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WULING CONFERO Service Manual This manual provides information about the WULING CONFERO series models of diagnosis information, adjust and repair procedures, specifications and other information. PT. SGMW Motor Indonesia authorized service center staff in understanding the issue of this manual and after PT. SGMW Motor Indonesia maintenance technology for the content of communication, the WULING CONFERO owners to provide better service. If the products with trade name, parts No. or special tools are mentioned in this Manual, we strongly recommend that you to purchase such products, parts and special tools via PT. SGMW Motor Indonesia Automobile Co., Ltd.. PT. SGMW Motor Indonesia All Rights Reserved The updated of information is June, 2017. Without the prior written permit from PT. SGMW Motor Indonesia, any part of this Manual shall not be copied or stored in the retrieval system, or propagated in any forms or means (including but not limited to electronic form, mechanical form, copy and recording). It is applicable to all characters, diagrams and tables.
Warning Warning: To reduce the possibility of injury and / or damage to property, observe the following instructions carefully:: This service manual provided by PT. SGMW Motor Indonesia, which is prepared for the use of qualified professional and technical personnel. Without proper training, without proper tools and equipment, when servicing process may result in injury to the service person himself or others. May also damage the vehicle or cause the vehicle to not operate properly. Proper vehicle maintenance and repairs are important for the personal safety of service personnel and the safe and reliable operation of all motor vehicles. If you need to replace a part, use the same part number or the part number specified by. Do not use replacement parts not approved by PT. SGMW Motor Indonesia
The service procedures recommended and described in this manual are an effective methode of servicing and repair. Some procedures, required specially designed tools. Therefore, if you want to use without PT. SGMW Motor Indonesia. recommended or recognized replacement parts, maintenance procedures or tools, must first of all personal safety or safety operation of vehicles without harm. This manual includes a variety of "caution" and "note", must be carefully observed in order to reduce the risk of injury in the service or repair. Improper repairs or repairs may damage the vehicle or pose a safety risk to the vehicle. These "caution" and "attention" are not exhaustive. PT. SGMW Motor Indonesia. cannot be a violation of these instructions brought about by all the potentially dangerous consequences are warning. This Manual includes servicing procedure of the vehicles equipped with supplementary restraint system (SIR). Refer to “Warnings” listed in “Warnings and Notes” and “Protective Device”. Before servicing on or around the component or circuit of supplementary restraint system, refer to the notes on servicing of supplementary restraint system listed in “Protective Device”. Violating such “Warnings” may cause the opening of supplementary restraint system, personnel injury or unnecessary repair of supplementary restraint system. To prevent accidental deployment and injury of the airbag, if the SRS system and other vehicle systems require repairs, it is recommended that the SRS system be repaired first before servicing the other systems.
Information Feedback This service manual contains information on the main service technology information of a specified series of vehicles up to the closing date. Please do not hesitate to contact us if you have any comments or suggestions when using this manual.
PT. SGMW Motor Indonesia After-sales Engineering Department Address: Greendland International Industrial Center (GIIC), Block BA No.1 Deltamas, Cikarang, Bekasi, West Java, Indonesia Postcode: 17530 Once your comment and suggestions are adopted, the Service Manual will be modified immediately and updated in a timely manner. Your enthusiastic support will help to perfect the servicing information and provide better service to the servicing station; meanwhile, you can obtain important information from other servicing station and benefit from it.
Section Index Foreword Chapter 1 General information Chapter 2 Metal components and decorating parts of body Chapter 3 Body repair Chapter 4 Vehicle body system
Volume A Chapter 5 Brake Chapter 6 Diagnostic overview, starting point and programming Chapter 7 Transmission system Chapter 8 Driver information and entertainment system Foreword
Volume B Chapter 9 Engine Foreword Chapter 10 Heater, vent and air conditioning system Chapter 11 Power and signal distribution Chapter 12 Roof (reserved)
Volume C
Chapter 13 Security and Protection Chapter 14 Seat Chapter 15 Steering system Chapter 16 Suspension system Chapter 17 Transmission
General Contents Chapter 0 Foreword ............................. 0-1 Danger, caution and warning ...................... 0-2
Chapter 1 General information ........... 1-1 1.1 General information .............................. 1-1 1.2 Air/wind noise ...................................... 1-10 1.3 Maintenance and lubrication ............... 1-12 1.4 Squeak and clicks ............................... 1-15 1.5 Vibration diagnosis and correction ...... 1-16 1.6 Water leak ........................................... 1-17
Chapter 2 Metal components and trim of body ..................................... 2-1
8.1 In-vehicle telephone, entertainment system and navigation system ........................... 8-1 8.2 Display and instrument ........................ 8-13 8.3 Auxiliary and configurable user control system .................................................. 8-32
Chapter 9 Engine ................................. 9-1 9.1 Engine control and fuel system ............. 9-1 9.2 Engine cooling system ....................... 9-81 9.3 Engine electrical system .....................9-102 9.4 Engine exhausts system ...................9-121 9.5 Engine mechanical system .................9-131
2.1 Exterior trimming ................................... 2-1 2.2 Floor coverings and headliner ............ 2-12 2.3 Instrument panel and console trim ...... 2-20 2.4 Interior and plate ................................. 2-39
Chapter 10 Heater, vent and air conditioning system ....... 10-1
Chapter 3 Body repair ......................... 3-1
Chapter 11 Power and signal distribution ........................................... 11-1
3.1 Body panel and partitions bolt .............. 3-1 3.2 Bumper and fascia ................................ 3-34 3.3 Collision repair .................................... 3-41 3.4 Frame and underbody ......................... 3-61 3.5 Paint and coatings .............................. 3-64
Chapter 4 Vehicle body system .......... 4-1 4.1 Fixed and movable windows ................. 4-1 4.2 Horn asm-generic ............................... 4-34 4.3 Lighting ................................................ 4-46 4.4 Rearview mirror ................................... 4-90 4.5 Vehicle access system ...................... 4-100 4.6 Wiper and washer ............................. 4-125
10.1 Heater, ventilation and air conditioning system .............................................. 10-1
11.1 Data communication .......................... 11-1 11.2 Power socket ...................................11-19 11.3 Circuit system and power management (placement of page number) ..............11-24
Chapter 12 Roof (reserved) ............... 12-1 Chapter 13 Safety and protection ..... 13-1 13.1 Theft deterrent module ........................ 13-1 13.2 Objects detection .............................13-11 13.3 Remote control function ..................13-20 13.4 Safety belt ........................................13-24 13.5 Supplementary restraint system .......13-44
Chapter 5 Brake ................................... 5-1
Chapter 14 Seat .................................. 14-1
5.1 Antilock braking system ........................ 5-1 5.2 ESC vehicle stability control system ... 5-49 5.3 Disc brake ........................................... 5-62 5.4 Hydraulic brake ................................... 5-79 5.5 Parking brake ...................................... 5-87
14.1 Metal components, trim and seat cover …….. .................................................. 14-1
Chapter 6 Diagnostic overview, starting point and programming ... 6-1 6.1 Programming and set up ....................... 6-1 6.2 Vehicle diagnostic information .............. 6-4
Chapter 7 Transmission system ......... 7-1 7.1 Front wheel driving shaft (Spacing) ...... 7-1
Chapter 8 Driver information and entertainment system ......... 8-1
Chapter 15 Steering system ............. 15-1 15.1 Electric power steering system .........15-1 15.2 Steering wheel and steering column (placement of page number) ..............15-27
Chapter16 Suspension systems ....... 16-1 16.1 Diagnostic information and procedures of suspension system ........................... 16-1 16.2 Front suspension ............................... 16-5 16.3 Rear suspension (coil spring semiindependent type) ..............................16-23 16.4 Tires and wheels ...............................16-33
16.5 Wheel alignment ............................. 16-43
Chapter 17 Transmission .................. 17-1 17.1 Manual transmission -(1.5L) ............... 17-1 17.2 Clutch .............................................. 17-14
Foreword -1
Foreword - 1 Foreword Content Danger, caution and warning ....................................... 2 Introduction .................................................................. 2 Definitions of “Danger”, “Caution”, “Warning” and “Special Notes” ..................................................... 2 Definition of “Danger” ........................................... 2 Definition of “Caution” .......................................... 2 Definition of “Warning”.......................................... 2 Definition of “Special Notes” or “Important Notes” 2 Cautions on handling the parts of antilock braking system .................................................................. 2 Cautions on handling the fuel .............................. 2 Cautions on assistant driving ............................... 2 Cautions on brake dust ........................................ 3 Cautions on irritation of brake fluid ...................... 3 Cautions on clutch dust ........................................ 3 Cautions on compressing valve spring ................ 3 Cautions on exhaust gas recirculation (EGR) system .................................................................. 3 Cautions on exhaust system servicing ................. 3 Cautions on eyes protection................................. 3 Cautions on fuel and evaporation emission pipe . 3 Cautions on hot exhaust system .......................... 3 Cautions on gasoline/gasoline vapor ................... 4 Cautions on releasing fuel pressure .................... 4 Cautions on safety glasses and gloves ................ 4 Cautions on knock sensor .................................... 4 Cautions on suspension spring ............................ 4 Warnings on the movement of catalytic converter 4 Warnings on the tightening the parts ................... 4 Warnings on tightening......................................... 4
Warnings on heated oxygen sensor and oxygen sensor ................................................................... 4 Warnings on placing the ignition switch onto OFF position when battery disconnected ..................... 5 Warnings on drive shaft ........................................ 5 Warnings on vehicle lifting and lifting positions .... 5 Cautions on opening the inflator module of SRS system .................................................................. 5 Cautions on the scraping of inflator module of SRS system .................................................................. 5 Cautions on treatment and storage of inflator module of SRS system ......................................... 5 Cautions on special tools of SRS system ............. 6 Cautions on SRS system...................................... 6 Warnings on removing the exterior trimming and emblem ................................................................. 6 Warnings on defroster outlet ................................ 6 Cautions on handling of glass and metal sheet ... 6 Special notes on installing windshield .................. 6 Warnings on transparent coating/UV protection materials ............................................................... 6 Warnings on brake caliper .................................... 6 Warnings on the influence of brake fluid on paint and electrical components .................................... 6 Cautions on movable parts and hot surface ......... 7 Cautions on battery disconnection ....................... 7 Cautions on removal of radiator cover ................. 7 Cautions on damaged fan blade .......................... 7 Cautions on electric coolant fan ........................... 7
Foreword -2
Danger, caution and warning Introduction Definitions of “Danger”, “Caution”, “Warning” and “Special Notes” The diagnosis and servicing procedures in the Manual include general and spesific “Danger”, “Caution”, “Warning”, “Special Notes” or “Important Notes”. If the technician fails to operate according to the recommended method, some procedures may be dangerous to the technician. “Danger”, “Caution”, “Warning”, “Special Notes” and “Important Notes” are prepared to prevent the occurrence of these dangers, but not all dangers are foreseen. Such information is listed clearly mentioned in the Manual. Such information is prepared to prevent the following situations: Serious physical injury or death caused to the technician. Damage to vehicles. Unnecessary servicing of vehicles. Unnecessary parts replacement. Improper servicing or replacement of vehicle components. Any caution or warning occurred in such servicing category are taken from each separate servicing category.
Definition of “Danger” You are required to adopt necessary operation or not to take the prohibited actions in case of “Danger”. The following consequences can be caused by “Danger” be ingnored: Serious physical injury or death caused to the technician. Serious physical injury or death caused to other technicians in the working area.
Definition of “Caution” You are required to adopt necessary operation or not to take the prohibited operation in case of “Caution”. The following consequences can be caused by “Caution”be ingonored: Serious injury caused to the technician. Serious injury or death caused to other technicians in the working area. In case of improper repair of vehicle, serious injury caused to the driver of this vehicle and/or its passengers
be ignored: Damage to vehicles. Unnecessary vehicle servicing. Unnecessary parts replacement. The operation or performance of the serviced system or abnormal component. Damage any system or component depends on the serviced system or component. Abnormal performance of any system and parts depends on the serviced system or component, Damage the tightener, basic tool or special tool. Leakage of coolant, lubricant or other main oil liquid.
Definition of “Special Notes” or “Important Notes” The necessity of some diagnosis or servicing procedures is emphasized in the statement of “Special Notes” or “Important Notes”. The purpose of these mentioned shown as follows: Define the procedures. Provide additional information to complete the procedure. Explain the reason of recommended procedures. Provide the information which can help the complete the procedures in a more efficient process. Provide the technician with past experience to make easily complete the process.
Cautions on handling the parts of antilock braking system Caution: Some parts of antilock braking system (ABS) can't be serviced separately. Trying to remove or disconnect some system parts may cause personal injury and/or abnormal running of system. The removal and installation parts are permitted can be serviced.
Cautions on handling the fuel Caution: The fuel steam will be built up when servicing fuel system parts in the enclosed area such as luggage compartment. To reduce the fire and explosion risk of fuel steam: Use forced air ventilation, such as placing a fan outside the luggage compartment. Plug or cover the opening of fuel system to reduce the formation of fuel steam. Clean up any spilled fuel immediately. Keep away from the spark and any ignition source. Remind others in the working area by signs that the fuel system is being serviced
.
Definition of “Warning”
Cautions on assistant driving
“Warning”, it requires to pay special attention to the necessary operation or prohibited operation. The following consequences can be caused by “Warning”
Caution: The assistant shall drive the vehicle when the technician views the failure part of the repair. Otherwise, it may result in personal injury.
Foreword -3
Cautions on brake dust Caution: The following operations shall be avoided when servicing the wheel brake parts: Don't polish the friction lining of brake. Don't polish the friction lining of brake by use of the sand paper. Don't clean the wheel brake parts by use of dry brush or compressed air. Some model or aftermarket parts brake parts may contain asbestos fiber, which will be mixed in the dust. Human body will be seriously damaged in case of inhalation of dust containing asbestos fiber. Please clean all dust on the brake parts by use of wet cloth. There are equipment for such cleaning process is available in the market. The usage wet cleaning process can be preventedfiber being mixed in the air
Cautions on irritation of brake fluid Caution: The brake fluid can irritate eyes and skin. Once it is touched, the following measures shall be taken: In case of affected the eyes –wash thoroughy with water. In case of contact the skin –wash with soap and water. In case of inhalation - seek medical advice immediately.
Cautions on clutch dust Caution: Don't polish the clutch disc or clean the clutch parts by use of dry brush or compressed air to avoid the generate dust. Use a damp cloth instead of a saturated cloth to clean it. There is asbestos fiber contained in the clutch disc which may be mixed in the dustduring the process of servicing. Inhalation of dust containing asbestos fibers can be seriously damage to the body.
Cautions on compressing valve spring Caution: Compressing valve spring applied high tension force to the valve spring compressor. If the valve spring is compressed or released improperly by valve spring compressor, the tension force will spring out the valve spring from the valve spring compressor. You must be careful when compressing or releasing the valve spring by use of valve spring compressor and removing or installing the lock pin of valve stem. Miss-operation will cause personal injury.
Cautions on exhaust gas recirculation (EGR) system Caution: Be careful not to inhale the exhaust gas or swallow its recirculation sediment when removing the parts for cleaning to avoid personal injury.
Cautions on exhaust system servicing Caution: To prevent burnt, do not attempt to service the exhaust system until it is cooled. Repair the exhaust system after it has cooled down. Use a damp cloth instead of a saturated cloth to clean it
Cautions on eyes protection Caution: When performed this procedure, have to use Safety glasses and gloves permitted to reduce the possibility of personal injury.
Cautions on fuel and evaporation emission pipe Caution: To reduce fire and injury risk, please observe the following notice: During the process installation, replace all scratched, bruised or damaged Nylon oil tube. Do not attempt to service all sections of the nylon tubing. When install the fuel pipe, prohibited hit the fuel pipe clampby hammer. Fuel leakage can be caused by damage of Nylon tube. Make sure to cover the nylon steam tube by using of wet towel before using torch closely. In addition, don't make the vehicle stay above 115°C (239°F) for more than 1h, or for longer than 90°C (194°F). Before connecting the fuel pipe connector, be sure to drop a few drops of clean engine oil on the end of the tube. To ensure proper reconnection and prevent possible of fuel leakage. (In normal condition, O-ring seal in the socket will be inflated, and the reconnection can't be properly by not lubricate).
Cautions on hot exhaust system Caution: The temperature of exhaust system become hot when the engine runs. To prevent burnt, should avoid touched to the exhaust system at high temperature.
Foreword -4
Cautions on gasoline/gasoline vapor Caution: Gasoline or gasoline vapor easily burnt. The fire existed by fire source. To prevent the fire or explosion hazard, do not use an open container to discharge or store gasoline or diesel oil. Please prepare a dry chemical (Class B) fire extinguisher nearby.
Warnings on the movement of catalytic converter Warning: The catalytic converter must be supported to prevent the internal damage of flexible joint in catalytic converter assembly. The vertical movement of rear catalytic converter have to not more than 6°.
Cautions on releasing fuel pressure
Warnings on the tightening the parts
Caution: During the process of servicing fuel system, Please remove the cover of fuel tank and release the pressure of fuel system to reduce the risk of personal injury. Remove the fuel system pressure, a small amount fuel overflow will be occurred during servicing the fuel line, fuel injection pump or joint. After releasing the pressure of fuel system, a small amount of fuel will be overflowed when servicing the fuel line, fuel injection pump or joint. To reduce the risk of personal injury, coverage the parts of fuel system by use of duster cloth before disconnection. The leaked fuel can be absorbed in the duster cloth. After disconnection, place the duster cloth into the approved container.
Warning: The replacement part No. must be correct. The partsneed thread locker, lubricant, inhibitor or sealant are applied in the servicing procedures. Some replacement parts may be equipped with these coatings. Don’t use these coatings on parts unless specified. These coatings will affect the final torque, which may affect the work of part. Use proper torque specification when installing the parts to prevent damage.
Cautions on safety glasses and gloves Caution: Make sure to wear the safety glasses and gloves when removing the parts of exhaust system, otherwise, serious personal injury will be caused by the rust and wear parts from the sharp edge of exhaust system.
Cautions on safety glasses Caution: Wear the safety glasses to avoid injury of eyes.
Cautions on knock sensor Caution: High temeperature engine coolant can cause the serious burnt. Even the coolant system already emptied, the water jacket still has residual coolant. The coolant will be discharged when removing the knock sensor.
Cautions on suspension spring Caution: To prevent personal injury and/or the damage of parts, the lower control arm supported by proper tools when removing the spiral spring. The spiral spring is in a high pressure state, in case the spring is separated from the lower control arm before releasing the internal pressure; it may cause the spring pop up.
Warnings on tightening Warning: Please use propertightening in the right position. The replacament part no. Must be correct. Don’t use paint, lubricants or corrosion inhibitor on the surface of tighteningor on the joint surface of tighteningunless otherwise specified. The coating tighteningtorque and clamping force will be affect damage of tightening. Use proper tightening sequence and tightening specification when installing the tightening, to prevent the damage of parts and system. Be careful not to strip the matching plastic part when using the tighteningput into the plastic directly. Only the hand tools can be used, don't use any impact tools or electric tools. The tighteningshall be tightened by hands, completely in place and can't fall out.
Warnings on heated oxygen sensor and oxygen sensor Warning: Don't remove the lead wire of heating type oxygen sensor (HO2S) or oxygen sensor (O2S). Removal of lead wire or connector will affect the work of sensor. Please take the oxygen sensor carefully. Don't make the heated oxygen sensor fall. The inline type electrical connector and grid type cooling end shall be kept away from lubricating grease, dust or other pollutant. Don't use any types of cleaning agents. Don't repair the wiring harness, connector or terminal. If the lead wire, connector or terminal are damaged, replace the oxygen sensor. The ambient air is obtained from the external environment through the signals of oxygen sensor and wire of heater. The standard air will be blocked and the performance of oxygen sensor will be reduced if try to
Foreword -5 repair the wire, connector or terminal. The following principles must be followed when repairing the heated oxygen sensor: Don't applied the contact agent or other materials on the harness connector of sensor or vehicle. These materials will enter the sensor, and cause malfunction. Don't damage the lead wire and wiring harness of sensor to make its internal wire exposed. This provides channel for the foreign matters entering the sensor, causing performance failure. Ensure that the sensor or the vehicle without large bending or twisted wire. The larger bending or twist will block the channel of ambient air of lead wire. Don't remove or damage of oxygen sensor by wire (if any). The use of ground type sensor vehicle may depend on the ground, and as the only point of ground sensor. Removal of ground wire will cause bad performance of engine. Ensure that the external seal of vehicle harness connector is in good condition to avoid damage caused by water inlet. The engine harness can be repaired by use of repair parts of Packard pressure splicing and joint sealing terminal. In any case, the welding is not allowed which will cause blockage of airpassage.
Warnings on placing the ignition switch onto OFF position when battery disconnected
Cautions on the inflator module coil of SRS system
Warning: The ignition switch have to on OFF position when battery disconnected or connected to the battery negative cable. It needed to prevent damage of the powertrain control module (PCM).
Warnings on drive shaft Warning: To prevent the damage of drive shaft, the control armsupport to normal level position. In the process of lifting vehicle, don't place the transmission onto the gear.
Warnings on vehicle lifting and lifting positions Warning: Before starting any vehicle lifting or lifting procedures, please follow as below: Remove or fix all items in the vehicle to prevent movement or any other motion when executing the lifting procedure. The rated weight of lifting device or lifting equipment must reach or exceed the weight of vehicle and it goods vehicle weight. The rated weight of lifting device or lifting equipment must meet the operation standard specified by the lifting equipment or lifting equipment manufacturer standard.
Execute vehicle lifting or lifting procedures on the cleaning, solid, dry and horizontal surface. Execute vehicle lifting or lifting procedure only in the specified lifting position. The lifting device or lifting equipment shall not contact any other vehicle parts. If not following the procedure above, it will damage the lifting device or lifting equipment, vehicle and/or goods. High temperature warning inflator device module of SRS system
Warning: The metal surface of SRS system parts may be extremely hot when opened. To prevent fire disaster and personal injury: There shall be enough cooling time before touching any metal surface of SRS system parts. Don't place the parts of opened SRS system near to any inflammable substance.
Cautions on opening the inflator module of SRS system Caution: Execute the opening procedure according to the listed sequence when opening the inflator module to be scrapped. Otherwise it may result in personal injury.
Warning: Incorrect location of metal wire winding displacement may damage the steering wheel module coil of the SRS system. This may cause potential coil failure and personal injury.
Cautions on the scraping of inflator module of SRS system Caution: to prevent accidental expansion of the charging module, personal injury, please don't dispose the unopened inflator module according to the conventional workshop waste treatment method. If the seal is damaged the process of scrapping, some substances contained in the inflatable module may cause serious illness or injury. Using the following expansion procedures, the safety of abandoned inflatable modules are not expanded. If not following the scrap methods, may violate federal, state or local laws and regulations.
Cautions on treatment and storage of inflator module of SRS system Caution: When taking the unopened inflator module: Don't take the inflator module by wire or connector. Ensure to turn back the airbag opening to you.
Foreword -6 Caution: When storing the unopened inflator module: Ensure to turn the back of airbag openings to the supporting surface of inflator module. There shall be enough space around the airbag for its accidental opening. The opening of airbag shall not be downward when storing the steering column; in addition, the steering column shall not be vertical. It shall be placed horizontally. Otherwise, it may result in personal injury.
Cautions on special tools of SRS system Caution: Failure to follow the instructions and instructions for use of the special tools may cause the airbag system to unfold, resulting in personal injury or unnecessary repair of the SRS system.
Cautions on SRS system Caution: This vehicle is equipped with SRS system. If not following with the correct procedure will afffect as follow: Airbag deploy Personal injury Unnecessary servicing of SRS system
Warning: Observe the following guidelines to avoid the occurrence of the above condition:
Refer to “SRS System Components View” to confirm whether you are servicing on or around the parts of SRS system or these circuit. SRS system shall be relieved if you are servicing on or around the part of SRS system or these circuit. Refer to “Relief of SRS System”.
Warnings on avoiding the touch of bulb Warning: Avoid contact with light bulbs or light bulbs and moist objects. When the bulb lights, the skin grease or touched moisture may make it explode. If you accidentally contact a light bulb, use alcohol or a suitable detergent to clean the bulb and dry the light bulb.
Warnings on removing the exterior trimming and emblem Warning: CAUTION: When disassembling the label / nameplate, use a flat blade tool to preventdamage of the paint
Warnings on the crack on window
Warning: If the window is cracked but not crushed, ape the tape across the window to reduce the risk of damage or personal injury.
Warnings on defroster outlet Warning: If the broken glass falls into the defroster outlet, it will blow into the passenger compartment and cause personal injury.
Cautions on handling of glass and metal sheet Caution: Wear any approved safety glasses and gloves when handling any glass or metal plate with sharp edges or burrs to reduce the risk of personal injury..
Special notes on installing windshield Important notes: Don't use gasket when installing windshield. The stress from the gasket will damage the windshield.
Warnings on transparent coating/UV protection materials Warning: Remove more than 0.5 mil transparent coating, it will lead to premature paint damage. The clear coat contains UV protection. Sandpaper grinding should be just to remove defects shall prevail.
Warnings on brake caliper Warning: use a steel wire to support the brake, to prevent damage of brake pipe.
Warnings on the influence of brake fluid on paint and electrical components Warning: avoid the brake fluid on the paint surface, electrical connectors, wiring harness, or cable. Brake fluid will damage the paint surface and lead to corrosion of electrical parts. If the brake fluid is contact to the paint surface, it should be washed immediately. If the brake fluid is in contact with an electrical connector, wire harness, or cable, wipe off the brake fluid with a clean cloth.
Cautions
on
inspecting
the
hot
Foreword -7
transmission oil through oil drain plug opening Caution: remove the transmission oil filling plug, the engine must be running, it will drain exceesive oil. The transmission oil may be hot. Because you do not know the actual oil level, therefore it shall be kept away when removing the filling plug. Prepare the container, and receive the fluid from the container. Do not turn off the engine after removing the filler plug, or it will be burnt by the thermal transmission oil sprayed from the filler.
Cautions on movable parts and hot surface Caution: Prevent contact with moving parts and hot surfaces during operation of the running engine to prevent personal injury.
Cautions on battery disconnection Caution: Before servicing any electrical parts, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be switched off unless otherwise stated in the operating procedure. Disconnect the battery negative cable to prevent the tool or equipment from touching the bare electrical terminals to create an electrical spark. Failure to follow these safety instructions may result in personal injury and / or damage to vehicle or vehicle parts.
Cautions on removal of radiator cover Caution: To prevent burnt, do not remove the radiator cap or reservoir lid when the engine is not cooling. If the radiator cap or reservoir lid is removed while the engine and radiator are not in cold condition, the cooling system will release hot liquids and vapors under pressure.
Cautions on damaged fan blade Caution: To prevent personal injury and damage to the vehicle, ensure to replace the fan blade or fan guard if it is bent, cracked, or damaged.
Cautions on electric coolant fan Caution: Even if the engine is not running, electric fans under engine hood may start, which could result in personal injury. Hands, clothes and tools should be kept away from the fan under the hood.
Chapter 1 General information Contents 1.1 General information .............................. 1 1.1.1 Introduction.............................................. 1
1.4 Squeak and noise ............................... 13 1.4.1 Diagnostic information and procedure . 13
1.1.1.1 Vehicle identification number and certificate of conformity ............... 1
1.4.1.1 Symptom - squeak and clicks .. 13
1.1.1.2 Engine identification No. and location ........................................ 4 1.1.1.3 Identification information of transmission ................................ 5 1.1.1.4 General option parts code list ..... 6 1.1.1.5 Lifting and Hoisting Vehicles ....... 9 1.2 Air/wind noise ...................................... 10 1.2.1 Diagnostic information and Procedure.. 10
1.4.2 Servicing instruction ............................. 14 1.4.2.1 Repair of squeak and noise ..... 14 1.5 Vibration diagnosis and correction ....... 14 1.5.1 Diagnostic information and procedure . 14 1.5.1.1 Vibration analysis - tires and wheels ...................................... 14 1.6 Water Leakage..................................... 15 1.6.1 Diagnostic information and procedure . 15 1.6.1.1 Water lekage test preparation .. 15
1.2.1.1 Air / wind noise.......................... 10
1.6.1.2 Dust leakage ............................ 15
1.2.1.2 Tracking powder or chalk test ... 10
1.6.1.3 Water pipe test ......................... 16
1.2.1.3 Air pressure test ........................ 10
1.6.1.4 Air hose test.............................. 16
1.2.1.4 Soap bubble or bubble test ....... 10
1.6.2 Servicing instruction ............................. 17
1.2.2 Servicing instruction .............................. 11
1.6.2.1 Repair the water body leakage 17
1.2.2.1 External wind noise................... 11
1.6.2.2 Repair water leak for fixed windows .................................... 17
1.2.2.2 Internal wind noise .................... 11 1.3 Maintenance and lubrication ............. 12 1.3.1 Specification .......................................... 12 1.3.1.1 Recommended oil liquid and approximate capacity parameter .. .................................................. 12
General information 1-1
1.1
General information
1.1.1
Introduction
Another vehicle identification code is located on the shock strut base at the right side of engine compartment.
1.1.1.1 Vehicle identification number and certificate of conformity Vehicle identification number (VIN)
15AJ0101002
14BT0101001
The vehicle identification number (VIN) plate belongs to a legal marker. Position of vehicle identification plate The vehicle identification plate shown by black arrow points, it can be seen from the front windshield glass outside the vehicle, and located at the top right corner of instrument panel.
15AJ0101001
General information 1-2 Vehicle identification number (VIN) system Position 1-3 4 5 6 7
Definition manufacturing identification Vehicle type Body type Maximum vehicle weight Engine fuel type
Character MKE
Instructions PT. SGMW Motor Indonesia
A
LZW6455JF、LZW6455JVF、LZW6455JY、 LZW6455JVY
C
One-box type body
A
1.0 ≤ G ≤ 2.5 (t)
G
Gasoline
8
Engine displacement
A
0.5 ≤ D ＜ 1.5 (litre)
B
1.5 ≤ D ＜ 2.5 (litre)
9
Check digit
-
Check digit
10
Model and year
H
A model in 2017
I
A model in 2018
11
Assembly plant
J
West Java
12-17
Manufacturer serial No.
-
-
General information 1-3
Plate – vehicle qualification certificate The vehicle qualification certification label is a laser sticker label located on the right front doorframe.
7
6
5 1
4
1 1
3
2
14BT0101005
Figure (1) Vehicle identification number (VIN) (2) Manufacturing country (3) Maximum permissable total mass (4) Maximum net power of the engine (5) Engine displacement (6) Seating capacity (7) Brand
General information 1-4
1.1.1.2 Engine identification No. and location
15AJ0906017
Notes: The picture is only for reference. There is a black engine label (1) on the cover of ignition coil; there is engine steel seal No. (2) impressed by the main engine plant or made through laser ablation at the rear left side of engine cylinder. 1. Hint of black engine label (1): Meaning of black engine label L2B*XXXXXXXXX*: L2B：1.5L DVCP XXXXXXXXX represents 11-bit or 9-bit serial No. 2. Engine No. Stamp (2): L2B*XXXXXXXXX* Meaning of Engine No. Stamp: L2B：1.5L DVCP XXXXXXXXX represents 11-bit or 9-bit serial No.
3. The white engine label (3) is pasted on the cover of engine ignition coil. Explanations: (1) Bar code (2) Part No. of engine assembly (3) (4) (5) (6) (7) (8) (9)
Engine code (1.5L DVCP is for PH) 9-digit serial No. Engine plant code Separator Engine code (1.5L DVCP is for PH) Separator The part identification No. of engine is 10
General information 1-5
1.1.1.3 Identification information of transmission Identification code label of manual transmission
14BT0101007
(1) (2) (3) (4) (5) (6) (7) (8)
Identification code (transmission) Supplier code Part No. Vendor custom Manufacturing serial No. Day Month Year
Identification code of Manual Transmission （1.5MT）
15AJ0101003
The identification code of manual transmission is located at the top of transmission housing at the engine side.
General information 1-6
1.1.1.4 General option parts code list
PB2
Large decorative cover of iron wheel
E87
Hub cap
The code meaning of conventional optional parts
QEG
Tire 195/60 R15
available to the vehicle is provided in the following table.
RU2
Market: Malaysia Market: Thailand and other ASEAN countries Right Hand Drive
JR9
Spare tire-iron wheels 195/60 R15 Braking - front disc and rear drum brake system without anti-lock braking system, but with braking force distribution function Brake - front disc and disc brake system. With anti lock braking system with braking force distribution function Load sensing proportional valve
RWL
Front-engine rear-drive
JBD
Vacuum booster
AXJ
Multi-purpose passenger car MPV
V33
5HD
Graphic trademark plate - SGMW
C41
E8R
Model identification plate-1.5L DVVT
K02
Driver’s tool Manual air conditioning, A/C Evaporator, with warmer Manual air conditioning, double evaporator air conditioning with a fan heater Electronic fan
BC1
Monochromatic instrument panel
8G6
UEK
Tinted instrument panel Store content box on the side of the driver (on the instrument panel) Hazard warning lamp
UTD
Internal control handle of engine cover
UEI
Clock
BA3
Glove box
General option parts code list CK9 CK8 CX7 RHD
Descrption
E8I
Font plate-CVT
V86
Vehicle nameplate
NT2
Emission standard: EURO II
NT4
Emission standard: EURO IV
LMH
Engine N12A
L2B
Engine B15D
TBD
J41
Market: Indonesia
Manual Transmission – N12A
J66
C34
BD3
ENI
Parking brake handle
EAR
Fabric A for seat, fabric
FGH
Fabric B for seat, fabric
D7L
Adjustable height of the head pillow Seat structure 1, general configuration -7 seats Seat structure 2, general configuration -8 seats Driver's seat – sliding back and forth, adjustable angle (manual) Driver's seat- sliding back and forth, adjustable angle (manual double adjuster), adjustable up and down Middle seat -2, Arm rest, adjustable angle, sliding back and forth Middle seat -6/4 three-person seats, foldable, reversible and non-adjustable angle
V5M
Stepless Automatic Transmission (rear drive / automatic)
KOE
Shift Lever (Manual Transmission) A
KS4
Shift Lever (Automatic Transmission) B
K20
EFI system A
ABA
K37
EFI system B
ABB
KUP
SJL
Electronic Throttle OBD vehicle mounted diagnostic instrument Iron fuel tank
NLC
Plastic fuel tank
ND8
Fuel tank cover
GZ3
Oil filler door (electronic lock)
KRR
Fuel Grade: 92 gasoline
N39
Non Teleschopic steering coloum
N33
Teleschopic steering coloum
NJ1
Electric power steering EPS
N3W
Steering wheel without an airbag
NR8
RRK
Steering wheel with an airbag Steering wheel, with an airbag, a sound control button with hands-free key Front suspension: McPherson type independent suspension Rear suspension: Spiral Spring dependent suspension (axle) (with drum brake Iron wheel, 15x6J
TZC
Aluminum alloy wheels 15X6J
UWT
N34
FE6
A95 A95 AKS AMG ARN
#N/A
ATL
Rear seat -3 connected, foldable, reversible
4CN
The interiors and color A- monochrome
4EY
The interiors and color B- tinted Door trim A, front and center door with storage box and armrest with multi function switch Door trim B, front and center door with storage box and armrest with multi function switch, color coated, fabric coated panel
BXM
BXO
General information 1-7 DAG
DAT
E44 E27 E28 E22
T8K E21 8M4 C81 SVA EBI B30 BJY AZ7 C75 U25
The sun visor A- rollover, the driver's seat are attached with make-up mirror, without light The sunshade B- rollover, the driver’s and the co-driver’s seats are attached with make-up mirror and trim cover of mirror, without light Grip handle for co-driver – fixed, without hook Grip handle for co-driver – folding, without hook Grip Handle for middle row – both side – fixed, without hook Grip Handle for middle row – both side – folding, without hook Grip Handle for third row – both side – folding, without hook Inner door open handle and safety switch – paint color Inner door open handle and safety switch – chrome plate Touch switch on the front, middle and rear doors # N/A Cup holder The seats on the front row are attached with storage bags Needle punched carpet + sound-absorbing layer Top cover hard lining Top cover hard lining- with heat insulating layer Front lights
AIK
Dome light Front seat belts – co-driver - 3+3 point mode (ordinary type) Safety belt in the middle row (corresponding to 6/4 three-person seats) -3+3 point type (limited force type) Safety belt in the middle row (corresponding to 6/4 three-person seats) B 3+3+3 point type Safety belt in the middle row (corresponding to 2 independent seats) -3+3 point type Rear seat belts-3+3+3 point type
AK5
AIA AWP
AWO
AT7
AE3 NCG AN4 D75 E20 JJE D9N
One-click decline of driver’s side window Protection lock for children at the rear side door Child seat fixing system External opening handles at the front door and midgate - body color External opening handles at the front door and midgate -chroming Rear door glass- standard
A03
Tailgate door handle: new style, silver Tailgate door handle: new style, chrome plate Front & rear fenders Manual external adjustment type external rearview mirror (outdoor adjustment) – body color; Side steering lamp integrated onto the rearview mirror Electrically adjustable outside rear-view mirror - body color; Side steering lamp integrated onto the rearview mirror Inside rear-view mirror Front windshield – shaded green glass with black edge Front windshield – shaded green glass
AJP
Door and window glass - white glass
TVV
E3E BAA DR1
DC2 D31 AKA
VU8
Rear spoiler: black belt, leather Rear spoiler – body color, with LED high mounted stop lamp Rear spoiler – body color, with LED high mounted stop lamp Decorative black film -the parts above the front door and midgate windows Front bumper- body color
VMU
Front bumper - tinted
VN5
Rear bumper- body color
VMG
Rear bumper - tinted
TW9 TVS B70
Grill A – sprayed black frame
TRI
Front
TQ2
Front Grill B – new style, chrome plate
VJQ
Front tow hook
5RB
Decorative skirt plate
NY2
Lower cover of engine
BCP
Trim cover of engine
Safety airbags for driver and co-driver
K1G
Front and rear wheel cover shield
AL3
Safety airbags for co-driver
T4F
45U
Candy white – Color Paint Starry Night Black – Metallic Paint
T4A
82U 12U
Sky Silver – Metallic paint
function Front combination lamp - with lens, height adjustable Front fog lamp
1IU
Agate Red – Metallic paint
GVX
Earth Brown – Metallic paint Front door and midgate windows electric Lower the window with remote control
A32 AA7 A20
AU4
Rear fixed window Central door locking system (Front, Middle, Tailgate) Speed sensing automatic unlock
KTK
Collision sensing automatic unlock
A59
T3Y T3S
T21
LED daytime running light Side steering lamp - integrated in the rear view mirror High mount stop lamp –LED typeintegrated on the spoiler Rear fog lamp: on the right rear bumper Double rear fog lamp- on the rear bumper Left rear combination lamp (with backup lamps) Reversing lamp
YPG
Double backup lamp
TUI TT9 M1J T79 TDJ
General information 1-8 TVJ
CD6
License plate lamp Front wiper and washer – intermittent type Front wiper and washer – intermittent wiper Rear wiper & washer
CB5
Roof molding-an entire one
C04
UDH
Roof molding-an segmented one Luggage carrier - black, with silver spray paint Combined Instrument A
UW4
4 speakers - the front door and midgate
UF7
UUQ
Radio (dual set) + with USB interface Single disc CD (dual set) +USB interface + electrically tuned radio Steering wheel, hands-free phone, hang-up keys, audible control keys Multimedia eintertainment System (visual reverse (static trajectory) + touchable 8-in HD screen + USB interface + standard SD card slot + radio + Bluetooth+ MirrorLink) Antenna
UKG
Reverse radar – four-point type
UD5
Front Radar – two point type
EQL
Tire pressure monitoring system – 4 tire
C13 CEC
V5F
UCK W1Y
UCJ
KA0
Mechanical Key, Key 2
KTM
Main Key: Folding remote control, Key 1
ATG
Remote control - synthesis in key
8Y1
MOE
Electronic theft deterrent engine Electronic theft deterrent system (remote control type) Body Control Module
MCY
USB Charrging – third row seat side
K3J
Battery
KD7
Starter
U04
Horn - single horn Unclosed lamp alarm- key is taken out or in the OFF position, the lamp or headlamp is not closed, voice prompts in case of opening the driving side door
AF8
T63
General information1-9
1.1.1.5 Lifting and Hoisting Vehicles Note: according to the situation of the lifting equipment used, to prevent unnecessary contact with the body and the structure, it may be require to use a low profile lift arm system.
