
2 B BlR 3 1 BR BlB GrBl 3 GrR VW RY BrW 4
1
0.5 0.5 0.5 0.5 0.75 0.75 0.5 0.75 0.5
207
RY
0.5
4

the A/C pressure switch the phase sensor the air intake temperature
and pressure sensor
Circuit Diagram 39
447B 445 434D

1 GrB BY GrBl 3 15B
0.75 0.75 0.5 448 449 BW
446B 444 443 1 GrY BlY 2 2.0
4 Bl/R BlW PB 6 0.5 0.5
0.75 0.5 0.5

the electronic throttle the knock sensor the starter generator magnet
1 401C 405 401B 404

R 1 RW BlP 2 1 RW BlW 2
20.0 0.85 0.75 0.85 0.75
FZ16 connected to the starter FZ17 connected to FZ18 connected to

the number 3 nozzle the number 2 nozzle
A C
61 60B 910C 401R 480
1 RW R 2 3 B RW RBl 1 438 435C
0.85 0.85 2.0 2.0 2.0 BlV GrR
0.5 0.5

the reverse switch the tank 1 ignition coil the coolant temperature sensor
432 401K
2 Gr RW 1
0.5 0.85 401Y 479
439c 433 450 451
2 BlG P 1 1 RW GR 2
4 BR WR 3
0.75 0.75 0.75 0.75
0.5 0.75

the front oxygen sensor the engine speed sensor the VVT valve
512 461 412 511

4 BR BrBl WBl BW 1
0.5 0.5 0.5 0.5
212 427 426 464
20 GB YG OrBl R 5
0.75 0.75 0.75 0.75
2 214
R WBl 15B 401M
16.0 0.85 BW RW 9
1 2.0 2.0
R 67D
20.0 22 GV
66 12
0.5
RBl WBl 12
0.5 0.5
503A 502A
19 R W 16
0.5 0.5

the battery cathode fuse (Generator) the battery positive (starter) the front cabin cabling
40 Circuit Diagram
910D 401S 481

401E 407 910E 401T 482
3 B RW RB 1
1 RW PY 2 3 B RW RW 1
2.0 2.0 2.0
0.75 0.85 2.0 2.0 2.0
FZ29 connected to FZ30 canister control valve FZ31 connected to

the tank 2 ignition coil the tank 3 ignition coil
523 529
910F 401U 483 522 RY 528
512 511 GW
3 B RW RG 1 1 OrW 0.5 0.5 BlR 4
2.0 2.0 2.0 1 BR BW 2 2.5 524 530 2.5
0.5 0.5 BlW GY
0.5 0.5
527 525 531 533
7 WR GrW BlY RBl 10
2.5 0.5 0.5 2.5
526 532
FZ32 connected to FZ33 connected to the transmission VW BrY
0.5 0.5
the tank 4 ignition coil oil temperature sensor 13 16
533 532 531 530 529 528 527 526 525 524 523 522
FZ34 connected to
1 RBl BrY BlY GY RY BlR 2
2.5 0.5 0.5 0.5 0.5 2.5
1 WR
2.5
VW
0.5
GrW
0.5
BlW
0.5
GW
0.5
OrW 2
2.5
the engine bay cabling A
FZ35 connected to FZ36 connected to

the shift-shaft controller 1 the shift-shaft controller 2
Circuit Diagram 41
ENGINE BAY CABLING CONNECTOR QZ
606 67e 47 65 235 421 38

8 WBl GV Bl/R R/B VW BrG YBl 1 38 421 235 65 47 7 67e 606 15A 353
0.5 0.5 0.85 0.85 0.5 0.5 0.5 1 YBl BrG VW R/B Bl/R W GV WBl BW GBl 10
503D 502D 41 464B 236 353 15 A 0.5 0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.5 0.5
16 R W RG R RB GBl BW 9 236 464B 41 62 502M 503M 506 507 508 509
0.5 0.5 0.85 0.5 0.5 0.5 0.5 11 RB R RG BR W R BBl RBl RW GB 20
0.5 0.5 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5
*AMT vehicle special model
QZ1 connected to the instrument cabling A
55C 54 163 165 13 4 71 33

9 GR GV WG Bl WG RG Lg RB 1
0.5 0.5 0.5 1.25 0.5 2.0 0.5 0.5 33 465A 71 4 13 165 163 54 55C 166 847
1 RB YW Lg RG WG Bl WG GV GR BlR Bl/Y 11
602 97 36 8E 35 34 848 847 166 1.25 0.5 0.5 0.85 0.5 1.25 0.5 0.5 0.5 1.25 0.85
18 RY WR RW Y RG RY Bl/R Bl/Y BlR 10 97
848 34 35 8E 36 602 504 505
0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.85 1.25 12 Bl/R RY RG Y RW WR RY YB YR 22
0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
QZ2 connected to the instrument cabling B
19 16
67D 14 A 66
22 GV WV RBl 12 14B
0.5 0.5 0.5 1 WV
214 618 616
WBl 401A 15B 0.5
1 GW GR 4
0.85 RW BW 9 0.5 0.5
212 2.0 2.0 905H
617 413 615 2 B
20 GB 5 GBl Bl GB
0.5 464A 426 427
0.5 1.25 0.5 10
0.5
R OrBl YG 5
0.75 0.5 0.5
412 461
4 WBl BrBl 1
0.5 0.5
QZ3 connected to QZ4 connected to QZ5 connected to

the engine wire cabling the body cabling the clutch switch
519 520 521

67 66 8E 65 3 G BlB GR 1
4 GV RBl Y RB 1 353 905B 2.5 0.5 0.5
1 GBl B 2 516 517 518
0.85 0.5 0.5 0.85 6 W WB RB 4
0.5 0.5
2.5 0.5 0.5

the brake lamp switch the brake fluid level warning switch the clutch motor controller
529 523
528 RY 522
GW
4 BlR 0.5 0.5 OrW 1
2.5 530 524 2.5
GY BlW
0.5 0.5
904B 32 A 71A 533 531 525 527
3 B BlR Lg 1 10 BlY GrW 7
RBl WR
1.25 1.25 0.5 514 513 0.5 0.5
2.5 2.5
33 A 904C 904F 1 R G 2 532 526
6 RB B B 4 0.5 0.5 BrY VW
1.25 1.25 0.5 0.5 0.5
16 13

the right headlamp assembly the input shaft speed sensor the engine wire wiring A
42 Circuit Diagram
12 11 10 9 8 7 6 5 4 3 2
2 5A 5 600 24
R 13 606 421 611 613
R R R W BrB YBl 1
WBl BrG
16.0 8.0 10.0 4.0 10.0 902A 0.5 0.5 0.5 0.5 600
B 612 615 618 614 502D R
Generator 2 4 6 8 4.0 4.0
24 BrR GB GW BlY W 14
903I 0.5 0.5 0.5 0.5 0.5 601
B 616 67C 617 602 503D WR
2.5 2.5
GR GV GBl RY R
38 0.5 0.5 0.5 0.5 0.5 25
37 36 35 34 33 32 31 30 29 28 27 26
QZ13 connected to the ESP ECU

ALT 120 A
EPS 80 A
ABS 40 A
MAIN 60 A
12 11 10 9 8 7 6 5 4 3 2
13 611 613
BrB YBl 1
902A 0.5 0.5 600
B 612 615 618 614 502D R
4.0 24 BrR GB GW BlY W 14 4.0
903I 0.5 0.5 0.5 0.5 0.5 601
1 3 5 7 B 421 616 67C 617 602 503D WR
2.5 2.5
700 BrG GR GV GBl RY R
L2 L1 L3 L4 38 0.5 0.5 0.5 0.5 0.5 0.5 25
R
6.0 battery 37 36 35 34 33 32 31 30 29 28 27 26
QZ12 connected to
the battery positive cable
QZ13 connected to the ABS ECU
903B 32B 71F

96B 907Q 96A 907Y
3 B BlR Lg 1
1 Gr B 2 1 Gr B 2
1.25 1.25 0.5
0.85 0.85 0.85 0.85
33B 903C 903F
6 RB B B 4
1.25 1.25 0.5
QZ14 connected to QZ15 connected to the horn QZ16 horn two

the left headlamp assembly
55C 903E 903A 41 904A 47

1 GR B 2 1 B RG 2 1 B Bl/R 2
0.85 0.85 0.85 0.85
0.5 0.5

the front left steering lamp the front left fog lamp the front right fog lamp
1 S
B 1
425A
BR 163 165
3.0 WG Bl
428A 906A 0.5 1.25 613 614
3 1 YBl BlY 2
2 BlW B
3.0 3.0 907A 166 0.5 0.5
B BlR
1.25 1.25
E 2

the radiator fan motor the wiper motor the front right wheel speed sensor
612 611 235 236

847 848 VW RB
2 BrR BrB 1 1 Bl/Y Bl/R 2 1 2
0.5 0.5 0.85 0.85 0.5 0.5
QZ24 connected to QZ25 connected to QZ26 outside temperature sensor

the front left wheel speed sensor the washer liquid motor
Circuit Diagram 43
5 71H 36B 904D 71G 36 A 903D

R 1 Lg RW B 3
10.0 1 Lg RW B 3
0.5 0.5 0.5 0.5 0.5 0.5
QZ27 driver's cab fuse box QZ28 connected to QZ29 connected to

the right headlamp the left headlamp assembly
assembly regulator motor regulator motor
1
425B
BR
54C 904E 3.0
1 GV B 2 428B 906B 38 A 903G
2 BlW B 3 1 YBl B 2
0.5 0.5 3.0 3.0 0.5 0.85

the front right steering lamp the radiator fan motor the left daytime running light
700
38B 904G R 21
1 YBl B 2 6.0
0.5 0.5 925
B 22
6.0
QZ33 connected to QZ34 connected to

the right daytime running light the EPS controller
464D 465A 530 531 518 521 515 523 511

15 R YW GY BlY RB GR B GW BW 27 500A 500B 516 533 527
0.75 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1 RB RB W RBl WR 5
2.5 2.5 2.5 2.5 2.5
506 501 508 512 524 525 520 62 529 504

28 BBl BY RW BR BlW GrW BlB BR RY YB 40
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 6 9
509 526 514 513 532 502C 503C 505 7
41 GB VW R G BrY W R YR W 53
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
931 932 528 522 519