Lifting vehicles- frame contact lifts Front lifting block As shown in Figure 1, when using the frame contact type lifting machine to lift the vehicle, place the front lifting block on the threshold outer plate weld flange. Rear lifting block As shown in the figure, when lifting a vehicle with a frame-contact lift, place the rear lift washer on the sill outer panel welding flange. Hoisting the vehicle Warning: When hoisting on the front position, ensure the jack or jack lifting block not in touch with the front under cover, the front bumper choke plate or front fender. If the above parts are touched, the vehicle may be damaged. When hoisting on the selected front position, the jacking point may require more clearance. When the vehicle is hoisted by a service jack, the wheel of the vehicle on the opposite side of the vehicle hoisting position shall be blocked. Provide additional support with jack stand.
15AJ0101004
Danger: to prevent vehicle damage, serious personal injury or death accident, when remove the main partsfrom the vehicle and using the lifting machine to support the vehicle, use the jack stand to support the part of the vehicle on the opposite side of the parts to be removed. Danger: in order to prevent damage to vehicle, serious injury or death accident, when using jack to lift the vehicle, ensure to use the jack stand to support the vehicle. Warning: Before starting to lift or jack the vehicle, perform the following steps: Remove or fix all items in the vehicle so that they will not move when the vehicle is lifted or jacked. The weight rating of lifting or jacking equipment shall meet or exceed the weight of the vehicle and items in the vehicle. Lifting or jacking equipment shall conform to the operation standards of the lifting or jacking equipment manufacturers. The vehicle lifting or jacking procedure shall be carried out on a clean, solid, dry level ground. The vehicle can only be liftted or jacked at the specified lifting point. Any other parts of the vehicle shall not be in contact with the lifting or jacking equipment. Failure to follow these steps can result in damage to lifting equipment or jacking equipment, vehicles, and / or in-vehicle items. Low profile lift arm systems for lifting equipment. See manufacturer's recommendations for Low profile lift arm systems for lifting equipment application.
The front of the vehicle When the front of the vehicle is hoisted by a service jack, any of the following positions may be used: As shown in Figure 2, the service jack pad is placed at the ends of the sub frame. The rear of the vehicle Notes: Place the jack stand only in the sturdy and stable vehicle structure. As shown in Figure 2, the service jack pads are placed on the rear suspension spring carrier.
General information 1-10
1.2
Air/wind noise
1.2.1
Diagnostic information and Procedure
1.2.1.1 Air / wind noise Warning: The vehicle should be driven by an assistant when the service technician checks the location of the fault. Otherwise, it may cause personal injury. The vehicle shall be carried out by test for determine accurate the location of wind noise. Usually, there are main leak and secondary leak. That all leaks only can be reduced not for eliminated the wind noise. During the test, the technician shall take the following tools to help determine the location of wind noise. Mechanical stethoscope or vacuum hose Tapes Leak-proof strip Marker pen Screwdriver Perform the road test as follows: 1. Select flat and straight streets in the north, south, east and west directions as test route. 2. Select the streets with less traffic or less noise so that not affected the test. 3. Drive according to the speed when the customer finds the noise or noise appeared. Don’t exceed the legal’s speed limit. 4. Wind noise is external noise if the following faults exist: Wind noise is caused by the wind. Lowering the door glass and when the vehicle runs, the wind noise can be heard. When the adhesive tape is stuck on the moulded parts and the clearance, the wind noise disappears. 5. Internal wind noise is generated when the air overflows from the vehicle, which shall be repaired according to the following methods: To determine the location of the leak, the tape can be attached to the body lock pillar relief valve. This allows air pressure to be accumulated in the vehicle, and enhance the wind noise. Use a stethoscope or vacuum hose to determine the leak location . Temporarily repair the leaks with tape.
Continue to test to determine whether the noise has been eliminated, or otherwise there is a leak. When all leakage locations are identified, return to the repair room and make permanent repairs using the appropriate positioning method and sealing material.
1.2.1.2 Tracking powder or chalk test 1. Clean the sealing strip and contact surface with the washing liquid. 2. Draw a continuous line with powder or chalk on the contact surface of the sealing strip along the border of the suspicious part. 3. Completely close the panel, but don’t closed fully. The sealing strip can be firmly pressed on the binding surface by closing the panel completely, 4. Check the lines drawn on the sealing strip. The line is damaged where the part is in good contact. A corresponding mark is left on the junction surface. 5. If the powder or chalk line on the junction surface is interrupted or irregular, it indicates that the position is badly sealed.
1.2.1.3 Air pressure test 1. Cover two pressure relief valves. 2. Close all windows. 3. Set the the vehicle vent fan to the ON position and set selector switch in high speed and defrost mode. 4. Lock and close the door. 5. Use a stethoscope or a length of heater hose to monitor air and door sound when the window seal is overflowing
1.2.1.4 Soap bubble or bubble test 1. Cover the pressure relief valves. 2. Close all windows and doors. 3. Set the the vehicle vent fan to the ON position and set the selector switch In high speed and defrost mode. 4. Lock and close the door. 5. Apply soapy water to all possible leaks. See if there are bubbles indicating air overflow.
General information1-11
1.2.2
Servicing instruction
1.2.2.1 External wind noise Warning: See "Warnings on assistant driving". When driving and lowering one or more windows, the exccess external wind noise appeared. When the air passes through the body plate, the joint or the opening, the external wind noise is generated. In the road test, use the following tools to provide help for the leak detection: The mechanic stethoscope or heater hose Tapes -51 mm (2 in.) wide Leak-proof strip Water soluble marker pen 1. Determine the location of external wind noise by lowering one window at a time while driving. If the position is consistent with that in Step 2, drive the car to the road side and carry out temporary repair with 51 mm (2 in.) wide tape. 2. Every time seal a gap and garnish molding. Test after each paste. Tape seams the gap and garnish molding for fault correction. 3. A temporary repair is conducted on the fault with the tape. Adjust the tape if necessary. 4. Continue to test to determine whether the noise has been eliminated, or there are other leak parts. 5. After all the leakage fault repair found, carry out permanent repair with proper positioning method and sealing materials.
1.2.2.2 Internal wind noise Warning: See the "Warnings on relevant assistant driving” in "Warnings and notes" When the window is lowered, the internal wind noise can not be heard. Internal wind noise is caused when air comes out of the car through the seal or the joint. 1. Tape the pressure relief valve to increase the air pressure inside the car. 2. Road test vehicle and monitor whether there is wind noise or vibration sound. 3. Drive the car to the roadside for temporarily repair with tape. If the internal source of wind noise can not be determined, perform one or more diagnostic tests: “Tracing powder or chalk test”, “air pressure test”, “soap bubble or bubble test" in the section.
General information 1-12
1.3
Maintenance and lubrication
1.3.1
Specification
1.3.1.1 Recommended oil liquid and approximate capacity parameter Recommended oil liquid and approximate capacity parameter Parts Engine oil Transmission oil Brake fluid Coolant Washer fluid Fuel tank fuel
Model SM/GF-4
5W-30
MTF 75W/90
Dosage
(litre)
4 1.5±0.15
DOT4
0.5
Ethylene glycol type antifreeze
6.5±0.5
Methanol-water solvent National 93# Standard or equivalent grade (landmark) vehicle gasoline and above
1.55±0.25 42
General information 1-13
1.4
Squeak and noise
1.4.1
Diagnostic information and procedure
1.4.1.1 Symptom - squeak and clicks Symptom - Squeak and Noise A side beam noise
Incorrect connection of brake pipe
Noise under the vehicle at a higher speed
Insulator touches the bottom of the body.
In cold weather conditions, the front of the vehicle squeaks
The vibration isolator of the front stabilizer shaft is not tightly sealed
The rear emits a loud pounding when the vehicle bumpy.
The spare tire is incorrectly fixed
Door lock solenoid is loose A door noise Electrical connector inside the door trim panel emits clicks
Door / engine hood / hinge pin of lifting tail-gate lacks lubrication Squeak when operating of door / engine hood / lifting tail-gate
The open-maintaining link arm of the door lacks lubrication.
Hinge pin of lifting tail-gate / torsion spring lacks lubrication
Squeak when the manual transaxle shifts- the failure occurs in cold weather conditions and when the engine is cold The instrument panel cluster squeakers
When the manual transmission transaxle shifts, the sheath under the control rod has faults
The trim instrument panel friction with instrument cluster
Tapping the brake pipe and monitor the clicks. Install plastic strap and fix the brake pipes together. Lift the vehicle and carry out a visual inspection. Slightly bend the insulator and increase the clearance to the lower part of the body. Test the vehicle when it is cold, drive through potholes on the road, and the front suspension reaches the maximum stroke. Remove shock pads and wrap the stabilizer shaft with Teflon tape. Re-install the shock pad on the tape. Visually inspect the spare tire and tools. Tighten the spare tire and all tools. Perform the road test, and check whether the noise is eliminated. Remove door trim panel, and check whether the solenoid coil is loose or not. Tighten solenoid coil bolt. Tap lightly the trim panel and monitor whether there are any clicks. Remove the trim panel and wrap the connector with the foam pad if necessary. Operate the door / engine hood / lifting tail-gate and monitor whether there is any squeak. Lubricate the door hinge pin with light machine oil and paint the lithium base grease. Lubricate open-maintaining link arm of the door with light machine oil and paint the lithium base grease. Operate lifting tail-gate and monitor whether there is any squeak. Lubricate hinge pin of lifting tail-gate (gooseneck hinge has one upper hinge pin and one lower hinge pin) and the contact position between hinge and the torsion spring with light machine oil, and paint lithium base grease
Change the shift control lever to different gears and monitor whether there is any squeak. Remove the floor console and replace the shift lever jacket or coat the shift lever jacket with talc. Test the vehicle to detect the fault. Remove the trim instrument panel of instrument cluster and install felt strip on the edge.
General information 1-14
1.4.2
Servicing instruction
1.4.2.1 Repair of squeak and noise Squeak and noise are caused by the unnecessary movement of the vehicle parts. There are three ways to prevent squeak or clicks. Fixed or faster the parts, so that no relative motion between the parts when the vehicle runs. The separated parts have to no contact to each otherwhen the vehicle runs. Isolate the parts so that not squeak or noise when it moved. Elimination of stick slip motion with uniform low friction surface.
1.5
Vibration diagnosis and correction
1.5.1
Diagnostic information and procedure
1.5.1.1 Vibration analysis - tires and wheels There are two ways to correct a tire that has been properly balanced but still vibrates. One method is calibrated with an automatic machine, which attaches the tire and grinds a small amount of rubber from the high points of the two rows of tires. The correction with this method is usually permanent, and if it works properly, it does not significantly affect the appearance of the tire and the life of the tire tread pattern. It is not recommended to trim the tire with a knife like machine, because it can significantly shorten the life of the tire, and usually cannot solve the problem fully. Another way is to remove the tire and turn it on the rim up to 180 degrees, which is used only after it is confirmed that the tire and wheel assembly is the cause of vibration, because it can also vibrate the intact wheel assembly. Warning: See "Warning and notes". Most of the high speed vibration problems come from the imbalance wheel. If there are following faults, then vibration still exists after the dynamic balance: Tire is not round Rim is not round There is deviation of tire hardness Measuring free runout of tire and wheel can determine the parts with faults. All these three reasons are known as the load diameter runout, and a known good tire and the substitution method of wheel assembly shall be used to check the vehicle with faults. The low velocity vibration below 64 km / h (40 miles/hour) is usually caused by runout. The high speed vibration above 64 km / h (40 miles/hour) is usually caused by imbalance or runout.
General information1-15
1.6
Water Leakage
1.6.1
Diagnostic information and procedure
1.6.1.1 Water lekage test preparation
SAIC-GM-Wuling automobile can operate under the normal environmental conditions. Design standards - sealing materials and parts are considered against the natural factors required for sealing force. These specifications cannot be considered in any case, such as high-pressure car wash. Water leakage test procedure are related to natural factors, which will determine the performance of the vehicle under the normal operating conditions. The first step to diagnosis the water leakage condition is to determine which leakage conditions occurred. If the general water leak area can be determined, then use a water pipe or air hose to find the exact point of leakage. To repair the leak, required remove of some trims panels or related parts.. If a leak is found near the door, window, back compartment lid or lifting door, it does not necessarily indicate that the sealing trip is damaged. The adjustment of these parts may be able to solve the fault.
Recommended material (leak repair) Leak position
Repair material
Bolts, studs and nuts
Leak-proof strip
Big hole
Automobile joint and joint sealants
Metal joint
The joint sealant that can be painted
Small crack and pin hole
Drip proof sealant or equivalent products Automotive primer and lustering agent or equivalent products Sealing strip adhesive or equivalent products Urethane adhesive, leak-proof strip components or equivalent products
Ventilating duct Sealing strip Sealing strip, rear window
1.6.1.2 Dust leakage The vehicle without water leak may leak dust. Especially the lower part will have such problems. The vehicle driving forward will produce a slight vacuum, which will air and dust suction vehicle. Determine the dust leak positions according to the following steps: 1. Remove the floor mats 2. Remove mat from pedal. 3. Remove vibration isolation pad from the floor. 4. Remove vibration isolation pad from the pedal. 5. Drive a vehicle on a dusty road. 6. Check the interior of the vehicle. The leak location can usually see a small taper dust - or elongated 7. Mark leakage location. Special notes: When performing this step, make sure the inside of the vehicle is dark. 8. Irradiate light from the floor and the bottom of the front access panel. 9. Get the assistant to mark any light spots in the vehicle. Check the weld joint. Check body mount. 10. Seal all leak location with dry body sealant.
General information 1-16
1.6.1.3 Water pipe test
Special notes: Usewater pipe without nozzle. 1. Let the assistant in the car, in order to determine the leakage location. 2. Start testing from the bottom of the window or the front windshield glass. Slowly move hose upwards to cover the entire roof.
1.6.1.4 Air hose test
Important notes: only the urethane adhesive on fully cured by air hose test. Otherwise, it will damage the urethane adhesive flange, which may result in additional leakage 1. Add water to the spray bottle to dilute the liquid cleaning agent, and use the cleaning agent to spray the window from the edge of the window. Start from the bottom and gradually move up to cover the entire roof.
Special notes: The pressure of the compressed air should not exceed 205 KPa 30 pounds per square inch. 2. Get the assistant into the car with the air hose. 3. Let the assistant point the compressed air to the suspicious position. A soap water leak will form bubbles.
General information 1-17
1.6.2
Servicing instruction
1. 2.
1.6.2.1 Repair the water body leakage Warning: If the vehicle interior is affected with damp, the harness of sensor and electrical module may be soaked. After power sensing and diagnostic module may be activated, resulting in airbag deployment, resulting in damage to personnel. Depending on the water leak location, some parts in the vehicle may have to be removed to repair the leak.
3. 4.
5. 6. 7.
If the carpet becomes wet, see the "Drying of carpet" in the "Interior trimming". from inside or outside the car, in the position of leakage in cut off part anti adhesive. Remove all loose parts of the old adhesive leak proof agent particles. The parts where old adhesive leak preventive is removed shall be coated with the body and joint sealant. Wait for the drying of adhesive leak preventives for a few hours. Test whether leak exists. Install trim if removed.
1.6.2.2 Repair water leak for fixed windows Warning: If the vehicle interior is affected with damp, the harness of sensor and electrical module may be soaked. After power sensing and diagnostic module may be activated, resulting in airbag deployment, resulting in damage to personnel. 1. If the carpet becomes wet, see the "Drying of carpet" in the "Interior trimming". 2. When necessary, remove the trim strip or roof liner to repair the leakage. 3. Determine the water inlet position 4. If the windscreen is at the edge of Water Leakage, use the urethane adhesive leak-proof strip components or equivalent products to re-seal the front windscreen. 5. If the water leaks into the vehicle from the side of the fixed window, use the urethane adhesive leak-proof strip components or equivalent products to re-seal the window.
Chapter 2 Metal components and decorating parts of body Contents 2.1
2.3.2.3
Exterior trimming ............................................. 1
2.1.1 Specification ...................................................... 1
end cover .......................................... 23
2.1.1.1 Tightening torque specification ............. 1
2.3.2.4
2.1.2 Service Instruction ............................................. 2 2.1.2.1
2.3.2.5
Replacement of radiator grille and
2.3.2.6 2.3.2.7
tailgate ................................................ 4 Replacement of radiator upper grille .. 6
2.1.2.5
Replacement of roof trim .................... 7
2.1.2.6
Replacement of roof rail ..................... 8
2.1.2.7
Replacement of Side Skirt Panel ....... 9
2.1.2.8
Replacement of Triangle Trim cover 10
2.1.2.9
Replacement of door skirt ................ 11
2.2
2.3.2.8 2.3.2.9
Replacement of insulation pad ......... 14
2.2.1.3
Replacement
of
front
floor
of
instrument
panel
of
air
conditioning
ventilation window – both side.......... 29 of
air
conditioning
ventilation window instrument panel. 30 2.3.2.11 Replacement
of
instrument
panel
assembly ........................................... 31 2.3.2.12 Replacement
2.2.1 Service Instruction ........................................... 13 2.2.1.2
Replacement
2.3.2.10 Replacement
Floor coverings and headliner ..................... 13 Drying of insulation pad ................... 13
Replacement
drawer ............................................... 28
Special tools ..................................... 12
2.2.1.1
Replacement of fuse box on instrument panel ................................................. 27
2.1.3 Special tools and equipment ........................... 12 2.1.3.1
Replacement of the co-driver side knee cover ................................................. 26
Replacement of emblem/word plate on
2.1.2.4
Replacement of the driver side knee cover ................................................. 25
emblem .............................................. 3 2.1.2.3
Replacement of middle trim instrument panel ................................................. 24
Replacement of front bumper towing hook cover .......................................... 2
2.1.2.2
Replacement of instrument panel side
of
instrument
panel
bracket assembly .............................. 33 2.3.2.13 Replacement
of
middle
bracket
instrument panel ............................... 34
mat
2.3.2.14 Replacement
of
instrument
panel
Soundproof ....................................... 15
harness ............................................. 35
Replacement of Interior Front Dash
2.3.2.15 Replacement of auxiliary instrument
Panel Soundproof ............................ 16
panel trim on front floor .................... 36
Replacement of Exterior Front Dash
2.3.2.16 Replacement of auxiliary instrument
Panel Soundproof ............................ 17
panel side trim panel on front floor ... 37
Replacement of headlinertrim .......... 18
2.3.2.17 Replacement of armrest on auxiliary
2.2.2 Special tools and equipment ........................... 19
instrument panel ............................... 38
2.2.1.4 2.2.1.5 2.2.1.6 2.2.2.1
Special tools ..................................... 19
2.3.2.18 Replacement
auxiliary
instrument
Instrument panel and console trim .............. 20
panel rear end cover on front floor ... 39
2.3.1 Specification .................................................... 20
2.3.2.19 Replacement of auxiliary instrument
2.3
Tightening torque specification ........ 20
panel on front floor ........................... 40
2.3.2 Service Instruction ........................................... 21
2.3.1.1
2.3.3 Special tools and equipment ............................ 41
2.3.2.1 2.3.2.2
Replacement of steering coloum trim
2.3.3.1 Special tools ........................................ 41
cover................................................. 21
2.4
Replacement of steering column under
2.4.1 Specification ..................................................... 42
trim cover ......................................... 22
2.4.1.1 Tightening torque specification ........... 42
Interior and panel ........................................... 42
2.4.2
Service Instruction ......................................... 43 2.4.2.1
Replacement of front door glass switch panel ................................... 43
2.4.2.2
Replacement of rear door glass switch panel ................................... 44
2.4.2.3 Replacement of Front door trim ...... 45 2.4.2.4 Replacement of Rear door trim ...... 46 2.4.2.5
Replacement of front door waterproof cover .............................................. 47
2.4.2.6
Replacement of rear door waterproof cover .............................................. 48
2.4.2.7
Replacement of front door sill trim panel .............................................. 49
2.4.2.8
Replacement of rear door sill trim panel .............................................. 50
2.4.2.9
Replacement of auxiliary hand grip51
2.4.2.10 Replacement of sun visor .............. 52 2.4.2.11 Replacement of upper trim front pillar (Pillar A) ......................................... 53 2.4.2.12 Replacement of lower trim front pillar (Pillar A) ......................................... 54 2.4.2.13 Replacement of upper trim center pillar (Pillar B) ................................ 55 2.4.2.14 Replacement of lower trim center pillar (Pillar B) ................................ 56 2.4.2.15 Replacement of upper rear side trim panel .............................................. 57 2.4.2.16 Replacement of lower rear side trim panel .............................................. 58 2.4.2.17 Replacement of tailgate carpet strip .. ..................................................... 59 2.4.2.18 Replacement
of
tailgate
upper
window frame trim panel................ 60 2.4.2.19 Replacement of tailgate side window frame trim panel ............................. 61 2.4.2.20 Replacement of tailgate trim panel 62 2.4.2.21 Replacement of tailgate handle ..... 63 2.4.3 Special tools and equipment .......................... 64 2.4.3.1
Special tools .................................. 64
Body metal components and decorating parts 2-1
2.1
Exterior trimming
2.1.1
Specification
2.1.1.1 Tightening Torque Specification Tightening Torque Specification Application
Specification Metric system
Fixed pieces for radiator grille and emblem
2±0.5 N.m
Fixed pieces for radiator upper grille
3±0.5 N.m
Tightening nuts for luggage carrier
8±2 N.m
Tightening screws for luggage carrier
8±2 N.m
Body metal components and decorating parts 2-2
2.1.2 Service Instruction 2.1.2.1 Replacement of front bumper towing hook cover
Replacement of front bumper towing hook cover Figure No.
Part Name Front bumper towing hook cover
1
Procedures Remove Front bumper towing hook cover eye hole cover from the gap below the towing hook cover carefully by use of a small flat blade tool.
Body metal components and decorating parts 2-3
2.1.2.2 Replacement of radiator grille and emblem
Replacement of radiator grille and emblem Figure No.
Part Name
Preparation procedure Remove the radiator upper grille. Refer to “Replacement of radiator upper grille”. Fixed pieces for radiator grille and emblem(quantity: 3） 1
Warning: Refer to “Warnings on tightening”. Tightening torque 2±0.5 N.m
2
Radiator grille and emblem
Body metal components and decorating parts 2-4
2.1.2.3 Replacement of emblem/word plate on tailgate
Replacement of emblem /word plate on tailgate Figure No.
Part Name Gate emblem Warning: Refer to the “Warnings on removing the exterior trimming and emblem” Procedures 1. The temperature of parts and surface shall be 21°C (70°F) before installation. The vehicle shall be kept at 21°C (70°F) within 1h after assembly, so that the bonding compound reaches enough bonding strength. 2. Remove the old emblem by use of “Heating Gun” or similar tools. When
1
installing a new logo, remove adhesive all the rear door, and to wipe the surface with a clean, lint free cloth. 3. Prohibited touch the bonding surface by hands when peeling down the protective gasket paper from the bonding surface of emblem, and prevent the bonding surface from affixing the dirt or foreign objects. 4.
Close the tailgate before bonding.
5. Align the positioning hole to press the emblem by palm, make it patched onto the tailgate, and ensure that the emblem is pasted on the tailgate completely.
Body metal components and decorating parts 2-5 Tailgate emblem Caution：see “warning about dissasembly exterior logo”. Procedure 1. Parts and surfaces should be 21 ° C (70 ° F) before installation. The vehicle should be held at 21 ° C (70 ° F) for 1 hour after assembly to achieve sufficient bond strength. 2. Remove the old plate with a "heat gun" or equivalent. Before installing the 2
new plate, remove all adhesive from the tailgate and wipe the surface with a clean, lint-free cloth. 3. When stripping the protective backing paper from the adhesive surface, be careful not to touch the adhesive surface with the hand. Prevent the adhesive surface from adhering to dirt or foreign matters before bonding. 4. Close tailgate before attaching 5. Using the palm of your hand, press the plate against the tailgate to ensure that the plate is completely attached to the tailgate.
Body metal components and decorating parts 2-6
2.1.2.4 Replacement of radiator upper grille
Replacement of radiator upper grille Figure No.
Part Name
Preparation procedure Open the engine hood, and remove the front damper mass of engine hood. Fixed pieces for radiator upper grille (quantity: 2） 1
Warning: Refer to “Warnings on tightening”. Tightening torque 3±0.5 N.m
2
Clips of radiator upper grille (quantity: 4）
3
Radiator upper grille
Body metal components and decorating parts 2-7
2.1.2.5 Replacement of roof trim
Replacement of roof trim Figure No.
Part Name
Preparation procedure Remove of roof trim (comfortable type and luxurious type). Refer to “Replacement of roof rail (comfortable type and luxurious type)”. 1
Clips for installing roof trim Roof trim Procedures
2
1.
Slip the roof trim smoothly and backwards, making the card slot away
from the clips for installing roof rail completely. 2.
The installation slot and decorative roof trim installation complete
alignment with the buckle.
Body metal components and decorating parts 2-8
2.1.2.6 Replacement of roof rail
Replacement of roof rail Figure No. 1
Part Name Roof rail end cover Tightening nuts for roof rail (quantity: 4） Procedures Carefully tipping of roof rail regarding the nuts tighten by spesific torque to
2
upper interior trim Warning: Refer to “Warnings on tightening”. Tightening torque 8±2 N.m Tightening screws for roof rail (quantity: 1） Note: Carefully tipping of middle roof rail regarding the screw tighten by
3
spesifi torque to upper interior trim. Warning: Refer to “Warnings on tightening”. Tightening torque 8±2 N.m
4
Roof rail
Body metal components and decorating parts 2-9
2.1.2.7 Replacement of Side Skirt panel
Replacement of Side Skirt panel Figure No.
Part Name
1
Ejection pin for Side Skirt Panel (quantity: 5）
2
Clip for Side Skirt Panel (quantity: 8）
3
Side Skirt Panel
Body metal components and decorating parts 2-10
2.1.2.8 Replacement of Triangular Trim Cover
Replacement of triangular trim cover Figure No.
Part Name
1
Clips for triangular trim cover (quantity: 3）
2
Triangular trim cover
Body metal components and decorating parts 2-11
2.1.2.9 Replacement of door skirt
16AJ0201001
Replacement of door skirt Figure No.
Part Name Front Door Trim Skirt
1
Procedure Front door trim skirt attached on the front door outer panel,carefully pry the front doortrim skirt. Rear door trim Skirt
2
Procedure Rear door trim skirt attached on the rear doorouter panel, carefully pry the rear doortrim skirt
Body metal components and decorating parts 2-12
2.1.3
Special tools and equipment
2.1.3.1 Special tools Figure
Tool No. / Description
BD-0003 Tools for removing clips of trim panel
Body metal components and decorating parts 2-13
2.2
Floor coverings and headliner
2.2.1 Service Instruction 2.2.1.1 Drying of insulation pad If the carpet, floor mat or insulating pad is wet, it shall be dried or replace the components according to the following principles: Replace the overall assembly or singe-piece insulation padassembly with adhesive pad or fibrous pad, Replace the liner only for two-piece insulation padassembly with cotton pad or fibrous pad. Place the insulation padoutside the vehicle, and applied drying treatment on this with the following method. Appliedconduct drying treatment on it with the following method for singe-piece insulation padassembly with adhesive foam pad or synthetic pad. Applied drying treatment on this with following method for two-piece carpet assembly with synthetic pad. Replace the cotton pad or fibrous pad for singe-piece insulation padassembly with separated cotton pad or fibrous pad. Place the insulation padoutside the vehicle, and applied drying treatment on thiswith the following method.
Drying method 1. 2. 3.
Absorb the excessive moisture on insulation pad by use of wet vacuum cleaner when finding puddle on the carpet surface. Use the cloth to wipe the insulation padsurface, so that to absorp Wipe the insulation pad surface by use of duster cloth, so as to absorb the water as much as possible. Dry by the fan faced to wet area of insulation paddirectly.
Body metal components and decorating parts 2-14
2.2.1.2 Replacement of insulation pad
Replacement of insulation pad Figure No.
Part Name
Preparation procedure 1.
Remove all seats. Refer to “Replacement of driver or passenger seats”, “Replacement of the second row of seats” and “Replacement of the third row of seats”.
2.
Remove the front floor side panel. Refer to “Replacement of front floor side panel”.
3.
Remove the front door sill trim panel. Refer to “Replacement of front door sill trim panel”.
4.
Remove the rear door sill trim panel. Refer to “Replacement of rear door sill trim panel”.
5.
Remove the tailgate trim insulation pad. Refer to “tailgate trim insulation pad”.
6.
Remove the front pillar A trim panel. Refer to “Replacement o front pillar A trim panel”.
7.
Remove the driver’s footrest. Refer to “driver’s footrest”.
8.
Remove the center pillar B trim panel. Refer to “Replacement center pillar B trim panel”.
9.
Remove the rear side trim panel. Refer to “Replacement rear side trim panel”.
Floor panel insulation pad 1
Procedures Take out all clips from the insulation pad.
Body metal components and decorating parts 2-15
2.2.1.3 Replacement of front floor mat Soundproof
Replacement of front floor mat Soundproof Figure No. 1
Part Name front floor mat Soundproof
Body metal components and decorating parts 2-16
2.2.1.4 Replacement of Interior Front Dash Panel Soundproof
Replacement of Interior Front Dash Panel Soundproof Figure No.
Part Name
1
Clips for Interior Front Dash Panel Soundproof (quantity: 10）
2
Interior Front Dash Panel Soundproof
Body metal components and decorating parts 2-17
2.2.1.5 Replacement of Exterior Front Dash Panel Soundproof
15BS 0202008
Replacement of Exterior Front Dash Panel Soundproof Figure No.
Part Name
1
Clips for Exterior Front Dash Panel Soundproof(quantity: 9）
2
Exterior Front Dash Panel Soundproof
Body metal components and decorating parts 2-18
2.2.1.6 Replacement of headliner trim
Replacement of headliner trim Figure No.
Part Name
Warning: Prohibited to repair or change attached to the headliner or trim head impact energy absorbing material. If the material is damaged, replace the headliner and / or trim. Otherwise, it may cause personal injury. Preparation procedure 1.
Remove the ceiling and reading lamp. Refer to “Replacement of ceiling lamp and reading lamp”.
2.
Remove air-out window of rear evaporator. Refer to “Replacement of air-out window of rear evaporator”.
3.
Remove the sun visor. Refer to “Replacement of sun visor”.
4.
Remove the sun visor holder. Refer to “Replacement of sun visor holder”.
5.
Remove the roof handgrip. Refer to “Replacement of roof handgrip”.
6.
Remove the front pillar A trim panel. Refer to “Replacement of front pillar A trim panel”.
7.
Remove the center pillar B trim panel. Refer to “Replacement of center pillar B trim panel”.
8.
Remove the rear side trim panel. Refer to “Replacement of rear side trim panel”.
9.
Remove the upper trim panel on center pillar B. Refer to “Replacement of upper trim panel on center pillar B”. 1
Fixed pieces for trim panel of roof lining. (quantity: 4） Finishing trim panel roof lining. (Without sunroof)
2
Procedures Disconnect the electrical connector.
Body metal components and decorating parts 2-19
2.2.2 Special tools and equipment 2.2.2.1 Special tools Figure
Tool No./Description
BD-0003 Tools for removing clips of trim panel
Body metal components and decorating parts 2-20
2.3
Instrument panel and console trim
2.3.1
Specification
2.3.1.1 Tightening torque specification Tightening torque Specification Application Tightening of steering column trim cover Tightening of lower steering coloum under trim cover
Specification Metric system 2±0.5 N.m 4±1 N.m
Tightening of instrument panel side end cover
2±0.5 N.m
Tightening 1 for the co-driver side knee cover
2±0.5 N.m
Tightening 2 for the co-driver side knee cover
5±1 N.m
Tightening of Fuse box
2±0.5 N.m
Tightening of instrument panel assembly
5±1 N.m
Tightening of tie bar instrument panel
22±3 N.m
Tightening of middle bracket instrument panel
8±2 N.m
Tightening of auxiliary instrument panel
3.5±0.5 N.m
Tightening of auxiliary instrument panel rear-end cover
3.5±0.5 N.m
English system
Body metal components and decorating parts 2-21
2.3.2 Service Instruction 2.3.2.1 Replacement of steering coloum trim cover
16BH 0203001
Replacement of steering coloum trim cover Figure No.
Part Name Steering coloum trim cover Procedures
1
1.
Put the steering wheel to the lowest position.
2.
Loosen the steering coloum trim covercarefully by use of pry instrument tool.
Body metal components and decorating parts 2-22
2.3.2.2 Replacement of steering column under trim cover
16BH 0203002
Replacement of steering column under trim cover Figure No.
Part Name Tightening of steering coloum under trim cover (quantity: 2）
1
Warning: Refer to “Warnings on Tightening”. Tightening torque 2±0.5 N.m Tightening of lower steering coloum under trim cover (quantity: 1）
2
Warning: Refer to “Warnings on Tightening”. Tightening torque 2±0.5 N.m
3
steering column under trim cover
Body metal components and decorating parts 2-23
2.3.2.3 Replacement of instrument panel side end cover
16BH 0203003
Replacement of instrument panel side end cover Figure No.
Part Name instrument panel side end cover
1
Procedures Open door to approach to instrument panel side end cover, and loosen from the lower trim by use pry instrument tool.
Body metal components and decorating parts 2-24
2.3.2.4 Replacement of middle trim instrument panel
16BH 0203004
Replacement of middle trim instrument panel Figure No.
Part Name middle trim instrument panel
1
Procedures Loosen the middle trim instrument panel carefully by use of pry tool instrument.
Body metal components and decorating parts 2-25
2.3.2.5 Replacement of the driver side knee cover
16BH 0203005
Replacement of the driver side knee cover Figure No.
Part Name
Preparation procedure Remove the left-side instrument panel end cover. Refer to “Replacement of instrument panel end cover”. Tightening driver side knee cover(quantity: 2） 1
Warning: Refer to “Warnings on Tightening”. Tightening torque 2±0.5 N.m The driver side knee cover Procedures
2
1.
Disconnect the electrical connector.
2.
Remove multi-function switch assembly and open the handle engine hood lock.
Body metal components and decorating parts 2-26
2.3.2.6 Replacement of the co-driver side knee cover
16BH 0203006
Replacement of the co-driver side knee cover Figure No.
Part Name
Preparation procedure 1.
Remove the left-side instrument panel cover. Refer to “Replacement of instrument panel side cover”.
2.
Remove of instrument panel fuse box. Refer to “Replacement of instrument panel fuse box”.
3.
Remove the left-side instrument panel trim. Refer to “Replacement of instrument panel triml”.
4.
Remove the driver side knee cover. Refer to “Replacement of driver side knee cover”.
5.
Remove the auxiliary instrument panel of front floor. Refer to “Replacement of auxiliary instrument panel of front floor”. Tigtening bolt for the co-driver side knee cover (quantity: 4） 1
Warning: Refer to “Warnings on Tightening”. Tightening torque 5±1 N.m Tightening bolt for the co-driver side knee baffle (quantity: 5）
2
Warning: Refer to “Warnings on Tightening”. Fastening 2±0.5 N.m side of co-driver’s knee cover
3
Procedures 1.
Disconnect the electrical connector.
2.
Remove audio-video socket and cigar lighter assembly.
Body metal components and decorating parts 2-27
2.3.2.7 Replacement of fuse storage box on instrument panel
Replacement of fuse storage box on instrument panel Figure No.
Part Name
Preparation procedure Remove the driver side knee cover. Refer to “Replacement of driver side knee cover” Tightening of fuse box(quantity: 4） 1
Warning: Refer to “Warnings on Tightening”. Tightening 2±0.5 N.m
2
Fuse storage box
Body metal components and decorating parts 2-28
2.3.2.8 Replacement of instrument panel drawer
16BH 0203007
Replacement of instrument panel drawer Figure No.
Part Name instrument panel drawer
1
Procedures Lift upward and loosen the lower positioning clip of instrument panel drawer, turn this to the side direction and removed.
Body metal components and decorating parts 2-29
2.3.2.9 Replacement of air conditioning ventilation window – both side
16BH 0203008
Replacement of air conditioning ventilation window – both side Figure No.
Name of component
Procedure 1. Remove left and right dashboard trim strip. See “dashboard trim strip replacement”. 2. Remove left and right dashboard cover. See“dashboard cover replacement”. Tightening Torque screw（Quantity：2） 1
Caution：Refer to “Tightening Torque Parts”。 Tightening Torque 2±0.5 N.m
2
Left Air conditioning ventilation window component
3
Right Air conditioning ventilation window component
Body metal components and decorating parts 2-30
2.3.2.10 Replacement of air conditioning ventilation window instrument panel
16BH 0203009
Replacement of air conditioning ventilation window instrument panel Figure No.
Name of component
Procedure Remove right dashboard trim panel。Refer to“ Replacement of dashboard trim panel”。 Air conditioning window instrument panel assembly screws (Quantity：4） 1
Caution：Refer to “Tightening Torque Parts”。 Tightening Torque 2±0.5N.m
2
Middle air conditioning window dashboard
Body metal components and decorating parts 2-31
2.3.2.11 Replacement of instrument panel assembly
16BH 0203010
Replacement of instrument panel assembly Figure No.
Part Name
Preparation procedure 1.
Remove steering wheel and move steering column to lowest position
2.
Remove the instrument cluster. Refer to “Replacement of instrument cluster”.
3.
Remove the instrument cluster shield. Refer to “Replacement of instrument shield”.
4.
Remove the instrument panel module of SRS system. Refer to “Replacement of instrument panel module of SRS system”.
5.
Remove the instrument panel side end cover. Refer to “Replacement of instrument panel side end cover”.
6.
Remove the front pillar A trim panel. Refer to “Replacement of front pillar A trim panel”.
7.
Remove the middle trim instrument panel. Refer to “Replacement of imiddle trim instrument panel”.
8.
Remove the air-conditioning window assembly of instrument panel. Refer to “Replacement of air-conditioning
9.
Remove the driver side knee cover. Refer to “Replacement of driver side knee cover”
window assembly of instrument panel”. 10. Remove the co-driver side knee cover. Refer to “Replacement of co-driver side knee cover”. 11.
Remove CD player or video entertainment system. Refer to “Replacement of CD player or video entertainment system”.
12. Remove the air-conditioning control mechanism. Refer to “Replacement of air-conditioning control mechanism”. 13. Remove front floor panel. Refer to :replacement of the front floor panel”.
Body metal components and decorating parts 2-32 Tightening nut for instrument panel assembly (quantity: 2） 1
Warning: Refer to “Warnings on tightening”. Tightening torque 7±1 N.m Tightening bolt for instrument panel assembly (quantity: 8）
2
Warning: Refer to “Warnings on tightening”. Tightening torque 5±1 N.m Instrument Panel Assembly
3
Procedure Disconnect the electrical connector and mark the harness connector location for installation.
Body metal components and decorating parts 2-33
2.3.2.12 Replacement of instrument panel bracket assembly
Replacement of instrument panel bracket assembly Figure No.
Part Name
Preparation procedure 1.
Remove the instrument panel assembly. Refer to “Replacement of instrument panel assembly”.
2.
Remove the steering column. Refer to “Replacement of steering column”.
3.
Remove the instrument panel harness. Refer to “Replacement of instrument panel harness”. Tightening for tie bar of instrument panel (quantity: 6） 1
Warning: Refer to “Warnings on tightening”. Tightening torque: 22±3 N.m Tightening for middle bracket of instrument panel (quantity: 4）
2
Warning: Refer to “Warnings on tightening”. Tightening torque: 8 ±2 N.m Instrument panel bracket assembly
3
Procedures 1.
Mark the harness position for installation.
2.
Disconnect the electrical connector.
Body metal components and decorating parts 2-34
2.3.2.13 Replacement of middle bracket instrument panel
Replacement of middle bracket instrument panel Figure No.
Part Name
Preparation procedure 1.
Remove the co-driver side knee cover. Refer to “Replacement of the co-driver side knee baffle”.
2.
Remove the auxiliary instrument panel trim on front floor. Refer to “Replacement of auxiliary instrument panel trim on front floor”. Middle bracket of instrument panel (quantity: 6） 1
Warning: Refer to “Warnings on tightening”. Tightening torque : 8±2 N.m
2
middle bracket of instrument panel
Body metal components and decorating parts 2-35
2.3.2.14 Replacement of instrument panel harness
Replacement of instrument panel harness Figure No.
Part Name
Preparation procedure Remove the instrument panel assembly. Refer to “Replacement of instrument panel assembly”. Instrument panel harness 1
Procedures 1.
Mark the harness position for installation.
2.
Disconnect the electrical connector.
Body metal components and decorating parts 2-36
2.3.2.15 Replacement of auxiliary instrument panel trim on front floor
16BH 0203011
Replacement of auxiliary instrument panel trim on front floor Figure No.
Part Name
Preparation procedure Remove the co-driver side knee cover. Refer to “Replacement of the co-driver side knee cover” auxiliary instrument panel trim on front floor 1
Procedures Remove the auxiliary instrument panel trim on front floor carefully by use of pry instrument tool.
Body metal components and decorating parts 2-37
2.3.2.16 Replacement of auxiliary instrument panel side trim panel on front floor
16BH 0203012
Replacement of auxiliary instrument panel side trim panel on front floor Figure No. 1
Part Name auxiliary instrument panelside trim panel (left side and right side)
Body metal components and decorating parts 2-38
2.3.2.17
Replacement of armrest on auxiliary instrument panel
Replacement of armrest on auxiliary instrument panel Figure No.
Part Name
Preparation procedure Remove the auxiliary instrument panel rear end cover. Refer to “Replacement of auxiliary instrument panel rear end cover on front floor”. 1
auxiliary instrument panel shaft
2
auxiliary instrument panel armrest
Body metal components and decorating parts 2-39
2.3.2.18
Replacement auxiliary instrument panel rear end cover on front floor
Replacement auxiliary instrument panel rear end cover on front floor Figure No.
Part Name Tightening auxiliary instrument panel rear end cover
1
Warning: Refer to “Warnings on tightening”. Tightening torque 1.5±0.5 N.m auxiliary instrument panel rear end cover
1
Procedures Disconnect the electrical connector, and remove the cigar lighter assembly.
Body metal components and decorating parts 2-40
2.3.2.19
Replacement of auxiliary instrument panel on front floor
16BH 0203013
Replacement of auxiliary instrument panel on front floor Figure No.
Part Name
Preparation procedure 1.
Remove the auxiliary instrument panel trim. Refer to “Replacement of auxiliary instrument panel trim”.
2.
Remove the both side of auxiliary instrument panel trim. Refer to “Replacement of both side auxiliary instrument panel trim on front floor”. Tightening for auxiliary instrument panel of front floor (quantity: 5） 1
Warning: Refer to “Warnings on tightening”. Tightening torque 3.5±0.5 N.m Auxiliary instrument panel assembly Procedures
2
1、 Move the seat forward, so that can be remove auxiliary instrument panel assembly. 2.
Remove the auxiliary instrument panel rear end cover.
Body metal components and decorating parts 2-41
2.3.3 Special tools and equipment 2.3.3.1 Special tools Figure
Tool No./Description
BD-0003 Tools for removing clips of trim panel
Body metal components and decorating parts 2-42
2.4
Interior and panel
2.4.1 Specification 2.4.1.1 Tightening torque specification Fasteners Tightening Specification Application
Specification Metric system
Tighteningoffront door glass switch panel
2±0.5 N.m
Tighteningofrear door glass switch panel
2±0.5 N.m
Tighteningof interior front door handle Tighteningof front side door handle Tighteningof interior rear door handle
1.5±0.5 N.m 2±0.5 N.m 1.5±0.5 N.m
Tighteningofrear side door handle
2±0.5 N.m
Tighteningoffront door armrest bracket
3±0.5 N.m
Tighteningofrear door armrest bracket
3±0.5 N.m
Tighteningof auxiliary pull handle
2.5±0.5 N.m
Tighteningof sun visor sunshade
1.5±0.5 N.m
Tighteningoftrim center pillar(Pillar B)
2±0.5 N.m
TighteningofTail door window
2±0.5 N.m
Body metal components and decorating parts 2-43
2.4.2 Service Instruction 2.4.2.1 Replacement of front door glass switch panel
Replacement of front door glass switch panel Figure No.
Part Name
Preparation procedure Remove the Front door trim Refer to “Replacement Front door trim”. Tightening for front door glass switch panel (quantity: 2） 1
Warning: Refer to “Warnings on tightening”. Tightening torque 2±0.5 N.m Front door glass switch panel Procedures
2
1.
Disconnect the electrical connector.
2.
Remove the front door glass switch panel, and remove front door glass assembly.
3.
Remove the electric regulator switch assembly. Conduct installation by opposite sequence.
Body metal components and decorating parts 2-44
2.4.2.2 Replacement of rear door glass switch panel
Replacement of rear door glass switch panel Figure No.
Part Name
Preparation procedure Remove the Rear door trim. Refer to “Replacement of Rear door trim”. Tightening for rear door glass bswitch panel(quantity: 2） 1
Warning: Refer to “Warnings on tightening”. Tightening torque 2±0.5 N.m Rear door glass switch panel Procedures
2
1.
Disconnect the electrical connector.
2.
Remove the rear door glass switch panel, and remove rear door glass assembly.
3.
Remove the electric regulator switch assembly. Conduct installation by opposite sequence
Body metal components and decorating parts 2-45
2.4.2.3 Replacement of Front door trim
Replacement of Front door trim Figure No.
Part Name
Preparation procedure Remove the front side door triangular trim. Refer to “front side door triangular trim”. Tigtening for front door handle(quantity: 1) Prompt: Remove the front door handle cover to approach its tightening. 1
Warning: Refer to “Warnings on Tightening”. Tightening torque 1.5±0.5 N.m Tightening for front door handle cover(quantity: 1) Prompt: Remove the handle cover panel of from front door trim to approach
2
its tightening. Warning: Refer to “Warnings on tightening”. Tightening torque 2±0.5 N.m front door side trim Procedures
3
1.
Disconnect the electrical connector.
2.
Remove front door handle assembly and front door glass switch panel.
Body metal components and decorating parts 2-46
2.4.2.4 Replacement of Rear door trim
Replacement Rear door trim Figure No.
Part Name
Preparation procedure Remove the rear side door triangular trim. Refer to “rear side door triangular trim”. Tightening for rear door handle (quantity: 1) Prompt: Remove the handle cover panel of from rear door trim to approach 1
its tightening. Warning: Refer to “Warnings on tightening”. Tightening torque 1.5±0.5 N.m Tightening for rear door handle cover (quantity: 1) Prompt: Remove the handle cover panel of from rear door trim to approach
2
its tightening. Warning: Refer to “Warnings on tightening”. Tightening torque 2±0.5 N.m Rear door sidetrim Procedures
3
1.
Disconnect the electrical connector.
2.
Remove rear door handle assembly and rear door glass switch panel.
Body metal components and decorating parts 2-47
2.4.2.5 Replacement of front door waterproof cover
Replacement of front door waterproof cover Figure No.
Part Name
Preparation procedure Remove the Front door trim. Refer to “Replacement of Front door trim”. Tightening for front door armrest bracket (quantity: 2） 1
Warning: Refer to “Warnings on tightening”. Tightening torque 3±0.5 N.m
2
Front door armrest bracket front door waterproof cover Procedures
3
1.
Remove the Front door armrest bracket.
2.
Guide the electrical connector and door lock lever to pass through when remove waterproof cover.
3.
During installation, the sealing tape must be pasted to the lower edge of drain hole, and there shall be no wringkle when pasted together with waterproof cover.
Body metal components and decorating parts 2-48
2.4.2.6 Replacement of rear door waterproof cover
Replacement of Replacement of rear door waterproof cover Figure No.
Part Name
Preparation procedure Remove the Rear door trim. Refer to “Replacement of Rear door trim”. Tightening for rear door armrest bracket (quantity: 2） 1
Warning: Refer to “Warnings on tightening”. Tightening torque 3±0.5 N.m
2
Rear door armrest bracket rear door waterproof cover Procedures
3
1.
Remove the rear door armrest bracket.
2.
Guide the electrical connector and door lock lever to pass through when remove waterproof cover.
3.
During installation, the sealing tape must be pasted to the lower edge of drain hole, and there shall be no wringklewhenpasted together with waterproof cover
Body metal components and decorating parts 2-49
2.4.2.7 Replacement of front door sill trim panel
16BH 0204001
Replacement of front door sill trim panel Figure No. 1
Part Name front door sill trim panel
Body metal components and decorating parts 2-50
2.4.2.8 Replacement of rear door sill trim panel
16BH 0204002
Replacement of rear door sill trim panel Figure No. 1
Part Name rear door sill trim panel
Body metal components and decorating parts 2-51
2.4.2.9 Replacement of auxiliary hand grip
Replacement of auxiliary hand grip Figure No. 1
Part Name Tightening auxiliary hand grip trim cover (quantity: 2） Prompt: protrusions toward the car direction Tightening for auxiliary hand grip(quantity: 2） Prompt: turn the handle and remove the auxiliary hand grip tightening trim
2
cover to approach the tightening. Warning: Refer to “Warnings on tightening”. Tightening torque 2.5±0.5 N.m
3
Auxiliary hand grip assembly
Body metal components and decorating parts 2-52
2.4.2.10
Replacement of sun visor
Replacement of sun visor Figure No.
Part Name Tightening for sun visor(quantity: 2） Prompt: Turn the sun visor to approach to the tightening.
1
Warning: Refer to “Warnings on tightening”. Tightening torque 1.5±0.5 N.m
2
Sun visor mounting Sun visor assembly
3
Procedure Disconnect the electrical connector.
Body metal components and decorating parts 2-53
2.4.2.11
Replacement of upper trim front pillar (Pillar A)
16BH 0204003
Replacement of upper trim front pillar (Pillar A) Figure No.
Part Name Upper trim front pillar (Pillar A) Procedures
1
1.
The upper trim removed from the upper the positioning clips
2.
Disconnect the electrical connector, and remove the loudspeaker
3.
Insert the lower tab into instrument panel during installation, and then press two clips on it tightly.
Body metal components and decorating parts 2-54
2.4.2.12
Replacement of lower trim front pillar (Pillar A)
16BH 0204004
Replacement of lower trim front pillar (Pillar A) Figure No.
Part Name
Preparation procedure 1.
Remove the front side door sill trim. Refer to “front side door sill trim”.
2.
Remove the driver foot pedal trim. Refer to “Replacement of driver foot pedal trim”. 1
lower front Pillar A screw(quantity: 1） Lower front Pillar A trim
2
Procedures Remove the outer trim clips from the lower trim panel from top to bottom and then loosen the positioning clip.
Body metal components and decorating parts 2-55
2.4.2.13
Replacement of upper trim center pillar (Pillar B)
16BH 0204005 Replacement of upper trim center pillar (Pillar B) Figure No.
Part Name
Preparation procedure 1.
Remove the driver or passenger' safety belts and its guide. Refer to “Replacement of driver or passenger' safety belts”.
2.
Remove the trim under center pillar (Pillar B) for replacement. Refer to “Replacement of lower trim center pillar (Pillar B)”. Tightening for upper trim center pillar (Pillar B) (quantity: 2） 1
Warning: Refer to “Warnings on tightening”. Tightening torque 2±0.5 N.m Upper trim center pillar (Pillar B)
2
Procedures Remove the outer trim clips from the upper trim panel from top to bottom and then loosen the positioning clip.
Body metal components and decorating parts 2-56
2.4.2.14
Replacement of lower trim center pillar (Pillar B)
Replacement of lower trim center pillar (Pillar B) Figure No.
Part Name
Preparation procedure 1.
Remove of front door sill trim panel. Refer to “Replacement of front door sill trim panel”.
2.
Remove the rear door sill trim panel. Refer to “Replacement of rear door sill trim panel”.
3.
Remove driver or passenger’s safety belts. Refer to “Replacement of driver or passenger’s safety belts”. 1
Lower trim center pillar (Pillar B) (quantity: 2） Lower trim of Pillar B
2
Procedures Remove the outer trim clips from the lower trim panel from top to bottom and then loosen the positioning clip.
Body metal components and decorating parts 2-57
2.4.2.15
Replacement of upper rear side trim panel
Replacement of upper rear side trim panel Figure No.
Part Name
Preparation procedure 1.
Remove the second-row and third-row seat belt. Refer to “Replacement of second-row seat belt” and “Replacement of third-row seat belt”.
2.
Remove the lower rear side trim panel. Refer to “Replacement of lower rear side trim panel”.
3.
Remove the third-row auxiliary handgrip. Refer to “Replacement of third-row auxiliary handgrip”. upper rear side trim panel. Procedures 1
1.
Loosen the positioning clips on upper part of upper rear side trim panel Remove the outer trim clips from the lower trim panel of pillar C from top to bottom and then loosen the positioning clip.
Body metal components and decorating parts 2-58
2.4.2.16
Replacement of lower rear side trim panel
Replacement of lower rear side trim panel Figure No.
Part Name
Preparation procedure 1.
Remove the tailgate insulation padassembly. Refer to “Replacement of tailgate insulation padassembly”.
2.
Remove the rear side door sill trim panel. Refer to “Replacement of rear side door sill trim panel”.
3.
Remove the lower safety belts of second-row seats. Refer to “Replacement of lower safety belts of second-row seats”. Lower lower rear side trim panel Procedures 1. 1
Remove the trim panel clip from the rear and lower part of lower rear side trim panel, and then loosen the positioning clip according from top to bottom. Disconnect the electrical connector, and remove the external USB socket.
Body metal components and decorating parts 2-59
2.4.2.17
Replacement of tailgate carpet strip
Replacement of tailgate carpet strip Figure No.
Part Name
1
Tail gate door latch
2
Tailgate carpet strip
Body metal components and decorating parts 2-60
2.4.2.18
Replacement of tailgate upper window frame trim panel
Replacement of tailgate upper window frame trim panel Figure No. 1
Part Name Tail gate upper window frame trim panel
Body metal components and decorating parts 2-61
2.4.2.19
Replacement of tailgate side window frame trim panel
Replacement of tailgate side window frame trim panel Figure No.
Part Name
Preparation procedure Remove the upper window frame trim panel on the tailgate. Refer to “Replacement of upper window frame trim panel on the tailgate”. Tighteningfor side window frame trim panel on the tailgate(quantity: 2) 1
Warning: Refer to “Warnings on tightening”. Tightening torque 2±0.5 N.m
2
Tail gate Side window frame
Body metal components and decorating parts 2-62
2.4.2.20
Replacement of tailgate trim panel
Replacement of tailgate trim panel Figure No.
Part Name
Preparation procedure 1.
Remove the tailgate upper window frame trim panel. Refer to “Replacement of tailgate upper window frame trim panel”.
2.
Remove the tailgate sidewindow frame trim panel. Refer to “Replacement of tailgate sidewindow frame trim panel”.
3.
Remove the tailgate handle. Refer to “Replacement of tailgate handle”. 1
Tail gate trim panel
2
Tail gate Side cover
Body metal components and decorating parts 2-63
2.4.2.21
Replacement of tailgate handle
Replacement of tailgate handle Figure No. 1
Part Name Tail Gate handle
Body metal components and decorating parts 2-64
2.4.3 Special tools and equipment 2.4.3.1 Special tools Figure
Tool No./Description
BD-0003 Tools for removing clips of trim panel
Chapter 3 Body repair Contents 3.1
Fixed Bolts of Body outer panel and partition ......................................... 1
3.1.1
Specification ................................................................................................. 1 3.1.1.1
3.1.2
Tightening torque specification ..................................................... 1
Service instruction ....................................................................................... .2 3.1.2.1
Replacement of engine hood cable assembly...............................2
3.1.2.2
Replacement of engine hood unlock handle................ .................3
3.1.2.3
Replacement of engine hood lock assembly.................................4
3.1.2.4
Adjustment of engine hood ........................................................... 5
3.1.2.5
Replacement of engine hood ........................................................ 6
3.1.2.6
Replacement of engine hood insulator.......................................... 7
3.1.2.7
Replacement of engine hood hinge.............................................. 8
3.1.2.8
Replacement of engine hood rod holder…....................................9
3.1.2.9
Replacement of engine hood sealing strip…...............................10
3.1.2.10 Replacement of front fender ....................................................... 11 3.1.2.11 Adjustment of front side door ...................................................... 12 3.1.2.12 Replacement of front side door ................................................... 13 3.1.2.13 Replacement of wiring harness of front side door …...................14 3.1.2.14 Replacement the front side door upper hinge and a lower hinge15 3.1.2.15 Replacement the front door stopper ..........................................16 3.1.2.16 Replacement of sealing strip of front side door – door side….....17 3.1.2.17 Replacement of sealing strip of front side door – body side….... 18 3.1.2.18 Adjustment of rear side door ....................................................... 19 3.1.2.19 Replacement of rear side door ................................................... 20 3.1.2.20 Replacement of rear door wiring harness…................................21 3.1.2.21 Replacement of upper hinge and lower hinge of rear side door. 22 3.1.2.22 Replacement of rear side door stopper ...................................... 23 3.1.2.23 Replacement of sealing strip of rear side door – door side ........ 24 3.1.2.24 Replacement of sealing strip of rear side door —body side ....... 25 3.1.2.25 Adjustment of tailgate ................................................................. 26 3.1.2.26 Replacement of tailgate .............................................................. 27 3.1.2.27 Replacement of tailgate hinge .................................................... 28 3.1.2.28 Replacement of tailgate wiring harness ...................................... 29 3.1.2.29 Replacement of tailgate sealing strip .......................................... 30 3.1.2.30 Replacement of fuel tank filler cover .......................................... 31 3.1.2.31 Replacement of fuel tank cover cover opening switch ............... 32 3.1.2.32 Replacement of fuel tank filler cover lock ................................... 33 3.2
Bumper and Cover ................................................................................... 34
3.2.1
Specification ............................................................................................... 34 3.2.1.1
Tightening torque specification ................................................... 34
Body repair 3-2 3.2.2
Service instruction ...................................................................................... 35 3.2.2.1
Replacement of front bumper bar ............................................... 35
3.2.2.2
Replacement of front bumper mounting cover ........................... 36
3.2.2.3
Replacement of front bumper mounting cover connector bracket37
3.2.2.4
Replacement of rear bumper mounting cover ............................ 38
3.2.2.5
Replacement of rear bumper cover connector bracket .............. 39
3.2.2.6
Replacement of pressure relief valve on rear side ..................... 40
3.3
Collision repair ......................................................................................... 41
3.3.1
Specification ............................................................................................... 41 3.3.1.1
Body size .................................................................................... 41
3.3.1.2
Plate identification ....................................................................... 52
3.3.2
Operation and description .......................................................................... 57
3.4
Frame and under carrier .......................................................................... 64
3.4.1
Specification ............................................................................................... 64
3.4.2
Service instruction ...................................................................................... 65 3.4.2.1
Replacement of front wheel housing liner .................................. 65
3.4.2.2
Replacement of rear wheel housing liner ................................... 66
3.4.2.3
Replacement of front fender ....................................................... 67
3.5
Paint and coating ..................................................................................... 68
3.5.1
Introduction ................................................................................................. 68
3.5.2
3.5.1.1
Anti corrosion and repair ............................................................. 68
3.5.1.2
Prime coating/ transparent coating paint system........................ 73
Servicing instruction ................................................................................... 73 3.5.2.1
Repair of transparent coating—no respraying ............................ 73
3.5.2.2
Thickness of transparent coating ................................................ 74
3.5.2.3
Natural precipitation (acid rain) ................................................... 74
3.5.2.4
Coating thickness gauge ............................................................ 74
3.5.2.5
Repair of steel cuttings, corrosion and damage of rail ............... 75
Body repair 3-1
3.1 Fixed Bolts of Body outer panel and partition 3.1.1 Specification 3.1.1.1 Tightening torque specification Tightening torque specification Application Engine hood lock open handle bolt Engine hood lock bolt
Specification Metric 4.5±1.5 N.m 9±1.5 N.m
Engine hood hinge bolt (hinge side)
22.5±2.5 N.m
Engine hood hinge bolt (body side)
22.5±2.5 N.m
Front fender bolt
5±1 N.M
The front door stopper nut (side)
6±1 N.m
The Front door stopper bolt (body side)
26±3 N.m
The rear position (side) bolt threshold
6±1 N.m
Rear side door retainer bolt (body side)
26±3 N.m
The front door hinge bolt – door side
26±3 N.m
The front door hinge bolt - body side
26±3 N.m
The front side door hinge bolt – door side
26±3 N.m
The front side door hinge bolt – body side
26±3 N.m
Rear door hinge bolt - door side
26±3 N.m
Rear door upper hinge bolt body side
26±3 N.m
Rear door lower hinge bolt - door side
26±3 N.m
Rear door lower hinge bolt body side
26±3 N.m
The rear door hinge bolt (tail side)
26±3 N.m
Tail door hinge nut body side
26±3 N.m
Fuel filler cover bolt
4±1 N.m
Body repair 3-2
3.1.2 Service instruction 3.1.2.1 Replacement of engine hood cable assembly
15AJ0301001
Replacement of engine hood cable assembly Leading No.
Name of components
Preparation procedure 1.
Remove engine hood lock assembly. Refer to “Replacement of engine hood lock assembly”.
2.
Remove front grille assembly. Refer to “Replacement of front grille assembly”. Engine hood cable assembly 1
Procedures Remove engine hood cable assembly from the engine hood handle assembly
Body repair 3-3
3.1.2.2 Replacement of engine hood unlock handle
15AJ0301002
Replacement of engine hood unlock handle Leading No.
Name of components Bolts (quantity: 2) Warning: Refer to “Warning on tightening.
1 Tightening torque 4.5±1.5 N.m
Engine hood unlock handle 2
Procedures Remove engine hood lock cable
Body repair 3-4
3.1.2.3 Replacement of engine hood lock assembly
15AJ0301003
Replacement of engine hood lock assembly Leading No.
Name of components
Preparation procedure Remove front grille assembly, refer to “Replacement of front grille assembly”. Bolts (quantity: 2) Warning: Refer to “Warning on tightening”. 1 Tightening torque 9±1.5 N.m Engine Hood lock components 2
Procedures Disconnect engine hood cable assembly.
Body repair 3-5
3.1.2.4 Adjustment of engine hood
15AJ0301004
Adjustment of engine hood Leading No.
Name of components Engine Hood Warning: Refer to “Warning on tightening”.
Procedures 1. 2. 1
Loosen the engine hood hinge bolts (quantity: 4) for adjusment. Adjust the engine hood uniform gap between it and the front grille, headlights and front fender, and make it with the front grille, headlamps and front fenders flush.
Adjustment •
Engine hood to front grille (a) 7±1.5mm
•
Engine hood to headlamp (b) 5±1.5mm
•
Engine hood Engine to front fender (c) 3.5±1.0mm
Body repair 3-6
3.1.2.5 Replacement of engine hood
14BT0301015
Replacement of engine hood Leading No.
Name of components Engine hood hinge bolt (hinge side) (quantity: 4) Warning: Refer to “Warning on tightening”.
1 Tightening torque 22.5±2.5 N.m Engine Hood Procedures 2
1.
Remove engine hood with the help of assistant.
2.
Remove all parts.
3.
Regulate the engine hood necessary. Refer to “Adjustment of engine hood”.
Body repair 3-7
3.1.2.6 Replacement of engine hood insulator
14BT0301017
Replacement of engine hood insulator Leading No.
Name of components
1
Engine hood isolator pad clip (quantity: 17)
2
Engine hood vibration isolator
Body repair 3-8
3.1.2.7 Replacement of engine hood hinge
15AJ0301005
Replacement of engine hood hinge Leading No.
Name of components
Preparation procedure 1.
Remove engine hood. Refer to “Replacement of engine hood”.
2.
Remove wheel fender. Refer to “Replacement of wheel fender”. Engine hood Hinge bolts (body side) (quantity: 4) Warning: Refer to “Warning on tightening”. 1 Tightening torque 22.5±2.5 N.m 2
Engine Hood hinge
Body repair 3-9
3.1.2.8 Replacement of engine hood rod holder
15AJ0301006
Replacement of engine hood rod holder Leading No.
Name of components
1
Engine hood rod holder support
2
Clip of Engine hood rod holder
3
Engine hood rod holder
Body repair 3-10
3.1.2.9 Replacement of engine hood sealing strip
15AJ0301007
Replacement of engine hood sealing strip Leading No. 1
Name of components engine hood sealing strip
Body repair 3-11
3.1.2.10
Replacement of front fender
15AJ0301008
Replacement of front fender Leading No.
Name of components
Preparation procedure 1. 2.
Remove the bolts on joint between headlamp and wheel fender. Remove the triangular trim cover component of wheel fender. Refer to “Replacement of the triangular trim cover component of wheel fender”.
3.
Remove side body trim panel. Refer to “Replacement of side body trim panel
4.
Remove the front wheel housing liner. Refer to “Replacement of front wheel housing liner”.
5.
Remove connector bracket of front bumper seat cover. Refer to “Replacement of connector bracket of front bumper seat cover”.
6.
Remove upper panel trim cover. Refer to “Replacement of upper panel trim cover”. Bolts for front fender (quantity: 14) Warning: Refer to “Warning on tightening”. 1 Tightening torque 5±1 N.m Front fender Procedure 2
Replacement, the firstly observe the gap front doors, hood, and headlamp, preload bolts, and then measured the gap with the feeler gauge to meet the requirements after the final tightening bolts.
Body repair 3-12
3.1.2.11
Adjustment of front side door
15AJ0301009
Adjustment of front side door Leading No.
Name of components Front side door Warning: Refer to “Warning on tightening”.
Procedure 1.
Loosen the front door hinge bolts (number: 8) to adjust the front door.
2.
Adjust the front door so that it is evenly spaced from the roof, rear door, sill plate, and front fender and flush with the roof, rear door, sill plate, and front fender.
1 Adjustment •
front side door to roof (a) 4±1mm
•
front side door to upper part of rear side door (b) 4±1mm
•
front side door to lower part of rear side door (c) 4±1mm
•
front side door to apron plate of front side door (d) 6±1.5 mm
•
front side door to front fender (e) 4±1mm
Tightening torque 26±3 N.m
Body repair 3-13
3.1.2.12
Replacement of front side door
15BS0301010
Replacement of front side door Leading No.
Name of components
Preparation procedure 1.
Remove the front door trim panel. Refer to “Replacement front door trim panel”.
2.
Remove trim apron plate of front door. Refer to “Replacement of trim apron plate of front door”. Front door stopper bolt (body side) (quantity: 2) Warning: Refer to “Warning on tightening”. Tightening torque
26±3N.m 1
Procedure 1.
Remove the waterproofing film and disconnect door harness connector
2.
Remove the hinge bolts and door mounting.
3.
Remove the door with the help of assistant.
Front door hinge bolt (quantity: 8) 2
Tightening torque 26±3N.m Front side door Procedure
3
1.
Remove all internal parts.
2.
If necessary, adjust the front door. See "Adjustment Front Side Door”.
Body repair 3-14
3.1.2.13
Replacement of wiring harness of front side door
15BS0301011
Replacement of wiring harness of front side door Leading No.
Name of components
Preparation procedure Remove the front door trim. See "Replacement Front door trim panel " Front side door wiring harness Warning: in the servicing of any electrical components before the ignition switch must be in the OFF or LOCK position, and all electrical loads must be closed unless otherwise specified operation procedures. Disconnect the negative battery cable to prevent electrical terminals exposed and contact tools or 1
equipment to produce electric spark. ailure to follow these safety instructions may result in personal injury and / or damage to vehicle or vehicle components.
Procedure 1.
Disconnect battery
2.
Remove the waterproof film.
3.
Disconnect the electrical connector.
Body repair 3-15
3.1.2.14
Replacement the front side door upper hinge and a lower hinge
15AJ0301010
Replacement of front side door upper hinge and a lower hinge Leading No.
Name of components
Preparation procedure 1.
Remove front fender. Refer to “Replacement of front fender”.
2.
Remove front side door. Refer to “Replacement of front side door”. front side door hinge bolts (quantity: 8) Warning: Refer to “Warning on tightening”.
Tightening torque 1
26±3N.m
Procedure If necessary, apply a proper amount of paint to the opening of the hinge and make sure to leave a mark. 2
Front side door upper hinge
3
Front side door lower hinge
Body repair 3-16
3.1.2.15
Replacement the front door stopper
15BL0301011
Replacement of front door stopper Leading No.
Name of components
Preparation procedure Remove front door trim panel. Refer to “Replacement of front door trim panel”. Front door stopper bolt (body side) (quantity: 2) Warning: Refer to “Warning on tightening”. 1 Tightening torque
26±3 N.m Front door stopper bolt (door side) (quantity: 4) 2
Tightening torque 6±1 N.m
3
Front door stopper
Body repair 3-17
3.1.2.16
Replacement of sealing strip of front side door – door side
15BS0301014
Replacement of sealing strip of front side door – door side Leading No.
Name of components
Preparation procedure Remove the front door stopper from the body bolts 1
Sealing strip of front side door —door side
Body repair 3-18
3.1.2.17
Replacement of sealing strip of front side door – body side
15AJ0301011
Replacement of sealing strip of front side door – body side Leading No.
Name of components
Preparation procedure Remove trim panel assembly of front doorsill. Refer to “Replacement of trim panel assembly of front door sill”. 1
Sealing strip of front side door—body side
Body repair 3-19
3.1.2.18
Adjustment of rear side door
15AJ0301012
Adjustment of rear side door Leading No.
Name of components Rear side door Warning: Refer to “Warning on relevant tightening”.
Procedure 1.
Loosen the rear door hinge bolt (number: 8) to adjust the rear door.
2.
Adjust back door and the rear roof, between the outer plate, and the front door sill uniform gap, and the roof, and rear panel, and front door sill flush
1
Adjustment •
Rear side door to front upper door(a) 4±1 mm
•
Rear side door to roof (b) 4±1mm
•
Rear side door to butterfly window strip (c) 4±1 mm
•
Rear side door to rear side (d) 4±1 mm
•
To rear side door sill (e) 6±1.5mm
•
among both side door (from to rear) to the lower side (f) 4±1 mm
Body repair 3-20
3.1.2.19
Replacement of rear side door
15BS0301017
Replacement of rear side door Leading No.
Name of components
Preparation procedure 1.
Remove the rear door trim. Refer to “Replacement of rear door trim”.
2.
Remove rear door trim skirt. Refer to “Replacement rear door trim skirt”. Rear side door stopper bolt (body side) (quantity: 2) Warning: Refer to “Warning on tightening”. Tightening torque 26±3 N.m 1
Procedure 1.
Remove the waterproofing membrane and disconnect the door harness connector.
2.
Remove the hinge bolts and support the door.
3.
With the help of the assistant, remove the door.
Rear door hinge bolt (quantity: 8) 2
Tightening torque 26±3N.m Rear side door
3
Procedure 1.
Remove all internal parts.
2.
If necessary, adjust the rear door. See "Adjustment of the rear door".
Body repair 3-21
3.1.2.20
Replacement of rear door wiring harness
14BT0301009
Replacement of rear door wiring harness Leading No.
Name of components
Preparation procedure Remove the rear door trim. Refer to “Replacement of rear door trim panel”. rear door wiring harness
Warning: in the servicing of any electrical components before the ignition switch must be in the OFF or LOCK position, and all electrical loads must be closed unless otherwise specified operation procedures. Disconnect the negative battery cable to prevent electrical terminals exposed and contact tools or 1
equipment to produce electric spark. Failure to follow these safety instructions may result in personal injury and / or damage to vehicle or vehicle components.
Procedure 1.
Disconnect battery
2.
Remove the waterproof film.
3.
Disconnect the electrical connector when necessary.
Body repair 3-22
3.1.2.21
Replacement of upper hinge and lower hinge of rear side door
15AJ030113
Replacement of upper hinge and lower hinge of rear side door Leading No.
Name of components
Preparation procedure Remove rear side door. Refer to “Replacement of rear side door”. Rear door hinge bolts (quantity: 8) Warning: Refer to “Warning on tightening”.
Tightening torque 1
26±3N.m
Procedure If necessary, apply a proper amount of paint to the opening of the hinge and make sure to leave a mark. 2
Upper hinge of rear side door
3
Lower hinge of rear side door
Body repair 3-23
3.1.2.22
Replacement of rear side door stopper
15BS0301019
Replacement of rear side door stopper Leading No.
Name of components
Preparation procedure Remove front door trim panel. Refer to “Replacement of front door trim panel”. Rear side door stopper bolts (body side) (quantity: 2) Warning: Refer to “Warning on tightening”. 1 Tightening torque 26±3N.m Rear side door stopper bolts (door side) (quantity: 4) 2
Tightening torque 6±1N.m
3
Rear side door stopper
Body repair 3-24
3.1.2.23
Replacement of sealing strip of rear side door – door side
15BS0301020
Replacement of sealing strip of rear side door – door side Leading No.
Name of components
Preparation procedure Remove the connecting bolt between rear door stopper and body. 1
Sealing strip of rear side door—door side
Body repair 3-25
3.1.2.24
Replacement of sealing strip of rear side door —body side
15AJ0301014
Replacement of sealing strip of rear side door—body side Leading No.
Name of components
Preparation procedure Remove rear side trim panel doorsill. Refer to “Replacement of rear side trim panel doorsill” 1
Sealing strip of rear side door—body side
Body repair 3-26
3.1.2.25
Adjustment of tailgate
15AJ0301015
Adjustment of tail gate Leading No.
Name of components Tailgate Warning: Refer to “Warning on tightening”.
Procedure 1. 2.
Loosen the four row of tailgate hinge bolts to adjust the tailgate Adjust the tailgate to make the gap between it and taillight and bumper seat cover even, and make it parallel to taillight and
1
bumper seat cover. Adjustment •
rear windshield to side panel (a) 4.5±1.5mm
•
tailgate to head cover (b) 8±1.5mm
•
tailgate to rear windshield (c) 3±1mm
•
tailgate to lower part of rear bumper 8±2mm
•
tailgate to rear bumper side (e)
•
tailgate to taillight (f) 4.5±1.5mm
•
tailgate to rear windshield (g) 3±1mm
gradient: 4-8±1.5mm
Body repair 3-27
3.1.2.26
Replacement of tailgate
15AJ0301016
Replacement of tailgate Leading No. 1
Name of components Tailgate gas spring (quantity: 2) Tailgate mounting bolts (door side) (quantity: 4) Warning: Refer to “Warning on relevant tightening”.
2 Tightening torque 26±3 N.m Tailgate
3
Procedure 1.
Remove the tailgate with the help of assistant
2.
Remove all parts.
3.
Adjust tailgate when necessary. Refer to “Adjustment of tailgate”.
Body repair 3-28
3.1.2.27
Replacement of tailgate hinge
15AJ0301017
Replacement of tailgate hinge Leading No.