517 507 10 B B BlR OrW G 14
54 WB RBl 66 2.5 2.5 2.5 2.5 2.5
0.5 0.5
QZ35 connected to the TCU
503M 503C 503D 503A

R R R R
0.5 0.5 0.5 0.5
502M 502C 502D 502A
W W W W
0.5 0.5 0.5 0.5
QZ60 shunt
44 Circuit Diagram
DASHBOARD CABLING CONNECTOR YZ
282A 303 315 317 313 302

73 909 106 105 150 55B 286
8 BlR BlY RY RB BlW WG 1
7 GB B BlV Bl Br GR BlY 1
1.25 2.0 2.0 2.0 2.0 2.0
0.5 2.0 0.5 0.5 0.5 0.5 0.5
913B 316 318 314 281A
GY Lg BlB PG 155A 152 153 252B 158A 157B 100E
16 B 9
14 PBl PY PG RV OrG OrW Or 8
0.5 2.0 2.0 2.0 1.25
0.5 0.5 0.5 0.5 0.5 0.5 0.5
YZ1 connected to the front left door cabling A (white) YZ2 connected to the front left door cabling B (white)
911F 911G 503 465B

1 B B R YW 8
0.5 0.5 0.5 0.5
502 464B
9 W R 16
0.5 0.5
YZ3 diagnostic interface
33C 71A 4 13 165 163 54C 55C 847 166 55C 54C 163 165 13 4 71A 465A 33C
1 RB Lg RG WG Bl WG GV GR 9 11 BlY BlR GR GV WG Bl WG RG Lg YW RB 1
0.5 0.5 2.0 0.5 1.25 0.5 0.5 0.5 0.85 1.25 0.5 0.5 0.5 1.25 0.5 2.0 0.5 0.5 0.5
166 847 848 34 35 8E 36 97 602B 505 504 602B 97 36 8E 35 34 848
10 BlR BlY BlR RY RG Y RW WR RY 18 22 YR YB RY WR RW Y RG RY BlR 12
1.25 0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.5 0.5 0.5 0.5 0.5 0.85
YZ4 connected to the front cabin cabling B
923 315 316 87 116 115 252 46 302B

80A 917 11 B RY GY Gr BlY BlOr RV BlGr WG 1
3 BlY B 1 0.5 2.0 2.0 0.5 0.5 0.5 2.0 0.85 2.0
0.85 2.0 61F 83 355 354 73C 749 745 747 748 172B 168
82A 60J 130 73B RW YBl YW YR GB BlG YBl BlR BlB RG RBl 12
22
8 BrR R WG GB 4 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.25 1.25
0.5 0.5 2.0 0.5
YZ5 connected to the ceiling cabling A YZ6 connected to the body cabling A
854 85 290 282C 281C 317 118 685 681 64 71B 69 291
13 BlY BrBl RW BlR PG RB BlB YBl PW RBr Lg RG BlY 1
0.5 0.5 0.5 2.0 2.0 2.0 0.5 0.5 0.5 0.5 0.5 0.5 1.25
352 88 89 318 117 683 684 55a 54a 68
26 WG W P Lg BlG YB YR GR GV RBl 14
0.5 0.5 0.5 2.0 0.5 0.5 0.5 0.5 0.5 0.5
YZ7 connected to the body cabling B

Circuit Diagram 45
38 421 235 65 47 67e 606

353 15A 606 67e 7 47 65 235 421 38
1 YBl BrG VW RB BlR GV WBl 8
10 GBl BW WBl GV W BlR RB VW BrG YBl 1
0.5 0.5 0.5 0.85 0.85 0.5 0.5
0.5 0.5 0.5 0.5 0.5 0.85 0.85 0.5 0.5 0.5
15A 353 236 464A 41 502D 503D 509 508 507 506 503M 502M 62 41 464A 236
9 BW GBl RB R RG W R 16 11
20 GB RW RBl BBl R W BR RG R RB
0.5 0.5 0.5 0.5 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.5 0.5
0.5 0.5
*AMT vehicle special

model
YZ8 connected to the front cabin cabling A
IG1
AM1 ACC
3 8 6
RBl Y G c d a b
396 397 398 399 1 3
YR GR GW 2.0 0.85 0.5 126 97B 381 382
4 YW 1
Y WR YR YBl
0.5 0.5 0.5 0.5 13 4 7 0.5 0.5 0.5 0.5
4 WG RG W 6
0.5 2.0 2.0
ST2 AM2 IG2
YZ9 connected to YZ10 connected to YZ11 clock spring connector two

the ceiling cabling B the ignition switch (white)
105
1 Bl
0.5
175 174 170 173 911N 172C 161 911M 162
106 10 1
GY RB BlG RBl B RG BlY B BlR
2 BlV
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
0.5
YZ12 front left tweeter YZ13 connected to the right combination switch (wiper)
3 108
108
841 840 911K 2 BlW
YR YB B 1 2 BlW
0.5
0.5 0.5 0.5 0.5
107
842 843 911J 844 845 846 911D 911I 107
1 BlR
12 GY GR B YG YBl GW B B 4 1 BlR
0.5
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
YZ14 connected to the combination switch (light) YZ16 front right tweeter YZ16 front right tweeter
464 459 422 465 913F

h g f e 1 R BrB VB YW 7 1 B
110 692 0.5 0.5 0.5 0.5 1.25
B RY 911A 350B 466A 90B
0.5 0.5 2 B WR BlOr 8 YV 2
0.5 0.5 0.5 1.25
YZ19 clock spring connector three YZ24 anti-theft ECU1 YZ28 connected to
the cigarette lighter (white)
381 382 383 384 389 390 391 392 387 388 394 395 396 397 398 399
1 YR YBl WBl WR Y YB G GB YB YW GW GB YW YR GR GW 16
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
386 393 376 377 378 379 465C 933 385
17 GBr Br YR YBl GY GR YW B R 32
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.75 0.75
YZ32 connected to the side airbag ECU (yellow)

46 Circuit Diagram
421
BrG
0.5
C19 C16 C13 C10 C7 C4 C1
61C 749 745 747

8 RW BlG YBl BlR 1
0.5 0.5 0.5 0.5
748 923E C18 C15 C12 C9 C6 C3
9 B
BlB B 16 103
0.5 0.5 Bl
0.5
C20 C17 C14 C11 C8 C5 C2
B7 B1
105 107
YZ34 connected to the reverse radar controller Bl BlR
0.5 0.5
106 108
BlV BlW
0.5 0.5
B8 B2
A7 A1
102B 61E 125 126
RW RW RY Y
1.25 0.5 0.5 0.5
921D 73Q 100F 110
B GB Or B
1.25 0.5 1.25 0.5
A8 A2
YZ37 connected to the MP5
350A 101 911C 559 353 459 354 355 386 352
1 WR GrW B Br GBl BrB YR YW GBr WG 20
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
371 362 363 364 361 369 911B 503E 502E 61G 351 356 16
21 RBl GBl VBl RG WB WG B R W RW WBl YV WB 40
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
YZ39 connected to the combination instrument (white)
422 207 60B 61 435 206 466A 7B 429 692 16

1 VB RY R RW GrR PG 9 1 BlOr W GrW RY WB 10
0.5 0.5 0.85 0.85 0.5 0.5 0.5 0.85 0.5 0.5 0.5
503C 502C 356 401J 431 441 430 440 439 442A 434A
10 R W YV 18 11 RW WBl V Y BrY BR RY GrBl 20
0.5 0.5 0.5 0.85 0.75 0.5 0.75 0.5 0.5 0.75 0.75
YZ40 connected to the engine wire wiring A (white) YZ41 connected to the engine wire cabling B (white)
206 435 921C 205 209 203A

1 PG GrR 2 73G 430B 125 B BlV BlR BlW
0.5 0.5 GB Y RY 2.0 0.5 0.5 2.0
0.5 0.5 0.5 S R G D
i j k l
YZ42 connected to the air-conditioner YZ43 clock spring YZ44 connected to

temperature sensor connector one the speed regulator resistor
282B 313 302A

1 73E 908C 108 107 54B
8 BlR BlW WG
7 GB B BlW BlR GV 1
1.25 2.0 2.0
0.5 0.85 0.5 0.5 0.5
314 281B
152 155A 153 252C 158B 157B
16 BlB PG 9
2.0 1.25 14 PY PBl PG RV OrG OrW 8
0.5 0.5 0.5 0.5 0.5 0.5
YZ45 connected to the front right door cabling A YZ46 connected to the front right door cabling B
Circuit Diagram 47
287 911E
1 RY B 2
0.5 0.5 103 383 384
Bl 1 WBl WR 2
0.5 0.5 0.5
YZ47 key detector switch YZ48 connected to YZ50 connected to

the antenna the front passenger air-bag
911A 283 284 33C 911T 36 371 362

1 B GW GY RB B RW RBl GBl 8 221B 223A 227 225 229
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 502H 503H 602A 914E 1 V GV BlG WB BlB 5
4 W R RY B 1
363 73L 911S 364 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
9 VBl GB B RG 16
0.5 0.5 0.5 0.5
YZ51 central control panel switch YZ52 turn angle sensor YZ53 connected to
the temperature damper actuator
207 222 227 223 235 238 237 236 921A 73I 229 225 231 639
A9 RY BlOr BlG GV VW BBl VB RB LgR
B7 B GB BlB WB BrBl
221A 223B 222 220 224 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.5 0.5
1 V GV BlOr BlG BlR 5 102A 60E 201D 209 205 204 239 921B 221 251 224 220
0.5 0.5 0.5 0.5 0.5 A1 RW R RG BlR BlV BlY BrY B1 B V WBl BlR BlG
0.5 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.5
YZ54 connected to YZ56 A/C controller A YZ57 A/C controller B

the mode damper actuator
201E
RG 1
231 239 3.0 434A 442A 439B 440 430A 441
1 BrBl BrY 5 203B 1 GrBl RY BR BrY Y V 6
0.5 0.5 BlW 2 0.75 0.75 0.5 0.5 0.5 0.5
3.0
YZ58 connected to YZ60 connected to the blower YZ61 connected to

the circulation throttle actuator the accelerator pedal module
7C 911H 707 705 703 701