Name of components
Preparation procedure 1.
Remove tailgate. Refer to “Replacement of tailgate”.
2.
Remove roof lining 1
Tailgate hinge tailgate hinge bolts (body side) (quantity: 4) Warning: Refer to “Warning on relevant tightening”.
2 Tightening torque 26±3 N.m
Body repair 3-29
3.1.2.28
Replacement of tailgate wiring harness
15AJ0301018
Replacement of tailgate wiring harness Leading No.
Name of components
Preparation procedure Remove tailgate trim panel. Refer to “Replacement of tailgate trim panel”. Tailgate wiring harness Warning: in the servicing of any electrical components before the ignition switch must be in the OFF or LOCK position, and all electrical loads must be closed unless otherwise specified operation procedures. Disconnect the negative battery cable to prevent electrical terminals exposed and contact tools or 1
equipment to produce electric spark. Failure to follow these safety instructions may result in personal injury and / or damage to vehicle or vehicle components.
Procedure 1.
Disconnect battery
2.
Disconnect the electrical connector when necessary
Body repair 3-30
3.1.2.29
Replacement of tailgate sealing strip
15AJ0301019
Replacement of tailgate sealing strip Leading No. 1
Name of components Replacement of tailgate sealing strip
Body repair 3-31
3.1.2.30
Replacement of fuel tank filler cover
14BT0301022
Replacement of fuel tank filler cover Leading No.
Name of components fuel tank filler cover bolts (quantity: 2) Warning: Refer to “Warning on tigthening”.
1 Tightening torque 4±1 N.m 2
Fuel tank filler cover
Body repair 3-32
3.1.2.31
Replacement of fuel tank cover cover opening switch
15AJ0301020
Replacement of fuel tank filler cover opening switch Leading No.
Name of components
Preparation procedure Remove the driver side knee stop assembly. Refer to “Replacement of Driver Side Knee Baffle Assembly”. 1
Multi-function switch assembly fuel tank filler cover opening switch
2
Procedure 1. 2.
Disconnect the fuel tank filler cover opening switch connector Remove the fuel tank filler opening switch from the multi-function switch assembly using the pry instrument tool
Body repair 3-33
3.1.2.32
Replacement of fuel tank filler cover lock
15AJ0301021
Replacement of fuel tank filler cover lock Leading No.
Name of components
Preparation procedure Remove rear side trim panel. Refer to “Replacement of rear side trim panel”. fuel tank filler cover lock 1
Procedure Rotate fuel tank filler cover lock to disassembly and installation in the neck on body side outer panel
Body repair 3-34
3.2
Bumper and Cover
3.2.1 Specification 3.2.1.1 Tightening Torque Specification Tightenig torque specification Application
Specification Metric
Bolts of Front bumper bar
22±3 N.m
Front bumper side mounting bolts
3±0.5 N.m
Front bumper cover upper mounting nut
6±1 N.m
Front bumper cover Lower mounting bolts
8±1 N.m
Front bumper cover connection bracket bolts Rear bumper Cover mounting bolts Rear bumper cover connection bracket bolts
10±2 N.m 5.5±1 N.m 5.5±1 N.m
Body repair 3-35
3.2.2 Service instruction 3.2.2.1 Replacement of front bumper bar
15AJ0302001
Replacement of front bumper bar Leading No.
Name of components
Preparation procedure 1.
Remove front grille assembly. See "front grille assembly replacement"
2.
Remove the front bumper mounting cover. Refer to “Replacement of front bumper mounting cover Front bumper upper bar bolts (quantity: 6) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 22±3 N.m 2
Front Bumper bar
Body repair 3-36
3.2.2.2 Replacement of front bumper mounting cover
15AJ0302002
Replacement of front bumper mounting cover Leading No.
Name of components
Preparation procedure 1.
Remove radiator grille. Refer to “Replacement of radiator grille”.
2.
Remove the front wheel housing liner. Refer to “Replacement of front wheel housing liner”.
3.
Remove the side trim skirt plate assembly. Refer to “Replacement of t the side trim skirt plate assembly”. Front bumper side cover mounting bolts (quantity: 2) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 3±0.5 N.m front bumper cover upper mounting nut (quantity: 2) 2
Tightening torque 6±1 N.m Retaining bolts for lower part of front bumper seat cover (quantity: 2)
3
Tightening torque 8±1 N.m
4
front air intake grille
5
Front fog lamp
6
Front air deflector
7
Front bumper seat cover
Body repair 3-37
3.2.2.3 Replacement of front bumper mounting cover connector bracket
15AJ0302003
Replacement of front bumper mounting cover connector bracket Leading No.
Name of components
Preparation procedure Remove the front bumper mounting cover. Refer to “Replacement of front bumper mounting cover”. front bumper mounting cover connector bracket bolts (quantity: 2) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 10±2 N.m 2
front bumper mounting cover connector bracket (quantity: 2)
Body repair 3-38
3.2.2.4 Replacement of rear bumper mounting cover
15AJS0302004
Replacement of rear bumper mounting cover Leading No.
Name of components
Preparation procedure 1.
Remove rear wheel housing liner. Refer to “Replacement of liner of rear wheel hood”.
2.
Remove taillight assembly (body) Refer to “Replacement of taillight assembly (body)”
3.
Remove the tailgate seal. See "Replacement of the tailgate seal".
4.
Remove the tailgate stopper. rear bumper mounitng cover bolt (quantity: 6) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 5.5±1 N.m Rear mounting cover
2
Procedure 1.
Remove parking sensor of vehicle
2.
Remove parking sensor wiring harness
3.
Remove rear fog lamp assembly
Body repair 3-39
3.2.2.5 Replacement of rear bumper cover connector bracket
15AJ0302005
Replacement of rear bumper cover connector bracket Leading No.
Name of components
Preparation procedure Remove rear bumper mounting cover. Refer to “Replacement of rear bumper mounting cover”. rear bumper cover connector bracket bolts (quantity: 8) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 5.5±1 N.m 2
rear bumper cover connector bracket
(quantity: 2)
Body repair 3-40
3.2.2.6 Replacement of pressure relief valve on rear side
15BS0302006
Replacement of pressure relief valve on rear side Leading No.
Name of components
Preparation procedure 1. Remove rear bumper mounting cover. Refer to “Replacement of rear bumper mounting cover”. 1
pressure relief valve on rear side (quantity: 2)
Body repair 3-41
3.3 Collision repair 3.3.1 Specification 3.3.1.1 Body size Engine compartment (upper part)
Position
Description
Length
Height
Width
1
Length datum line
0
—
—
2
Width datum line
—
—
0
3
Height datum line: The lowest point of the bottom of the curved beam is the datum
—
0
—
420
653
630
726
627
540
A
B
Location hole for left extension piece of upper camber beam at the front of 10.0mm Mounting hole for front suspension support of 97mm
All dimensions are measured from the datum line, the center line and the common reference. All dimensions are symmetrical except for a particular description.
Body repair 3-42 Position
a
b
c
d
e
f
g
Description
Length
From location hole for extension piece of upper camber beam at the front
320
to front suspension mounting hole (same side) From mounting hole of front suspension to location hole of front wheel
277
hood (same side) From front mounting hole of suspension to location hole of extension
1210
piece of upper crossbeam at the front (different sides) From mounting hole of front suspension to location hole of front wheel
1134
hood (different sides) From location hole of extension piece of upper camber beam at the front
12112
to location hole of front wheel hood (different sides) From location hole of extension piece of upper crossbeam at the front to
681
hood plunger latch hole From hood plunger latch hole to mounting hole of front suspension
680
All dimensions are measured from the zero line, the center line and the common reference. Except that all dimensions are symmetrical. Note: Note: the length is measured between two points in space, not a projection to the ground.
Body repair 3-43 Engine compartment (lower part)
Position
Description
Length
Height
Width
1
Length Datum line for length
0
—
—
2
Width Datum line for width
—
—
0
430.0mm
347.8mm
298.0mm
736.0mm
767.8mm
560.0mm
890.0mm
484.228mm
390.0mm
A
B
C
Lower crossbeam location hole at the front of 10mm Front wheel hood location hole away from 20.0mm Front
location
hole
of
front
longitudinal beam away from 14mm
All dimensions are measured from the center line of the parts and the common reference. All dimensions are symmetrical except for the particular description.
Body repair 3-44
Position
Description
Length
a
Locating hole of front side beam to front wheel cover
364.7315mm
b
Locating hole of front sill to front lower beam (same side)
488.5454mm
c
d
e
Front beam positioning hole to front wheel cover positioning hole (opposite side) Positioning hole of front wheel cover to lower cross beam (same side) Front wheel housing positioning hole to the front end of the lower cross beam positioning hole (different side)
1003.3091mm
581.9622mm
1003.0952mm
All dimensions are measured from the center line of the parts and the common reference. All dimensions are symmetrical except for the particular description. Note: the length is measured between two points in space, not a projection to the ground.
Body repair 3-45
Engine Compartment (Lower)
Figure-1
Position
1
2
3
Description Length datum: the previous point of the previous fender is the datum Width datum: The center point of the curved beam above is the datum Height datum: The bottom of the curved beam is the datum
Length(mm)
Height(mm)
Width(mm)
0
—
—
—
—
0
—
0
—
A
Positioning hole on hinge on front door
1077
680
741
B
Positioning hole on the lower door hinge
1077
316
757
C
Positioning hole on rear side door hinge
2117
718
753
D
Positioning hole on rear door Lower hinge
2099
358
756
E
Positioning hole on the rear side door
3209
683
778
All dimensions are measured from part centerline and common reference. All dimensions are symmetrical except for the Special Description. This table corresponds to Figure -1.
Body repair 3-46 Position
a
b
c
d
e
Description Positioning hole of front side rail to front wheel cover (same side) Positioning hole of front sill to front lower beam (same side) Front rail positioning hole to front wheel cover positioning hole (opposite side) Front wheel cover positioning hole to the front lower beam positioning hole (ipsilateral) Front wheel cover positioning hole to the front lower beam positioning hole (the other side)
Length(mm)
365
489
1003
582
1003
All dimensions are measured from part centerline and common reference. All dimensions are symmetrical except for the Special Description. Note: Length is the straight line distance between two points in the measurement space, not the projection to the ground.
Body repair 3-47
Side View
Figure-1
Position
1
2
3
Description Length datum: The previous point of the previous fender is the datum Width datum: The center point of the curved beam above is the datum Height datum: the bottom of the curved beam to the bottom of the lowest point is the datum
Length(mm)
Height(mm)
Width(mm)
0
—
—
—
—
0
—
0
—
A
Positioning hole on hinge on front door
1077
680
741
B
Positioning hole on the lower door hinge
1077
316
757
C
Positioning hole on rear side door hinge
2117
718
753
D
Positioning hole on rear door Lower hinge
2099
358
756
E
Positioning hole on the rear side door
3209
683
778
All dimensions are measured from part centerline and common reference. All dimensions are symmetrical except for the Special Description. This table corresponds to Figure -1.
Body repair 3-48
Side View
Figure-2
Position
a
b
c
d
e
f
Description Positioning hole on hinge on front door to hinge mounting hole on rear door Positioning hole on hinge on front door to hinge mounting hole on rear door Positioning hole on the front door lower hinge to the hinge mounting hole on the rear door Front door hinge mounting hole to positioning hole of rear side door Rear side door hinge mounting hole to the Positioning hole of rear door Rear side door hinge mounting hole to the Positioning hole of rear door
Length(mm)
1041
10712
1116
1023
1092
1157
All dimensions are measured from part centerline and common datum. All dimensions are symmetrical except for the Special Description. Note: Length is the straight line distance between two points in the measurement space. This table corresponds to Figure -2.
Body repair 3-49
Rear View
Position
1
2
3
Description Length datum: The previous point of the previous fender is the datum Width datum: The center point of the curved beam above is the datum Height datum: the bottom of the curved beam to the bottom of the lowest point is the datum
Length(mm)
Height(mm)
Width(mm)
0
—
—
—
—
0
—
0
—
A
Positioning hole of rear plate
4297.
160
403
B
Positioning hole of tail light
4118
670
704
C
Positioning hole of tail light gas spring
3948m
1253
585
All dimensions are measured from part centerline and common datum. All dimensions are symmetrical except for the Special Description.
Body repair 3-50 Position
a
b
c
d
e
f
Description Positioning hole of rear crossbeam outer to taillight positioning hole (ipsilateral) Positioning hole of rear cross-beam outer plate to gas spring mounting hole (ipsilateral) Positioning hole of rear cross-plate outer plate to the gas spring mounting hole (the other side) Positioning hole of
rear crossbeam outer plate to taillight
positioning hole (opposite side) Taillight positioning hole to gas spring Positioning hole (ipsilateral) Taillight positioning hole to the gas spring Positioning hole (the other side)
Length(mm)
619
1162
1515
1232
619.
1425
All dimensions are measured from part centerline and common datum. All dimensions are symmetrical except for the Special Description. Note: Length is the straight line distance between two points in the measurement space.
Body repair 3-51
Bottom View
Position
1
2
3
Description Length datum: The previous point of the previous fender is the datum Width datum: The center point of the curved beam above is the datum Height datum: the bottom of the curved of the lowest point is the datum
Length(mm)
Height(mm)
Width(mm)
0
—
—
—
—
0
—
0
—
A
Φ10 measuring hole
211
261
2981
B
Φ14 measuring hole
671
1621
3901
C
Φ16 measuring hole
1201
15
405
D
Φ20 measuring hole
2031
14
482
E
Φ20 measuring hole
2728
43
507
F
Φ16 measuring hole
3339
164
508
G
Φ10 measuring hole
4049
188
508
All dimensions are measured from part centerline and common datum. All dimensions are symmetrical except for the Special Description.
Body repair 3-52
3.3.1.2 Plate identification Front structure
15AJ0303001
Figure (1)
Reinforcing fittings assembly for outer panel of right front
(11) Welded parts for left front crossbeam
wheel hood
(12) Welded parts for mounting bracket of left front bumper
(2)
Welded parts for outer panel of right front wheel hood
(13) Welded parts for upper camber beam
(3)
Welded parts for right front side plate
(14) Assembly of lower camber beam
(4)
Mounting parts on front partition
(15) Assembly of front upper bumper bar
(5)
Welded assembly of front panel
(16) Welded parts for right front crossbeam
(6)
Welded parts for outer panel of left front wheel hood
(17) Welded parts for mounting bracket of right front bumper
(7)
Welded parts for left front side plate
(18) Welded parts for right section of upper camber beam
(8)
Reinforcing parts
(19) Welded parts for right front wheel hood
(9)
Welded parts of left front wheel hood
for outer plate of left front wheel hood
(10) Welded pats for left section of upper camber beam
(20) Parts of storage battery support plate
Body repair 3-53 Front floor
15AJ0303002
Figure (1) Welded fittings for internal plate of right doorsill (2) Welded assembly for front floor (3) Welded fittings for internal plate of right doorsill
Body repair 3-54 Rear floor
15AJ0303003
Figure (1)
rear floor welding assembly
(8)
the rear outer plate beam welding
(2)
pump inspection window cover components
(9)
Left D-pillar lower corner panel
(3)
left front fender welding parts
(10) left rear fender
(4)
welding pieces of the right rear wheel cover
(11) left rear wheel cover welding pieces
(5)
right rear fender
(12) shock absorber pin welding
(6)
the lower corner of the right D column
(13) rear frame welded assembly
(7)
the back end welding beam
(14) the right front fender weldment
Body repair 3-55 Side panel structure
15AJ0303004
Figure (1) the right rear side wall inner plate welding (2) the right pillar D reinforced plate welding (3) Right pillar B inner plate welding parts (4) the right pillar Bouter plate reinforcement welded pieces (5) the right pillar A welded pieces on the inner plate (6) Right pillar A reinforcement board welding parts (7) fender welding bracket in the installation bracket (8) Right side outer panel (9) the right rear wheel cover plate welding element (10) fuel tank filler bracket welding part (11) right rear protection mounting nut plate assembly (12) the right pillar D welding assembly
Body repair 3-56 Structure of roof
15AJ0303005
Figure (1) Head cover (2) The roof beam welding part (3) Roof beam #4 assembly (4) Roof bracket support (5) Roof beam #3 assembly (6) Roof beam #2 assembly (7) Roof beam #1 assembly (8) Roof holder assembly (9) Head cover front beam welding
Body repair 3-57
3.3.2 Operation and description General welding protective measures
•
Indirect welding is prohibited.
•
Soldering and acetylene welding are prohibited, unless otherwise stipulated in the production.
•
When welding three or more types of metal, the MIG plug welding method must be used to ensure the
Summary
joint strength. For reference purpose, the layout of the following pages
•
Use MIG plug welds where resistance spot welders cannot be used for repair seams. To replace each
shows only the types of repair with different types of
production spot weld, a hole of approximately 8 mm
production.
length must be drilled and / or punched, and then MIG plug welds are made at that location. Plug
Alternate welding methods in the welding arrangement
welding number. Be sure to exclude the number of
are indicated by the following symbols.
spot welding exactly the same. •
After the spot welding is eliminated, the holes are left on the faceplate and a single thickness MIG plug weld is to be applied at each hole as appropriate.
Electrical control unit Before conducting welding and repair operation, in view of the electronic control unit (ECU) installed on the vehicle, the following protective measures shall be taken. During these operation, it will produce large amount of heat and violent vibration, which may damage electronic control unit. When disconnecting or removing the diagnostic control A= single/multi-thickness plug welding B=MIG seam welding The following criteria must be followed when performing
unit (DCU) of airbag restraint system, the following appropriate protective measures shall be especially met: Protective measures for auxiliary protection system
welding operations: During the implementation of any work related to any •
If resistance spot welding has been used in the production process, new resistance spot welding must be carried out in other possible locations. All
item of disassembly or replacement of auxiliary protection system, the personnel shall be more careful and comply with appropriate protective measures.
this kind of new Spot welding must be spaced 30mm. •
in the spot, made of the same metal gauges and test recommended materials hanging, to perform the peel test to ensure that the use of welding equipment. To prepare a qualified seam. If the satisfaction of spot welding is not achieved, the Plug welding shall be used..
•
Equipment
The welding electrode holding length of welding gun of handheld spot shall not exceed 300mm.
When starting to conduct test for vehicle, you should guarantee that the operation of relevant test equipment is normal and all wiring harnesses and connectors are in good conditions. It is especially important to electronic control unit.
Body repair 3-58
Riveting point of safety belt Riveting point of safety belt is the key of safety. During repairing for these areas, it is very important to abide by the following design specifications. Note: High-strength low alloy steel (HSLA) can be adopted at the installation location of safety belt Original production assembly shall be used as much as possible, including riveting point of safety belt of seat. Or, the arrangement of cutting line shall not obstruct the riveting point of safety belt of original seat. The welding quality of joint of riveting point of safety belt within 250mm must be checked carefully, including spot welding interval. Note: Before exposing spot welding, within the Panel replacement steps
wheel hood area, it is necessary to soften the coating at the bottom of vehicle with hot air blower.
The steps are designed to interpret the methods for disassembly and replacement of basic panel. The main
2.
Cobalt drill cutting weld.
3.
A clamped-in type spot and rowing welding
standard for disassembly and replacement of body sheet is to maintain original standards as much as possible. For differences in the details of individual repair, the simplified maintenance shall be highlighted in such steps design to reduce unnecessary work. Body panels made of high-strength steel have increased gradually to meet the design requirements to safety and weight reduction. Because it is difficult to visually identify the high-strength steel panels which are more sensitive to waste heat than to low-carbon steel panel, it is recommended to follow the steps below all the time. Disassembly of panel 1.
Exposed resistance spot welding. As the spot welding is not obvious, use a rotary roller grinder or wire brush mounted to the gas drill, or hand-held wire brush.
machine also can be used.
Body repair 3-59
4.
Cut large panel with air saw when necessary. Trim old surface 1.
Eliminate all residual sealer with hot air blower to reduce poison gas generated due to hot during welding
2.
Trim the joint edges of all panels to be bright and flat with belt polishing machine.
Note: Before cutting large panels, use a grinder to remove MIG welds and brazing at some panel joints. 5.
Separate electrical welding contact with hammer, plate chisel and pincher and eliminate panel scrap.
Body repair 3-60
3. Straighten the joint edge of existing panel with form block and hammer.
3.
Polish the joint of trimmed new panel with abrasive paper to mirror surface for welding. Internal surfaces include:
Trim new surface 1.
Mark the outline of new panel, trim it to the specified dimension and reserve the overlapping part of 50mm for existing panel. Supply new panel/section and align it with relevant panel (such as: side panel for new body, door and trunk cover) and clamp it to place.
4.
Coat the panel jointing surface with appropriate through welding primer through brush or aerosol can for welding.
2.
Cut off new panel and existing panel to form butt joint, joggle joint or brazing joint when necessary. Take away all clamps and clean metal scraps.
Body repair 3-61
Note: The length of welding arm used shall not 5.
Coat the panel jointing surface with appropriate
exceed 300mm.
sealer or adhesive if possible. 2.
Install resistance spot welding arm and test equipment with test silfigure wafer to meet the operation requirements. If there is no monitoring equipment, you should inspect the wiredrawing in separated weld pool around the metal under tension in the process of stretch to verify weld strength.
Supply and alignment Supply new panel and align it with relevant panel. Clamp it in place with electrode holder or pincer. For the places with butt jointing or brazed jointing, a device shall be placed beside the jointing edge of the panel, or stay wire shall be inserted behind the joint. Note: If it is difficult to insert electrode holder, positioned welding shall be adopted.
3.
Resistance spot welder also can be used. Welding quality monitoring machine can be used to
1.
Select welding arm for resistance spot welding and form the electrode tip with weld nozzle trimming machine. Trim the welding nozzle to make its diameter equivalent to twice of the thickness of metal to be welded plus 3.0mm.
guarantee welding quality if possible.
Body repair 3-62
4.
6.
Butt joint for MIG seam welding
7.
MIG plug welding shall always be used for thick
MIG positioned welding shall be used for butt jointing to recheck alignment situation and panel outline when necessary. A metal saw blade shall be inserted with approximate guidance to reserve gap and reduce welding deformation.
metal or the restricted area of welding nozzle, resistance spot welding is unpractical. Plug welding shall be conducted at the hole reserved by 5.
Trim MIG positioned welding with 36 sand tray
spot welding and cutting machine. What’s more,
polishing machine or belt polishing machine.
hole (diameter of about 8mm) can be specially punched or drilled for plug welding.
Body repair 3-63
8.
Trim all welding with 36 sand tray polishing machine or belt polishing machine and/or wire brush. When trimming the welding, times of surface cleaning shall be reduced as much as possible to protect zinc coating.
Body repair 3-64
3.4 Frame and under carrier 3.4.1 Specification 3.4.1.1 Tightening torque specification Tightening torque specification Application
Specification Metric
Front wheel housing liner bolts
1.5±0.5 N.m
Rear wheel housing liner bolts
1.5±0.5 N.m
Front fender fastening bolts
1.5 ± 0.5 N · m
Body repair 3-65
3.4.2 Service instruction 3.4.2.1 Replacement of front wheel housing liner
15AJ0304001
Replacement of front wheel housing liner Leading No.
Name of components
Preparation Procedure Remove front fender. See "Front Fender Replacement". 1
Front wheel housing liner clips (quantity: 18) Front wheel housing liner bolts (quantity: 10) Warning: Refer to “Warning on relevant tightening”.
2 Tightening torque 1.5±0.5 N.m 3
front wheel housing liner
Body repair 3-66
3.4.2.2 Replacement of rear wheel housing liner
15AJ0304002
Replacement of rear wheel housing liner Leading No. 1
Name of components Rear wheel housing liner clips (quantity: 10) Rear wheel housing liner bolts (quantity: 10) Warning: Refer to “Warning on relevant tightening”.
2 Tightening torque 1.5±0.5 N.m 3
Rear wheel housing liner
Body repair 3-67
3.4.2.3 Replacement of front fender
16BH0304003
Replacement of front fender Leading No.
Name of components
1
Front fender set bolts (quantity:6)
2
Front Fender
Body repair 3-68
sound insulation layer is damaged due to the
3.5
Paint and coating
maintenance operation or the replacement of the new board, the sound insulating material must be replaced.
3.5.1 Introduction
The way and position of spraying noise material can be determined according to the form and position of the original installation.
3.5.1.1 Anti corrosion and repair Warning: spraying insulation or anti-corrosion
Welding or heating operation, the original galvanized or
materials, must be careful operation and take
other anticorrosive coatings have been burned, plate
preventive measures to avoid spraying in the doors
surface needs to be cleaned and the bottom of the car
and rear side mechanism, such as hanging parts
body. On the inner surface of the box structure, or when
lock, window slot, window lifter and seat belt
the layout of the metal plate cannot be close to the inner
retractor and any movement, rotation mechanism or
surface, the burning residue should be removed.
the bottom of the body, especially the parking brake pull. After painting, to ensure the smooth flow of all
General information
the drainage holes. Improper operation will increase the corrosion damage or limit the work of the
The process reliability, function, high environmental
moving parts, resulting in personal injury.
requirements show that the anti-corrosion protection of
Any operation that affects these special processing
the vehicle parts also require high requirements. It is
methods, such as changing the board or the collision
necessary to distinguish between the measures taken
repair operation, will cause the metal to lose protection
in production and the preservation measures taken in
and lead to corrosion. It is critical to use the
the maintenance of the vehicle body (eg, damage to the
maintenance - type corrosion protection material to re
vehicle or accident).
spray the surface. After installation of maintenance and / or replacement parts, all exposed metal surfaces must
Our customers require their motor vehicles to receive
be treated with metal modifiers and primers.
the same high quality corrosion protection as the new car. Body repair work in the protection of the effect of a
Flange joints, lap joints and joints should be sealed with
similar requirement.
a high quality, medium consistency sealant. The sealant used must be kept ductile and can be sprayed with paint
Anticorrosion protection measures taken for metal
after curing.
sheet and aluminum parts needed to be maintained.
High consistency packing should be used to seal the
Electrophoretic coating
open joints with closed spaces. Press the label on the selected material to operate. In order to make the repair
High-quality internal and external electrophoretic paints
parts (such as bonnet, fender, door, rear cover plate,
are supplied for parts needing body maintenance.
roof, nacelle, underbody and car plate etc.) may need
Electrophoretic paints can be directly obtained from the
to be restored, painting color. It must be carried out
paint shop. If the fitting is needed to be repaired due to
according to routine coating pretreatment, primer
damage during transportation, the previously scraped
spraying process and color etc.
part must be insulated with primer.
Use a sound insulation material (spray type) on various
Bonded folding and cohesive/sealed folding
metal plates to prevent corrosion and to seal the seal. This material can be used to control the general noise
On most hoods, doors and lift gates, the folded flange
level of the passenger area inside the vehicle. When the
on external plate shall be bonded on the frame with bonding rubber. The edge of flange must be sealed.
Body repair 3-69
1.
Prepare the body to be sprayed
2.
Spraying/ immersion bath-- phosphating
3.
Electrical immersion bath and primer spraying
Typical cycle plan and anti-corrosion protection stage.
4.
Sealer
Note: The following patterns indicate all stages of
5.
PVC body bottom protection
processes for delivered car parts
6.
PVC peeling protection
Anti-corrosion
protection
measures—cycle
of
typical delivered parts
Anti-corrosion
protection
measures—
body
trimming General information For better understanding, some different manual operations are shown below by pattern and crosssection diagram of body. During body trimming, the joint shall be sealed Note: The sealer must be coated on clean surface, or surfaces with primer or paint. If it is coated on bright metal plates, it will result in distinct weakening of adhesive force and quality defect of durability. The following cross-section diagram shows the sealing operations on body.
Body repair 3-70
12a0301001
Body repair 3-71
12a0301001
A
Flange seal cutting edge
B
Filled round corner
C
Flatten the visible joints with a flat brush
Body repair 3-72
Peeling protection for
The illustration shows the PVC protective material door sill and door
body trimming
standard parts
15AJ0305001
A
Doorsill
B
The door, front fender, rear side panel parts
Note: If exposed to standard PVC protective material, substitute for the material When the material is treated, it cannot cause any phenomena caused by dissolution. in principle , The substitute material must be installed on a clean, primed base. Using heat The wind blower heats the standard PVC protective material using a scraper removal. Do not use a diluent containing a high concentration of solvent to flush out. Must remove the recesses or weld the parts and replace the standard PVC Protection materials. There are standard parts of the general protection of PVC material in the body. Wheel hood (at the front and rear of the car) Doorsill, lower part of door, wheel fender, right side panel Floor and external part of car Crossbeam of car frame
Body repair 3-73
Protection for under carrier during body trimming
12a0301001
Note: Protection material at the bottom of the vehicle must be installed on clean basal plane with primer or coating. Whole-body spray is not applicable to these delivered parts. In most cases, protection materials at the bottom of the body shall be used for trimming or maintenance. During body trimming, it is better to use sealer to spray. Advantages: Universal, and can be sprayed for the whole body when necessary.
3.5.1.2 Prime coating/ transparent coating paint system Warning: During coating preparation and paint spraying, diffuse isocyanate will result in serious respiratory disease. Read the instructions of manufacturer of paint materials, equipment and protective device carefully as well as operate following it strictly.
3.5.2 Servicing instruction 3.5.2.1 Repair of transparent coating—no respraying Repair procedures 1.
Wash the part to be repaired thoroughly with cleaning fluid and wax.
2.
Environmental damage can be corrected. Refer to “Natural precipitation (acid rain)” or “Maintenance of steel cuttings, corrosion and damage of rail”
Important notes: Follow all instructions from the manufacturer of the polishing material.. 3.
Before polishing and/or buffing with abrasive paper and after neutralization of the whole process, you should measure it with coating thickness gauge to prevent eliminating overmuch transparent coatings. Refer to “Coating thickness gauge”.
Body repair 3-74
3.5.2.2 Thickness of transparent coating Generally, transparent coating thickness of a vehicle is 0.059-0.078mm (1.5-2 mil [0.0015-0.0020 inch]). There is UV protection material containing in the transparent coating. Removal quantity of transparent coating exceeding 0.5 mil (0.019 inch) will lead to early damage of coating.
3.5.2.3 Natural precipitation (acid rain) Warning: Refer to “Warning on transparent coating/UV protection materials”. Note: Please refer to the packaging instructions of the manufacturer to understand material prescription and/or detailed steps of polishing. Due to different conditions at different places, definite diagnosis of contamination degree is the key for successful repair. After appropriate cleaning of vehicle surface with cleaning fluid and wax, you should diagnose the horizontal surfaces (such as hood, roof or trunk cover) under the lighting of high-brightness fluorescent lamp. Acid rain damages can be divided into three fundamental types: Surface contamination: It only needs to wash the vehicle by washing surface with silfiguree wax and oil cleaning agent, neutralizing acid residue and fine burnishing—refer to “Repair of surface contamination”. Acid etching of transparent coating: After the above cleaning and fine burnishing procedures is finished, mild acid etching still can be found. Refer to “Mild damage of transparent coating—polishing with wet abrasive paper and fine burnishing”. Acid etching of primer layer: if the serve acid etching of relevant parts has penetrated into transparent coating and entered into primer layer, the surface needs to be trimmed. Refer to “prime coating/ transparent coating paint system”. Repair of surface pollution 1.
Clean and dry contaminative parts with liquid detergent and wax thoroughly.
2.
Clean the corresponding part by silfiguree, wax and grease cleaning agent.
3.
Clean contaminative parts with the mixture of sodium bicarbonate and water (1L or 1 quart water with 1 spoon of sodium bicarbonate) to eliminate and neutralize acid residues. Wash and dry the whole panel thoroughly.
4.
Conduct fine burnishing with foam pad. If the damaged part is recovered, double-acting track polishing machine and foam pad shall be used for eliminating vortex trace.
5.
For damage, refer to “Mild damage of transparent coating—polishing with wet abrasive paper and fine burnishing”.
Mild damage of transparent coating—polishing with wet abrasive paper and fine burnishing 1.
Select a patch of contamination test position.
2.
Measure the film thickness before sanding and polishing. See "Coating Thickness Gages".
3.
Conduct polishing and burnishing with abrasive paper for the contamination test position. During polishing, if you
suspect or find that the acid etching has permeate to primer coating, or more transparent coatings were removed when polishing with abrasive paper or primer color was brought to the surface polishing pad when burnishing, then relevant parts shall be conducted with surface trimming. Refer to “Prime coating/ transparent coating paint system”
3.5.2.4 Coating thickness gauge Measure the total thickness of vehicle finishing coat with coating thickness gauge. Due to the different thicknesses of finishing coats of different vehicles, therefore, it is important to measure the thickness of finishing coat of each vehicle. In order to precisely measure the finishing coat thickness before, during and after sanding, please use coating thickness gauge before sanding. Coating thickness gauges have magnetic type, advanced electronic type and other various types. There are many manufacturers as well. The maximal precision of old magnetic thickness gauge is 5% which is not enough for removing transparent coating of 0.02 mm (0.5 mil,0.0005 inch). The precision of new magnetic thickness gauge has been improved. Most thickness gauges can only be used for ferrous metal plate, steel plate, nonferrous metal plate or
Body repair 3-75
aluminum plate. Recently, no available thickness gauge can be used to measure the thickness of coating on the composite material plate. More advanced electronic coating thickness gauge can be used to measure the thickness of coating on ferrous metal plate and nonferrous metal plate. The precision of digital electronic thickness gauge is 1%, including the standard component for recalibrating thickness.
3.5.2.5 Repair of steel cuttings, corrosion and damage of rail Warning: Refer to “Warning on eyes protection”. Note: if the chip has worn through the end of rail steel corrosion paint, plate parts need surface dressing. Before finishing the surface, to ensure that all the tracks of steel scrap rust has been cleared, otherwise there will be rust. The steel cuttings, corrosion and damage of rail are caused by small steel cuttings generated by friction between train wheel and rail. If the vehicle is parked close to the factories generating scrap iron (such as iron mine), the scrap iron will deposit on the vehicle. Such scrap iron will spread all over the coating surface or permeate into the coating. Generally, it can be determined according to the protuberance or rust spot on the surface of coating. 1.
Move the vehicle to a cool place to ensure that the vehicle surface is cold during the removal process..
2.
Clean the repair area thoroughly with cleaning solution and wax.
3.
Dry this area.
4.
Clean the area with silfiguree, wax, and grease cleaner.
5.
Perform the cleaning procedure according to the instructions supplied by the manufacturer of the used repair material (colloidal oxalate or clay-based non-acid). If the inspection found that there are still some steel scrap, repeat the clean-up procedures. If the damage has been repaired, the repair of the entire plate is completed.
6.
Repair the whole piece after polishing. If repairs are still spotted after repair, refer to "Repainting Transparent Coating - No Repainting".