506 507 508 509
10 W B GrBr GrBl GrY GrW 1
4 BBl RBl RW GB 1 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5 502B 503B 708 706 704 702
911E 73D 504 505 20 W R Gr GrB GrG GrR 11
8 B GB YB YR 5 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5
YZ62 connected to the gear YZ66 connected to the EPS controller (C)
shift operation assembly
705 706 707 708

C5 GrBl GrB GrBr Gr C8
0.5 0.5 0.5 0.5
701 702 703 704
C1 GrW GrR GrY GrG C4
0.5 0.5 0.5 0.5
YZ67 connected to the sensor plug

48 Circuit Diagram
A1 A7 A13 A19 A25 A31 A37 A43 A1 A7 A13 A19 A25 A31 A37 A43
34 838 78 159 85 290 161 842 15A 393
RY GY BlY Bl BrBl RW BlY GY BW Br
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
53 42 835 839 559 83 287 150 843 100G 284 61M
BR Bl BlGr BrW Br YBl RY Br GR Or GY RW
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
35 156 503F 502F 89 846 845 9D 283 163
RG P R W P GW YBl RW GW WG
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
73A 97C 319 87 173 844 841
GB WR RB Gr RBl YG YR
0.5 0.5 0.5 0.5 0.5 0.5 0.5
68 836 834 175 88 7H 67e
RBl BlBr BlB GY W W GV
0.5 0.5 0.5 0.5 0.5 0.5 0.5
69 45 52 162 840 286
RG Y BY BlR YB BlY
0.5 0.5 0.5 0.5 0.5 0.5
A6 A12 A18 A24 A30 A36 A42 A48 A6 A12 A18 A24 A30 A36 A42 A48
832 64 38 913A 282 280 913B 913C

B1 RW RBr YBl B B4 B1 BlR R B B B4
2.0 0.5 0.5 0.85 1.25 2.0 0.85 1.25
46 54 55 833 281 913D 71 82

B5 BlGr GV GR RB B8 B5 PG B Lg BrR B8
0.85 0.85 0.85 2.0 1.25 0.85 1.25 0.5
YZ70 connect BCM-J1 YZ71 connect BCM-J2
913I
1 B 73K 606
1.25 5 GB WBl 1
0.5 0.5 503E 503F 503H 503C
90A
YV 911Y R R R R
1.25 12 B 6 0.5 0.5 0.5 0.5
0.5 502E 502F 502H 502C
2
W W W W
0.5 0.5 0.5 0.5
YZ72 connected to YZ73 central control panel switch two YZ80 shunt
the spare power supply (white)
351 389 391 395 394 376 377 369

1 WBl Y G GB GW YR YBl WG 9
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
503 503D 503B 361 390 392 388 387 379 378
R R R 10 WB YB GB YW YB GR GY 18
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
502 502D 502B
W W W
0.5 0.5 0.5
YZ81 shunt YZ90 connected to the body cabling D (white)
429 401J
2 GrW RW 1
0.5 0.85 52 53 73J 913E
439A 431 1 BY BR GB B 6
4 BR WBl 3 0.5 0.5 0.5 0.5
0.5 0.75
YZ91 connected to YZ91 hazard indicator switch

the rear oxygen sensor
Circuit Diagram 49
VEHICLE BODY CABLING CONNECTOR CZ
616 618
252 172B 290 681 61F 4 GR GW 1
2 RV RG 1 3 RW PW RW 1 0.5 0.5
2.0 1.25 0.5 0.5 0.5
615 413 617
291 168 920E 71D 85 64 683 684 685 10 GB Bl GBl 5
6 BlY RBl B Lg 3 8 BrBl RBr YB YR YBl 4 0.5 1.25 0.5
1.25 1.25 2.0 0.5 0.5 0.5 0.5 0.5 0.5
CZ1 connected to CZ2 back door cabling A2 CZ5 connected to

the back-door cabling A1 the front cabin cabling
391 392
1 G GB 2
0.5 0.5
351 918B 918F 361

1 WBl B 2 2 B WB 1
0.5 0.5 0.5 0.5
CZ7 driver seat belt switch CZ8 front passenger CZ9 front passenger
seat belt switch seat belt retractor
73E 302C 317 318

5 GB WG RB Lg 1
0.5 2.0 2.0 2.0
281D 282D 118 117
9 PG BlR BlB BlG 6 83
89 1.25 1.25 0.5 0.5 YBl
P 0.5
0.5
17 10
CZ10 front right door light switch CZ11 rear right door cabling CZ12 front left door light switch
73D 302B 315 316 389 390

5 GB WG RY GY 1 1 Y YB 2 355 354
0.5 2.0 2.0 2.0 0.5 0.5 1 YW YR 3
0.5 0.5
281C 282C 116 115
9 PG BlR BlY BlOr 6 413 919A
1.25 1.25 0.5 0.5 4 Bl B 5
1.25 1.25
17 10
CZ13 rear left door cabling CZ14 driver seat belt retractor CZ15 oil pump and fuel sensor
46
3 BlGr 1
0.85
618 617
745 923B 2 GW GBl 1
6 Y/Bl B 4 88
0.5 0.5
0.5 1.25 W
0.5
748 749 747
9 B
BlB BlG BlR 7
0.5 0.5 0.5
CZ16 connected to CZ17 rear right wheel CZ18 rear-right door

the rear body cabling speed sensor light switch
50 Circuit Diagram
87 55A 71B
616 615 Gr 2 GR Lg 1
2 GR GB 1 0.5 0.5 0.5
0.5 0.5 920G 68
4 B RBl 3
0.85 0.5
CZ19 rear left wheel speed sensor CZ20 rear left door light switch CZ22 rear left lamp assembly
54A 71C
2 GV Lg 1
0.5 0.5 302 46 252 115 116 87 316 315 923E
920M 69 1 WG BlGr RV BlOr BlY Gr GY RY B 11
4 B RG 3 2.0 0.85 2.0 0.5 0.5 0.5 2.0 2.0 0.5
0.85 0.5 168 172B 748 747 745 749 73 354 355 83 61F
12 RBl RG BlB BlR Y/Bl BlG GB YR YW YBl RW 22
1.25 1.25 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
CZ28 rear right lamp assembly CZ30 dashboard cabling A
291 69 71 64 681 685 118 317 281 282 290 85 854

1 BlY RG Lg RBr PW YBl BlB RB PG BlR RW BrBl BlY 13 854 85B
1.25 0.5 0.5 0.5 0.5 0.5 0.5 2.0 2.0 2.0 0.5 0.5 0.5 1 BlY BrBl 2
68 54A 55A 684 683 117 318 89 88 352 0.5 0.5
14 RBl GV GR YR YB BlG Lg P W WG 26
0.5 0.5 0.5 0.5 0.5 0.5 2.0 0.5 0.5 0.5
CZ31 dashboard cabling B CZ32 trunk light
918D 369 352 377 376

1 B WG 2 WG 1 YBl YR 2
0.5 0.5 0.5 0.5 0.5
CZ33 front passenger seat CZ36 connected to CZ48 driver-side

pressure sensor the parking brake switch knock sensor
369 377 376 394 395 391 389 351

378 379 9 WG YBl YR GW GB G Y WBl 1 387 388
1 GY GR 2 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1 YB YW 2
0.5 0.5 378 379 387 388 392 390 361 0.5 0.5
18 GY GR YB YW GB YB WB 10
0.5 0.5 0.5 0.5 0.5 0.5 0.5
CZ49 front passenger CZ52 connected to CZ62 connected to

side knock sensor the dashboard cabling D the left-side airbag
394 395
1 GW GB 2
0.5 0.5
CZ63 connected to
the right-side airbag
Circuit Diagram 51
DOOR CABLING CONNECTORS ZQ, YQ, ZH, YH
305
302 313 317 315 303 282 286 55B 150 105 106 909 73 1 G 2
1 WG BlW RB RY BlY BlR 8 1 BlY GR Br Bl BlV B GB 7
2.0
2.0 2.0 2.0 2.0 2.0 1.25 0.5 0.5 0.5 0.5 0.5 2.0 0.5
306
281 314 318 316 913B 100 157 158 252B 153 152 155 A R 6
3
9 PG BlB Lg GY B 16 8 Or OrW OrG RV PG PY PBl 14 2.0
1.25 2.0 2.0 2.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
ZQ1 connected to ZQ2 connected to ZQ3 adapter plug

the instrument cabling A the instrument cabling B
318 317 909E 303 315 316

7 Lg RB B BlY RY GY 12
105 2.0 2.0 2.0 2.0 2.0 2.0
1 Bl 306 305
0.5 314 313 302 73F 305 306 2 R G 1
1 BlB BlW WG GB G R 6 2.0 2.0
106
2 BlV 2.0 2.0 2.0 0.5 2.0 2.0
0.5
ZQ4 front left bass speaker ZQ6 power window main controller switch ZQ7 front left power
window motor
153 151 152 154

6 PG PB PY PBr 10
0.5 0.5 0.5 0.5 306 3
286 913B 282 281 150 155 909M 73C 100 R
6 BlY B BlR PG 1 6 2.0
1 Br PBl B GB Or 5
0.5 0.5 1.25 1.25 0.5 0.5 0.5 0.5 0.5 305
2 G
2.0 1
ZQ8 front left door lock motor ZQ10 connected to the power side mirror ZQ11 adapter plug
regulator switch (white) left
1 6
909B 909C 158 157 55B 252B
B B OrG OrW GR RV
0.5 0.5 0.5 0.5 0.5 0.5
151 154 155B
7 PB PBr PBl
0.5 0.5 0.5
12
ZQ12 left side mirror
309
302A 313 282 54B 107 108 908C 73E 1 G 2
1 YW BlW BlR 8 1 GV BlR BlW B GB 7 2.0
2.0 2.0 1.25 0.5 0.5 0.5 1.25 0.5
281 314 310
157 158 252C 153 155A 152
9 PG BlB 16 3 R 6
8 OrW OrG RV PG PBl PY 14
1.25 2.0 2.0
0.5 0.5 0.5 0.5 0.5 0.5
YQ1 connected to YQ2 connected to YQ3 adapter plug

the instrument cablingA the instrument cabling B
1 313 302A 314 3

107 BlW YW BlB
1 BlR 2.0 2.0 2.0
0.5 310 309
310 73E 309 2 R G 1
108 R GB G 6
4 2.0 2.0
2 BlW 2.0 0.5 2.0
0.5
YQ4 front right bass speaker YQ6 front right door power YQ7 connected to the front
window switch right power window motor
52 Circuit Diagram
309 1
2 G 1 908B 908H 158 157 54B 252C
282 281 2.0 6 B B OrG OrW GV RV
1 BlR PG 6 0.85 0.5 0.5 0.5 0.5 0.5
310
1.25 1.25
6 R 3 152 153 155 A
2.0 12 PY PG PBl
7
0.5 0.5 0.5
YQ8 front right door lock motor YQ9 adapter plug YQ10 right side mirror
316 315 302B 73E