Body repair 3-76
Blank
Chapter 4 Body system Contents 4.1 Mounting and movable windows ....................... 1 4.1.1 Specification .......................................................... 1 4.1.1.1 Tightening torque specification .............. 1 4.1.2 Schematic and wiring diagram .............................. 2 4.1.2.1 Schematic diagram of movable windows ................................................. 2 4.1.2.2 Schematic diagram of defroster ............. 5 4.1.3 Diagnostic information and procedure ................... 6 4.1.3.1 DTC B110D12 B110D13 ........................ 6 4.1.3.2 DTC B110F12 ........................................ 7 4.1.3.3 Symptom - mounting and movable windows ................................................. 8 4.1.3.4 Fault of defogger of rear window ........... 9 4.1.3.5 Fault of power window .......................... 11 4.1.4 Service Instruction ............................................... 14 4.1.4.1 Replacement of windshield .................. 14 4.1.4.2 Replacement of triangular trim cover of fender ............................................... 16 4.1.4.3 Adjustment of glass of front side door.. 17 4.1.4.4 Replacement of glass of front side door ...................................................... 18 4.1.4.5 Replacement of window glass lifter of front side door ...................................... 19 4.1.4.6 Replacement of front door left side window switch ...................................... 20 4.1.4.7 Replacement of front door right side window switch ...................................... 21 4.1.4.8 Replacement of rear lower glass guide slot of front door ......................... 22 4.1.4.9 Replacement of outer glass sealing strip of front side door .......................... 23 4.1.4.10 Replacement of inner glass sealing strip of front side door .......................... 24 4.1.4.11 Replacement of glass sealing strip of front side door ...................................... 25 4.1.4.12 Adjustment of glass of rear side door .. 26 4.1.4.13 Replacement of glass of rear side door ...................................................... 27 4.1.4.14 Replacement of window glass lifter of rear side door ....................................... 28 4.1.4.15 Replacement of window switch of rear side door .............................................. 29 4.1.4.16 Replacement of rear glass guide slot of rear side door ................................... 30 4.1.4.17 Replacement of outer glass sealing strip of rear side door ........................... 31 4.1.4.18 Replacement of inner glass sealing strip of rear side door ........................... 32 4.1.4.19 Replacement of glass sealing strip of rear side door ....................................... 33 4.1.4.20 Replacement of rear side mounting window glass (high-configuration) ........ 34 4.1.4.21 Replacement of rear side butterfly window glass (low-configuration) ......... 35 4.1.4.22 Replacement of rear side window sealing strip (low-configuration) ........... 36
4.1.4.23 Replacement of tailgate door ................37 4.1.5 Description and operation ....................................39 4.1.5.1 Description and operation of power window ..................................................39 4.1.5.2 Description and operation of defogger for rear window .....................................39 4.1.5.3 Description and operation of mounting window ..................................................39 4.2 Horn .....................................................................40 4.2.1 Specification .........................................................40 4.2.1.1 Tightening torque specification .............40 4.2.2 Schematic and wiring diagram .............................41 4.2.2.1 Horn schematic diagram .......................41 4.2.3 Diagnostic information and procedure .................42 4.2.3.1 DTC B113112 ........................................42 4.2.3.2 Symptoms - horn...................................43 4.2.3.3 Horn faults .............................................43 4.2.4 Service Instruction ................................................46 4.2.4.1 Replacement of horn.............................46 4.2.5 Description and operation ....................................47 4.2.5.1 Description and operation of horn system ...................................................47 4.3 Lighting ...............................................................48 4.3.1 Specification .........................................................48 4.3.1.1 Tightening torque specification .............48 4.3.2 Schematic and wiring diagram .............................49 4.3.2.1 Schematic diagram of lighting lamp ......49 4.3.3 Diagnostic information and procedure .................58 4.3.3.1 DTC B110112 B110113 .........................58 4.3.3.2 DTC B110312 B110313 ........................59 4.3.3.3 DTC B110412 B110413 ........................60 4.3.3.4 DTC B110712 B110713 ........................61 4.3.3.5 DTC B110813 B110811.........................62 4.3.3.6 DTC B111011 ........................................63 4.3.3.7 DTC B110513 B110511.........................64 4.3.3.8 DTC B110613 B110611.........................65 4.3.3.9 DTC B110A12 .......................................66 4.3.3.10 Symptom-lighting system ......................67 4.3.3.11 Fault of turn lamp ..................................67 4.3.3.12 Fault of high mount stop lamp ..............68 4.3.3.13 Fault of headlamp-high beam ...............68 4.3.3.14 Fault of headlamp-low beam ................69 4.3.3.15 Fault of tail door lamp ...........................69 4.3.3.16 Fault of reverse lamp ............................71 4.3.3.17 Fault of dome lamp/courtesy lamp........72 4.3.3.18 Fault of front fog lamp ...........................73 4.3.3.19 Fault of rear fog lamp ............................74 4.3.4 Service Instruction ................................................75 4.3.4.1 Replacement of front reading lamp and bulb ................................................75 4.3.4.2 Replacement of reading lamp and rear bulb ................................................76 4.3.4.3 Replacement of rear spoiler ..................77 4.3.4.4 Replacement of high-mounted stop lamp ......................................................78 4.3.4.5 Replacement of front side door switch
post ...................................................... 79 Replacement of rear side door switch post ...................................................... 80 4.3.4.7 Replacement of Combination switch (switch lamp) ........................................ 81 4.3.4.8 Replacement of multifunction switch.... 82 4.3.4.9 Replacement of headlamp ................... 83 4.3.4.10 Replacement of headlamp bulb (upper side) .......................................... 84 4.3.4.11 Replacement of headlamp bulb (lower side) ..................................................... 85 4.3.4.12 Aiming of headlamps............................ 86 4.3.4.13 Replacement of front fog lamp ............. 87 4.3.4.14 Replacement of front fog lamp ............. 88 4.3.4.15 Replacement of daytime running light.. 89 4.3.4.16 Replacement of rear fog lamp.............. 90 4.3.4.17 Replacement of rear fog lamp bulb ...... 91 4.3.4.18 Fog lamp aiming................................... 92 4.3.4.19 Replacement of front side turn lamp .... 93 4.3.4.20 Replacement of rear register plate lamp ..................................................... 94 4.3.4.21 Replacement of rear register plate lamp bulb .............................................. 95 4.3.4.22 Replacement of tailgate ....................... 96 4.3.4.23 Replacement of tail lamp (tailgate side) ............................................................. 97 4.3.4.24 Replacement of taillamp bulb (body side) ..................................................... 98 Description and operation ................................... 99 4.3.5.1 Description and operation of exterior lighting system ..................................... 99 4.3.5.2 Description and operation of inside lighting system ..................................... 99 Rearview mirror ............................................... 100 Specification ...................................................... 100 4.4.1.1 Tightening torque specification .......... 100 Schematic and wiring diagram .......................... 101 4.4.2.1 Schematic diagram of exterior rearview mirror ................................... 101 Diagnostic information and procedure ............... 102 4.4.3.1 Symptom - rearview mirror ................. 102 4.4.3.2 Fault of power rearview mirror ........... 102 Service Instruction ............................................. 104 4.4.4.1 Replacement of outside rearview mirror .................................................. 104 4.4.4.2 Replacement of cover of outside rearview mirror ................................... 105 4.4.4.3 Replacement of outside rearview mirror glass ........................................ 106 4.4.4.4 Replacement of inside rearview mirror107 4.4.4.5 Replacement of outside remote rearview mirror switch ........................ 108 Description and operation ................................. 109 4.4.5.1 Description and operation of outside rearview mirror ................................... 109 Vehicle access system .....................................110 Specification ....................................................... 110 4.5.1.1 Tightening torque specification ........... 110 Schematic and wiring diagram ........................... 111 4.5.2.1 Schematic diagram of door lock/indicator ....................................... 111 Diagnostic information and procedure ................ 113 4.3.4.6
4.3.5
4.4 4.4.1 4.4.2
4.4.3
4.4.4
4.4.5
4.5 4.5.1 4.5.2
4.5.3
4.5.4
4.5.5
4.6 4.6.1 4.6.2 4.6.3
4.6.4
4.5.3.1 Symptom – door lock .......................... 113 4.5.3.2 Fault of door ajar indicator .................. 113 4.5.3.3 Door lock failure .................................. 115 Service Instruction .............................................. 116 4.5.4.1 Replacement of front side door inside handle ................................................. 116 4.5.4.2 Replacement of front side door outside handle ..................................... 117 4.5.4.3 Replacement of rear side door inside handle ................................................. 118 4.5.4.4 Replacement of rear side door outside handle ................................................. 119 4.5.4.5 Replacement of front side door latch central lock ..........................................120 4.5.4.6 Replacement of front side door key cylinder rod .........................................121 4.5.4.7 Replacement of front side door open handle .................................................122 4.5.4.8 Adjustment of front side door open handle .................................................123 4.5.4.9 Replacement of front side door interlocking and inside open handle ...124 4.5.4.10 Replacement of rear side door latch central lock ..........................................125 4.5.4.11 Replacement of rear side door open handle .................................................126 4.5.4.12 Adjustment of rear side door open handle .................................................127 4.5.4.13 Replacement of rear side door interlocking and inside open handle door .....................................................128 4.5.4.14 Replacement of tailgate lock ...............129 4.5.4.15 Replacement of front side door lock ...130 4.5.4.16 Replacement of rear side door lock ....131 4.5.4.17 Replacement of tailgate lock ...............132 Description and operation ..................................133 4.5.5.1 Description and operation of door unclosed indicator ...............................133 4.5.5.2 Description and operation of tailgate ..133 4.5.5.3 Description and operation of power door latch ............................................133 4.5.5.4 Description and operation of power door lock .............................................133 Wiper and washer .............................................135 Specification .......................................................135 4.6.1.1 Tightening torque specification ...........135 Schematic diagram and wiring diagram .............136 4.6.2.1 Schematic diagram of wiper/washer ...136 Diagnostic information and procedure ...............138 4.6.3.1 DTC B110912 B110913 ......................138 4.6.3.2 DTC B111413 B111412 .......................140 4.6.3.3 Faults of windshield wiper system ......141 4.6.3.4 Washer fault ........................................143 Service Instruction ..............................................145 4.6.4.1 Replacement of windshield washer nozzle hose .........................................145 4.6.4.2 Replacement of windshield washer nozzle ..................................................146 4.6.4.3 Replacement of windshield washer reservoir filler neck ..............................147 4.6.4.4 Replacement of windshield washer fluid reservoir ......................................148
4.6.4.5
Replacement of windshield washer pump .................................................. 149 4.6.4.6 Replacement of air inlet grille ............. 150 4.6.4.7 Replacement of front windshield wiper arm ..................................................... 151 4.6.4.8 Replacement of front windshield wiper motor and gear lever .......................... 152 4.6.4.9 Replacement of combination switch wiper and washer ............................... 153 4.6.4.10 Replacement of rear windshield wiper arm ..................................................... 154 4.6.4.11 Replacement of rear windshield wiper motor .................................................. 155 4.6.4.12 Replacement of rear windshield wiper blade .................................................. 156 4.6.4.13 Replacement of front windshield wiper blade (boneless wiper) ....................... 157 4.6.4.14 Replacement of front windshield wiper strips (boned wiper) ............................ 158 4.6.4.15 Replacement Front windshield wipers wiper (bone wiper).............................. 158 4.6.5 Description and operation ................................. 159 4.6.5.1 Description and operation of wiper/ washer system ................................... 159
Body system 4-1
4.3
Mounting and movable windows
4.3.1 Specification 4.3.1.1 Tightening torque specification Tightening torque specification Application Front side door glass regulator mounting nut Front side door glass outer seal screw Front side glass screws
Specification Metric 4.5±1 N. m 2.5±1 N. m 4.5±1 N. m
rear glass guide groove of front door screw
4.5±1 N. m
Front side glass switch screw Rear door glass regulator mounting nut Front side door glass outer seal screw Rear side door glass switch screw Rear side door glass screws Rear side door glass rear guide screw Rear window glass nut (High) Rear window glass nut (low) Rear side window screws (with low) Rear side window glass screw (with low)
2±0.5 N. m 4.5±1 N. m 2.5±1 N. m 2±0.5 N. m 4.5±1 N. m 4.5±1 N. m 6±1 N. m 9±3 N. m 4±1.5 N. m 4±1 N. m
KR10 Window Relay
K9 Body Control Module
X51A Fuse box – instrument panel
M74D Window Motor Driver Side
S79D Window Switch – Driver Side
X50A
Side
Module – Driving
Motor Window
M35D
KR53 Fuse Box – Pparking lamp relay Under Hood
M74P Window Motor Passenger Side
S79P Window switch Passenger side
Body system 4-2
4.3.2 Schematic and wiring diagram
4.3.2.1 Schematic diagram of movable windows Schematic diagram of movable windows (Left Front Door, Right Front Door), (BCM)
S79D Window Switch – Driver Side
X51A Fuse box – Instrument Panel
KR53 Parking Lamp Relay
M74P Window Motor – Driver Side
X50A Fuse Box – Under Hood
M74P Window Motor – Passenger Side
S79P Window Switch Passenger side
Body system 4-3 Schematic diagram of movable windows (Rear Left Door, Rear Right Door), (BCM)
M74LR Window Motor – Rear Left
S79LR Window Switch - Rear Left
M74RR Window Motor – Rear Right
S79RR Window Switch – Rear Right
Body system 4-4
Schematic diagram of movable windows (Rear Left Door, Rear Right Door)
K9 Body Control Module
X50A Fuse Box – Under hood
E18 Rear Defogger Grille
KR5 Rear Defogger Relay
K33 HVAC Control Module
X51A Fuse Box – Instrument Panel
Body system 4-5
4.3.2.2 Schematic diagram of defroster Schematic diagram of defroster
Body system 4-6
4.3.3 Diagnostic information and procedure 4.3.3.1 DTC B110D12 B110D13 Diagnostic description Before using this diagnostic program, perform "Diagnostic System Check - Vehicle". Review Policy-Based Diagnostics for an overview of the diagnostic methods.. The Diagnostics Description provides an overview of each diagnostic category Description of fault diagnostic code DTC B110D12： Short circuit between power window power supply relay and power supply DTC B110D13： Open circuit of power window power supply relay Conditions for running fault diagnostic code B110D12 When the power window power supply relay works B110D13 When the power window power supply relay does not work Conditions for setting up fault diagnostic code DTC will be recorded once fault is detected Action to be taken when setting the fault diagnostic code Close power window power supply output Record DTC Conditions for clearing fault diagnostic code The historical fault diagnostic code will be cleared after cycling fault-free ignition for 5 times. Body control module receives an order on clearing fault code sent by the diagnostic tool. Reference information Reference of schematic diagram Schematic drawing of the power window Connector End View Reference "Part connector end view" Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan Tool Reference Refer to “Control module reference”, to obtain the scan tool information Circuit/System Verification Turn on the ignition switch and perform the test of power window power supply relay, and the power window shall work/ not work.
Circuit/system test 1. Turn the ignition switch OFF and disconnect the instrument panel fuse box. 2. Set the ignition switch to the ON position and perform the power window power relay test. When switching between command states, the test lamp should be on and off. If the test lamp is always on, the test control circuit is short-circuited to ground. If the circuit test is normal, replace the body control module. If the test lamp is always off, the test control circuit is shorted to voltage or open circuit / resistance is too large. If the circuit test is normal, replace the body control module. Service Instruction After completing the diagnostic procedure, perform the Diagnostic Repair Check. Refer to the "Control Module Reference" for replacement, setup and programming of the control module.
Body system 4-7
4.3.3.2 DTC B110F12 Diagnostic description Before using this diagnostic program, perform "Diagnostic System Check - Vehicle". Review Policy-Based Diagnostics for an overview of the diagnostic methods. The Diagnostics Description provides an overview of each diagnostic category”. Description of fault diagnostic code DTC B111F12：Power window falls for short circuit between it and power supply Conditions for running fault diagnostic code B110F12 When power window falls to make it work Conditions for setting up fault diagnostic code DTC will be recorded once fault is detected Action to be taken when setting the fault diagnostic code Power window falls to make its output closed Record DTC Conditions for clearing fault diagnostic code The historical fault diagnostic code will be cleared after cycling fault-free ignition for 5 times. Body control module receives an order on clearing fault code sent by the diagnostic tool. Reference information Reference of schematic diagram Power window falling schematic diagram Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan Tool Reference Refer to “Control module reference”, to obtain the scan tool information Circuit/System Verification Turn on the ignition switch and perform the test of power window falling, and the power window shall work/ not work. Circuit/system test 1. Turn off the ignition switch and disconnect the driver side window switch. 2. Confirm whether the resistance between driver side window switch terminal and ground is less than 1 Ω. In case of being larger than the specified scope, you should test whether open circuit occurs to the ground circuit, or the resistance is too large. 3. Turn on the ignition switch and perform the test of power window falling. The test lamp shall light up and go out when switching among the order state. If the test lamp always lights up, you should test whether the control circuit is open or shorted to ground. In case that the circuit is normal after test, you should replace body control module.
-
If the test lamp always goes out, you should test whether voltage short circuit occurs to the control circuit. In case that the circuit is normal after test, you should replace body control module. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “control module reference”, so as to replace, set up or program the control module.
Body system 4-8
4.3.3.3 Symptom - mounting and movable windows Important preliminary inspection before start: 1. Before using the "Symptom Chart", perform "Diagnostic System Check - Vehicle" to confirm that the following situation: Do not set up fault diagnostic code. The control module can communicate via the serial data link. 2. heck the operation of the power window system or the operation of the rear window defogger system to understand the system functions. See the following: Description and operation of rear window defogger Description and operation of power window Visual inspection/ appearance Inspect whether there is after sales equipment possibly affecting the work of rear window defogger. Refer to “Inspection of after sales accessories”. Inspect whether the touchable or visible system units have obvious damage or fault to cause such symptom. Intermittent fault Note: In case there is intermittent fault, then check whether the correct installation of electronic parts. Intermittent failure may be caused by an electrical connection or a wiring harness. Refer the "test of intermittent faults and bad contact” The failure is not necessarily the fault indicator lamp or stored fault diagnosis code. Do not use symptoms to diagnose intermittent failure. Failure must occur in order to determine the location of the fault. Most intermittent failure caused by poor electrical contact or wiring harness fault. Perform a visual / visual inspection to confirm the presence of the following: The plug improperly or not completely into the terminal card connector shell The terminal is deformed or damaged Connector terminal - shaping or replacement of the fault circuit to ensure proper tension contact. In case of bad contact between terminal and conductor, you should remove the terminal from the connector shell to inspect. Symptoms List See the symptom diagnosis procedure in the following table to diagnose the symptoms: Fault of defogger of rear window Fault of power window
Body system 4-9
4.3.3.4 Fault of defogger of rear window Diagnostic description Before using this diagnostic program, perform "Diagnostic System Check - Vehicle".
Review Policy-Based Diagnostics for an overview of the diagnostic methods. Diagnostics Description provides an overview of each diagnostic category.
Diagnostic information of fault Circuit
ground short circuit
Open circuit/too-large resistance
Voltage short circuit
Signal performance
1
—
—
1
2
—
1
1
—
1
1
—
Rear window defogger relay 1 switch B + Rear window defogger grille 1 control Real window defogger relay 2 control Rear window defogger grille — ground 1. Rear window defogger does not work Rear window defogger always ON
Circuit/system description The HVAC control module provides ground to the relay coil when a rear window defogger request signal is received from the HVAC control panel. The relay coil and relay switch input voltage is always the battery positive voltage. This causes the battery positive voltage to be input from the relay switch input through the switch contacts and from the relay switch output to the rear window defogger grille. Reference information Reference of schematic diagram Defogger schematic diagram Connector End View Reference Part connector end view Description and operation Description and operation of defogger for rear window Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Circuit/System Verification When the rear window heating switch is pressed, observe the operation of the rear window defogger indicator. The indicator light should be on or off each time the rear window heating switch is pressed. If the indicator does not light or goes off each time the switch is pressed, replace the Heater, Ventilation and Air Conditioning System Control Switch Circuit/system test 1. Turn ignition switch OFF and disconnect harness connector at rear defogger grille E18. 2. Test if the resistance between ground circuit terminal 2 and ground is less than 10 ohms. If it is larger than the specified range, test the ground circuit is open / resistance is too large.
3. 4.
5.
6.
7.
Connect the harness connector of the E18 rear window defogger grille. In the case of engine operation, connect a jumper with a 30 amp fuse between the control circuit terminal 45 and the ground. Verify that the E18 rear window defogger grille is activated. If the E18 rear window defogger grille is not activated, the test control circuit is short-circuited to the battery or the open circuit / resistance is too large. If the circuit test is OK, test or replace the E18 rear window defogger grille. Connect a test lamp between the E18 rear window defogging grid control circuit terminal and the ground circuit terminal. Test lamp should be on and off by pressing rear window heating switch command E18 Rear window defogger grille on and off, switching between command states. If the test lamp is always on, the test control circuit is short-circuited to the voltage. If the circuit test is normal, then replace the K33 heater, ventilation and air conditioning system control module. If the test lamp is always off, the test control circuit is short to ground or open / resistance is too large. If the circuit test is normal, then replace the K33 heater, ventilation and air conditioning system control module. If all circuits are tested properly, test or replace the KR5 rear window defogger relay.
Body system 4-10 Units test Rear window defogger grille test 1. Under the condition of operation of engine, you should open E18 rear window defogger grille. 2. Confirm that the test lamp between each rear window defogger grille line and ground lights up. When the test is vehicleried out on the side of grille ground, the test lamp shall go out. When the test lamp moves to the side of grille power supply, the test lamp lights up. When testing the grille line in the middle, the test lamp shall be dimmed. － If the test lamp maintains the brightness when testing the grille line in the middle, you should test whether it is open circuit between the test point and grille ground side. － If the test lamp goes out when testing the grille line in the middle, you should test whether it is open circuit between the test point and grille power supply voltage side. Relay test 1. Turn off the ignition switch and disconnect KR5 rear window defogger relay. 2. Test the resistance between terminals 86 and 85 whether the 60-180 ohms. If more than the specified range, replace KR5 rear window defogger relay. 3. Test whether the resistance between the following terminals is infinite: 30 and 85 30 and 87 30 and 86 86 and 87 If more than the specified range, replace the KR5 rear window defogger relay. 4. Install a jumper wire with 25A fuse between the relay terminal 86 and 12V voltage. Install a jumper wire between the relay terminal 85 and ground. Test whether the resistance between terminals 30 and 87 is less than 2Ω. － If more than the specified range, replace KR5 rear window defogger relay. Service Instruction After completing the diagnostic procedure, perform the Diagnostic Repair Check. "Replacement of the relay (connected to the wiring harness)" and "Replacement of the relay (in the electrical center)". Refer to the Control Module Reference for replacement, setup and programming of the HVAC, HVAC, HVAC, HVAC, and HVAC control systems.
Body system 4-11
4.3.3.5 Fault of power window Diagnostic description Before using this diagnostic program, perform "Diagnostic System Check - Vehicle".
Circuit
Review Policy-Based Diagnostics for an overview of the diagnostic methods. The Diagnostics Description provides an overview of each diagnostic category Fault diagnostic information
Description and operation of power window Open circuit/ ground Voltage too-large short circuit short circuit resistance
Driver side window 1,3 switch B + Passenger side window 2,4 switch B + Passenger side window 1,2,3,4 switch signal Left rear window switch 1,2,3,4 signal Right rear window switch 1,2,3,4 signal Driver side window motor 1 control Left rear window motor 3 control Passenger side window 2 motor control Right rear window motor 4 control Lock switch control 2,3,4 Driver side window — switch ground 1. Driver side window failure 2. Passenger side of the window failure 3. Left rear window failure 4. Right rear window failure
Circuit/system description The power window system can be operated at any time when the ignition switch is in the ACC or RUN position. The driver power window switch includes a separate window switch for each power window. The rise and fall of all windows can be controlled by the driver's power window switch. The individual passenger power window switches can only control the rise and fall of their respective power windows. Each power window contains a two-way power window motor. The power window motor control circuit connects to the ground by normally closing the rising and falling contacts of the power window switch. When the power switch is placed in the lowered position, the power window motor lowering control circuit is switched to the 12-volt power source and the power source is supplied to the falling side of the power window motor. As the other side of the electric motor has been the normal closure of the rising switch contacts connected to the ground, so the window movement. The power window switch is placed in the ascending position, the polarity of the power window is reversed, the window is moved upward Reference information Reference of schematic diagram Schematic diagram of movable windows
Signal performance
1,3
—
—
2,4
—
—
2
1,2,3,4
1,2,3,4
2
1,2,3,4
1,2,3,4
2
1,2,3,4
1,2,3,4
1
1
—
3
3
—
2
2
—
4
4
—
2,3,4
2,3,4
—
1,2,3,4
1,2,3,4
—
Connector End View Reference Part connector end view Description and Operation Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan Tool Reference Refer "Control Module Reference" for information on the diagnostics Circuit/System Verification 1. Set the ignition switch to the ON position and use the S79D driver's window switch to instruct the driver's window "UP" and "DOWN". The driver's window should be raised and lowered. If the driver's window does not perform the up / down function, refer to "Driver's Window Failure". 2. Use the S79D window switch on the driver's main control switch and its respective S79 window switch to instruct the passenger and rear windows "UP" and "DOWN". Each window shall perform the up and down functions required by each switch. If the passenger / rear window does not perform the up / down function, refer to "Passenger / Rear Window Failure". 3. Deactivate and enable the passenger / rear window switch by pressing and holding the lock
Body system 4-12 switch on the S79D driver's main control switch. When switching between command states, the passenger / rear window switch should be enabled and deactivated. If the passenger / rear window switch continues to function after deactivation, refer to "Locking switch failure". Short circuit on the ground short circuit / resistance is too large for short - circuit voltage signal performance Circuit/system testing Driver window faults 1. Turn off the ignition switch and disconnect the wiring harness connector of S79D driver window switch. 2. Test whether the resistance between ground circuit terminal 8 and ground is less than 10 Ω. － In case of being larger than the specified scope, you should test whether open circuit occurs to the ground circuit, or the resistance is too large. 3. Turn on the ignition switch and confirm the test lamp between ignition circuit terminal 4 and ground lights up. － If the test lamp does not light up, you should test whether it is short circuit or open circuit between the ignition circuit and ground / resistance is too large. 4. Turn off the ignition switch, connect the wiring harness connector of S79D driver window switch and disconnect the wiring harness connector of driver window motor. 5. Test whether the resistance between control circuit terminal 1 and ground is lower than 10Ω. － In case of being larger than the specified scope, you should test whether voltage short circuit or open circuit occurs to the control circuit, or the resistance is too large. In case that the circuit is normal after test, you should replace S79D driver window switch. 6. Test whether the resistance between control circuit terminal 2 and ground is less than 2 Ω. － In case of being larger than the specified scope, you should test whether voltage short circuit or open circuit occurs to the control circuit / the resistance is too large. In case that the circuit is normal after test, you should replace S79D driver window switch. 7. Connect a test lamp between control circuit terminals 1 and 2. 8. When ordering the driver window “UP” and “DOWN” by using S79D driver window switch, the test lamp shall light up. － If the test lamp does not light up all the time during any order period, test whether it is short circuit between any control circuit and ground. If the circuit is normal after test, replace S79D driver window switch. 9. If all circuits are normal after test, you should test or replace M74D Driver window motor Passenger/rear window faults 1. Set the ignition switch to the OFF position and
disconnect the harness connector from the corresponding passenger / rear window switch. Note: Check the lock switch inside the driver's window switch to confirm the passengers Window switch and rear window switch are enabled. 2. Set the ignition switch to the ON position, and confirm that the test lamp between the control circuit terminal 4 and the ground is lighted. If the test lamp does not light, test control circuit is open circuit / resistance is too large. 3. Set the ignition switch to the OFF position to test if the resistance between the ground circuit terminal 8 and ground is less than 10 ohms. If the specified range is exceeded, test the ground circuit for voltage short circuit or open circuit / resistance is too large. If the circuit test is normal, replace the driver's window switch. 4. Test if the resistance between signal circuit terminal 3 and ground is less than 10 ohms. - If the specified range is exceeded, the test signal circuit is short-circuited or the open circuit / resistance is too large. If the circuit test is normal, replace the driver's window switch. 5. Connect a test lamp between signal circuit terminal 4 and ground. 6. Set the ignition switch to the ON position and instruct the corresponding passenger / rear window "UP" and "DOWN" using the corresponding window switch on the driver's main control switch. The test lamp should illuminate during the "UP" and "DOWN" commands. If the test lamp does not turn on during the execution of the command "UP" or "DOWN", test whether any of the control circuits is short to ground. If the circuit test is normal, test or replace the driver's window switch. 7. Set the ignition switch to the OFF position and connect the window switch. Disconnect the harness connector of the corresponding passenger / rear window motor. 8. Test whether the resistance between the control circuit terminal 1 and ground is less than 10 ohms. If the voltage is greater than the specified range, the test control circuit is short-circuited or open-circuit / resistance is too large. If the circuit test is normal, replace the passenger / rear window switch. 9. Test if the resistance between the control circuit terminal 2 and ground is less than 10 ohms. If the voltage is greater than the specified range, the test control circuit is short-circuited or open-circuit / resistance is too large. If the circuit test is normal, replace the passenger / rear window switch. 10. Connect a test lamp between the control circuit terminal 1 and the control circuit terminal 2. 11. Set the ignition switch to the ON position and use the window switch to instruct the window "UP" and "DOWN". When the command is "UP" and "DOWN", the test lamp should be lit. If the test lamp does not turn on during the
Body system 4-13 execution of the command "UP" or "DOWN", test whether any of the control circuits is short to ground. If the circuit test is normal, test or replace the passenger / rear window switch. 12. If all circuit tests are normal, test or replace the passenger / rear window motor. Lock switch faults 1. Set the ignition switch to the OFF position and disconnect the harness connector from the corresponding passenger / rear window switch. 2. Connect a test lamp between the control circuit terminal 6 and the ground. 3. Press and release the lock switch on the driver's main control switch to instruct the window to lock "ON" or "OFF". When switching between command states, the test lamp should be on and off. If the test light is always on, the test control circuit is shorted to the voltage. If the circuit test is normal, test or replace the driver's window switch. If the test lamp is always off, the test control circuit is short to ground or open / resistance is too large. If the circuit test is normal, test or replace the driver's window switch. 4. If all circuits are properly tested, test or replace the passenger / rear window switch. Units test Window motor 1. 1. Set the ignition switch to the OFF position and disconnect the harness connector on the corresponding M74 window motor. 2. Install a jumper with a 25 amp fuse between one of the control terminals and the 12 volt supply. Temporarily install a jumper between the other control terminals and the ground. The M74 window motor should perform the UP / DOWN function at least twice. If not, replace the M74 motor. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Replacement of front side door window lifter motor Replacement of rear side door window lifter motor Replacement of side window and multi-functional switch (high-configuration) Replacement of front side door window switch – right side Replacement of window switch of rear side door
Body system 4-14 Note: It needs two operators to respectively hold one adhesive discs for operation.
4.3.4 Service Instruction 4.3.4.1 Replacement of windshield Disassembly procedure Warning: Refer to “Warning on crack of relevant window”. Warning: Refer to “Warning on defroster air outlet”. Warning: Refer to “Warning on treating relevant glass and metal sheet”. Note: Park the vehicle on the horizontal ground, and move the front wheel to the right ahead position. 1. Remove the grille plate for air inlet. Refer to “Replacement of grille plate for air inlet”. 2. Remove the sealing strips around the front windshield glass.
1248253
Mounting procedure Important notes: Refer to “Special notes on windshield mounting” in “Warnings and notes”. 1. Install new sealing strip on the front windshield.
1256749J
1248254
2.
1248252
3. Cut the adhesive around the windshield glass with tools for removing glass sealer. Note: Be vehicleeful not to scratch the body, and use the protective tape if necessary. 4. Remove the windshield glass from vehicle with adhesive disc.
Paint the primer of adhesive on the windshield window frame and around windshield.
Body system 4-15 7. 8.
9.
1248255
3.
Paint the glass adhesive on the windshield window frame.
1248256
Warning: In case that the polyurethane adhesive is not completely cured, the passenger failing to take safety measures may be popped from the vehicle and cause personnel injury. For moisture-curable type polyurethane adhesive, it shall be cured for at least 6 hours under the temperature of 21°C (70°F) or above and relative humidity of above 30%. For polyurethane adhesive, it needs at least 24 hours for complete curing. For chemical-curable type polyurethane adhesive, it needs at least 1 hour for curing. Don’t touch the repaired part before reaching the shortest curing time. 4. Install the windshield into its window frame. Install the windshield into its window frame with the adhesive disc. Note: It needs two operators to respectively hold one adhesive disc for operation. 5. Paste the adhesive tape on the windshield and its window frame to tighten the windshield. 6. Keep the adhesive dry for 24 hours.
Remove the tape. Sprinkle water over the windshield to inspect whether there is leakage. In case of leaking, dry the windshield and block the leakage part with adhesive. In case of still leaking, you should disassemble the windshield and perform the whole repair procedure repeatedly. Install the grille plate for air inlet repeatedly.
Body system 4-16 4.3.4.2 Replacement of triangular trim cover of fender
15BS0401001
Replacement of triangular trim cover of fender Figure No. 1 2
Part Name Mounting clips (quantity: 6) Triangle trim cover of fender
Body system 4-17
4.3.4.3 Adjustment of glass of front side door
15BL0401002
Adjustment of glass of front side door Figure No.
Part Name
Preparation procedure Remove the waterproofing membrane of front side door. Refer to “Replacement of waterproofing membrane of front side door”. Remove the outer glass sealing strip of front side door, and refer to “Replacement of outer glass sealing strip of front side door”. Remove the glass sealing strip of front side door, and refer to “Replacement of glass sealing strip of front side door”. Screws for glass of front side door (quantity: 2） Warning: Refer to “Warning on relevant tighten”. 1 Tightening torque 4.5±1 N. m Glass of front side door Procedure 1. Connect the trim panel wiring harness connector of front side door. Note: Start the vehicle, to ensure that the maximum power of glass motor is provided. It needs to position the glass completely, so as to make adjustment. 2. Start the vehicle. 2 3. Make the glass be lifted to the top position by power glass switch. 4. Loosen the nuts used for glass lifter, and then tighten them after the adjustment is finished. 5. Inspect whether the glass acts are correct, or whether the sealing is good, and repeat to execute Step 4 in case that the adjustment is not in place. 6. Tighten the nut to the specified torque in case that inspection of Step 5 passes: 9±1.5 N. m, stop the vehicle.
Body system 4-18
4.3.4.4 Replacement of glass of front side door
15BL0401002
Replacement of glass of front side door Figure No. Part Name Preparation procedure 1. Remove the inner glass sealing strip of front side door, and refer to “Replacement of inner glass sealing strip of front side door” 2. Tear the sealing proofing membrane of front side door and avoid the glass screws of front side door. 3. Remove the outer glass sealing strip of front side door, and refer to “Replacement of outer glass sealing strip of front side door”. 4. Remove the glass sealing strip of front side door, and refer to “Replacement of glass sealing strip of front side door”. 5. Remove the rear glass guide slot of front side door, and refer to “Replacement of rear glass guide slot of front side door”. Screws for glass of front side door (quantity: 2） Warning: Refer to “Warning on relevant tighten”. 1 Tightening torque 4.5±1 N. m Glass of front side door
2
Procedure 1. Lift the glass to the middle and lower position of door. 2. Loosen the glass clip at the opening of inner door panel and pull it up so as to loosen the glass from the window frame. 3. Revolve the front side door glass when necessary to remove it from the door.
Body system 4-19
4.3.4.5 Replacement of window glass lifter of front side door
15BL0401003
Replacement of window glass lifter of front side door Figure No.
Part Name
Preparation procedure Remove glass of front side door. Refer to “Replacement of glass of front side door”. Mounting nuts for glass lifter of front side door (quality: 14） Warning: Refer to “Warning on relevant tightening”. 1
2
Tightening torque 4.5±1 N. m Glass lifter of front side door
Body system 4-20
4.3.4.6 Replacement of front door left side window switch
15BS0401004
Replacement of front door left side window switch Figure No. Part Name Preparation Procedure 1. Disconnect the battery negative line. See "Battery Disconnection and Connection". 2. Remove the front door left side window switch. See "Front Door Switch Panel Replacement". Screws for front door left side window switch (quantity: 3) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 2±0.5 N. m 2 Front door left side window switch
Body system 4-21
4.3.4.7 Replacement of front door right side window switch
15BS0401005
Replacement of front door right side window switch Figure No.
Part Name
Preparation procedure Remove the front door right side window switch. See "Front Door Switch Panel Replacement Screws for front door right side window switch (quantity: 2） Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 2±0.5 N. m front door right side window switch 2
Procedure Remove the wiring harness connector clip of front door.
Body system 4-22
4.3.4.8 Replacement of rear lower glass guide slot of front door
15BL0401007
Replacement of rear lower glass guide slot of front door Figure No. Part Name Preparation procedure Remove the inside trim panel of front side door. Refer to “Replacement of trim panel of front side door”. Tear the front side door waterproofing membrane covering outer upper angle. Screws for rear glass guide slot of front side door (quantity: 2） 1
2
Tightening torque 4.5±1 N·m Real glass guide slot of front side door Procedure Lift the front door glass to the highest position. Remove the rear glass guide slot of front side door.
Body system 4-23
4.3.4.9 Replacement of outer glass sealing strip of front side door
15BS0401006
Replacement of outer glass sealing strip of front side door Figure No.
Part Name Screws for outer glass sealing strip of front side door (quantity: 2） Warning: Refer to “Warning on relevant tightening”.
1
2
Tightening torque 2.5±1 N. m Outer glass sealing strip of front side door
Body system 4-24
4.3.4.10 Replacement of inner glass sealing strip of front side door
15BS0401007
Replacement of inner glass sealing strip of front side door Figure No. Part Name Preparation procedure Remove thinner trim panel of front side door. Refer to “Replacement of trim panel of front side door”. Inner glass sealing strip of front side door 1
Procedure Remove the inner sealing strip from inner trim panel.
Body system 4-25
4.3.4.11 Replacement of glass sealing strip of front side door
15BS0401008
Replacement of glass sealing strip of front side door Figure No. Part Name Preparation procedure Remove the inner glass sealing strip of front side door, and refer to “Replacement of inner glass sealing strip of front side door” Remove the outer glass sealing strip of front side door, and refer to “Replacement of outer glass sealing strip of front side door”. Remove the glass sealing strip of front side door, and refer to “Replacement of glass sealing strip of front side door”. Glass sealing strip of front side door 1
Procedure 1. Drop the glass to the lowest position. 2. Remove the glass sealing strip of front side door.
Body system 4-26
4.3.4.12 Adjustment of glass of rear side door
15BS0401009
Adjustment of glass of rear side door Figure No. Part Name Preparation procedure Remove the waterproofing membrane of rear side door. Refer to “Replacement of waterproofing membrane of rear side door”. Remove the outer glass sealing strip of rear side door, and refer to “Replacement of outer glass sealing strip of rear side door”. Remove the glass sealing strip of front side door, and see “Replacement of glass sealing strip of rear side door”. Screws for glass of rear side door (quantity: 2) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 4.5±1 N. m Glass of rear side door Procedure 1. Connect the trim panel wiring harness connector of rear side door. 2. Note: Start the vehicle, to ensure that the maximum power of glass motor is provided. It needs to position the glass completely, so as to make adjustment. 3. Start the vehicle 2 4. Make the glass be lifted to the top position by power glass switch. 5. Loosen the nuts used for glass lifter, and then tighten them after the adjustment is finished. 6. Inspect whether the glass acts are correct, or whether the sealing is good, and repeat to execute Step 4 in case that the adjustment is not in place. 7. Tighten the nuts to the specified torque in case that inspection of Step 5 passes: 9±1.5 N. m, stop the vehicle.
Body system 4-27
4.3.4.13 Replacement of glass of rear side door
15BS0401009
Replacement of glass of rear side door Figure No. Part Name Preparation procedure Remove the inner glass sealing strip of rear side door, and refer to “Replacement of inner glass sealing strip of rear side door”. Tear the waterproofing membrane of rear side door and avoid the glass screws of rear side door. Remove the outer glass sealing strip of rear side door, and refer to “Replacement of outer glass sealing strip of rear side door”. Remove the glass sealing strip of rear side door, and refer to “Replacement of glass sealing strip of rear side door”. Remove the rear glass guide slot of rear side door, and refer to “Replacement of rear glass guide slot of rear side door”. Screws for glass of rear side door (quantity: 2) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 4.5±1 N. m Glass of rear side door
2
Procedure Lift the glass to the middle and lower positions of door. Loosen the glass screw and pull it up to loosen the glass from the lifter. Revolve the rear side door glass when necessary to remove it from the door.
Body system 4-28
4.3.4.14 Replacement of window glass lifter of rear side door
15BS0401010
Replacement of window glass lifter of rear side door Figure No. Part Name Preparation procedure Remove the glass of rear side door, and refer to “Replacement of glass of rear side door”. Mounting nuts for glass lifter of rear side door (quantity: 7) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 4.5±1 N. m 2 Glass lifter of rear side door
Body system 4-29
4.3.4.15 Replacement of window switch of rear side door
15BS0401011
Replacement of window switch of rear side door Figure No. Part Name Preparation procedure Remove the window switch panel of rear side door. Refer to “Replacement of window switch panel of rear side door”. Screws for glass switch of rear side door (quantity: 2) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 2±0.5 N. m Glass switch of rear side door 2
Procedure Remove the wiring harness connector clip of rear door.
Body system 4-30
4.3.4.16 Replacement of rear glass guide slot of rear side door
15BS0401012
Replacement of rear glass guide slot of rear side door Figure No. Part Name Preparation procedure Remove the inner glass sealing strip of rear side door, and refer to “Replacement of inner glass sealing strip of rear side door”. Tear the waterproofing membrane of rear side door of outer upper angle. Remove the outer glass sealing strip of rear side door, and refer to “Replacement of outer glass sealing strip of rear side door”. Remove the glass sealing strip of rear side door, and refer to “Replacement of glass sealing strip of rear side door”. Remove the glass sealing strip of rear side door near the upper screw. Screws for rear glass guide slots of rear side door (quantity: 2) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 4.5±1 N·m 2 Rear glass guide slot of rear side door
Body system 4-31
4.3.4.17 Replacement of outer glass sealing strip of rear side door
15BS0401013
Replacement of outer glass sealing strip of rear side door Figure No.