1 GY RY WG GB 5 1 315 302B 316
2.0 2.0 2.0 0.5 RY WG GY 3
115 116 282C 281C 308 307 2.0 2.0 2.0
BlOr BlY BlR PG 1 R G 2 308 73E 307
0.5 0.5 1.25 1.25 2.0 2.0 R GB G
4 6
2.0 0.5 2.0
10 17
ZH1 connected to the body cabling ZH2 power window motor ZH3 rear left door power
window switch
116 115 282C 281C

6 BlR PG 1
2 BlY BlOr 1
1.25 1.25
0.5 0.5
ZH4 rear left door subwoofer ZH5 rear left door lock motor
318 317 302C 73E

1 Lg RB WG GB 5
2.0 2.0 2.0 0.5
1 317 302C 318
117 118 282D 281D 312 311 RB WG Lg 3
6 BlG BlB BlR PG 9 1 R G 2 2.0 2.0 2.0
0.5 0.5 1.25 1.25 2.0 2.0
312 73E 311
4 R GB G 6
10 17 2.0 0.5 2.0
YH1 connected to the body cabling YH2 connected to the rear YH3 rear right door
right power window motor power window switch
118 117 282D 281D

2 BlB BlG 1 1 BlR PG 6
0.5 0.5 1.25 1.25
YH4 rear right door subwoofer YH5 rear right door lock motor
Circuit Diagram 53
REAR CABLING CONNECTOR BZ
172B 252 61C 681 290

1 RG RV 2 1 RW PW RW 3
1.25 2.0 0.85 0.5 0.5 920H 64
685 684 683 64 85 A 1 B RBr 2
71J 920E 168 291
3 Lg B RBl BlY 6 4 YBl YR YB RBr BrBl 8 0.5 0.5
0.5 2.0 1.25 1.25 0.5 0.5 0.5 0.5 0.5
BZ1 connected to the body cabling A BZ2 connected to the body cabling B BZ3 high-mount brake lamp
920C 61D 291 172B

2 B RW 1 1 BlY RG 2
0.5 0.5 1.25 1.25
252 920E 168 61F
RV 71B
2.0 3 Lg 4 3 B RBl RW 6
0.5 2.0 1.25 0.85
BZ4 rear defroster "+" BZ5 connected to BZ6 connected to

the left back door lamp the back-door cabling B1
290 71C 681

1 RW Lg PW 3
0.5 0.5 0.5
85A 683 684 685
4 BrBl YB YR YBl 8
0.5 0.5 0.5 0.5
BZ7 connected to
the back-door cabling B2
172B 291 681 71C 290

2 RG BlY 1 3 PW Lg RW 1 921P 85A
1.25 1.25 d B BrBl c
0.5 0.5 0.5
0.5 0.5
61F 168 920E 685 684 683 85 A
RW RBl B 3 8 4 921R 291
6 YBl YR YB BrBl
0.85 1.25 2.0 0.5 0.5 0.5 0.5 b B BlY a
1.25 1.25
BZ11 connected to BZ12 connected to BZ13 back door lock motor

the back-door cabling A1 the back-door cabling A2
907F 920M 61F

2 B 1 2 B RW 1
1.25 0.5 0.5
290 921Z
172B 168 1 RW B 2 71C
3 RG RBl 4 0.5 0.5 3 Lg 4
1.25 1.25 0.5
BZ14 rear wiper motor BZ15 back-door opening switch BZ16 connected to
the right back door lamp
685 681
920J 71E 920F 71D 2 YBl PW 1
1 B Lg 2 1 B Lg 2 0.5 0.5
0.5 0.5 0.5 0.5 684 683
3 YR YB 4
0.5 0.5
BZ17 right license plate light BZ18 left license plate light BZ19 reverse camera
54 Circuit Diagram
46
1 BlGr 3
0.85
923 745 46A 920B
4 B YBl 6 923A 745
0.5 1 BlGr B 2 1 B YBl 2
1.25
0.5 0.5 0.5 0.5
747 749 748
7 BlR BlG BlB 9
0.5 0.5 0.5
BZ21 connected to BZ22 connected to BZ23 connected to

the body cabling the rear right fog lamp the left probe
923C 749 923D 748

923B 747 1 B BlG 2 1 B BlB 2
1 B BlR 2 0.5 0.5 0.5 0.5
0.5 0.5

the center-left probe the center-right probe the right probe
46A 923F
1 BlGr B 2
0.5 0.5
BZ27 connected to
the rear left fog lamp
71D 920F
71D 920F B
B 1 Lg 2
2 Lg 1 0.5 0.5
0.5 0.5
921Z 290 71E 920J
921Z 290 71E 920J
909G B RW Lg B 3 3 B RW Lg B 6
B 6 0.5 0.5 0.5 0.5
0.5 0.5 0.5 0.5
2.0

the rear defroster "-" the back-door cabling C the back-door cabling B
CEILING WIRING CONNECTOR DZ

909 80
1 B BlY 3
2.0 0.85 80B 909R 909S 80A 82A
82A 1 Bl/Y B 2 1 B Bl/Y BrR 3
4 BrR 8 0.5 0.5 0.5 0.5 0.5
0.5
DZ1 connected to DZ2 connected to DZ3 connected to

the dashboard cabling the reading lamp the ceiling lamp
396 397 398

1 W WBl 2 399
0.5 0.5 1 WR WV 2
0.5 0.5
DZ4 connected to DZ5 connected to

the left-side curtain airbag the right-side curtain airbag
A-59
Circuit Diagram 55
SYSTEM SCHEMATIC
POWER, STARTUP, CHARGE SYSTEM
30a 30b 30c 30d 30a 30c 30a 15b
F01 F42 F03

30 A 15 A 15 A
To P 57
Connected to the EPS
controller 21 pin
24 600 5 5A 700
W R R R R
10.0 4.0 10.0 8.0 8.0
3 8 6 4 7
RBl Y G RG W
2.0 0.85 0.5 2.0 2.0
Terminal 1 2 3 4 5 6
8 6 4 1 Gear
AM1 IG1 ACC ST2 AM2 IG2
position
Ignition switch
LOCK
ACC
MAIN ABS 40 A (MT) EPS

ON
60 A (MT) TCU 60 A (AMT) 80 A
Battery cathode case
80 A (AMT)
START
13
WG
AMT dedicated
0.5
Connected to the engine ECU#77 pin To P 57
ALT 120 A
2
instrument 4 base
To the combination
To P 73
17 13
RBl WG
2.0 0.5
30 85
Starter relay
12
87 86 WBl
0.5 AMT dedicated
Connected to the
15 14 engine ECU#52 pin To P 58
BW WV
2.0 0.5
Connected to the engine ECU#74 pin
14B To P 61
15A 15 A WV
To P 58
To P 84
Clutch switch
BW BW 0.5 1
0.5 0.5
Engine BCM
2
ECU-56 J2-A25
AMT dedicated
1 15B
2 16
R BW
R WB
20.0 2.0
16.0 0.5
C B B+ L
Battery
12 V
Generator
60 Ah
Starter
U>
M
E
900 905H
B B
10.0 16.0 0.5
GX01 GQ03
GX02
A-60
56 Circuit Diagram
30c To P 55 15a 30c X1 X2
F29 F30
25 A 25 A
8A 51 10
Y R R
Connected to the brake 0.5 2.0 2.0
lamp switch 2 pin 85 30 85 30
To P 66
ACC relay
IG1 relay
86 87 86 87
911 9 911 104

B RW B YW
0.5 2.0 0.5 2.0
9D
RW
GY01 GY01
0.5
F15
15 A
BCM J2-A27 To P 83
100 A
Or
1.25
100G
Or
0.5
BCM J2-A26 To P 83
A-61
Circuit Diagram 57
POWER STEERING SYSTEM
15b To P 55
To P 55
Connected to the battery
positive case 1 pin
To the diagnostic connector

CAN-H
CAN-L
700 502B 503B 7C

R W R W
8.0 0.5 0.5 0.5
21 16 15 10
EPS controller
5 22 1 11 2 12 3 13 4 14 23 24
701 702 703 704 705 706 707 708
GrW GrR GrY GrG GrBl GrB GrBr Gr
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Le
ft
tu
rn
VCC1 VCC2 PWM-P PWM-T1 PWM-T2 PWM-S GND2 GND1

Right turn
B1 B2 B3 B4 B5 B6 B7 B8
Torque sensor
M
EPS steering motor

From gnd
911H 925
B B
0.5 8.0
GQ03 GQ02
A-62
58 Circuit Diagram
ENGINE CONTROL UNIT (ECU)
30a To P 55
F04
25 A
400A
RY
2.0
400 400B
RY RY
2.0 0.5
30 85
Main relay
87 86
401 461
RW BrBl
2.0 0.5
401E
Fuel injector RW
1 2 3 4 0.75
1 Canister control valve
2 1 2 1 2 1 2 1 2
401A 401B 401C 401D
RW RW RW RW
0.85 0.85 0.85 0.85
404 406 401L 401M 401N

U.U.UBR
403 405 407

U.U.UBR
U.U.UBR
A.T.EV4
A.T.EV2
A.T.TEV
A.T.EV1
A.T.EV3
BlG BlW BlP BlB PY RW RW RW

0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
14 27 6 7 47 46 44 45 63
ME797 ECU
AMT dedicated
77 52 56 48 79 55 36 28 18 26
439
M.R.SEN2
A.S.LSHK
A.T.VVT
A.S.LSHVK
Connected to the starter relay 85 pin
E.F.ZYHA
F.A.LSHK
E.A.LSHK
BR
0.75
401Y 479 439D 411 434C 429 439A 431 432 439C 433
RW GR GrW BR
To P 55
To P 55
To P 55
BR BlB GrBl WBl Gr BR WR

0.75 0.75 0.5 0.5 0.75 0.5 0.5 0.75 0.5 0.5 0.75
1 2 1 2 3
2 4 2 4
401J 401K
RW RW
VVT valve Phase sensor 0.85 1 3 0.85 1 3
Rear oxygen sensor Front oxygen sensor

A-63
Circuit Diagram 59
Ignition coil
401R 401S 401T 401U

RW RW RW RW
1 tank 2.0 2 tank 2.0 3 tank 2.0 4 tank 2.0
2 2 2 2
3 1 3 1 3 1 3 1
910C 910D 910E 910F

B B B B
2.0 2.0 2.0 2.0
A.P.ZUE1I
A.P.ZUE4I
A.P.ZUE2I
480 481 482 A.P.ZUE3I 483

GF02 GF02 GF02 GF02
GF03 RBl GF03 RB GF03 RW GF03 RG
2.0 2.0 2.0 2.0
5 1 2 4
ME797 ECU
33 37 17 42 39 35 40 32 16
442 435 430 434
M.R.SEN1
E.A.TANS
E.A.DS
E.A.SP2S
E.A.SP1S
A.U.5V2
E.A.TM0T
RY GrR Y GrBl
0.75 0.75 0.75 0.75
442B 436 435A 437 438 435C 430B 430A 441 434A 439B 440 442A
RY BrW GrR VW BlV GrR Y Y V GrBl BR BrY RY
0.75 0.5 0.75 0.5 0.5 0.5 0.5 0.5 0.5 0.75 0.5 0.5 0.75
3 4 1 2 B A C 5 6 1 3 4 2
the clock spring j2 pin
Connected to
To P 71
Air intake temperature and pressure sensor Coolant temperature sensor Accelerator pedal module
A-64
60 Circuit Diagram
15b To P 55 30c To P 55 To P 55 30a F07
F08 F07
15 A 10 A
464
R
0.75
401G 414
RW BlR
0.5 1.25
85 30 Oil pump relay
86 87
412 413
WBl Bl
0.5 1.25
To P 68
Connected to the immobilizer controller A5 pin
4
Oil pump
M
5
919A
B
1.25
464A
E.S.KL15
7B
U.U.UBD
422
A.S.SVS
GC02
A.S.EKP
W R VB
0.85 0.75 0.5
13 70 12 29
ME797 ECU
73 54 38 78 64 65 66 67 22 19 20
434B 446 446A 447 447A
E.A.1P1S
A.T.DCP
E.A.1P2S
M.R.SEM
E.A.KS1A
E.A.KS1B
GrBl BlR BlR GrB GrB

0.5 0.75 0.75 0.75 0.75
443 434D 444 445 446B 447B 435B 206 448 449
PB GrBl BlW BY BlR GrB GrR PG GrY BlY
0.5 0.5 0.5 0.75 0.75 0.75 0.5 0.5 0.5 0.5
6 3 5 2 4 1 1 2
1
M
2
Knock sensor
Electronic throttle body Air-conditioner temperature sensor
A-65
Circuit Diagram 61
30d To P 55 30d 30d
F11 F13 F14
10 A 30 A 40 A
401t 215 401H 424 467 401I

RW WG RW R RBl RW
0.5 0.85 0.5 3.0 3.0 0.5
85 30 85 30 30 85
Compressor relay
Fan relay high

Fan relay low
86 87 86 87 87 86
212 214 427 425 428
GB WBl YG RB BlW
0.5 0.85 0.5 3.0 3.0
428b 428a
BlW BlW
3.0 3.0
2 2
1 425a 1 425b
Compressor clutch
RB RB
3.0 3.0
Radiator fan one
Radiator fan two

R
M R M
3 3
906 906
B B
3.0 3.0
A.S.FAN2
A.S.FAN1
A.S.KOS
426
GQ04 GQ04 OrBl
0.5
69 50 68
ME797 ECU
34 15 3 61 80 51 53 57 74
211 14 A
M.M.EL1
M.M.ES1
M.M.ZUE
E.S.PSW
E.F.DGB
M.M.EL2
E.S.PSW
M.M.ES2
E.F.DGA
BlR WV
0.5 0.5
Air-conditioner medium-voltage switch
Connected to the clutch switch 1# pin

To P 55
451 450
P BlG 3
0.75 0.75
1 2
930A 930B 930C 910A 910B 922E

B B B B B B
Engine speed sensor
2.0 0.75 0.75 0.75 0.75 0.5
GF01 GF01 GF01 GF02 GF02 GF02
GF03 GF03
A-66
62 Circuit Diagram
F07 To P 60
To P 68 Connected to the immobilizer controller A7 pin

To P 64 Connected to the airbag module A27 pin
465B 464B
YW R
0.5 0.5
CAN-L
502
To P 68
Diagnostic tester W
0.5 Connected to the immobilizer
controller A8 pin
9 16
1 8
503
R
0.5
CAN-H
CAN-H
CAN-L
911F 911G
B B
0.5 0.5
502A 503A GY01 GY01 466

W-LINE
W R BlOr
0.5 0.5 0.5
81 62 71
ME797 ECU
75 21 58 43
208 67D 66
E.S.BR
E.S.AC
E.S.BL
MP5 A2 base
To P 71
RB GV RBl
0.5 0.5 0.5
110 692
B RY
0.5 0.5
Air-conditioner hv/lv switch 1#
Brake lamp switch 4#

To P 66
To P 66
To P 74
To P 75
h2 g2 f2 e2
Cruise control switch

A-67
Circuit Diagram 63
TRANSMISSION CONTROL SYSTEM
F07 To P 60 30b To P 55 15b To P 55 15a To P 56
F17
10 A
To P 66
Connected to
Connected to the BCM J1-A4 pin To P 79 the brake lamp switch 1 pin
510B 510A 65B 60B

R R RB R
0.5 5.0 0.5 0.85
73D
Reverse lamp relay

85 30 85 30
GB
TCU Relay
Selector
0.5
B7
86 87 86 87
500 61
RB RW
5.0 0.85
To right reverse lamp

To P 69
To P 62
Connected to
B8 B6 B5 B4 B3 B2 B1 the diagnostic interface 7 pin
911E
B
0.5
CAN-H
CAN-L
Reverse_light_cotrol
O_V_SENSOR5V2
G_R_SENSOR6
V_V_PERMBAT
B_D_CANH1
B_D_CANL1
V_V_BATR1
V_V_BATR2
B_D_DIAK
O_S_MR
I_S_T15
464D 501 500a 500b 7 504 505 506 507 508 509 62 503C 502C 465A
I_A_S3
I_A_S4
I_A_S2
I_A_S1
R BY RB RB W YB YR BBl RBl RW GB BR R W YW
0.75 0.5 2.5 2.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
15 30 1 2 51 40 50 29 56 31 41 38 49 48 16
TCU transmission control system

27 32 44 43 25 3 54 23 14 36 24 13 26 33 35 42 5 12 39 21 22 45 4 10 11
511 512 513 514 515
O_V_SENSOR5V1
G_R_SENSOR1
G_R_PWRGND1
I_F_INPUTSPEEDB
I_F_INC3B
O_T_MOTOR3+
G_R_SENSOR4
I_F_INC2B
O_V_SENSOR5V4
I_F_INC1B
O_V_SENSOR5V3
G_R_SENSOR3
O_T_MOTOR1+
I_F_INPUTSPEEDA
O_T_MOTOR3-
O_T_MOTOR2-
O_T_MOTOR1-
I_A_GT
O_T_MOTOR2+
I_F_INC3A
I_F_INC1A
G_R_PWRGND2
G_R_SENSOR5
G_R_SENSOR2
I_F_INC2A
BW BR G R B
0.5 0.5 0.5 0.5 0.5
516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533
W WB RB G BlB GR OrW GW BlW GrW VW WR BlR RY GY BlY BrY RBl
2.5 0.5 0.5 2.5 0.5 0.5 2.5 0.5 0.5 0.5 0.5 2.5 2.5 0.5 0.5 0.5 0.5 2.5
2 1 2 1 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1
M M M
S
Transmission oil Input shaft speed sensor Clutch motor controller Shift motor controller 2 Shift motor controller 1
temperature sensor
931 932
B B
2.5 2.5
GQ05 GQ05
A-68
64 Circuit Diagram
AIRBAG CONTROL SYSTEM
15b To P 55
F25
15 A
To P 62
Connect the diagnostic interface 7 pin
DIAGNOSTIC K
465C 385
YW R
0.85
IG
0.5
A27 A32
Electronic airbag control module

Connected to the mp5#a1 pin
To P 71
Horn relay 86 base

To P 81
A1 A2 A3 A4 A5 A6 A7 A8
381 382 383 384 389 390 391 392

R-
WBl
D PT F
WR
DAB F
PAB F
PPT F
YR YBl
DAB R -
Y YB G GB
DPT R -
PPT R -
0.5 0.5
0.5 0.5 0.5 0.5
PAB
0.5 0.5
126 97b
Y WR
0.5 0.5
c2 d2 a2 b2 1 2 1 2 1 2
Clock spring
Front passenger air-bag Left-side seat belt Right-side seat belt

pretensioner pretensioner
Front passenger air-bag

A-69
Circuit Diagram 65
Combination instrument 17 base

To P 73
Connected to the BCM J2-A31

To P 79
SRS indicator light
WARNING LAMP
CRASH OUT
386 393
GBr Br
0.5 0.5
A17 A19
Electronic airbag control module
A9 A10 A11 A12 A13 A14 A15 A16 A23 A24 A25 A26 A30
387 388 394 395 396 397 398 399 376 377 378 379
DSAB R -
PC F
PSAB F
DC F
S-RSU P F
DSAB F
PC R -
PSAB R -
S-RSU D F
S-RSU P R -
S-RSU D R -
DC R -
YB YW GW GB YW YR GR GW YR YBl GY GR
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
1 2 1 2 1 2 1 2
1 2 2 1
Left-side collision Right-side collision

sensor sensor
Left-side side airbag Right-side side airbag Left-side side Right-side side
curtain airbag curtain airbag
933
B
0.85
GY03
A-70
66 Circuit Diagram
VEHICLE STABILIZATION SYSTEM
15b To P 55 30d To P 55 30b To P 55 30c To P 55
F24 F10 F33