Part Name Screws for outer glass sealing strip of rear side door (quantity: 2) Warning: Refer to “Warning on relevant tightening”.
1
2
Tightening torque 2.5±1 N. m Outer glass sealing strip of rear side door
Body system 4-32
4.3.4.18 Replacement of inner glass sealing strip of rear side door
15BS0401014
Replacement of inner glass sealing strip of rear side door Figure No. Part Name Preparation procedure Remove the inner trim panel of front side door. Refer to “Replacement of trim panel of front side door”. Inner glass sealing strip of rear side door 1
Procedure Remove the inner sealing strip from inner trim panel.
Body system 4-33
4.3.4.19 Replacement of glass sealing strip of rear side door
15BS0401015
Replacement of glass sealing strip of rear side door Figure No. Part Name Preparation procedure Remove the inner glass sealing strip of rear side door, and refer to “Replacement of inner glass sealing strip of rear side door”. Remove the outer glass sealing strip of rear side door, and refer to “Replacement of outer glass sealing strip of rear side door”. Remove the glass sealing strip of rear side door, and refer to “Replacement of glass sealing strip of rear side door”. Glass sealing strip of rear side door 1
Procedure 1. Lift the glass to the lowest position. 2. Remove the rear side door glass sealing strip.
Body system 4-34
4.3.4.20 Replacement of rear side mounting window glass (high-configuration)
15AJ0401001
Replacement of rear side mounting window glass Figure No. Part Name Preparation procedure Remove the trim panel of quarter panel. Refer to “Replacement of trim panel of quarter panel”. Nuts (quantity: 8) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 6±1 N. m Fix window glass at rear side
2
Procedure Push the glass out hard after removal of clamp nut of the glass (because there is a sealer between the glass and window frame). Clean up the residual sealer on the window frame before mounting. Peel off the release paper of the sealer on the glass to tighten the glass on the window frame.
Body system 4-35
4.3.4.21 Replacement of rear side butterfly window glass (low-configuration)
15AJ0401002
Replacement of rear side butterfly window glass Figure No.
Part Name
Preparation procedure Remove the trim panel of quarter panel. Refer to “Replacement of trim panel of quarter panel”. Screws (quantity: 4) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 4±1.5 N. m Screws (quantity: 4) 2 3 4 5
Tightening torque 4±1 N. m Butterfly window catch assembly Nuts (quantity: 4） Tightening torque 9±3 N. m Rear side butterfly window glass
Body system 4-36
4.3.4.22 Replacement of rear side window sealing strip (low-configuration)
14AK0401022
Replacement of rear side window sealing strip Figure No. Part Name Preparation procedure Remove the rear side butterfly window glass, and refer to “Replacement of rear side butterfly window glass” (low-configuration). 1 Rear side window sealing strip
Body system 4-37
4.3.4.23 Replacement of tailgate door Warning: Refer to “Warning on crack of relevant window”. Warning: Refer to “Warning on treating relevant glass and metal sheet”. Warning: See “Warnings on disconnecting the battery” in “Warning and precautions”.
1248257
Note: Park the vehicle on the horizontal ground, and move the front wheel to the right ahead position. 1. Remove the tailgate trim panel and refer to “Replacement of tailgate trim panel”. Disconnect battery negative cable. 2. Disconnect the rear window defogger electrical connector. Remove the rear windshield wiper motor. Refer to “Replacement of rear windshield wiper motor”. 3. Cut the glass adhesive around the rear window glass with the tool. Note: Be careful not to scratch the body, and use the protective tape if necessary.
4.
Remove the rear window glass from vehicle with adhesive disc.
1248260
Note: It needs two operators to respectively hold one adhesive disc for operation. 5. Clean up the glass adhesive on the rear window glass with the blade. 6. Clean up the glass adhesive on the rear window glass frame with the blade.
1248258
Body system 4-38 Installation procedure 1. Paint the primer of glass adhesive on the rear window glass frame and around rear window glass. 2. Paint the glass adhesive on the rear window glass frame.
1248262
Warning: In case that the polyurethane adhesive is not completely cured, the passenger failing to take safety measures may be popped from the vehicle and cause personnel injury. For moisture-curable type polyurethane adhesive, it shall be cured for at least 6 hours under the temperature of 21°C (70°F) or above and relative humidity of above 30%. For polyurethane adhesive, it needs at least 24 hours to complete curing. For chemical-curable type polyurethane adhesive, it needs at least 1 hour for curing. Don’t touch the repaired part before reaching the shortest curing time. 3. Install the rear glass into its window frame with adhesive disc. Note: It needs two operators to respectively hold one adhesive disc for operation.
1248264 4. 5. 6. 7.
8.
9.
1248257
Paste the tape on the rear window glass and rear window glass frame for curing rear window glass. Keep the adhesive dry for 24 hours. Remove the tape. Sprinkle water over the rear window glass to inspect whether there is leakage. In case of leaking, you should dry the rear window glass and block the leakage part with glass adhesive. In case of still leaking, you should remove rear window glass and perform the whole repair procedure repeatedly. Connect the rear window defogger electrical connector. Install the rear windshield wiper motor. Refer to “Replacement of rear windshield wiper motor”. Connect battery negative cable.
Body system 4-39
4.3.5 Description and operation 4.3.5.1 Description and operation of power window Units for power window system The power window system includes the following units: Driver side window switch Passenger side window switch Left rear window switch Right rear window switch Window motor of each door Relevant protection: Fuse block of front cabin: F25UA 40A fuse and F22UA 30A fuse Fuse block for instrument panel: F33D 30A fuse (power window) and F10D 15A mini safety piece (power window motor) Power window system The power window is controlled by the switch on the control console and operated by the motor of the window lifter. Press the switch to make the window DOWN and pull up the switch to make the window UP. When releasing the switch or fully-opening or fully-closing the window, the window stops moving. There is a window lock knob on the power window control console. After pressing this knob, all passenger side windows cannot be operated. A key for UP and DOWN (AUTO) (high-configuration) Pull up the switch, and the window is up until it is fully closed. Press the switch and the window is down until it is fully open. Anti-pinch function (high-configuration) For obstacle with rigidity of more than (10±0.5) N/mm, within the opening range of 200mm - 4mm, and before the clamp force is more than 100N, the window automatically shrinks.
4.3.5.2 Description and operation of defogger for rear window Units of rear window defogger system The rear window defogger system includes the following units: Air-conditioning controller Rear window defogger relay Rear window defogger grille Relevant protection: Fuse block of front cabin: F25UA 40A fuse Fuse block for instrument panel: F21D 25A fuse (rear defrosting) Operation of rear window defogger The air-conditioning controller panel provides a switch for passenger, including an indicator, to inform the passenger of current state of the system. Press the rear window heating switch on the air-conditioning controller panel and the rear window defogger relay coil side is grounded, the relay is energized, the relay switch contact is closed, and B+ voltage passes to the rear window defogger grille via rear window defogger grill control circuit.
4.3.5.3 Description and operation of mounting window Most of mounting windows, especially windshield, are mount on body with polyurethane adhesive. Paste the window on the body with the adhesive. This enhances the structure integration. Re-install the glass with polyurethane adhesive.
Body system 4-40
4.4
Horn
4.4.1 Specification 4.4.1.1 Tightening torque specification Tightening torque specification Application Screws for mounting horn
Specification Metric 9±1.5 N. m
P12 horn
KR3 horn relay
K9 body control module assemb ly
S33 hor n swit ch
X85 air bag coil of steeri ng wheel
X50A fuse block – under hood
Body system 4-41
4.4.2 Schematic and wiring diagram
4.4.2.1 Horn schematic diagram Horn schematic diagram
Body system 4-42
4.4.3 Diagnostic information and procedure 4.4.3.1 DTC B113112 Diagnostic description Execute “Inspection of diagnostic system - vehicle” before adopting such diagnostic procedure. Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of fault diagnostic code DTC B113112：Short circuit between horn relay and power supply Conditions for running fault diagnostic code B113112 When the horn relay runs Conditions for setting up fault diagnostic code DTC will be recorded once fault is detected Operation adopted when setting up the fault diagnostic code Close the horn output Record DTC Condition for clearing fault diagnostic code The historical faults diagnostic code will be cleared after cycling fault-free ignition for 5 times. Body control module receives an order on clearing fault code sent by the diagnostic tool. Reference information Reference of schematic diagram Horn schematic diagram Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan Tool Reference Refer to “Control module reference”, to obtain the scan tool information Circuit/system verification Turn on the ignition switch and perform the test of horn relay, and the horn shall work/ not work. Circuit/system test 1. Turn off the ignition switch, and disconnect the fuse block of instrument panel. 2. Confirm that the test lamp between the fuse block terminal (horn relay) of instrument panel and ground lights up. In case that the test lamp does not light up, you should test whether ground short circuit or open circuit occurs to B+ circuit / the resistance is too large. In case that the circuit is normal after test, you should conduct test or replacement 3. Connect a test lamp between B+ and fuse block circuit terminal (horn relay) of instrument panel. 4. Turn on the ignition switch and perform the test of
horn relay. The test lamp shall light up and go out when switching among the order state. In case that the test lamp always lights up, test whether ground short circuit occurs to the control circuit. In case that the circuit is normal after test, you should replace body control module. In case that the test lamp always goes out, you should test whether voltage short circuit or open circuit occurs to the control circuit / the resistance is too large. In case that the circuit is normal after test, you should replace body control module. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “Control module reference”, so as to replace, set up or program the control module.
Body system 4-43
4.4.3.2 Symptoms - horn Important notes: The following steps must be completed before using Symptoms List: 1. Execute “Inspection of diagnostic system - vehicle” before adopting “Symptoms List”, to confirm authenticity of the following situations: Does not set up fault diagnostic code. Communication can be realized in control module through serial data link. 2. Look up system operation, and be familiar with system function. Refer to “description and operation of the horn system” Visual /appearance inspection Inspect whether the aftermarket equipment affects operation of horn. Refer to “Inspection of aftermarket accessories”. Inspect whether the touchable or visible system units have obvious damage or fault to cause such symptom. If the horn sends hum or hard sound, the following steps shall be executed. － Inspect whether fragments exist at the part where the horn is mount on the vehicle. － Test the torque of the horn installation member. The tightening torque of the horn mounting member shall be 10 N. m (7 foot-pound). Intermittent faults The intermittent fault may be caused by electrical connecting fault or wiring harness fault. Refer to “Intermittent fault and bad contact test”. Symptoms List Diagnose symptoms with reference to “Horn defects” in the symptom diagnosis procedure.
4.4.3.3 Horn faults Diagnostic description Execute “Inspection of diagnostic system - vehicle” before adopting such diagnostic procedure. Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Diagnostic information of faults Circuit/system description When the horn disc is pressed down, the horn switch will provide ground for the horn relay inside the fuse under the hood. Then, the fuse block under the hood will supply B+ voltage to the horn control circuit and the horn sends sounds. The body control module is also able to provide ground for the horn relay so as to make the horn sound.
Diagnostic assistance If the ground short circuit or voltage short circuit of horn control circuit occurs to the horn relay control circuit, the horn will continuously sound until it overheats and does not work. When the horn disc is being pressed down, you should rotate the steering wheel so as to confirm whether the steering column suffers from an intermittent fault and bad contact. If the diagnosis is “horn-sound quality is poor”, you should inspect whether there are the following situations: There are fragments or water in the horn assembly The correct torque of the horn installation member-refer to “tightening torque specifications of relevant tightening”. There are fragment at the part connecting the horn and the vehicle Fragments directly contact the horn When the horn is sounding, the vehicle’s part is vibrating. Reference information Reference of schematic diagram Horn schematic diagram Connector End View Reference Part connector end view Description and operation Description and operation of horn system Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan Tool Reference Refer to “Control module reference”, to obtain the Scan tool information Circuit/system verification 1. Use the scan tool to order P12 horn to be energized and powered off. When the order state is switched, P12 horn shall sound and not sound. － If P12 horn is turned ON (sounding) or OFF (closed) all the time, refer to “horn or horn order fault”. － If sounds sent by P12 horn are not clear and peaceful, please refer to “horn-sound quality is poor”. 2. Press down and loose the horn disc to order P12 horn to be turned ON (sounding) or OFF (closed). When the order state is switched, P12 horn shall be turned ON (sounding) and OFF (closed). － If P12 horn is always turned OFF (closed), refer to “horn switch faults”.
Body system 4-44
Circuit
Ground circuit
short
Open circuit/too-large resistance
Voltage circuit
short
Signal performance
Horn switch signals
1
2
2
—
Horn relay control
1
2
2
—
Control of rear window defogger relay
2
2
1
—
Horn ground
—
2
2
—
3. A horn is connected all the time A horn does not work
Circuit/system test Horn or horn instruction defects 1. Disconnect KR3 horn relay 2. Turn on the ignition switch and confirm the test lamp between the control circuit terminal 87 and ground lights up. － If the test lamp lights up, you should test whether voltage short circuit occurs to control circuit. 3. Confirm that the test lamp between B+ circuit terminal 30 and the ground lights up. － If the test lamp does not light up, test whether ground short circuit or open circuit occurs to B+ circuit /resistance is too large. 4. Confirm that the test lamp between B+ circuit terminal 86 and the ground lights up. － If the test lamp does not light up, test whether open circuit occurs to B+ circuit / resistance is too large. 5. Disconnect the wiring harness connector of corresponding P12 horn. 6. Test whether the resistance between ground circuit terminal 2 and ground is lower than 2Ω. － In case of being larger than the specified scope, you should test whether open circuit occurs to the ground circuit / the resistance is too large. 7. Connect the wiring harness connector of P12 horn 8. Set a jumper wire with 20A fuse connecting B+ circuit terminal 30 and control circuit terminal 87. Confirm that the horn starts up. － If the horn does not start, you should test whether ground short circuit or open circuit occurs to control circuit / resistance is too large. If the circuit is normal after test, you should test or replace the horn. 9. Connect a test lamp between B+ circuit terminal 86 and control circuit terminal 85. 10. Press down and loose the horn disc on the steering wheel. The test lamp shall light up and go out when switching among the order state. － In case that the test lamp always lights up, you should test whether ground short circuit occurs to the control circuit. If the circuit is normal after test, you should inspect whether S33 horn switch is blocked. － If the test lamp always goes out, you should test whether voltage short circuit or open circuit occurs to control circuit / resistance is too large. If the circuit is normal after test, you should inspect whether S33 horn switch open.
11. If all circuits are normal after test, you should test or replace KR3 horn relay. Horn-sound quality is poor 1. Turn off the ignition switch and disconnect the wore harness connector of corresponding P12 horn. 2. Test whether the resistance between ground circuit terminal 2 and ground is lower than 2Ω. － In case of being larger than the specified scope, test whether the resistance of ground circuit is too large. 3. Disconnect KR3 horn relay 4. Test between the control circuit terminal 83 on KR3 horn rely and control circuit terminal 1 on P12 horn － In case of being larger than the specified scope, you should test whether the control circuit has too-large resistance. 5. If all circuits are normal after test, you should test or replace P12 horn. Horn switch faults 1. Turn off the ignition switch and disconnect the wiring harness connector of S33 horn switch. 2. Test whether the resistance between ground circuit terminal and ground is less than 30 Ω. － In case of being larger than the specified scope, you should test whether the resistance of ground circuit is too large. 3. Turn on the ignition switch and test whether the voltage between signal circuit terminal 1 and ground is higher than 10 Ω. － In case of less than the specified value, you should test whether ground short circuit or open circuit occurs to signal circuit / resistance is too large. 4. If all circuits are normal after test, you should test or replace S33 horn switch. 5. If all circuits are normal after test, you should test or replace P12 horn. Units test Horn test 1. Turn off the ignition switch and disconnect the wiring harness connector of P12. 2. Install a jumper wire with 15A fuse between the control terminal 1 and 12V voltage. Install a jumper wire between the ground terminal 2 and ground. Confirm that P12 horn sends clear and even sounds.
Body system 4-45 － If sounds sent are not clear or even, replace P12 horn. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Replacement of the horn switch on the steering wheel Replacement of the relay (connecting to the wiring harness) or replacement of the relay (inside the electrical center) Horn replacement Refer to “control module reference”, so as to replace, set up and program body control module
Body system 4-46
4.4.4 Service Instruction 4.4.4.1
Replacement of horn
15AJ0402001
Replacement of horn Figure No. Names of components Preparation procedure Disconnect the battery negative line. See "Battery Disconnection and Connection". Remove the front grille. See "Front grille replacement". Mounting Screw of the horn (quantity: 1) Warning: Refer to “Warning on Relevant tightening”. 1 Tightening torque 9 ±1.5N. m Horn (quantity: 1) 2
Procedure Disconnect the electrical connector.
Body system 4-47
4.4.5 Description and operation 4.4.5.1 Description and operation of horn system System description The horn system is made up of the following components. � Horn fuse � Horn relay � Horn assembly � Body control module (BCM) System operation � Press down the horn switch, the vehicle’s horn will sound � In any one of the following circumstances, the body control module will instruct the horn to sound: － When the theft deterrent button on the remote control door lock transmitter is pressed down. Refer to “Description and Operation of Remote Control Door Lock System” for detailed information. － When the content theft deterrent (CTD) system monitors that the vehicle is being invaded. Refer to “Description and Operation of Content Theft Deterrent (CTD) System” for detailed information. － When the remote control door lock system is used to lock the vehicle, the horn may sound chirp to remind the driver that the vehicle has been locked. The prompting function can be started or stopped according to individual setting. Refer to “Description and Operation of Remote Control Door Lock System” for detailed information. Circuit operation The battery positive voltage always supplies power to the horn relay coil and the horn relay switch. Press down the horn switch to provide ground for the horn relay control circuit. When the horn relay control circuit grounds, the horn relay is powered on and the battery positive voltage will supply power to the horn through the horn control circuit. No matter how long the horn relay control circuit grounds, the horn will sound for the same period.
Body system 4-48
4.5
Lighting
4.5.1 Specification 4.5.1.1 Tightening torque specification tightening torque specification Application Mouting screws of the headlamp Mounting nuts of the rear spoiler Mouting screws of the tail lamp Mounting Screws of the front side turn signal lamp Mounting screws of Indoor Ceiling lamp Mounting screws of Front side door lamp Mounting Screws of the front fog lamp Mounting Screws of Daytime running light
Specification (N. m) Metric
4±0.5 N.m 4±0.5 N.m 3±0.5 N.m 1.5±0.5 N.m 1.5 ±0.5 N.m 1.5 ±0.5N.m 2.5±0.5 N.m 2.5±0.5 N.m
E13 L hea dla mp – left sid e
E13 R hea dla mp – right side
KR48 headlam p high beam relay
S78 turn signal/m ulti-funct ion switches
K9 body contr ol mod ule
E13R headl amp – right side
KR49 headlamp low beam relay
E13L headlamp – left side
X50A fuse box – under the hood
Body system 4-49
4.5.2 Schematic and wiring diagram
4.5.2.1 Schematic diagram of lighting lamp Schematic diagram of the headlamp (low beam and high beam)
E 29 R F fo g la m prig ht fr on t
X50 A fuse box – und er the hoo d
E29LF fog lamp-left front
X50A fuse box – under the hood
S78 Turn signal/mult i-function switches
S19B fog lamp switch-r ear
E 2 9 L R fo g la m ple ft re ar
E29RR fog lamp-righ t rear
K9 body control module
Body system 4-50
Schematic diagram of the fog lamp
E7 licens e plate lamp
E5H right inside tail lamp E5G left inside tail lamp
E5AL tail lamp - right latera l
E5AK tail lamp left lateral
E13L headl amp – left side
E13R headlam p – right side
KR53 parking lamp relay
S78 turn signal/multi-f unction switches
K9 body control module
X50A fuse box – under the hood
Body system 4-51 Schematic diagram of the exterior lamp (license plate lamp and position lamp)
E1 3L he adl am p– left sid e E5 AK tail la mp left lat era l A9A outside rearview mirror – driver side
S78 turn signal/ multi-f unctio n switch es A11 wirele ss
A9 8 out sid e rea rvie w mir rorpas sen ger sid e
E5 AL tail lam prig ht late ral
K9 body control mod
E13R headl amp – right side
Body system 4-52
Schematic diagram of the exterior lamp (hazard warning lamp and turn signal lamp)
E5L brak e lamp -left E5R brak e lamp -right
E6 middle high mount parking lamp
B103 brake lamp switch
K17 electro nic brake control module
X51A fuse box – instrum ent panel
K20 engine control module
X50A fuse box – under the hood
Body system 4-53 Schematic diagram of the exterior lamp (stop lamp)
K9 body control module
E5A bac k-up lam p-lef t
E5B back-up lamp-right
B16 back-up lamp switch
X51A fuse box – instrumen t panel
Body system 4-54
Schematic diagram of the exterior lamp (back-up lamp)
K9 body control module
M3L headl amp’s horizo ntal motorleft
KR49 headlamp low beam relay
M3R headla mp’s horizo ntal motorright
KR53 parking lamp relay
S42 headlamp horizontal adjustment switch
X50A fuse box – under the hood
Body system 4-55 Schematic diagram of the exterior lamp (horizontal adjustment of the headlamp)
E13L sunshad e mirror front lamp-left
E13R sunshad e mirror front lamp-righ t E37F rear dome lamp/rea ding lamp
E37R rear dome lamp/readi ng lamp
K9 body control module
Body system 4-56
Schematic diagram of the interior lamp (interior lighting)
K9 body contr ol modu le
K33A HVAC control module – auxiliary
KR53 parking lamp relay l module
S79D window switch – driver’s side
X50A fuse box – under the hood l module
S24 fuel tank flap release switch
S42 headlam p horizontal adjustme nt switch
A11 wirele ss
P6 clock
P16 instru ment cluste r
K33 HVAC control module
Body system 4-57 Schematic diagram of the interior lamp (interior backlight)
Body system 4-58
4.5.3 Diagnostic information and procedure 4.5.3.1 DTC B110112 B110113 Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Description of diagnostic trouble code DTC B110112： Short circuit between position lamp relay and power supply DTC B110113： The position lamp relay is open circuit Conditions for running diagnostic trouble code B110112 The position lamp is working B110113 The position lamp is not working Conditions for setting up diagnostic trouble code DTC will be recorded once fault is detected Operations adopted when setting up diagnostic trouble code The position lamp output is closed Record DTC Conditions for erasing diagnostic trouble code The historical diagnostic trouble code will be erased after fault-free ignition cycle for 5 times. Body control module receives an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of the position lamp Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system verification Set the ignition switch at ON. Then carry out the position lamp relay test and the position lamp shall be on/off. Circuit/system testing 1. Shift the ignition switch to OFF position, and disconnect the harness connector of the fuse box under the hood. 2. Confirm that the test lamp between the terminal of the fuse box under the hood and the ground is lighted up. In case that the test lamp is not lighted up, test whether there is ground short circuit or open circuit
occurs to B+ circuit, or the resistance is too large. In case that the circuit test is normal, then test or replace the fuse box. 3. Connect a test lamp between B+ and the terminal of the fuse box under the hood. 4. Shift the ignition switch to ON position and perform the test of position lamp relay. The test lamp shall be lighted up and out when switching among the order state. In case that the test lamp is always on, test whether there is ground short circuit occurs to the control circuit. In case that the circuit test is normal, replace body control module. In case that the test lamp is always off, test whether there is voltage short circuit or open circuit occurs to the control circuit, or the resistance is too large. In case that the circuit test is normal, replace body control module. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up or programming of the control module.
Body system 4-59
4.5.3.2 DTC B110312 B110313 Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Description of diagnostic trouble code DTC B110312： Short circuit between low beam relay and power supply DTC B110313： The low beam relay is open circuit Conditions for running diagnostic trouble code B110312 The low beam is working B110313 The low beam is not working Conditions for setting up diagnostic trouble code DTC will be recorded once fault is detected Operations adopted when setting up diagnostic trouble code The low beam output is closed Record DTC Conditions for erasing diagnostic trouble code The historical diagnostic trouble code will be erased after fault-free ignition cycle for 5 times. Body control module receives an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of the low beam Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system verification Shift the ignition switch to ON position. Then carry out low beam relay test and low beam shall be on/off. Circuit/system testing 1. Shift the ignition switch to OFF position, and disconnect the fuse box under the hood 2. Respectively confirm that the test lamp between the terminal of the fuse box under the hood and the ground is lighted up. In case that the test lamp is not lighted up, test whether there is bonding short circuit or open circuit occurs to B+ circuit, or the resistance is too large. In case that the circuit test is normal, then test or replace 3. Shift the ignition switch to ON position and perform the test of low beam relay. The test lamp shall be
lighted up and out when switching among the order state. In case that the test lamp is always on, test whether there is bonding short circuit occurs to the control circuit. In case that the circuit test is normal, replace K9 body control module. In case that the test lamp is always off, test whether there is voltage short circuit or open circuit occurs to the control circuit, or the resistance is too large. In case that the circuit test is normal, replace body control module. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up or programming of the control module.
Body system 4-60
4.5.3.3 DTC B110412 B110413 Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Description of diagnostic trouble code Short circuit between high beam DTC B110412： relay and power supply The high beam relay is open DTC B110413： circuit Conditions for running diagnostic trouble code B110412 The high beam is working B110413 The high beam is not working Conditions for setting up diagnostic trouble code DTC will be recorded once fault is detected Operations adopted when setting up diagnostic trouble code The high beam output is closed Record DTC Conditions for erasing diagnostic trouble code The historical diagnostic trouble code will be erased after fault-free ignition cycle for 5 times. Body control module receives an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of the high beam Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system verification Shift the ignition switch to ON position. Then carry out high beam relay test and the high beam shall be on/off. Circuit/system testing 1. Shift the ignition switch to OFF position, and disconnect the fuse box under the hood 2. Respectively confirm that the test lamp between the terminal of the fuse box under the hood (high beam relay) and the ground is lighted up. In case that the test lamp is not lighted up, test whether there is ground short circuit or open circuit occurs to B+ circuit, or the resistance is too large. In case that the circuit test is normal, then test or replace
3.
Shift the ignition switch to ON position and perform the test of high beam relay. The test lamp shall be lighted up and out when switching among the order state. In case that the test lamp is always on, test whether there is ground short circuit occurs to the control circuit. In case that the circuit test is normal, replace K9 body control module. In case that the test lamp is always off, test whether there is voltage short circuit or open circuit occurs to the control circuit, or the resistance is too large. In case that the circuit test is normal, replace body control module. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up or programming of the control module.
Body system 4-61
4.5.3.4 DTC B110712 B110713 Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Description of diagnostic trouble code DTC B110712： Short circuit between front fog lamp relay and power supply DTC B110713： Front fog lamp relay is open circuit Conditions for running diagnostic trouble code B110712 The front fog lamp is working B110713 The front fog lamp is not working Conditions for setting up diagnostic trouble code DTC will be recorded once fault is detected Operations adopted when setting up diagnostic trouble code The front fog lamp output is closed Record DTC Conditions for erasing diagnostic trouble code The historical diagnostic trouble code will be erased after fault-free ignition cycle for 5 times. Body control module receives an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of the fog lamp Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system verification Shift the ignition switch to ON position. Then carry out front fog lamp relay test and the front fog lamp shall be on/off. Circuit/system testing 1. Shift the ignition switch to OFF position, and disconnect the instrument panel fuse box. 2. Shift the ignition switch to ON position and perform the test of front fog lamp relay. The test lamp shall be lighted up and out when switching among the order state. In case that the test lamp is always on, test whether there is ground short circuit occurs to the control circuit. In case that the circuit test is normal, replace body control module. In case that the test lamp is always off, test whether
there is voltage short circuit or open circuit occurs to the control circuit, or the resistance is too large. In case that the circuit test is normal, replace body control module. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up or programming of the control module.
Body system 4-62
4.5.3.5 DTC B110813 B110811 Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Description of diagnostic trouble code Rear fog lamp is open circuit DTC B110813： The rear fog lamp is short DTC B110811： circuit to the ground or overloaded Conditions for running diagnostic trouble code B110813 The rear fog lamp is working B110811 The rear fog lamp is not working Conditions for setting up diagnostic trouble code B110813 The current feedback value is lower than or equal to open-circuit threshold value DTC will be recorded once fault is detected B110811 The current feedback value is higher than overload threshold value DTC will be recorded once fault is detected Operations adopted when setting up diagnostic trouble code The rear fog lamp output is closed Record DTC Conditions for erasing diagnostic trouble code The historical diagnostic trouble code will be erased after fault-free ignition cycle for 5 times. Body control module receives an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of BCM pin Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system testing 1. Shift the ignition switch to ON position. 2. Use the scan tool and in the data list, observe whether the rear fog lamp’s input parameter state will change with different states of the rear fog lamp switch. If it fails to change normally, test whether the rear fog lamp switch’s power supply positive voltage
circuit is short circuit to the ground/resistance is too high. If the circuit test is normal, test whether the rear fog lamp switch circuit and the body control module (BCM) are open circuit/resistance is too high. 3. Detect whether the connector of the rear fog lamp switch is intact. In case of corrosion of connector assembly or bad contact, repair corresponding harness fault. If it is normal upon detection, replace the rear fog lamp switch. 4. Detect whether the harness connector of body control module (BCM) is intact. In case of corrosion of connector assembly or bad contact, repair corresponding harness fault. If it is normal upon detection, replace the body control module (BCM). Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up or programming of the control module.
Body system 4-63 4.5.3.6
DTC B111011
Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Description of diagnostic trouble code DTC B111011: daytime running light shorted to the ground or overload Conditions for running diagnostic trouble code B111011 Daytime running light when not working Conditions for setting up diagnostic trouble code B111011 Current feedback is greater than the overload threshold If a fault is detected, the DTC is recorded Operations adopted when setting up diagnostic trouble code The daytime running light off output Record DTC Conditions for erasing diagnostic trouble code The historical diagnostic trouble code will be erased after fault-free ignition cycle for 5 times. Body control module receives an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of BCM pin Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system testing 1. Shift the ignition switch to ON position 2. Use the scan tool and in the data list, observe whether the daytime running light’s input parameter state will change with different states of operation of the engine and the position lights. If it fails to change normally, test whether the right turn lamp switch’s power supply positive voltage circuit is short circuit to the ground/resistance is too high. If the circuit test is normal, test whether the daytime running light circuit and the body control module (BCM) are open circuit/resistance is too high. 3. Detect whether the connector of the daytime running light is intact. In case of corrosion of connector assembly or bad contact, repair corresponding harness fault. If it is
normal upon detection, replace the daytime running light connector. 4. Detect whether the harness connector of body control module (BCM) is intact. In case of corrosion of connector assembly or bad contact, repair corresponding harness fault. If it is normal upon detection, replace body control module (BCM). Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up or programming of the control module.
Body system 4-64
4.5.3.7 DTC B110513 B110511 Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Description of diagnostic trouble code DTC B110513: left front turn lamp open DTC B110511: left turn lamp on the short circuit or overload Conditions for running diagnostic trouble code When the left front turn lamp work Conditions for setting up diagnostic trouble code The current feedback value is less than overload threshold value If a fault is detected, the DTC is recorded Operations adopted when setting up the diagnostic trouble code Record DTC The output is off Conditions for erasing diagnostic trouble code The historical diagnostic trouble code will be erased after fault-free ignition cycle for 5 times. Body control module receives an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of BCM pin Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system testing 1. Use the scan tool and in the data list, observe whether the left front turn lamp’s input parameter state will change with different states of left front turn lamp switch If it fails to change normally, test whether the right turn lamp switch’s power supply positive voltage circuit is short circuit to the ground/resistance is too high. If the circuit test is normal, test whether the left front turn lamp switch circuit and the body control module (BCM) are open circuit/resistance is too high. 3. Detect whether the connector of the left front turn lamp switch is intact. In case of corrosion of connector assembly or bad contact, repair corresponding harness fault. If it is normal upon detection, replace the left front turn
lamp switch. Detect whether the harness connector of body control module (BCM) is intact. In case of corrosion of connector assembly or bad contact, repair corresponding harness fault. If it is normal upon detection, replace body control module (BCM). Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up or programming of the control module. 4.
Body system 4-65
4.5.3.8 DTC B110613 B110611 Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Description of diagnostic trouble code DTC B110613: right front turn lamp open DTC B110611: right turn lamp on the short circuit or overload Conditions for running diagnostic trouble code When the right front turn lamp work Conditions for setting up diagnostic trouble code The current feedback value is less than overload threshold value If a fault is detected, the DTC is recorded Operations adopted when setting up the diagnostic trouble code Record DTC The output is off Conditions for erasing diagnostic trouble code The historical diagnostic trouble code will be erased after fault-free ignition cycle for 5 times. Body control module receives an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of BCM pin Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system testing 1. Shift the ignition switch to ON position 2. Use the scan tool and in the data list, observe whether the right front turn lamp’s input parameter state will change with different states of right front turn lamp switch If it fails to change normally, test whether the interior lamp control circuit is short circuit to the power supply. If the circuit test is normal, test whether the right front turn lamp switch and the body control module (BCM) are open circuit/resistance is too high. 3. Detect whether the connector of the left front turn lamp switch is intact. In case of corrosion of connector assembly or bad contact, repair corresponding harness fault. If it is normal upon detection, replace the left front turn lamp switch.
4.
Detect whether the harness connector of body control module (BCM) is intact. In case of corrosion of connector assembly or bad contact, repair corresponding harness fault. If it is normal upon detection, replace body control module (BCM). Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up or programming of the control module.
Body system 4-66
4.5.3.9 DTC B110A12 Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Description of diagnostic trouble code DTC B110A12: interior lamp open Conditions for running diagnostic trouble code B110A12 When the interior lamp work Conditions for setting up diagnostic trouble code The current feedback value is less than overload threshold value If a fault is detected, the DTC is recorded Operations adopted when setting up the diagnostic trouble code Record DTC The output is off Conditions for erasing diagnostic trouble code The historical diagnostic trouble code will be erased after fault-free ignition cycle for 5 times. Body control module receives an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of BCM pin Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system testing 1. Shift the ignition switch to ON position 2. Use the scan tool and in the data list, observe whether the interior lamp’s input parameter state will change with different states of door switch. If it fails to change normally, test whether the interior lamp control circuit is short circuit to the power supply. If the circuit test is normal, test whether the power circuit and the body control module (BCM) are open circuit/resistance is too high. 3. Detect whether the connector of the interior lamp switch is intact. In case of corrosion of connector assembly or bad contact, repair corresponding harness fault. If it is normal upon detection, replace the interior lamp switch. 4. Detect whether the harness connector of body
control module (BCM) is intact. In case of corrosion of connector assembly or bad contact, repair corresponding harness fault. If it is normal upon detection, replace body control module (BCM). Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up or programming of the control module. -
Body system 4-67
4.5.3.10 Symptom-lighting system IMPORTANT: The following steps must be completed before using the symptom list: Look up the system operation contents and get familiar with system functions. Refer to “General Description and Operation”. Visual inspection/appearance inspection Inspect whether aftermarket devices which may affect the operation of the horn exist. Refer to “Inspection of Aftermarket Accessories” in the “Circuit System”. Inspect whether the touchable or visible system components have obvious damage or fault which may cause such symptom. Intermittent fault An intermittent fault may be caused by electrical connection or wire fault. Refer to “Tests of Intermittent Fault and Bad Contact” in the “Circuit System”. Symptom list Refer to the following symptom diagnosis procedure to diagnose the symptom: Fault of turn lamp Fault of high mount stop lamp Fault of headlamp-high beam Fault of headlamp-low beam Fault of luggage compartment lamp Fault of reverse lamp Fault of dome lamp/courtesy lamp Fault of front fog lamp Fault of rear fog lamp
4.5.3.11 Fault of turn lamp Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Circuit/system description The power supply voltage supplies voltage to the turn lamp through the body control module. When the hazard warning lamp switch or the turn signal/multi-function switches are open, the body control module will send power signals of certain frequency to the turn lamp. Reference information Reference of schematic diagram Schematic diagram of the exterior lamp Connector End View Reference Part connector end view Description and operation Description and operation of interior lighting system
Electrical Information Reference
Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair
Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system testing 1. Shift the ignition switch to OFF position, adjust S78 turn signal/multi-function control switches and use the multi-meter to measure whether resistance between terminals 2 and 1/3 is less than 5Ω. － If it is more than the given value, test whether the surrounding circuit is open circuit/resistance is too high. If the circuit test is normal, replace S78 multi-function control switch. 2. Shift the ignition switch to ON position, connect S26 hazard warning lamp switch and disassemble the hazard warning lamp bulb not working from the lampholder. Whether the battery voltage on the lampholder positive terminal is fluctuating between 0 to 14V according to certain frequency. － If not, test whether K9 body control module circuit terminal is good. If so, replace K9 body control module. 3. Shift the ignition switch to OFF position, and use the ohmmeter to measure whether the turn lamp grounding terminal has resistance less than 5Ω. － If the value exceeds the given range, test whether the ground circuit is open circuit/resistance is too high. If the test result is normal, replace the faulted turn lamp/hazard warning lamp bulbs. 4. Disassemble S26 hazard warning lamp switch, press down the hazard warning lamp button and test whether resistance between terminal 5 and terminal 6 is less than 5Ω. － If the value exceeds the given range, replace S26 hazard warning lamp switch. 5. If the above is normal, repair the open circuit fault between the hazard warning lamp switch and the power supply circuit. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Replacement of hazard warning lamp switch Replacement of front side turn signal lamp Refer to “Control module reference”, so as to replace and set up body control module
Body system 4-68
4.5.3.12 Fault of high mount stop lamp Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Circuit/system description The brake pedal supplies battery voltage to the central high mount stop lamp control circuit. Reference information Reference of schematic diagram Schematic diagram of the exterior lamp Connector End View Reference Part connector end view Description and operation Description and operation of interior lighting system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system testing 1. Shift the ignition switch to ON position and step down the brake pedal. Whether the parking lamp and E6 high mount stop lamp are on. － If they are not on, inspect whether the brake pedal switch is faulted. If they are normal, test whether the parking lamp bulb or the circuit is faulted. 2. Shift the ignition switch to OFF position and disassemble E6 high mount stop lamp bulb. 3. Shift the ignition switch to ON position, and use a small test lamp to connect E6 high mount stop lamp power supply terminal and grounding terminal. Whether this small lamp is on. － If the small lamp is on, replace E6 high mount stop lamp bulb. If they are normal, test whether the power circuit of E6 high mount stop lamp is open circuit or the resistance is too high. 4. Shift the ignition switch to OFF position, and test the ohmmeter to measure whether the resistance between E6 high mount stop lamp ground terminal 2 and the ground is lower than 10Ω. － If the value exceeds the given range, test whether the grounding terminal is open circuit/resistance is too high. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Replacement of high mount stop lamp bulb Refer to “Control module reference”, so as to replace and set up body control module
4.5.3.13 Fault of headlamp-high beam Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Circuit/system description High beam relay is controlled by body control module, when the switch of headlamp is at the headlamp position, relay will activate signal circuit, switch on the high beam to light up the high beam at this time. Reference information Reference of schematic diagram Schematic diagram of the headlamp (low beam and high beam) Connector End View Reference Part connector end view Description and operation Description and operation of exterior lighting system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system testing 1. Shift the ignition switch to OFF position, replace KR48 headlamp high beam relay, and switch on the high beam. － If the high beam is not lighted up, replace corresponding high beam fuse. 2. Shift the ignition switch to OFF position, and disconnect the harness connector of S78 multi-function control switch (K9 body control module). 3. Confirm that the test lamp between the ground terminal and the ignition switch 2 is lighted up. － In case that the test lamp is not lighted up, test whether the ground circuit is open circuit, or the resistance is too large. In case that the circuit is normal, replace S78 multi-function control switch (K9 body control module). 4. Shift the ignition switch to ON position, connect one small test lamp between the high beam terminal 2 and the ground, and switch on the high beam. － If the small lamp is lighted up, test whether the ground circuit is open circuit, or the resistance is too large. If circuit test is normal, replace the high beam bulb. 5. In case that all circuit tests are normal, repair B+ power circuit. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. “Relay Replacement (connecting with wiring
Body system 4-69 harness)” or “Relay Replacement (in the electrical center)” Replacement of front compartment fuse box shell Replacement of headlamp bulb Refer to “Control module reference”, so as to replace and set up body control module .