5A 25 A 10 A
To P 56
Connected to the
ignition switch 2 pin
602 8E 65
RY Y RB
0.5 0.5 0.85
2 1
Brake lamp switch

3 4
66 67
RBl GV
0.5 0.85
Speed output
Connected to the engine ECU 58 pin
To P 62
67B 67D 67E 67C

GV GV GV GV
0.5 0.5 0.5 0.5
To P 62
To P 67
the engine ECU 21 base
Connected to
To P 79
the BCM J2-A35
Connected to
the ABS 30 pin

Connected to
602A 602B 601 600 421

UB_MR
VALVE
RY RY WR R BrG
WAU
0.5 0.5 2.5 4.0 0.5

28 25 1 30 10
ESP control unit
26 14 12 8 19 4 16 18 31 29 17 13 38
503H 502H 606 611 612 613 614 615 616 617 618
GND_ECU
WSP_RL
WSS_FR
WSP_FR
WSP_RR
WSS_RL
WSP_FL
TCS_OFF
WSS_FL
GND_MR
CAN_H
WSS_RR
CAN_L
R W WBl BrB BrR YBl BlY GB GR GBl GW

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
CAN-L
CAN-H
To P 82
control panel switch two 2 pin
Connected to the central
1 2 3 4 1 2 1 2 1 2 1 2
SAS
Turn angle sensor Front left wheel Front right wheel Rear left wheel Rear right wheel
914E 902I 903H
B speed sensor speed sensor speed sensor speed sensor B B
0.5 4.0 2.5
GY01 GQ01 GQ01

A-71
Circuit Diagram 67
ANTI-LOCK BRAKING CONTROL SYSTEM
30d To P 55 30b 15b To P 55
F10 F24
25 A 5A

To P 66
Speed output
CAN-H
CAN-L
BRAKELIGHT SWITCH
421 601 600 602 502D 503D 67C

MOTOR
VALVE
BrG WR R RY W R GV
0.5 2.5 4.0 0.5 0.5 0.5
IG
0.5
33 25 1 28 14 26 30
ABS control ECU
13 38 8 19 4 16 18 31 29 17
611 612 613 614 615 616 617 618
WP FL
WP RR
WS FL
WP RL
WS RL
WS RR
WS FR
WP FR
BrB BrR YBl BlY GB GR GBl GW

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
1 2 1 2 1 2 1 2
902I 903H Front left wheel speed sensor Front right wheel speed sensor Rear left wheel speed sensor Rear right wheel speed sensor
B B
4.0 2.5
GQ01 GQ01
A-72
68 Circuit Diagram
ANTI-THEFT CONTROL SYSTEM
F23 To P 72 F07 To P 60
To the combination instrument 9 pin

To P 73
To P 62
To P 62 Connected to To P 60
Connected to the diagnostic Connected to
the EFI ECU 71 pin interface 7 pin the EFI ECU 29 pin
466A 465 422 350B 464B 459

W-LINE
R-LINE
K-LINE
BlOr YW VB WR R BrB
LED
B+
0.5 0.5 0.5 0.5 0.5 0.5

IG
A8 A7 A5 A4 A1 A3
Immobilizer controller
A2 B1 B2 B3
GND
ANTB
GND
ANTA
Immobilizer coil
911A
B
0.5
GY01
A-73
Circuit Diagram 69
REVERSE LAMP AND REVERSE RADAR CONTROL SYSTEM
To P 55 30c F17
F17
10 A
60
R
0.85
To P 63
Connected to
the reverse lamp 60B
relay 87 pin R
0.85
Reverse lamp switch
2
AMT vehicle special model
1
special model
MT vehicle
61
RW
0.85
61C
RW
0.5
8
61E 61G 61M

RW
0.5
RW
0.5
RW
0.5
Collision avoidance
radar ECU 16
To CD retractable, integrated A5
To the combination instrument 33
To BCM J2-A38 pin

To P 83
To P 73
To P 70
2 1 5 15
745 747 749 748
YBl BlR BlG BlB
61D 61F 0.5 0.5 0.5 0.5
RW RW
Left reverse lamp
Right reverse lamp
0.5 0.5
1 1 923A 923B 923C 923D
B B B B
0.5 0.5 0.5 0.5
2 2
2 1 2 1 2 1 2 1
Detector 1 Detector 2 Detector 3 Detector 4
920C 920M 923E

B B B
0.5 0.5 0.5
GY01 GC02 GY01 GC02 GC02

GC01 GB01 GC01 GB01
A-74
70 Circuit Diagram
AUDIO CONTROL SYSTEM
X2 To P 56 F20 30c To P 55 J07
J07
40 A
800 800
RG RG
3.0 2.0
800
To P 79
Connected to the BCM J1-A4 pin RG
1.25
Ceiling-mounted antenna
F20
102
15 A
RW
1.25
To P 69
To the reverse lamp switch 1#
Antenna
Antenna
amplifier
ACC power supply
100B 73Q 102B 103 61E

Or GB RW Bl RW
1.25 0.5 1.25 0.5 0.5
A4 A6 A7 C8 A5
CD/cassette player
B5 B6 B7 B8 A8
+ 105 - 106
Bl BlV + 115 - 116
0.5 0.5 BlOr BlY
0.5 0.5
1 + - 2 1 + - 2 1 + - 2
Front left tweeter

Front left bass speaker Rear left bass speaker
921D
B
1.25
GY01
GB01
A-75
Circuit Diagram 71
Connected to the BCM J1-A4 pin To P 79
Camera
To P 65 To ABS 33#
To P 66 To ESP 10#
2 4 3 1
Shielded
LIN communications
wire
Speed input
Singal-
Singal+
421 639 685 683 684 681

BrG LgR YBl YB YR PW
0.5 0.5 0.5 0.5 0.5 0.5
126
C10 C3 C7 C5 C4 C6
Y Steering wheel To P 64
0.5 left-side input Connected to
A1
the clock spring c2
110
CD/cassette player
B To P 62
0.5 GND Connected to
A2
the clock spring f2
125
RY
0.5 Steering wheel right-side input
A3
B1 B2 B3 B4
+ 117 - 118 + 107 - 108
BlG BlB BlR BlW
0.5 0.5 0.5 0.5 To P 59
Connected to
the engine ECU
35 base
73G 430B 125

LEDPOWER
GB Y RY
0.5 0.5 0.5
i2 j2 k2 l2
Clock spring
Steering wheel
1 + - 2 1 + - 2 1 + - 2
Front right tweeter

switch
Rear right bass speaker Front right bass speaker
A-76
72 Circuit Diagram
COMBINATION INSTRUMENT SYSTEM
To P 55 15b F23
F23
10 A
371 362 363 364 350A

RBl GBl VBl RG WR
73L
0.5 0.5 0.5 0.5 0.5
GB
21 22 23 24 1
0.5
Turn the page upwards

Central panel switch
Turn the page down

Combination
SET
LIMRSET
instrument
Connector terminal 12 11 10 9 8 7 6 5 4 3 2 1
19 35 25
352 351 361
WG WBl WB
0.5 0.5 0.5
Parking brake switch
Driver seat belt buckle
Front passenger seat belt buckle
1 1 1
2 2 2
From ground
911S 911T 911A 918B 918F

B B B B B
0.5 0.5 0.5 0.5 0.5
GY01 GY01 GY01 GC01 GC01

A-77
Circuit Diagram 73
J07 To P 70
F19
10 A
Connected to the reverse switch 1 base

To P 69
To P 68
Immobilizer controller A3
Airbag control unit A17
To P 65
Generator L base
To P 55
To BCM J1-A38
To P 79
CAN-H
CAN-L
502E 503E 101 61G 386 459 16 559

W R GrW RW GBr BrB WB Br
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
29 28 2 33 17 9 4 5
Combination instrument
26 6 3 27 12 11 37
369 353 PGND AGND 355 354 356
WG GBl YW YR YV
0.5 0.5 0.5 0.5 0.5
Front passenger weight sensor
2(+)
Fuel sensor
1
Q
Brake fluid level switch
Oil pressure switch
3(-)
1
2
2
From ground
918B 905B 911C 911B

B B B B
0.5 0.5 0.5 0.5
GC01 GQ03 GY01 GY01

A-78
74 Circuit Diagram
A/C CONTROL SYSTEM
F17 F20 To P 69 F17 30c To P 55

To P 70
J05
40 A
60g 200
R R
To P 79
Connected to 0.5 3.0
the BCM J1-A4 pin 85 30
Blower relay
Engine ECU 75#
To P 62
86 87 1
912F 201
B RG M
0.5 3.0
2
201E 203b
208
RG BlW
RB
3.0 3.0
0.5
1
GB01 201A 203
HV/LV switch
RG BlW
0.5 3.0 High-speed blower relay 203A
85 30
BlW
D 2.0
4
Speed regulator module
86 87
G R S
912d 921C
B B
3.0 2.0
207 60E 102A 73I 201D 204 GY01 209 205 GB01
RY R RW GB RG BlY GB01 BlR BlV
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
A9 A2 A1 B8 A4 A7 A5 A6 B3
Air-conditioner ECU
B7 B12 A16 A13 A14 A15 B6 B2 A10 A12 B5 B10 A11 B9 B11 A8 B1
639 236 235 238 237 220 221 222 223 224 225 227 229 231 239
LgR RB VW BBl VB BlG V BlOr GV BlR WR BlG BlB BrBl BrY
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
LIN communications
1 2 1 5
1 3 2 1 3 2
Outside temperature sensor
Cabin temperature sensor
t t
- +
- + - +
4 5 4 5
2 1 Mode actuator Heat/cooling actuator Internal circulation actuator
921A 921B
B B
0.5 0.5
GB01 GB01
GY01 GY01
A-79
Circuit Diagram 75
To P 69 F17 30c To P 55 F17 F20 To P 70 30c F17
F17
F37 J05
25 A 40 A
60R 253 200 60G

To P 79 R R
R RG
Connected to the
0.5 2.0 BCM J1-A4 pin 3.0 0.5
86 30 30 86
Defroster relay
Engine ECU 75#