4.5.3.14 Fault of headlamp-low beam
low beam bulb. In case that all circuit tests are normal, repair B+ power circuit. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. “Relay Replacement (connecting with wiring harness)” or “Relay Replacement (in the electrical center)” Replacement of front compartment fuse box shell Replacement of headlamp bulb Refer to “Control module reference”, so as to replace and set up body control module 5.
Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to 4.5.3.15 Fault of tail door lamp obtain overview of diagnostic method. Provide overview of each diagnostic category in Diagnostic description “Description of Diagnostic Procedure”. Execute “Inspection of Diagnostic System Circuit/system description Vehicle” before adopting such diagnostic Low beam relay is controlled by body control module, procedure when the switch of headlamps is at the headlamp Look up “Diagnosis Based on Strategy”, so as to position, relay will activate signal circuit, switch on the obtain overview of diagnostic method. low beam to light up the low beam at this time. Provide overview of each diagnostic category in Reference information “Description of Diagnostic Procedure”. Reference of schematic diagram Circuit/system description Schematic diagram of the headlamp (low beam and Power voltage offers voltage to the trunk lamp via fuse high beam) inside the fuse box under the instrument panel, the Connector End View Reference negative terminal of trunk lamp is connected to the trunk Part connector end view handle, and the trunk lamp will be lighted up after Description and operation opening the trunk. Description and operation of exterior lighting system Reference information Electrical Information Reference Reference of schematic diagram; Schematic diagram of Circuit test the interior lamp Repair of connector Connector End View Reference: Part connector end Test intermittent fault and bad contact view Circuit repair Description and operation Scan Tool Reference Description and operation of interior lighting system Refer to “Control module reference”, so as to obtain the Electrical Information Reference information of scan tool Circuit test Circuit/system testing Repair of connector 1. Shift the ignition switch to OFF position, replace Test intermittent fault and bad contact KR49 headlamp low beam relay, and switch on the Circuit repair low beam. Scan Tool Reference － If the low beam is not lighted up, replace Refer to “Control module reference”, so as to obtain the information of scan tool corresponding low beam fuse. Diagnostic help 2. Shift the ignition switch to OFF position, and Bulb test. Make one end of jumper wire stuck onto the disconnect the harness connector of S78 negative terminal of battery. Make another end of multi-function control switch (K9 body control jumper wire stuck onto one end of bulb. Make the end of module). the bulb that no jumper wire is connected contact with 3. Confirm that the test lamp between the ground the positive terminal of battery terminal and the ignition switch 2 is lighted up. Circuit/system testing － In case that the test lamp is not lighted up, test 1. Shift the ignition switch to OFF position, remove whether the ground circuit is open circuit, or the fuse F20 under the instrument panel, and detect resistance is too large. In case that the circuit is whether the resistance between the two ends of normal, replace S78 multi-function control switch fuse is lower than 2Ω with an ohmmeter (K9 body control module). － If the value exceeds the given range, test 4. Shift the ignition switch to ON position, connect one whether the fuse is open circuit/resistance is too small test lamp between the low beam terminal 2 high. and the ground, and switch on the low beam. 2. Shift the ignition switch to ON position, test whether － If the small lamp is lighted up, test whether the the voltage of power supply for fuse is within 10 to ground circuit is open circuit, or the resistance is 14V. too large. If the circuit test is normal, replace the
Body system 4-70 － If the value exceeds the given range, repair the fuse power circuit, otherwise test whether the negative circuit of fuse is open circuit/resistance is too high. 3. Shift the ignition switch to OFF position, disassemble the bulb of E8S trunk lamp, and check whether the lamp filament is open. － If it is open, test the bulb with vehicle battery and jumper wire. 4. Shift the ignition switch to OFF position, and use an ohmmeter to measure whether the resistance between negative terminal of E8S trunk lamp connector and harness ground is less than 10Ω. － If the value exceeds the given range, test whether the E8S trunk lamp ground circuit is open circuit/resistance is too high. 5. If the above tests are normal, replace E8S trunk switch assembly. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Replacement of trunk lamp bulb Replacement of trunk lamp Refer to “Control module reference”, so as to replace and set up body control module
Body system 4-71
4.5.3.16 Fault of reverse lamp Diagnostic description Execute “Inspection of Diagnostic System - Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Fault diagnostic information
Circuit Ground short circuit Reverse gear signal 1 1. Rear gear light is not working Rear gear light is always lighted up
Open circuit/resistance is too large 1
Circuit/system description When transmission is placed on reverse gear position, B16 back-up lamp switch is closed, fuse 13 under the instrument panel offers battery voltage to back-up lamp, and back-up lamp will be lighted up. Permanent ground of back-up lamp Once driver move shift level from reverse gear position, B16 back-up lamp switch will be opened, the battery voltage on back-up lamp control circuit will be released, and the back-up lamp will be out. Reference information Reference of schematic diagram Schematic diagram of the exterior lamp Connector End View Reference Part connector end view Description and operation Description and operation of exterior lighting system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Circuit/system verification Shift the ignition switch to ON position, and carry out back-up lamp gear test. Back-up lamp shall be lighted up / out. Circuit/system testing 1. Shift the ignition switch to OFF position, and disconnect the harness connector at B16 back-up lamp switch
2.
Voltage short circuit 2
Signal performance —
Shift the ignition switch to ON position, use jumper wire with 10A fuse to bridge terminals 1 and 2 of control circuit harness connector, and back-up lamp shall be lighted up. － If the back-up lamp is not lighted up, test whether there is ground short circuit or open circuit occurs to the control circuit, or the resistance is too large; Whether the ground circuit is open circuit, or the resistance is too large. － If the back-up lamp is lighted up, replace B16 back-up lamp switch
Component test Static test 1. Shift the ignition switch to OFF position, and disconnect the harness connector at B16 back-up lamp switch Engage reverse gear, and test whether the resistance between terminals 1 and 2 of B16 back-up lamp switch is less than 2Ω. － If it is higher than the specified value, replace B16 back-up lamp switch. 2. Disengage reverse gear, and test whether the resistance between terminals 1 and 2 of B16 back-up lamp switch is infinitely great. － If it is less than the specified value, replace B16 back-up lamp switch. Service Instruction Execute “Diagnosis inspection and repair effect” Replacement of tail lamp
Body system 4-72
4.5.3.17 Fault of dome lamp/courtesy lamp Diagnostic description Execute “Inspection of Diagnostic System - Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Fault diagnostic information
Circuit
Ground circuit
Control of courtesy lamp
2
short
Open circuit/resistance too large 2
is
Voltage circuit 1
short
Signal performance —
1． Courtesy lamp is always on Courtesy lamp isn’t lighted up
Circuit/system description Body control module always offers battery voltage to dome lamp / courtesy lamp. The body control module controls the grounding of dome lamp / courtesy lamp when the control switch is shifted to “DOOR” position; When BCM receives the signal for lighting up dome lamp / courtesy lamp, it will provide grounding for the control circuit of courtesy lamp to light up the courtesy lamp. When the control switch is shifted to “ON” position, the body ground will directly provide grounding and the dome lamp / courtesy lamp will normally on. Reference information Reference of schematic diagram Schematic diagram of the interior lamp Connector End View Reference Part connector end view Description and operation Description and operation of exterior lighting system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Circuit/system verification Courtesy lamp When the control switch is shifted to “DOOR” position, open and close each door and liftgate, and observe the information center of driver. The information center of driver shall display the information that door isn’t closed / liftgate isn’t closed only when the door/liftgate is open. － If the information center of driver displays the information that door isn’t closed / liftgate isn’t closed when the door or liftgate is closed, refer to “Fault of Indicator Indicating the Door is Open”. － If the function that door isn’t closed / liftgate isn’t closed is normal, refer to “Fault of Courtesy Lamp Circuit”. Dome lamp When the control switch is shifted to “ON” position, dome lamp / courtesy lamp will normally on.
Circuit/system testing 1. Shift the ignition switch to OFF position and disconnect the harness connector of E37 dome lamp/reading lamp. 2. Test whether the resistance between ground circuit terminal 2 and the ground is lower than 10Ω. － If the value exceeds the specified range, test whether the ground circuit is open circuit, or the resistance is too large. 3. Connect a test lamp between control circuit terminal 1 and ground circuit terminal 2. 4. Open the door, order the courtesy lamp to be lighted up and out for test. The test lamp shall be lighted up and out when switching among the order state. － In case that the test lamp is always on, test whether there is voltage short circuit occurs to the control circuit. － In case that the test lamp is always off, test whether there is ground short circuit or open circuit occurs to the control circuit, or the resistance is too large. 5. Test the bulb of E37 dome lamp / reading lamp. 6. If all circuit tests are normal, replace body control module. Diagnostic help Bulb test. Make one end of jumper wire stuck onto the negative terminal of battery. Make another end of jumper wire stuck onto one end of bulb. Make the end of the bulb that no jumper wire is connected contact with the positive terminal of battery. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Replacement of dome lamp Replacement of dome lamp bulb Refer to “Control module reference”, so as to replace and set up body control module
Body system 4-73
4.5.3.18 Fault of front fog lamp Diagnostic description Execute “Inspection of Diagnostic System - Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure” Fault diagnostic information Circuit
Ground circuit 1
Front fog lamp signal Right front fog lamp — ground Left front fog lamp — ground 1. Front fog lamp is not working 2. Front fog lamp is always on 3. Right front fog lamp is not working 4. Left front fog lamp is not working
short
1
Voltage circuit 2
3
—
—
4
—
—
Open circuit/resistance is too large
Circuit/system description Front fog lamp relay is always powered by battery. Open the switch of front fog lamp to make the signal circuit of front fog lamp switch ground instantaneously. Body control module (BCM) makes the front fog lamp relay powered on through providing ground to the control circuit of front fog lamp relay. When the relay of front fog lamp is powered on, the switch contacts of relay are closed, battery voltage is supplied to front fog lamp via the fuse of front fog lamp, thus lighting up front fog lamp. Reference information Reference of schematic diagram Schematic diagram of the exterior lamp Connector End View Reference Part connector end view Description and operation Description and operation of exterior lighting system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Electrical Information Reference Refer to “Control module reference”, so as to obtain the information of scan tool
Circuit/system verification Shift the ignition switch to ON position, and carry out front fog lamp relay test. Front fog lamp shall be lighted up / out.
Circuit/system testing 1.
Shift the ignition switch to OFF position, and disconnect the harness connectors corresponding to the following front fog lamps: E29LF left front fog lamp E29RF right front fog lamp 2.
Test whether the resistance between ground circuit harness connector terminal 1 and the
short
Signal performance —
ground of corresponding front fog lamp is less than 10Ω. － If it is higher than the specified value, test whether the ground circuit is open circuit, or the resistance is too large. 3. Connect harness connector to fog lamp. 4. Shift the ignition switch to OFF position, and replace the same type of relay with KR46 front fog lamp relay. 5. Shift the ignition switch to ON position, and test whether the fault still remains. － If the fault has been cleared, replace the damaged relay. 6. Shift the ignition switch to OFF position, and disconnect corresponding harness connector. Test whether the circuit of S78 multi-function switch is normal. － If the circuit breaks down, replace corresponding S78 multi-function switch. 7. Connect one jumper wire with 10A fuse between B+ and output contact 87 of KR46 front fog lamp relay. － If the front fog lamp is lighted up, replace F19UA fuse － If the front fog lamp is not lighted up, test whether there is ground short circuit or open circuit occurs to the control circuit, or the resistance is too large. 8. If all the tests are normal, replace K9 body control module. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Relay replacement Replacement of front fog lamp Refer to “Control module reference”, so as to carry out replacement, setting up and programming of body control module
Body system 4-74
4.5.3.19 Fault of rear fog lamp Diagnostic description Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Circuit/system description Press down the switch of rear fog lamp to make the signal circuit of rear fog lamp switch ground instantaneously. Body control module (BCM) makes the power supply voltage circuit of rear fog lamp powered on, so as to light up the rear fog lamp. Reference information Reference of schematic diagram Schematic diagram of the fog lamp Connector End View Reference Part connector end view Description and operation Description and operation of exterior lighting system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference”, so as to obtain the information of scan tool Circuit/system verification 1. Shift the ignition switch to ON position, and execute scan tool “rear fog lamp switch” parameters. Reading shall be variable between “Started/Not Started” while switching between press down and loosen the push button of rear fog lamp switch. － If parameter isn’t variable within the range of specified value, please refer to “Fault of Rear Fog Lamp Switch” 2. Shift the ignition switch to ON position, open and close all indicators of instrument cluster for test. Rear fog lamp indicator shall be lighted up / out － If rear fog lamp indicator isn’t switched among the order state, please refer to “Fault of Rear Fog Lamp Indicator”. Circuit/system testing Fault of rear fog lamp switch 1. Shift the ignition switch to OFF position, and disconnect corresponding harness connector of K9 body control module. 2. Shift the ignition switch to ON position, and test whether the voltage between the signal circuit terminal of K9 body control module and the ground is less than 0.3V. － If it is higher than the specified value, test whether there is voltage short circuit occurs to the signal circuit. 3. Test whether the voltage between the circuit connector terminal with 12V reference voltage of
K9 body control module and the ground is less than 0.3V. － If it is higher than the specified value, test whether there is voltage short circuit occurs to the circuit with 12V reference voltage. 4. Shift the ignition switch to OFF position, and test whether the resistance between the signal circuit connector terminal of K9 body control module and the ground is infinitely great. － If it is less than the specified value, test whether there is ground short circuit occurs to the signal circuit. 5. Test whether the resistance between the circuit harness connector terminal with 12V reference voltage of K9 body control module and the ground is infinitely great. － If it is less than the specified value, test whether there is ground short circuit occurs to the circuit with 12V reference voltage. 6. Press and hold the push button of rear fog lamp switch. 7. Test whether the resistance between the circuit harness connector terminal with 12V reference voltage of K9 body control module and the signal circuit harness connector terminal of K9 body control module is within 100 to 200Ω. If it exceeds the specified range, test whether the circuit with 12V reference voltage and the signal circuit are open circuits, or the resistance is too large. If the circuit test is normal, replace S78 rear fog lamp switch. 8. If all circuit tests are normal, replace K9 body control module. Fault of rear fog lamp indicator Shift the ignition switch to ON position, open and close all indicators of instrument cluster according to the orders of scan tool. Rear fog lamp indicator shall be lighted up / out when switching among the order state. If the rear fog lamp indicator is always on or off, replace P16 instrument cluster. Service Instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Relay replacement Replacement of rear fog lamp Refer to “Control module reference”, so as to carry out replacement, setting up and programming of body control module or instrument cluster
Body system 4-75
4.5.4 Service Instruction 4.5.4.1 Replacement of front reading lamp and bulb
15AJ0403001
Replacement of front reading lamp and bulb Figure No.
Names of components
Preparation Procedure CAUTION: Refer to "WARNING TO AVOID TOUCH LAMPS". Disconnect the battery negative line. See "Battery Disconnection and Connection". Cover of front reading lamp Procedure 1 Loosen the cover of front reading lamp to get access to the bulb by use pry instrument tool 2 Bulb of front reading lamp Mounting screws of front reading lamp Warning: Refer to “Warning on Relevant tightening”. 3 Tightening torque 1.5±0.5 N. m 4 Front reading lamp assembly
Body system 4-76
4.5.4.2 Replacement of reading lamp and rear bulb
15AJ0403002
Replacement of reading lamp and rear bulb Figure No.
Part Name
Preparation Procedure CAUTION: Refer to "WARNING TO AVOID TOUCH LAMPS". Disconnect the battery negative line. See "Battery Disconnection and Connection". Cover of rear reading lamp Procedure 1 Loosen the cover of rear reading lamp to get access to the bulb by use pry instrument tool 2 Bulb of rear reading lamp Mounting screws of rear reading lamp Warning: Refer to “Warning on relevant tightening”. 3 Tightening torque 1.5±0.5 N. m 4 Rear reading lamp assembly
Body system 4-77
4.5.4.3 Replacement of rear spoiler
14BT0403004
Replacement of rear spoiler Figure No.
Part Name
Preparation procedure 1. Remove the upper window trim panel on tailgate. Refer to “Replacement of finishing plate of window frame on gate”. Mounting nuts for rear spoiler (quantity: 4) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 5.5±1 N. m Rear spoiler 2
Body system 4-78
4.5.4.4 Replacement of high-mounted stop lamp
14BT0403005
Replacement of high-mounted stop lamp Figure No.
Part Name
Preparation procedure Remove rear spoiler. Refer to “Replacement of rear spoiler”. 1
Nuts for high-mounted stop lamp (quantity: 2)
2
High-mounted stop lamp
Body system 4-79
4.5.4.5 Replacement of front side door switch post
14BT0403006
Replacement of front side door switch post Figure No.
Part Name
Preparation procedure Disconnect the battery negative line. See "Battery Disconnection and Connection." Front side door switch Procedure 1 Disconnect the front side door switch wire harness plug Mounting screws for door post switch of front side door (quantity: 1) Warning: Refer to “Warning on relevant tightening”. 2 Tightening torque 1.5±0.5 N. m
Body system 4-80
4.5.4.6 Replacement of rear side door switch post
14BT0403007
Replacement of rear side door switch post Figure No.
Part Name
Preparation procedure Disconnect the battery negative line. See "Battery Disconnection and Connection." Mounting screws for door post switch of rear side door (quantity: 1) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 1.5±0.5 N. m rear side door switch 2
Body system 4-81
4.5.4.7 Replacement of Combination switch (switch lamp)
16BH0403010
Replacement of Combination switch (switch lamp) Figure No.
Part Name
Preparation procedure 1, Disconnect the battery negative line. See “Disconnect and connection of battery negative line". 2, Remove the steering column trim cover. See "replacement steering column trim cover". 3, Remove the trim cover under steering column. See " Trim cover under steering column ". Combination switch (switch lamp) Procedure 1 Disconnect the electrical connector.
Body system 4-82
4.5.4.8 Replacement of multifunction switch
16BH0403011
Replacement of multifunction switch Figure No.
Part Name
Preparation procedure 1, Disconnect the battery negative line. See "Battery Disconnection and Connection". 2. Remove the driver's knee stopper. See "Replacing the Driver's Knee Baffle".
1
Multifunction switch
Body system 4-83
4.5.4.9 Replacement of headlamp
15AJ0403003
Replacement of headlamp Figure No.
Part Name
Preparation procedure 1. Remove the radiator grille. Refer to “Replacement of radiator grille”. 2. Remove the front bumper seat cover. Refer to “Replacement of front bumper seat cover”. Mounting screw for headlamps (quantity: 4) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 4±0.5 N. m 2
Left Headlamp
3
Right Headlamp
Body system 4-84
4.5.4.10 Replacement of headlamp bulb (upper side)
15AJ0403004
Replacement of headlamp bulb (upper side) Figure No.
Part Name
Preparation procedure Warning: Refer to “Warning on avoiding touch of bulb”. Disconnect the battery negative line. See "Battery Disconnection and Connection". Remove the air filter assembly. See "Replacing the Air Filter Assembly (N12A)". Low beam lamp bulb 1 2
Position lamp bulb
3
High beam lamp bulb
Body system 4-85
4.5.4.11 Replacement of headlamp bulb (lower side)
16BH0403004
Replacement of headlamp bulb (lower side)
Figure No.
Part Name
Preparation procedure Warning: Refer to “Warning on avoiding touch of bulb”. Remove the headlamp. See "Headlamp Replacement". Turn lamp bulb 1
2
Position lamp bulb
3
Far (near) light lamp bulb
Body system 4-86
313832
4.5.4.12 Aiming of headlamps 1. Calibrate headlamps to obtain better road lighting. In case of the following situations, you should inspect headlamps for calibration: Mount new headlamp housing. If the front maintenance has (may) affected headlamps or its support. 2. Prior to calibrating headlamps, please firstly take the following measures: if any maintenance is carried out, please make sure to install all units to their original positions. Park the vehicle on flat ground. Stop all other work on vehicle. Fill fuel tank to half level. If vehicle is to be used as heavy load or drawbar trailer, these loads must be simulated. Calibrate headlamps by screen method 1. Park vehicle on the position parallel to screen, make the front part of headlamps align to the reference line (7) which has been drawn on ground. 2. Determine the center line of calibration screen, and keep it in a straight line with the center of vehicle. 2.1 Mark the centers of front and rear windows with narrow adhesive tape. 2.2. Keep the center line (2) of calibration screen and vehicle axes (8) in a straight line with adhesive tape. Equipment required 1. Mark screen 2. Enough test space Required calibration space 1. There shall be certain calibration space at the dark position. Ensure that there is enough space inside room, and it is necessary to reserve a distance of 7.6m from the front part of headlamps to the front part of screen.
3. Ensure the ground where vehicle is parked is flay and parallel to the bottom of screen. If ground is not flat, it is necessary to try to remedy. Calibration screen 1. Ensure that screen meets the following requirements: 1.5m (h) × 3.6m (l), unpolished, white and lucifugal surface Correctly adjust it relative to the round where vehicle is parked 2. Provide screen’s amount of movement to make it parallel to rear axle. 3. Provide screen’s amount of movement to make the distance of horizontal line drawn vertical to the line of screen is within two headlamps. 4. Prepare the following units for screen: One mouting and two vertical adhesive tapes which can be transversely adjusted vertical to the center line. One horizontal adhesive tap which can be vertically adjusted. 5. If there is no common calibration screen, it can be replaced by vertical wall with about 1.8m (h) × 3.6m (l) and without obvious break-joint. The washable and lackluster white paint can be available to finish surface. 6. Draw one reference line at the bottom of lamp cover after mounting calibration screen to indicate the correct location of headlamps while calibrating. Aiming procedure of headlamps 1. Park vehicle on the correct location and correctly load, turn headlamps to low beam or high beam. 2. Observe the left and top edges of highlights in the screen. All edges of highlights shall be within the specified specifications: The height of headlamps’ low beam cut-off line corner or midpoint shall be 0.7 to 0.9Hj, the cut-off line of optical axis shall be distinct, and the deviation to the left and right shall not respectively exceed 153mm and 315mm along the horizontal direction. The height of headlamps’ high beam cut-off line corner or midpoint shall be 0.85 to 0.95Hj, the cut-offline of optical axis of high beam shall be distinct, the deviation of left headlamp to the left and right shall not respectively exceed 153mm and 315mm along the horizontal direction, while the deviation of right headlamp to the left or right shall not exceed 315mm along the horizontal direction. 3. If adjustment is necessary, it shall follow the method below: With regard to horizontal adjustment, you should use the internal adjusting screws for adjustment. With regard to vertical adjustment, you should use the upper adjusting screws for adjustment.
Body system 4-87
4.5.4.13 Replacement of front fog lamp
15AJ0403005
Replacement of front fog lamp Part Name
Figure No. Preparation procedure 1. Disconnect the battery negative line. See "Battery Disconnection and Connection". 2. Remove the front cover gasket screw and push the front cover gasket. See "Front Wheel Cover Replacement". 3. Lifting vehicles. Front Fog Lamp mounting Screws (Quantity: 5) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 2.5±0.5 N. m Front Fog Lamp Decorative Cover Screws (Qty: 4) Warning: Refer to “Warning on relevant tightening”. 2 Tightening torque 2.5 ± 0.5 N · m 3 Front fog lamp decorative cover 4
Front fog lamp assembly
Body system 4-88
4.5.4.14 Replacement of front fog lamp
15AJ0403006
Replacement of front fog lamp bulb Figure No. Part Name Preparation procedure Warning: Refer to “Warning on avoiding touch of bulb”. Disconnect the battery negative line. See disconnect and connection of battery negative line". Remove the front cover gasket screws, through the front wheel housing liner. See "front wheel liner gasket replacement". 1 Front fog lamp bulb 2
Front turn signal lamp
Body system 4-89
4.5.4.15
Replacement of daytime running light
16BH0403006
Replacement of daytime running light Figure No.
Part Name
Preparatory procedure Disconnect the battery negative line. See "Battery Disconnection and Connection". Remove the front cover gasket screw and push the front cover gasket. See "Front Wheel Cover Replacement". Remove the front fog lamp assembly. See "Front Fog Lamp Replacement". Daytime Running Light Screws (Quantity: 2) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 2.5 ±0.5 N · m Daytime running light program 2 Disconnect the harness connector from the harness for daytime running light
Body system 4-90
4.5.4.16 Replacement of rear fog lamp
15AJ0403007
Replacement of rear fog lamp Figure No.
Part Name
Preparation procedure Remove rear bumper seat cover, Refer to “Replacement of rear bumper seat cover”.
1 2
Mounting screws for rear fog lamp (quantity: 4) Warning: Refer to “Warning on relevant tightening”. Tightening torque 1.5±0.5 N. m Rear fog lamp
Body system 4-91
4.5.4.17 Replacement of rear fog lamp bulb
15AJ0403008
Replacement of rear fog lamp bulb Figure No.
Part Name
Preparation procedure Warning: Refer to “Warning on avoiding touch of bulb”. Disconnect the battery negative line. See disconnect and connection of battery negative line". Remove the rear cover assembly. See "replacement of rear skin assembly". Rear fog lamp bulb Procedure 1 Rotate to the appropriate position to pull out Note: low with rear left fog lamp without bulb
Body system 4-92
4.5.4.18 Fog lamp aiming
2191664
Preparation procedures Note: This vehicle’s horizontal aiming is unable to be adjusted. Vertical aiming shall be realized relying on the rotary table under the fog lamp. Before the fog lamp aiming, The following steps shall be executed: 1. All units shall be reliably installed on the vehicle. 2. Park the vehicle on the horizontal surface. 3. Stop operation or work that may affect the vehicle driving height. 4. Close the door and confirm that the trunk is empty. 5. Shake the vehicle transversely to stabilize the suspension. 6. Guarantee that the fuel oil level is full 7. Guarantee that the wheel has been inflated to appropriate pressure. 8. Guarantee that the driver sits on driver seat or a similar weight (about 75 kg) is placed on the seat. Aiming procedure 1. Park the vehicle at the place 7.6m away from the optical screen. 2. Measure the distance from the center of fog lamp to the ground. Mark the horizontal center (2) of fog lamp directly on the optical screen at the front of the vehicle through this method. 3. Light up the fog lamp. Top of fog lamp beam image (1) on the optical screen shall be 102mm below the fog lamp lens center. 4. When necessary, fog lamp shall be adjusted with the rotary table under the fog lamp and behind the front bumper fascia. 5. Light off the fog lamp.
Body system 4-93
4.5.4.19 Replacement of front side turn lamp
14BT0403013
Figure No.
Replacement of front side turn lamp Part Name
Preparation procedure 1. Disconnect the battery negative line. See disconnect and connection of battery negative line". 2. Remove the outside rearview mirror glass. Refer to “Replacement of outside rearview mirror glass”. 3. Remove the internal actuator of outside rearview mirror. Front side turn lamp screw (quantity: 3) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 1.5±0.5 N. m Front side turn lamp Procedure 2 Disconnect the electrical connector.
Body system 4-94
4.5.4.20 Replacement of rear register plate lamp
16BH0403007
Figure No.
Replacement of rear register plate lamp Part Name
Preparation Procedure 1, disconnect the battery negative line. See "Battery Disconnection and Connection". 2, remove the tailgate handle components. See "Replacing the tailgate handle assembly". rear register plate lamp 1
Body system 4-95
4.5.4.21 Replacement of rear register plate lamp bulb
15BS0403016 Replacement of rear register plate lamp bulb Figure No.
Part Name
Warning: Refer to “Warning on avoiding touch of bulb”. Disconnect the battery negative line. See "Battery Disconnection and Connection". Remove the license plate lamp. See "Replacement of rear license plate lamp"。 Rear registration plate lamp shade Rear registration plate lamp bulb Rear registration plate lamp holder Procedure Rotate to the appropriate position to pull out
Body system 4-96
4.5.4.22 Replacement of tailgate
15AJ0403009
Replacement of tailgate Figure No.
Part Name
Preparation procedure 1. Remove the trim panel under quarter panel. Refer to “Replacement of trim panel under quarter panel”. 2. Disconnect the wiring harness plug of tailgate at door side 3. Remove tailgate side cover. Refer to “Replacement of tailgate side cover” Mounting nuts for tailgates (quantity: 3) Warning: Refer to “Warning on relevant tightening”. 1 tightening torque 2±0.5 N. m Mounting screws for tailgates (quantity: 2) Warning: Refer to “Warning on relevant tightening”. 2 Tightening torque 3±0.5 N. m 3
Tail lamp retainer (quantity: 1)
4
Tail lamp (tail gate side)
5
Tail lamp (body side)
Body system 4-97
4.5.4.23 Replacement of tail lamp (tailgate side)
15AJ0403010
Figure No.
Replacement of tail lamp (tailgate side) Part Name
Preparation procedure Warning: Refer to “Warning on avoiding touch of bulb” 1. Remove tail lamp (tailgate side). Refer to “Replacement of tailgate”. Position lamp bulb 1 Note: There is no position lamp bulb in low tail light (tailgate) Reverse lamp bulb 2 Note: There is no reverse lamp bulb in the low right taillight (tailgate)
Body system 4-98
4.5.4.24 Replacement of taillamp bulb (body side)
16BH0403009
Figure No.
Replacement of taillamp bulb (body side) Part Name
Preparation procedure Warning: Refer to “Warning on avoiding touch of bulb” 1. Remove the tail lamp (body side). See "Tail lamp replacement". 1 Brake / position bulb 2
Turn signal bulb
Body system 4-99
4.5.5 Description and operation 4.5.5.1 Description and operation of exterior lighting system Exterior lamps Exterior lighting lamps system includes the following lamps (if equipped): Headlamp Front frog lamp Rear fog lamp Parking lamp, tailgate and license lamp Turn signal Lamp Hazard warning lamp Brake lamp Backup lamp LED daytime running lamps Low beam headlamp Headlamp includes a single-filament bulb providing low beam and high beam. Body control module controls the headlamp with the headlamp switch input signal. After receiving the request of low beam, the body control module provides B+ voltage to low beam headlamp to light up the headlamp. After receiving the request of high beam light, the body control module provides headlamp high beam relay control circuit with ground. Overtaking flashlight When the headlamp with low beam lights up and the steering signal / multi-functional switch is placed on the overtaking flashlight instantaneously, provide ground for turn signal/multi-functional switch. Steering signal/multi-functional switch provides ground for body control module by overtaking flashlight switch signal circuit. Then, the body control module provides ground for high beam relay control circuit. It makes the high beam relay energize, closes the contactor at the side of high beam relay switch at the same time to supply voltage of battery to the high beam fuse at left and right sides. Provide the high beam headlamp assembly with voltage of battery from high beam fuse through high beam power supply voltage circuit. It makes the high beam headlamp light up instantaneously to full bright or until releasing overtaking flashlight switch Front frog lamp Press down the front frog lamp switch to make the signal circuit of front fog lamp ground instantaneously. Body control module makes the front fog lamp relay energize through providing ground to the control circuit of front fog lamp relay. When the relay of front fog lamp is energized, the switch contact of relay is closed, battery voltage is supplied to power supply voltage circuit of front fog lamp via the fuse of front fog lamp, thus lighting up front fog lamp. Rear fog lamp Press down real frog lamp switch to make rear frog lamp switch signal circuit ground instantaneously through resistor. Body control module makes the voltage circuit of rear fog lamp energize, so as to light up rear fog lamp. Turn on the rear fog lamp switch, body control module will send information to instrument cluster through serial data to require instrument cluster
to light up rear frog lamp indicator lamp. Parking lamp, tailgate and license lamp When headlamp switch is turned at parking lamp or low beam position or it requires to turn on the headlamp at any time, parking light, tailgate and license plate lamp will light up. When receiving the request of lighting up the parking light from headlamp, body control module will send pulse width modulation signals to light up parking light, tailgate and license lamp Steering signal Lamp Provide ground to steering signal/multi-functional switch all the time. Only the ignition switch is turned to ON or START position can make the steering signal lamp light up. When the steering signal/multi-functional switch is turned to right or left, you should provide the ground to the body control module with right or left steering signal circuit. And then, body control module provides impulse voltage to front and rear turn signal lamps through corresponding power supply voltage circuit. After receiving the request of steering signal, body control module will send serial data information to instrument cluster to request to light up and go out all steering signal lamps. Hazard warning flashlight Hazard warning flashlight can start under any power supply mode. Hazard warning lamp switch is grounded permanently. When hazard warning lamp switch is turned on, hazard warning lamp switch signal circuit shall provide ground to body control module. Body control module provides all steering signal lamps with battery voltage in the duty ratio form of ON and OFF. Body control module send serial data information to the instrument cluster when enabling the switch of hazard warning lamp, and ask the steering signal indication lamp to light up and go out circularly. Backup lamp Engine control module (ECM) sends serial data information to body control module when the transmission is shifted to reverse gear position. Such information indicates that the shift level is turned to the reverse gear position. Body control module provides the backup lamp with battery voltage. Backup lamp is grounded. Once the driver removes the shift level from the reverse gear position, engine control module will send information through serial data, and ask body control module to revoke the battery voltage from the control circuit of backup lamp.
4.5.5.2 Description and operation of inside lighting system Inside lamps The inside lamps consist of 2 groups of lamps, including beam variable lamp and beam invariable lamp. For beam variable lamp, it may use vacuum fluorescent illumination, LED and incandescent lamp, and be installed on the following parts: Radio Instrument panel combination Various switch
Body system 4-100
4.6
Rearview mirror
4.6.1 Specification 4.6.1.1 Tightening torque specification
Application Remote car rearview mirror switch mounting screws inside rearview mirror screws outside rearview mirror mounting screws
tightening torque specification Specification (N. m) Metric 1.5±0.5 N. m 1.5±0.5 N. m 3.5±1 N. m
Body system 4-101
4.6.2 Schematic and wiring diagram 4.6.2.1 Schematic diagram of exterior rearview mirror
A9B exterior rearview mirrorpassenge r side
X51A fuse block – instru ment panel
A9A exterior rearview mirror – driver side
S52 exterior rearvie w mirror switch
Schematic diagram of exterior rearview mirror
15BS0404001
Body system 4-102
4.6.3
Diagnostic information and procedure
4.6.3.1 Symptom - rearview mirror Important notes: The following steps must be completed before using Symptoms List: 1. Execute “Inspection of diagnostic system vehicle” before adopting “Symptoms List”, to confirm authenticity of the following situations: Do not set up fault diagnostic code. Communication can be realized in control module through serial data link. 2. Look up system operation, and be familiar with system function. Refer to “Description and operation of exterior rearview mirror”. Visual /appearance inspection Inspect whether there is aftermarket equipment possibly affecting the work of rearview mirror. Refer to “Inspection of aftermarket accessories”. Inspect whether the touchable or visible systemunits have obvious damage or fault to cause such symptom. Intermittent faults The intermittent fault may be caused by electrical connecting fault or wiring harness fault. Refer to “Intermittent fault and bad contact test”. Symptoms List Refer to power rearview mirror of diagnostic procedure of symptoms for symptom diagnosis.
4.6.3.2 Fault of power rearview mirror Diagnostic description Execute “Inspection of diagnostic system vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Diagnostic information of faults Electrical circuit Horizontal control of rearview mirror motor at left /right side Vertical control of rearview mirror motor at left /right side Public end control of rearview mirror motor at left /right side Switching ground 7.
sent to the ordered rearview mirror through the control circuit of rearview mirror. The control circuit of rearview mirror at another side, as two-way ground circuit of rearview mirror motor, provides ground through switch. Reference information Reference of schematic diagram Schematic diagram of exterior rearview mirror Connector End View Reference Part connector end view Description and operation Description and operation of exterior rearview mirror Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan Tool Reference Refer to “Control module reference”, to obtain the Scan tool information Circuit/System Verification 1. Order the rearview mirror to move up, down, left and right by use of direction switch of rearview mirror when turning on the ignition switch and turning the select switch of rearview mirror to the driver position. A9A exterior rearview mirror at the driver side shall be moved according to order. 2. Order the rearview mirror to move up, down, left and right by use of direction switch of rearview mirror when turning the select switch of rearview mirror to passenger position. A9B exterior rearview mirror at the passenger side shall be moved according to order. Circuit/system test 1. Turn off the ignition switch and disconnect the wiring harness connector of S52 exterior rearview switch. 2. Wait for one minute and test whether the resistance between ground circuit terminal 10 and ground is less than 10 Ω. － In case of being larger than the specified scope, you should test whether open circuit occurs to the ground circuit / the resistance is too large.