To P 62
Blower relay
85 87 87 85
251 252 201 912F
1
WBl RV RG B
0.5 2.0 3.0 0.5 M
208 2
RB
0.5 201E 203B
1 RG BlW
GY01
3.0 3.0
HV/LV switch
201A 203
RG BlW
3.0
High-speed blower relay

0.5
203A
4 85 30
BlW
D 2.0
Speed regulator
module
86 87
204 912D G R S
BlY B
0.5 3.0
209 205
60E 102A 73I 207 201 BlR BlV
R RW GB RY RG 0.5 0.5
GY01
0.5 0.5 0.5 0.5 0.5
B3 A2 A1 B8 A9 A4 A7
A5
Electronic air-conditioner ECU A6
B7 B6 B2 A10 A12 B5 B10 A11 B9 B11 A8 B1

252D 252B 252C 220 221 222 223 224 225 227 229 231 239
RV RV RV BlG V BlOr GV BlR WR BlG BlB BrBl BrY
2.0 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Left exterior rearview mirror defroster
Right exterior rearview mirror defroster
1 1
Rear defroster
1 3 2 1 3 2 1 5
5 5
- +
- + - +
4 5 4 5
Door positioning micro-motor Door temperature micro-motor Fresh air micro motor
920Q 909C 908H 921A 921B 921C

B B B B B B
2.0 0.5 0.5 0.5 0.5 2.0
GY01 GC02 GB02 GY02 GB01 GB01 GB01

GC01 GB01 GY04 GY01 GY01 GY01
A-80
76 Circuit Diagram
ELECTRIC REARVIEW MIRROR CONTROL SYSTEM
X2 To P 56
100
Or
0.5
5
Power side mirror regulator switch
3 10 6 2 9 7
154 153 155 152 151

PBr PG PBl PY PB
0.5 0.5 0.5 0.5 0.5
155A
PBl
12 left 0.5
M
11 10 top
M
Mirror-adjuster right motor
10 top
11 12 left
155B
PBl
Mirror-adjuster left motor 0.5
909M
B
0.5
GB02
GY04
A-81
Circuit Diagram 77
REAR WIPER AND WASHER SYSTEM
15a To P 56
F21
10 A
172
RG
1.25
Auto return
MIST to position
OFF
172B
Front wiper switch
INT
RG
3 1.25 LO
Rear wiper motor
HI
2 M Wash
Auto return
to position
INT adjustment
4 168 Auto return

Rear wiper switch
Wash to position
RBl
1.25 OFF
ON
Auto return
Wash to position
Connector terminal 10 9 8 7 6 4 3 2
172E
RG
0.5
Rear wiper relay
87 86
30 85
174
RB
0.5
907F 920 911N 911M

B B B B
1.25 1.25 0.5 0.5
GQ03 GB01 GY01 GC02 GY01 GY01

GQ04 GC01 GB01
A-82
78 Circuit Diagram
VEHICLE BODY CONTROL SYSTEM
15a To P 56
F18
15 A
160
BlW
1.25
172C 172D 160E 160F 160B 160C 160D

RG RG BlW BlW BlW BlW BlW
0.5 0.85 0.85 0.5 0.5 1.25 0.5 H L
Front wiper speed relay

Rear washer relay
Front washer relay
87 86
Front wiper relay
86 87 86 87 86 87
87a
166 165
87a 912K 912L 87a 87a
BlR Bl
B B 1.25 1.25
85 30 0.85 0.85 30 85 85 30 85 30
2 1
170 848 847
BlG BlR BlY
0.5 0.85 GY01 0.85 912A M S
Front wiper motor

B
1.25
Intermittent regulation
GY01
E
2 M 1 164
Wash
BlG
Washing motor 907A
1.25
B
Wiper return signal

1.25
173 175 834 835 836 GB01 163

GQ03
RBl GY BlB BlGr BlBr WG
GQ04
0.5 0.5 0.5 0.5 0.5 0.5
J2-A10
J1-A47
J1-A17
J1-A20
J1-A11
J2-A39
BCM
J2-A12
J2-A13
162 161
BlR BlY
0.5 0.5
High speed Low speed

79
Back door unlock relay

GY01 GB01
Back door lock motor

912R
301a
1.25
BlGr
1.25
1.25
291
BlY
Front right door status switch

B
M
1
0.5
2
30
87
89
From ground
P
15 A
F36
J2-A3
301b
BlGr
BlGr
1.25
30c
838
301
GY
0.5
0.5
J1-A13
85
86
73A
Backlight power supply
GB
0.5
J1-A4 Front left door status switch
YBl
0.5
From ground
83
J2-A2
Vehicle anti-theft
559
To P 73
0.5
system indicator light
Br
J1-A38
Connected to the combination instrument 5 pin
Circuit Diagram
Back door status switch
921P
BrBl
BrBl
85A
0.5
0.5
Unlock-upon-collision
0.5
85
GB01
GY01
B
393
To P 65
BCM
0.5
J2-A1
input
Br
2
1
Airbag control module A19
J2-A31
BrBl
85B
To P 83
0.5
Connect the trunk light. 2 base
67E
To P 66
GV
0.5
J2-A35
20 A
F28
280
30c
2.0
R
J2-B2
BCM3
Unlock
GW
283
0.5
2
J2-A33
30c To P 55
20 A
F27
833
RB
2.0
J1-B8
BCM2
Lock
911A
284
GY
0.5
0.5
GY01
1
B
3
J2-A32
J07 To P 70
25 A
F22
Console lock and unlock switch
832
RW
2.0
J1-B1
BCM1
A-83
A-84
80 Circuit Diagram
30a To P 55 30a
F05 F06
15 A 15 A
To P 82
Connected to the BCM J2-B7 base
31 To P 79
30
BBl Connected to the BCM J1-A4 pin
RB
2.0
2.0
30a 30b 31B 31A

RB RB BBl BBl
2.0 0.5 0.5 2.0
30 85 85 30
High beam relay
Low beam relay
73L 33C
86 86 GB RB
Central control panel switch
87 87
10 0.5 4 0.5 36
32 34 35 33
RG RB RW
BlR RY
0.5 2.0 0.5
2.0 0.5
6
32B 32A 36A 71G 36B 71H
Right headlamp regulator motor

33B 33A
Left headlamp regulator motor

11 5
BlR BlR RB RB RW Lg RW Lg
1.25 1.25 1.25 1.25 0.5 0.5 0.5 0.5
2 1 2 1
Right high beam lamp
911S 911T
Right low beam lamp
Left high beam lamp
Left low beam lamp
2 2 6 6 B B M M
0.5 0.5
3 3
5 3 3
5
903C 904C 903B 904B 903D 904D
B B B B B B
1.25 1.25 1.25 1.25 0.5 0.5
GQ01 GQ04 GQ01 GQ04 GY01 GQ01 GQ04

J1-A15
J1-A7
BCM
J2-A4
J2-A5
J2-A7
J1-B2
J1-A5
J1-A6
J1-B3
87 88 290 64 68 69 38
Gr W RW RBr RBl RG YBl
0.5 0.5 0.5 0.5 0.5 0.5 0.5
Rear left door status switch
Rear right door status switch
Back-door opening switch
38A 38B
YBl YBl
2
Front left daytime running light
Front right daytime running light
0.5 0.5
Right brake lamp
3
Left brake lamp
2 3
1 1
High-mount brake lamp
4 4 2 2
1
921Z 920H 920G 920M 903G 904G
B B B B B B
0.5 0.5 0.85 0.85 0.5 0.5
GB01 GC01 GB01 GC01 GB01 GQ01 GQ04

GY01 GC02 GY01 GC02 GY01
A-85
Circuit Diagram 81
30c To P 55 30c 30d To P 55 30c
F34 F32 F09 J04
10 A 10 A 15 A 30 A
43 44 95 304
RBl RG Br R
0.85 0.85 1.25 3.0
43a 43b 44a 44b 95A 95B 304b 304a

RBl RBl RG RG Br Br R R
Front right fog lamp relay
0.85 0.5 0.85 0.5 0.5 1.25 0.5 2.0

Front left fog lamp relay
30 85 30 85 85 30 85 30
Window relay
Horn relay
87 86 87 86 86 87 86 87
41 42 47 45 97 96 303
RG Bl BlR Y WR Gr BlY
0.85 0.5 0.85 0.5 0.5 1.25 2.0
97b 96A
window main controller switch 10 pin

Connected to the front-door power
96B
WR Gr
Gr
0.5 0.85
0.85
Front left fog lamp
Front right fog lamp
spring d2 base
Connected to the clock
To P 64
1 1
2 2
Tweeter
Woofer
2 2
1 1
903A 904A 319
97C 907Y
B B RB
WR B
0.85 0.85 0.5
0.5 1.25
GQ01 GQ04 GB01 GQ03 GQ04

J1-A8
J1-A36
J1-A10
J1-A16
BCM
J1-B5
J1-B7
J1-B6
46 55 54
BlGr GR GV
0.85 0.85 0.85
46a 46b 55C 55A 55B 54C 54A 54B

BlGr BlGr GR GR GR GV GV GV
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
Rear left fog lamp
Rear right fog lamp
Front left steering lamp
Rear left steering lamp
steering lamp
Left rearview mirror
Front right steering lamp
Rear right steering lamp
steering lamp
Right rearview mirror
1 1 2 2 2 2 2
2
2 2 1 4 6 1 4 6
923A 923B 903E 920G 909B 904E 920M 908B

B B B B B B B B
0.5 0.5 0.5 0.85 0.5 0.5 0.85 0.5
GC02 GC02 GQ01 GC01 GB01 GB02 GQ02 GC01 GB01 GY02
GC02 GY01 GY04 GC02 GY01
A-86
82 Circuit Diagram
30d To P 55
F35
10 A
853
RW
0.85
304C 853B 853C 304D 304E 853D

R RW RW R R RW
0.5 0.5 0.5 0.5 0.5 0.5
Economizer relay fuse
86 87 87 86 86 87 80A 80B 80C

Turn on relay
87a
Stow relay
87a BlY BlY BlY

87a
2 0.5 2 0.5 2 0.5
30 85
Luxury reading lamp

85 30
Interior ceiling light

85 30
Reading lamp
912B 912C 912E
B B B
0.5 0.5 0.5
GY01 GY01
GY01 80
157 158 BlY 1 3 3 4 5 1
OrW 3 M 4 OrG 0.85
0.5 0.5
4 917F 917 917

3 M
B B B
Stow motor 0.5 0.5 0.5
82A 82C 82C
GY04 BrR GY04 BrR GY04 BrR
0.5 0.5 0.5
156 159 839 82

P Bl BrW BrR
0.5 0.5 0.5 0.5
J1-A32
J2-B8
J1-A33
J1-A25
BCM
J2-B7
J2-A8
71 287
Lg RY
1.25 0.5
Key detector switch
71F 71B 71D 71A 71C 71E 71

Lg Lg Lg Lg Lg Lg Lg
0.5 0.5 0.5 0.5 0.5 0.5 0.5 2
Front left position light
Rear left position lamp
Left license plate lamp
Front right position lamp
Rear right position lamp
Right license plate lamp
1 1 2 1 1 2
motor 1 pin
Connected to the headlamp
To P 80
4 4 1 4 4 1
903F 920G 920F 904F 920M 920J 911E

B B B B B B B
0.5 0.85 0.5 0.5 0.85 0.5 0.5
GQ01 GC01 GB01 GC01 GB01 GQ02 GC01 GB01 GC01 GB01 GY01
GC02 GY01 GC02 GY01 GC02 GY01 GC02 GY01
A-87
Circuit Diagram 83
30c To P 55 X2 To P 56 15b To P 55
F40
5A
Connected to the ESP 12 pin

To P 66
To P 79
Connected to the BCM J1-A4 pin
To P 79
Connected to
the BCM J1-A4 pin
To P 79
Connected to
the BCM J1-A4 pin
100E 73C 73J

Or GB GB
0.5 0.5 0.5 606 73K
WBl GB
0.5 0.5
Terminal 3 5 1 4 Danger indicator switch

Rearview mirror stow switch
Function 4 R2
2 1 3
LED2
Central control panel switch two

1
Reset 2 R1 5
LED1
Trunk light
Fold
ESC OFF
HAZARD SW1
Backlight ESC
2 1
85B 909I
BrBl B
0.5 0.5 8 911Y
B
GB02 913E 0.5
door status switch 1 pin
Connected to the back
To P 79
GY04
B
0.5
IG2 signal detection
GY02 GY01
150 53 52
7h
Br BR BY W
0.5 0.5 0.5 0.5
J2-A29
J2-A14
J1-A2
J1-A48
BCM
J1-A19
J2-A30
J2-A26
J2-A27
J2-A38
J2-B1
J2-B5
78 Unlock 282 Lock 281 286 100G 9D 61M

BlY BlR PG BlY Or RW RW
0.5 1.25 1.25 0.5 0.5 0.5 0.5
2
Ignition keyhole light
2 1 4
Key position
282A 281A signal
BlR M PG
1.25 1.25 Front left door
Connected to the acc fuse
Connected to the ig1 relay 87#

To P 56
To P 56
Connected to the reverse lamp switch 1#

To P 69
lock body
1 3
282B 1 2 281B
BlR M PG
1.25 Front right door 1.25
lock motor
282C 2 1 281C
BlR M PG
1.25 1.25
Rear left door
lock motor
282D 281D
1 M 2
BlR PG 909H
911
1.25 1.25 B
B Rear right door
0.5 lock motor 0.5
GY01 GB02
GY04
A-88
84 Circuit Diagram
Left turn Right turn Low beam High beam Position lamp Front fog lamp Rear fog lamp
842 843 844 845 846 841 840

GY GR YG YBl GW YR YB
0.5 0.5 0.5 0.5 0.5 0.5 0.5
J2-A19
J2-A20
J2-A22
J2-A21
J2-A9
J2-A34
J2-A24
BCM
J2-A25
J1-A39
J1-A45
J2-B4
J2-B3
J1-B4
J2-B6
15 A 503F 502F
START
GND-POWER
GND-SIGNAL-0
GND-SIGNAL-1
GND-SIGNAL-2
BW R W
0.5 0.5 0.5
CAN-L
CAN-H
Connected to the starter relay 87 base
To P 55
913C 913B 913A 913D

B B B B
1.25 0.85 0.85 0.85
GY02 GY02 GY02 GY02

A-89
Circuit Diagram 85
Terminal
1 2 3 4 6 7 8 9 10 11 12
Function
OFF
Main light switch
Low beam
While the
main light High beam
switch is off
Dimmer switch
Overtaking
vehicle
Low beam
While the
main light High beam
switch is on
Overtaking
vehicle
Steering switch Central
Front fog
lamp
Fog lamp switch
Front fog
lamp
911K 911I 911D 911J

B B B B
0.5 0.5 0.5 0.5
GY01 GY01 GY01 GY01

A-90
86 Circuit Diagram
WINDOW CONTROL SYSTEM
73F
GB
0.5
303
To P 81 BlY
Connected to 4
2.0
the window relay
10 Manual raising
87 pin
Manual lowering
lowering
Automatic
IC module
Backlight
Backlight
Backlight
Backlight
Backlight
UP
DOWN
5 6 9
305 306
output 1
output 2
G R
2.0 2.0
1 2
UP DOWN
Front left door motor
909E
B
2.0
GB02
GY04
A-91
Circuit Diagram 87
To P 79
Connected to the BCM J1-A4 pin
Left front-door lifter switch

73E
GB
0.5
PCUT
R R R
GND
GND
GND
GND
GND
GND
1 3 1 3 1 3 1 3 1 3 1 3
2 2 2 2 2 2
FRU FRD RLU RLD RRU RRD

3 2 1 11 l2 8 7
302 313 314 315 316 317 318
WG BlW BlB RY GY RB Lg
2.0 2.0 2.0 2.0 2.0 2.0 2.0
302A 302B 302C

WG WG WG
2.0 2.0 2.0
2 1 3 5 2 1 3 5 2 1 3 5
Front right window light switch
Rear right window light switch

Rear left window light switch
2 1 2 1 2 1 2 1 2 1 2 1
3 3 3 3 3 3
6 309 4 310 6 307 4 308 6 311 4 312
G R G R G R
2.0 2.0 2.0 2.0 2.0 2.0
UP 1 2 DOWN UP 2 1 DOWN UP 2 1 DOWN
Right front-door motor Left back-door motor Right back-door motor

A-92
88 Circuit Diagram
CIGARETTE LIGHTER, ON-BOARD POWER SOURCE, SUNROOF

CONTROL SYSTEM
X1 To P 56 F17 To P 69 30c To P 55
F16 F43
25 A 25 A
90
RBl 60J 130 73B
2.0 R WG GB
0.5 2.0 0.5
3 6
Sunroof ECU + -
2 1 5 10
909J 909W 131 132
B B BlV BlY
0.5 1.25 0.5 0.5
90B 90A
RBl RBl
1.25 1.25
4 3 2 1
Sunroof switch
2 2 On
Cigarette Lighter
On-board power source
Middle
Off
1 1
909G 909T
B B
1.25 0.5
913F 913I 909

B B B
1.25 1.25 1.25
GY02 GY02 GB02

GY02
Memorandum
Memorandum
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H1 Service Manual

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INTRODUCTION

THE FOLLOWING IS ONE OF THE MANUALS CONCERNING THIS VEHICLE. PLEASE

AS THE EDITOR'S SKILL IS LIMITED, THIS MANUAL INEVITABLY WILL BE DEFICIENT

IF YOU HAVE ANY SUGGESTIONS REGARDING THE CONTENTS OR PRESENTATION

IF YOU ENCOUNTER OTHER TECHNICAL PROBLEMS DURING REPAIR, PLEASE CON-

Great Wall Motor Co., Ltd

FILLING VOLUME AND SPECIFICATIONS

Location Code Definition Description

2. The vehicle identification number (2) is located on

3. The vehicle identification number (3) is located on

LIFTING AND SUPPORTING THE VEHICLE

TRACTION AND TOWING

1. Engine Bay Warning Label 4. Front Airbag Warning Label

REGULAR MAINTENANCE CHECK

TIMING CHAIN AND TENSIONING DEVICE

BRAKE PAD AND BRAKE DISC

N•m Specified torque

1. Left Engine Suspension Assembly 3. Rear Engine Suspension Assembly

N•m Specified torque

1. Left Engine Suspension Assembly 3. Rear Engine Suspension Assembly

Fastener Quantity (units) Tightening torque (N•m)

Fastener Quantity (units) Tightening torque (N•m)

PROCEDURES FOR REPAIR

5. Remove left suspension assembly

RIGHT ENGINE SUSPENSION

3. Remove the three bolts that connect the right sus-

4. Remove right suspension assembly

REAR ENGINE SUSPENSION

4. Remove the bolts that connect the rear suspension

5. Remove rear suspension assembly

1. Fuel Tank Lock Assembly 8. Fuel Filter

1. Desorption Hose No. 2 9. Fuel Intake Hose No. 1

ACCELERATOR CONTROL MECHANISM

1. Accelerator Pedal Bracket Assembly 3. Accelerator Pedal Decorative Cover

PROCEDURES FOR REPAIR

4. Remove the quick connectors that connect desorp-

5. Squeeze open the elastic hoop that connects the

6. Lift and support vehicle

FUEL PUMP AND ACTIVATED-CARBON

4. Remove fuel pump

FUEL FILTER ASSEMBLY

3. Lift and support vehicle

REFUELING PIPE ASSEMBLY

2. Remove the two refueling pipe protective plate

3. Remove the fixing bolts that join the refueling pipe

4. Remove the hoops and clips on the refueling hose,

1. Intake Hose 4. Air Filter Element

1. Intake Hose 4. Air Filter Element

PROCEDURES FOR REPAIR

2. Unscrew the type B worm drive hose hoop on both

1. Gasket 7. Three-Hole Rubber Block

PROCEDURES FOR REPAIR

3. Remove secondary silencer assembly

(b) Remove the three rubber suspensions on the secondary

3. Remove the front exhaust pipe and catalytic con-

3. Remove middle heat shield.

4. Remove front heat shield

1. Radiator Assembly 8. Expansion Tank Ventilation Pipe

FAULT ANALYSIS AND TROUBLESHOOTING