Ground short circuit
Open circuit/too-large resistance
1
1
1
1
1
1
—
1
Voltage short circuit — — — —
Signal performance — — — —
Fault of power rearview mirror
Circuit/system description The exterior rearview mirror switch controls the exterior rearview mirror according to the position of selective switch of rearview mirror and selected moving position. There are four positions for exterior rearview mirror: Up, down, left and right. The ignition voltage from power rearview mirror fuse is provided to one position moving switch when selecting such switch, and the voltage is
3.
4.
Turn on the ignition switch and confirm the test lamp between B+ circuit terminal 5 and ground lights up. － If the test lamp does not light up, you should test whether ground short circuit or open circuit occurs to B+ circuit / the resistance is too large. Turn off the ignition switch, and connect wiring harness connector of S52 exterior rearview mirror
Body system 4-103 switch. Disconnect the wiring harness connector of corresponding A9 exterior rearview mirror. 6. Connect a test lamp between control circuit terminals 1 and 2. 7. Turn on the ignition switch, and make vertical regulating switch UP and Down. The test lamp shall light up when ordering “UP” and “DOWN”. － In case that the test lamp goes out under such two orders, you should test whether voltage short circuit, ground short circuit or open circuit occurs to the control circuit / the resistance is too large. Replace S52 exterior rearview mirror switch if the circuit is normal after test. 8. Connect a test lamp between control circuit terminals 2 and 3. 9. Make horizontal regulating switch LEFT and RIGHT. The test lamp shall light up when ordering “LEFT” and “RIGHT”. － In case that the test lamp still goes out under such two orders, you should test whether voltage short circuit, ground short circuit or open circuit occurs to the control circuit / the resistance is too large. Replace S52 exterior rearview mirror switch if the circuit is normal after test. 10. If all circuits are normal after test, you should test or replace A9 rearview mirror. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Replacement of actuator inside exterior rearview mirror – power Replacement of exterior remote rearview mirror switch 5.
Body system 4-104
4.6.4 Service Instruction 4.6.4.1 Replacement of outside rearview mirror
15BS0404001
Replacement of outside rearview mirror – electric Figure No.
Part Name
Preparation procedure Remove the outside rearview housing cover. Refer to “Replacement of outside rearview mirror cover”.
1
Mounting screws for outside rearview mirror (quantity : 3) Warning: Refer to “Warning on relevant tightening”. Tightening torque 3.5±1 N. m
2
Outside rearview mirror
Body system 4-105
4.6.4.2 Replacement of cover of outside rearview mirror
14BT0404003
Replacement of outside rearview mirror cover Figure No. 1
Part Name Outside rearview mirror cover
Body system 4-106
4.6.4.3 Replacement of outside rearview mirror glass
14BT0404004
Replacement of outside rearview mirror glass Figure No.
1
Part Name Outside rearview mirror glass Warning: Refer to “Warning on treating relevant glass and metal sheet”. Procedures Pull out to make the outside rearview mirror glass loose from back of rearview mirror fame.
Body system 4-107
4.6.4.4 Replacement of inside rearview mirror
14BT0404004
Replacement of inside rearview mirror Figure No. 1 2
Part Name Mounting screws for inside rearview mirror (quantity: 1） Warning: Refer to “Warning on relevant tightening”. Tightening torque 1.5±0.5 N. m Inside overview mirror
Body system 4-108
4.6.4.5 Replacement of outside remote rearview mirror switch
14BT0404005
Replacement of outside remote rearview mirror switch Figure No.
Part Name
Preparation procedure 1. Disconnect the battery negative line. See "Battery Disconnection and Connection". 2. Remove the right front door switch panel. See "Replacement of Front Door Switch Panel". 1 Mounting screws for outside remote rearview mirror switch
Body system 4-109
4.6.5 Description and operation 4.6.5.1 Description and operation of outside rearview mirror Units of power rearview system The power rearview mirror system is composed of the following units: Outside rearview mirror switch Rearview mirror select switch Outside rearview mirror at the driver side Outside rearview mirror at the passenger side Each outside rearview mirror includes two motors. The vertical motor makes the rearview mirror run up and down, and the horizontal motor makes the rearview mirror run left and right. Control of power rearview system Outside rearview mirror switch is a four-position direction switch: Up, down, left and right. Rearview mirror select switch is a three-position switch: Left, middle and right sides. Operation of power rearview system Outside rearview mirror switch receives the battery voltage from fuse block under hood, and power rearview mirror switch connects with the ground constantly. There are bi-switch contacts for 4 positions of direction switch. Each contact is connected to the opposite side of corresponding power rearview mirror motor through select switch. The select switch is connected to such circuits according to its position (L or R). In case of turning the select switch to L position and pressing the UP switch, then the battery voltage is provided to the vertical motor of left side outside rearview mirror through vertical control circuit of left rearview mirror motor, and the ground is provided through the control circuit at the public end of left rearview mirror motor. In case of pressing the DOWN switch, then the battery voltage is provided to the vertical motor of left side outside rearview mirror through control circuit at the public end of left side rearview mirror motor, and the ground is provided through the vertical control circuit of left side rearview mirror motor. The remaining functions of rearview mirror are same with those above. Turn the power rearview mirror switch to the opposite position, left/right or up/down will make the polarity of rearview mirror motor opposite, and make the movement direction opposite.
Body system 4-110
4.7
Vehicle access system
4.7.1 Specification 4.7.1.1 Tightening torque specification tightening torque specification Application Front side door inside handle mounting screw Front side door outside handle mounting screw Rear side door outside handle mounting screw Rear side door inside handle mounting screw Front side door central locking screw Rear side door central locking screw Tailgate lock screw Front side door locking screw Rear side door lock screw Tailgate lock screw
Specification (N. m) Metric 1.5±0.5 N. m 4.5±0.5 N. m 4.5±0.5 N. m 1.5±0.5 N. m 9±1.5 N. m 9±1.5 N. m 22±3 N. m 25±5 N. m 25±5 N. m 25±5 N. m
B28D driver door micro switch
B28P pass enge r door micro switc h B28L R left rear door micro switc h
B28RR right rear door micro switch
M14B door lock actuator lift door
Electric circuit diagram of horn
Electrical circuit diagram of exterior lamp
K9 body control template
Body system 4-111
4.7.2 Schematic and wiring diagram
4.7.2.1 Schematic diagram of door lock/indicator Schematic diagram of door lock indicator (door touch switch and body anti-theft)
S13D door lock switch – driver side
S13A door lock switch – rear trunk M14B door lock actuat or - lift door
M14 D door lock actua tor – drive r side
M14P door lock actua tor – passe nger side
M14L R door lock actua tor – left rear
M14R R door lock actua tor – right rear
K9 body control templat e
Body system 4-112
Schematic diagram of door lock indicator (door lock)
Body system 4-113
4.7.3 Diagnostic information and procedure 4.7.3.1 Symptom – door lock
4.7.3.2 Fault of door ajar indicator
Important notes: The following steps must be completed before using Symptoms List: 1. Execute “Inspection of diagnostic system - vehicle” before adopting “Symptoms List”, to confirm authenticity of the following situations: Do not set up fault diagnostic code. Communication can be realized in control module through serial data link. 2. Look up system operation, and be familiar with system function. Refer to “Description and operation of power door lock”. Visual /appearance inspection Inspect whether there is aftermarket equipment possibly affecting the work of door lock. Refer to “Inspection of aftermarket accessories”. Inspect whether there is obvious damage or fault of touchable or visible system units to cause such symptom.
Diagnostic description Execute “Inspection of diagnostic system vehicle” before adopting such diagnostic procedure. Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”.
Intermittent fault The intermittent fault may be caused by electrical connecting fault or wiring harness fault. Refer to “Intermittent fault and bad contact test”. Symptoms List Diagnose symptoms with reference to power door lock fault in the symptom diagnosis procedure.
Body system 4-114
Diagnostic information of fault Circuit The driver door unclosed signal Passenger door unclosed signal Left rear door unclosed signal Right rear door unclosed signal Driver door latch ground Left rear door latch ground Passenger car door latches ground Right rear door latches ground 8. The door unclosed fault indicator lamp
ground short circuit 1 1 1 1 — — — —
Open circuit/too-large resistance 1 1 1 1 1 1 1 1
Circuit/system description Body control module receives the discrete input signal from inside ajar switch of driver and passenger door locks. Then such module communicates such state to instrument panel combination (IPC) through serial data information. Instrument panel combination will light up ajar icon of driver information center (DIC) once it receives such serial data information. Door ajar switch provides ground to body control module when opening the door. Door ajar switch will open once the door is closed, and the ground to body control module can be removed. Body control module sends signal to instrument panel combination when opening the door, to light up door ajar indicator. Reference information Reference of schematic diagram Schematic diagram of door lock/indicator Connector End View Reference Part connector end view Description and operation Description and operation of power door Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan Tool Reference Refer to “Control module reference”, to obtain the Scan tool information Circuit/System Verification Turn on the ignition switch, and observe the parameter of “Ajar switch of driver door” from scan tool when opening and closing the driver door. The parameter shall be changed between “Door closed” and “Door not closed”. Circuit/system test 1. Turn off the ignition switch, and disconnect wiring harness connector of B28D driver side door post switch. 2. Turn on the ignition switch, and confirm the parameter of “Ajar switch of driver door” from scan tool as “Door closed”. - In case that it is not specified value, you should test whether ground short circuit occurs to signal circuit terminal 1 of wiring harness connector. In case that the circuit is normal after test, you should replace body control module.
Voltage short circuit — — — — — — — —
Signal performance — — — — — — — —
Units test 1. Turn off the ignition switch, and disconnect wiring harness connector of B28D driver side door post switch. 2. Test whether the resistance between signal terminal 1 and ground is infinite under the condition on turning on the switch. - In case that it is not specified value, you should replace B28D driver side door post switch. 3. Test whether the resistance between signal terminal 1 and ground is less than 10Ω under the condition on turning off the ignition switch. - In case that it is not specified value, you should replace B28D driver side door post switch. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Replacement of door post switch at front side Refer to “control module reference”, so as to replace, set up and program body control module
Body system 4-115
4.7.3.3 Door lock failure Diagnostic description Execute “Inspection of diagnostic system vehicle” before adopting such diagnostic procedure. Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Diagnostic information of faults Circuit/system description The signal circuit of outside door lock switch at the driver side provides the input signal to remote door lock receiver when enabling the outside handle switch of left front door. This input will ask remote door lock receiver to detect the door lock request once exiting from vehicle. Remote door lock receiver provides the door lock switch at the driver side with voltage through the signal circuit of door lock switch signal at the driver side. The switch closes when enabling the door lock at the driver side, and the voltage signal from remote door lock receiver is connected to ground. Reference information Reference of schematic diagram Schematic diagram of door lock / indicator Connector End View Reference Part connector end view Description and Operation Description and operation of power door lock Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan Tool Reference Refer to “control module reference”, to obtain the Scan tool information Circuit/System Verification Turn on the ignition switch, open the door at the driver side by key, meanwhile, observe the parameter of “Key cylinder unlocking switch for door at the driver side” from scan tool body control module. The parameter shall be changed between “Start” and “Not start”. Circuit/system test 1. Turn off the ignition switch, disconnect wiring harness connector of S13D door lock switch, and test whether the resistance between door lock switch ground circuit termina 2 at driver side and ground is less than 10Ω. - If it exceeds the specified range, you should test whether the open circuit occurs to ground circuit / the resistance is too large. Replace door lock switch at the driver side in case that it is normal after test. 2. Connect a test lamp between door lock switch signal circuit terminal 3 of driver side door and ground. 3. The test lamp shall light up when turning on the ignition switch. - In case that the test lamp doesn’t light up, you
should test whether open circuit occurs to signal circuit of door lock switch at the driver side / the resistance is too large. If it it normal after test, you should replace K9 body control module. Units test Static test 1. Turn off the ignition switch and disconnect the wiring harness connector of door lock switch at driver side. 2. Test whether the resistance between signal circuit terminal 3 and ground circuit terminal 2 is less than 10Ω under the condition of inserting the key. - In case of being larger than the specified scope, you should replace the door lock switch at the drive side. 3. Test whether the resistance between signal circuit terminal 3 and ground circuit terminal 2 is infinite under the condition of failing to insert the key. － In case of being larger than the specified scope, replace the door lock switch at the drive side. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Replacement of door lock switch of front side door Refer to “control module reference”, so as to replace, set up and program body control module
Body system 4-116
4.7.4 Service Instruction 4.7.4.1 Replacement of front side door inside handle
15AJ0405001
Replacement of front side door inside handle Figure No.
Part Name
Preparation procedure Remove the front side door trim panel. See "Replacement of front side door trim panel."
1 2
Mounting screws for front side door handle (quantity: 1) Warning: Refer to “Warning on relevant tightening”. Tightening torque 1.5±0.5 N. m Front side door inside handle
Body system 4-117
4.7.4.2 Replacement of front side door outside handle
15AJ0405002
Replacement of front side door outside handle Figure No.
Names of parts
Preparation procedure 1. Remove the front door trim. See "Replacement of front side door trim panel." 2. Remove the front door waterproofing membrane. See " Replacement of front door waterproof film". 1 Manhole plug screw Mounting screws for front side door outside handle door (quantity: 2) Warning: Refer to “Warning on relevant tightening”. 2 Tightening torque 4.5±0.5 N. m Key cylinder for front side door outside handle 3 4
Key cylinder cover for front side door outside handle
5
Cover gasket for front side door outside handle
6
front side door outside handle
Body system 4-118
4.7.4.3 Replacement of rear side door inside handle
15AJ0405003
Figure No.
Replacement of rear side door inside handle Part Name
Preparation procedure Remove the rear door trim. See " Replacement of rear side door trim panel."
1 2
Mounting screw for rear side door inside handle (quantity: 1) Warning: Refer to “Warning on relevant tightening”. Tightening torque 1.5±0.5 N. m rear side door inside handle
Body system 4-119
4.7.4.4 Replacement of rear side door outside handle
15AJ0405004 Replacement of rear side door outside handle Figure No. Part Name Preparation procedure Remove the rear door trim. See "Replacement of rear side door trim panel." Remove the rear side door waterproofing membrane. See " Replacement of the rear side door waterproof film." Remove the rear door. See " Replacement of the rear door lock". Mounting screws for rear side door outside handle (quantity: 2) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 4.5±0.5 N. m 2 Cover gasket for rear side door outside handle 3
Cover of rear side door outside handle
4
rear side door outside handle
Body system 4-120
4.7.4.5 Replacement of front side door latch central lock
14BT0405001
Figure No.
Replacement of front side door latch central lock Part Name
Preparation procedure Remove the front door trim. See "Replacament of Front door trim panel". Remove the front side door waterproofing membrane. See "Replacament of front door waterproof film". 1 Front side door latch central lock screws (quantity: 3） Warning: Refer to “Warning on relevant tightening”. Tightening torque 9±1.5 N. m 2 Front side door latch central lock
Body system 4-121
4.7.4.6 Replacement of front side door key cylinder rod
15AJ0405005 Replacement of front side door key cylinder rod Figure No. Part Name Preparation procedure Remove the front door trim. See "Replacament of Front door trim panel". Remove the front side door waterproofing membrane. See "Replacament of front door waterproof film". 1 front side door key cylinder rod 2
Clamp for front side door key cylinder rod
Body system 4-122
4.7.4.7 Replacement of front side door open handle
15AJ0405006
Figure No.
Replacement of front side door open handle Part Name
Preparation procedure Remove the front door trim. See "Replacament of Front door trim panel". Remove the front side door waterproofing membrane. See "Replacament of front door waterproof film". Clamp of front side door open handle 1 Procedure Open the clamp from threaded rod of connecting lock and outside handle by use pry instrument tool 2 front side door open handle 3 Connector
Body system 4-123
4.7.4.8 Adjustment of front side door open handle
15AJ0405007
Adjustment of front side door open handle Figure No.
Part Name
Preparation procedure 1. Remove the front door trim. See "Replacament of Front door trim panel". 2. Remove the front side door waterproofing membrane. See "Replacament of front door waterproof film". Clamp of front side door open handle 1 Procedure Open the clamp from threaded rod of connecting lock and outside handle by use pry instrument tool front side door open handle rod 2 Procedure 1. Place open handle (2) of front side door into clamp (1), to eliminate any clearance in door outside handle. 2. Adjust the handle stroke through moving threaded rod among the rods. 3. Close clamp cover next to open handle threaded rod of door 4. Inspect whether door lock system runs normally. 3 Connector
Body system 4-124
4.7.4.9 Replacement of front side door interlocking and inside open handle
15AJ0405008
Replacement of front side door interlocking and inside open handle Figure No. Part Name Preparation procedure Remove the front door trim. See "Replacament of Front door trim panel". Remove the front side door waterproofing membrane. See "Replacament of front door waterproof film". 1 Front side door interlock and inside open handle 2
Clamp for front side open door handle
Body system 4-125
4.7.4.10 Replacement of rear side door latch central lock
14BT0405014
Replacement of rear side door latch central locking Figure No. Part Name Preparation procedure 1. Remove the rear door trim. See "Replacament of rear door trim panel". 2. Remove the rear side door waterproofing membrane. See "Replacament of rear door waterproof film". 1 Rear side door latch central locking screw (quantity: 3） Warning: Refer to “Warning on relevant tightening”. Tightening torque 9±1.5 N. m 2 Rear side door latch central locking
Body system 4-126
4.7.4.11 Replacement of rear side door open handle
15AJ0405009
Replacement of rear side door open handle Figure No.
Part Name
Preparation procedure Remove the rear door trim. See "Replacament of rear door trim panel". Remove the rear side door waterproofing membrane. See "Replacament of rear door waterproof film". Clamp of rear side door open handle Procedure 1 Open the clamp from threaded rod of connecting lock and outside handle by use pry instrument tool Rear side door open handle rod 2
Body system 4-127
4.7.4.12 Adjustment of rear side door open handle
15AJ0405010
Adjustment of rear side door open handle Figure No. Part Name Preparation procedure Remove the rear door trim. See "Replacament of rear door trim panel". Remove the rear side door waterproofing membrane. See "Replacament of rear door waterproof film". Clamp of rear side door open handle Procedure 1 Open the clamp from threaded rod of connecting lock and outside handle by use pry instrument tool Rear side door open handle rod Procedure Place open handle (2) of front side door into clamp (1), to eliminate any 2 clearance in door outside handle. Adjust the handle stroke through moving threaded rod among the rods. Close clamp cover next to open handle threaded rod of door Inspect whether door lock system runs normally.
Body system 4-128
4.7.4.13 Replacement of rear side door interlocking and inside open handle door
15AJ0405011
Replacement of rear side door interlocking and inside open handle door Figure No. Part Name Preparation procedure Remove the rear door trim. See "Replacament of rear door trim panel". Remove the rear side door waterproofing membrane. See "Replacament of rear door waterproof film". 1 Rear side door interlock and inside open handle 2
Clamp for rear side open door handle
Body system 4-129
4.7.4.14 Replacement of tailgate lock
15AJ0405012
Replacement of tailgate lock Figure No. Part Name Preparation procedure 1. Remove the upper door window frame trim panel. See "Replacement of the window frame trim on the tail door". 2. Remove the left side door window frame trim. See "Replacement of the window frame trim on the rear door". 3. Remove the right side door window frame trim. See "Replacement of the window frame trim on the rear door". 4. Remove the tailgate trim. See "Replacement of the tailgate trim". Tailgate lock screw (quantity: 2） Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 22±3 N. m 2 Tailgate lock 3
Tailgate lock cover
Body system 4-130
4.7.4.15 Replacement of front side door lock
14BT0405022
Replacement of front side door lock Figure No.
Part Name
1
Front side door lock screw (quantity: 2) Warning: Refer to “Warning on relevant tightening”. Tightening torque 25±5 N. m If necessary, the amount of color with the role of marking the paint applied to the lock around the car body, to ensure that leave the mark to facilitate the replacement of the door after the adjustment. Front side door lock
2
Body system 4-131
4.7.4.16 Replacement of rear side door lock
14BT0405023
Replacement of rear side door lock Figure No.
1
2
Part Name Rear side door lock screw (quantity: 2) Warning: Refer to “Warning on relevant tightening”. Tightening torque 25±5 N. m If necessary, the amount of color with the role of marking the paint applied to the lock around the car body, to ensure that leave the mark to facilitate the replacement of the door after the adjustment. Rear side door lock
Body system 4-132
4.7.4.17 Replacement of tailgate lock
14BT0405024
Replacement of tailgate lock Figure No.
1
2
Part Name Tailgate lock screw (quantity: 2) Warning: Refer to “Warning on relevant tightening”. Tightening torque 25±5 N. m If necessary, the amount of color with the role of marking the paint applied to the lock around the car body, to ensure that leave the mark to facilitate the replacement of the door after the adjustment. Tailgate lock
Body system 4-133
4.7.5 Description and operation 4.7.5.1 Description and operation of door unclosed indicator Door unclosed Indicator system component Door ajar indicator system consists of the following units: Body control module Instrument cluster Door lamp switch at driver side Door lamp switch at passenger side Door lamp switch at left rear side Door lamp switch at right rear side Door unclosed Instrument cluster receives one discrete input signal respectively from each door ajar switch, to indicate the door state. Instrument cluster lights up the corresponding door ajar indicator according to the received CAN bus information when the speed is larger than 8km/h (5km/h), and enables door unclosed audio warning.
4.7.5.2 Description and operation of tailgate Units of tailgate release system They include the following units: Body control module Turn on switch of tailgate Trunk cover release actuator Trunk cover release relay Release operation of tailgate The signal circuit of trunk cover release switch is connected to ground when pressing outside release switch of trunk cover. Body control module makes response, and supplied the battery voltage to trunk cover release motor, so as to make trunk cover released. The outside release switch of trunk cover is permanently grounded through mounting body ground. Require that the effective remote door lock transmitter is located within the distance 30m away from the vehicle when opening the tailgate by it. This makes access communication free of key possible between remote receiver (integrated in BCM) and remote door lock transmitter. Refer to “Description and operation of remote door lock system” for detailed information of remote door lock.
4.7.5.3 Description and operation of power door latch Units of power door latch system The power door latch system includes the following units: Remote door lock receiver (in case of device) Body control module (in case of device)
Latch of driver door Latch of passenger door Latch of left rear door Latch of right rear door Latch of tailgate Door handle assembly Control of power door latch system For power door latch system, its control depends on the door lock state. In case that the state of door lock system is unlocking, then power door latch will be released after lifting door outside handle. In case that the state of door lock system is locking, then one of following signal needs to be input before releasing the latch: Start of door unlocking switch Unlocking order of remote door lock (high configuration) Remote door lock receiver receives unlocking order information of passive remote door lock (high configuration) Power door latch will be released after lifting outside door handle according to any above signal received. Refer to “Description and operation of power latch” for detailed information on state of power latch. Refer to “Description and operation of remote door lock system” for detailed information of active and passive remote door lock system. Unlocking operation of power door latch The ground signal of switch is transmitted to remote latch receiver through signal circuit of door handle switch when lifting any door outside handle. Remote latch receiver will inspect the door lock state of above-mentioned system according to such input signal received. Once meeting the start standard, remote door lock receiver will provide power supply and ground to the control circuit of door latch, and the door will be released.
4.7.5.4 Description and operation of power door lock Units of door lock system The power door lock system includes the following units: Door lock switch Body control module Latch of driver door Latch of passenger door Latch of left rear door Latch of right rear door Control device for door lock system Power door lock system can be controlled by one of the following conditions: Start the power door lock switch Locking or unlocking order for remote door lock Execute to unlock the door key cylinder switch Delayed locking order Locking order for automatic door
Body system 4-134 Locking and unlocking operation of door Body control module will receive a ground signal from locking or unlocking signal circuit of door lock switch when such switch is turned on in the position of locking or unlocking. Once body control module receives locking or unlocking signal for door lock switch, the battery voltage will be provided to locking or unlocking control circuit of door lock actuator. As the opposite side of door lock actuator is connected to ground through control circuit of other door lock actuator, the door will be locked or unlocked according to order. Three circuits below are used for operating door lock: Unlocking of driver door Unlocking of passenger door Locking of all doors The actuator for driver door is isolated, and remote door lock transmitter can be used for self-unlocking.
Body system 4-135
4.8
Wiper and washer
4.8.1 Specification 4.8.1.1 Tightening torque specification tightening torque specification Application Windshield washer fluid reservoir mounting screws Windshield wiper arm mounting nut Windshield wiper motor mounting screws Windshield wiper linkage mounting nut Rear windshield wiper arm retaining nut Rear windshield wiper motor mounting screws Windshield washer fluid reservoir filler neck screws
Specification (N. m) Metric 7±1 N. m 18±2 N. m 7±1 N. m 9±1 N. m 7±1 N. m 7±1 N. m 4±0.5 N. m
Body system 4-136
4.6
Wiper and washer
4.8.2 Schematic diagram and wiring diagram 4.8.2.1 Schematic diagram of wiper/washer
KR7 rear wiper relay
X51 A fuse bloc k– instr ume nt pane l
X50 A fuse bloc k– und er hoo d
Schematic diagram of wiper and washer (wiper switch and rear wiper)
S82 windshield wiper/washe r switch
K9 body control module assem bly
KR7 rear wiper relay
Relay for KR12 B winds hield wiper
M75 windshiel d wiper motor
Speed control relay for KR12C windshield wiper
X50A fuse block – under hood
G24 windshiel d washer pump
K9 bod y con trol mo dul e ass em bly
Body system 4-137 Schematic diagram of wiper and washer (front wiper and washer)
Body system 4-138
4.8.3 Diagnostic information and procedure 4.8.3.1 DTC B110912 B110913 Diagnostic description Execute “Inspection of diagnostic system vehicle” before adopting such diagnostic procedure. Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of fault diagnostic code DTC B110912：Front wiper low-speed relay is shorted to the power supply DTC B110913：Front wiper low-speed relay open Conditions for running fault diagnostic code B110912 When low-speed relay for front wiper doesn’t work B110913 Low-speed relay for front wiper doesn’t work Conditions for setting up fault diagnostic code DTC will be recorded once fault is detected Operation adopted when setting up the fault diagnostic code For low-speed drive of front wiper, its output is closed Record DTC Condition for clearing fault diagnostic code The historical fault diagnostic code will be cleared after cycling fault-free ignition for 5 times. Body control module receives an order on clearing fault code sent by the diagnostic tool. Reference information Reference of schematic diagram Schematic diagram of front wiper Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test the intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “control module reference”, to obtain the Scan tool information Circuit/System Verification Turn the ignition switch to ON position and perform the test of front wiper low-speed relay, and the front wiper shall work/ not work. Circuit/system test 1. Turn the ignition switch to OFF position, and disconnect the fuse block under hood 2. Confirm that the test lamp between the fuse block terminal (front wiper relay) under hood and ground lights up. In case that the test lamp does not light up, test whether ground short circuit or open circuit occurs
to B+ circuit / the resistance is too large. In case that the circuit is normal after test, conduct test or replacement 3. Connect a test lamp between B+ and fuse block circuit terminal (front wiper low-speed relay) under hood. 4. Turn the ignition switch to ON position and perform the test of front wiper low-speed relay. The test lamp shall light up and go out when switching among the order state. In case that the test lamp always lights up, test whether ground short circuit occurs to the control circuit. In case that the circuit is normal after test, replace body control module. In case that the test lamp always lights up, test whether voltage short circuit or open circuit occurs to the control circuit / the resistance is too large. In case that the circuit is normal after test, replace body control module.. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished.
Refer to “control module reference”, so as to replace, set up or program the control module.
Body system 4-139
4.6.3.2 DTC B110C12 B110C13 Diagnostic description Execute “Inspection of diagnostic system vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of fault diagnostic code DTC B110C12: Front wiper high-speed relay is short-circuited to the power supply DTC B110C13: Front wiper high-speed relay open Conditions for running fault diagnostic code B110C12 When high-speed relay for front wiper doesn’t work B110C13 When high-speed relay for front wiper doesn’t work Conditions for setting up fault diagnostic code DTC will be recorded once fault is detected Operation adopted when setting up the fault diagnostic code For high-speed drive of front wiper, its output is closed Record DTC Condition for clearing fault diagnostic code The historical fault diagnostic code will be cleared after cycling fault-free ignition for 5 times. Body control module receives an order on clearing fault code sent by the diagnostic tool. Reference information Reference of schematic diagram Schematic diagram of front wiper Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test the intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “control module reference”, to obtain the Scan tool information Circuit/System Verification Turn the ignition switch to ON position and perform the test of front wiper high-speed relay, and the front wiper shall work/ not work. Circuit/system test 1. Turn the ignition switch to OFF position and disconnect the fuse block under hood. 2. Confirm that the test lamp between the fuse block terminal (front wiper high-speed relay) under hood and ground lights up. In case that the test lamp lights up, test whether ground short circuit or open circuit occurs to B+ circuit / the resistance is too large. In case that the circuit is normal after test, conduct test or replacement 3. Connect a test lamp between B+ and fuse block
circuit terminal (front wiper high-speed relay) under hood. 4. Turn the ignition switch to ON position and perform the test of front wiper high-speed relay. The test lamp shall light up and go out when switching among the order state. In case that the test lamp always lights up, test whether ground short circuit occurs to the control circuit. In case that the circuit is normal after test, replace body control module. In case that the test lamp always goes out, test whether voltage short circuit or open circuit occurs to the control circuit / the resistance is too large. In case that the circuit is normal after test, replace body control module. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “control module reference”, so as to replace, set up or program the control module.
Body system 4-140
4.8.3.2 DTC B111413 B111412 Diagnostic description Execute “Inspection of diagnostic system vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of fault diagnostic code DTC B111413: Rear wiper relay open DTC B111412: Rear wiper relay is shorted to the power supply Conditions for running fault diagnostic code When the rear wiper relay does not work Conditions for setting up fault diagnostic code DTC will be recorded once fault is detected Operation adopted when setting up the fault diagnostic code Rear wiper output is off Record DTC Condition for clearing fault diagnostic code The historical fault diagnostic code will be cleared after cycling fault-free ignition for 5 times. Body control module receives an order on clearing fault code sent by the diagnostic tool Reference information Reference of schematic diagram Schematic diagram of rear wiper Connector End View Reference “Part connector end view” Description and operation Description and operation of data link communication Electrical Information Reference Circuit test Repair of connector Test the intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “control module reference”, to obtain the Scan tool information Circuit/System Verification Turn the ignition switch to ON position and perform the test of rear wiper relay, and the rear wiper shall work/ not work. Circuit/system test 1. Turn the ignition switch to OFF position and disconnect the fuse block under hood. 2. Confirm that the test lamp between the fuse block terminal (rear wiper relay) under hood and ground lights up. In case that the test lamp lights up, test whether ground short circuit or open circuit occurs to B+ circuit / the resistance is too large. In case that the circuit is normal after test, conduct test or replacement 3. Connect a test lamp between B+ and fuse block circuit terminal (rear wiper relay) under hood. 4. Turn the ignition switch to ON position and perform the test of front wiper high-speed relay. The test lamp shall light up and go out when switching
among the order state. In case that the test lamp always lights up, test whether ground short circuit occurs to the control circuit. In case that the circuit is normal after test, replace body control module. In case that the test lamp always goes out, test whether voltage short circuit or open circuit occurs to the control circuit / the resistance is too large. In case that the circuit is normal after test, replace body control module. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “control module reference”, so as to replace, set up or program the control module. -
Body system 4-141
4.8.3.3 Faults of windshield wiper system Diagnostic description Execute “Inspection of diagnostic system vehicle” before adopting such diagnostic procedure. Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method.
Get overview of each diagnostic category from “Description of diagnostic procedure”.
Diagnostic information of fault
Circuit
ground short circuit
Open circuit/too-large resistance
Voltage short circuit
Signal performance
Windshield wiper switch low signal Windshield wiper switch high signal Windshield wiper motor stop switch signal Windshield wiper relay control Windshield wiper motor low speed control Windshield wiper switch Low level reference voltage
1 4 3 4 1
1 2 3 DTC B110C13 2
1 2 — DTC B110C12 4
— — — — —
—
1,2
1,2
—
Windshield Wipers Motor Ground
—
1,2,3
—
—
Delay or low speed wipers malfunction High-speed wiper malfunction The wiper can’t stop The wiper is always running
Body system 4-142
Circuit/system description Body control module controls the wiper motor according to input signal from windshield wiper/washer switch. Body control module monitors wiper/washer switch through two independent signal circuits and one ground circuit. The high-speed signal circuit for windshield wiper switch is used to confirm high-speed running of wiper, the low-speed signal circuit for windshield wiper switch is used to confirm low-speed operation, and the signal circuit for windshield washer switch is used to confirm running of washer. Reference information Reference of schematic diagram Schematic diagram of wiper/washer Connector End View Reference Part connector end view Description and operation Description and operation of wiper/washer system Electrical Information Reference Circuit test Repair of connector Test the intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “control module reference”, to obtain the Scan tool information Circuit/system test 1. S82 window wiper/washer switch is placed in a low-speed position, confirm the windshield wiper cycles in a low-speed position. 2. S82 windshield wiper/washer switch is placed in a high-speed position, confirm the windshield wiper cycles in a high-speed position. 3. S82 windshield wiper/washer switch is placed in a the Intermittent position, confirm the wiper cycles in the delay position. Circuit/system test 1. Turn the ignition switch to OFF position, and disconnect M75 front wiper motor. 2. Test whether the resistance between ground circuit terminal 4 and ground is lower than 10Ω. － In case of being larger than the specified scope, test whether open circuit occurs to the ground circuit / the resistance is too large. 3. Turn the ignition switch to ON position, and confirm that the test lamp between signal circuit terminal 5 and ground lights up when S82 switch is in the LOW position. － In case that the test lamp does not light up, test or replace fuse F22UA under hood. 4. Turn the ignition switch to ON position, and confirm that the test lamp between signal circuit terminal 6 and ground lights up when S82 switch is in the HIGH position. － In case that the test lamp does not light up, test or replace fuse F22UA under hood. 5. In case that all circuits are normal after test, replace M75 wiper motor. Units test Windshield wiper/washer switch
1.
Disconnect wiring harness connector of S82 window wiper/washer switch. 2. S82 windshield wiper/washer switch is placed in a high-speed position, test whether the resistance between the signal terminals 3 and 9 is less than 2Ω. － In case of being larger than the specified value, replace S82 windshield wiper/washer switch. 3. Turn S82 windshield wiper/washer switch to interim position, and test whether the resistance between signal terminals 3 and 7 is lower than 2Ω. － In case of being larger than the specified value, replace S82 windshield wiper/washer switch. 4. Turn S82 windshield wiper/washer switch to low-speed position, and test whether the resistance between signal terminals 3 and 5 is lower than 2Ω. － In case of being larger than the specified value, replace S82 windshield wiper/washer switch. Windshield wiper motor 1. Turn the ignition switch to OFF position, and disconnect wiring harness connector of M75 windshield wiper motor. 2. Install a jumper wire with 25A fuse between control terminal 5 and 12V voltage. Install a jumper wire between ground terminal 4 and ground. 3. Confirm that M75 windshield wiper motor is running under low-speed mode. － In case that M75 windshield wiper motor is not running under low-speed mode, replace M75 windshield wiper motor. 4. Install a jumper wire with 25A fuse between control terminal 6 and 12V voltage. Install a jumper wire between ground terminal 4 and ground. 5. Confirm that M75 windshield wiper motor is running under high-speed mode. － In case that M75 windshield wiper motor is not running under high-speed mode, replace M75 windshield wiper motor. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Replacement of windshield wiper motor Relay replacement Replacement of switch for windshield wiper and washer Refer to “control module reference”, so as to replace, set up and programme body control module.
Body system 4-143
4.8.3.4 Washer fault Diagnostic description Execute “Inspection of diagnostic system vehicle” before adopting such diagnostic procedure. Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Diagnostic information of fault ground short circuit
Open circuit/too-large resistance
Voltage short circuit
Signal performance
Windshield washer switch signal
2
1
1
—
Windshield washer solvent pump control
1
1
2
—
Windshield washer solvent pump ground
—
1
—
—
Rear window washer switch signal
4
3
3
—
Rear window washer solvent pump control
3
3
4
—
Rear window washer solvent pump ground
—
1,2
—
—
Circuit
1. 2. 3. 4.
Windshield washer malfunction Windshield washer always runs Rear window washer malfunction Rear window washer always runs
Body system 4-144 Circuit/system description S82 windshield wiper/washer switch signal controls the windshield washer solvent pump and rear washer solvent pump. Body control module monitors the washer switch via S82 switch signal circuit. When the washer switch is closed, body control module will provide battery voltage to the washer pump for its operation. Reference information Reference of schematic diagram Schematic diagram of wiper/washer Connector End View Reference Part connector end view Description and operation Description and operation of wiper/washer system Electrical Information Reference Circuit test Repair of connector Test the intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “control module reference”, to obtain the Scan tool information Circuit/system test Turn the ignition switch to ON position. 1. Use S82 windshield wiper/washer switch to operate the windshield washer. Confirm G24 windshield washer solvent pump starts. － If the G24 windshield washer solvent pump has not been started, refer to “Washer solvent pump failures”. 2. Use S82 windshield wiper/washer switch to operate the rear window washer. Confirm G19 rear window washer solvent pump starts. － If G19 rear window washer solvent pump fails to start, refer to “Washer solvent pump faults”. Circuit/system test 6. Turn the ignition switch to OFF position, and disconnect M75 front wiper motor. 7. Test whether the resistance between ground circuit terminal 4 and ground is lower than 10Ω. － In case of being larger than the specified scope, test whether open circuit occurs to the ground circuit / the resistance is too large. 8. Turn the ignition switch to ON position, and confirm that the test lamp between signal circuit terminal 5 and ground lights up when S82 switch is in the LOW position. － In case that the test lamp does not light up, test or replace fuse F22UA under hood. 9. Turn the ignition switch to ON position, and confirm that the test lamp between signal circuit terminal 6 and ground light up when S82 switch is in the HIGH position. － In case that the test lamp does not light up, test or replace fuse F22UA under hood. 10. In case that all circuits is normal after test, replace M75 wiper motor.
Units test Windshield wiper/washer switch 5. Disconnect wiring harness connector of S82 window wiper/washer switch. 6. S82 windshield wiper/washer switch is placed in a high-speed position, test whether the resistance between signal terminals 3 and 9 is less than 2Ω. － In case of being larger than the specified value, replace S82 windshield wiper/washer switch. 7. Turn the S82 windshield wiper/washer switch to intermittent position, and test whether the resistance between signal terminals 3 and 7 is lower than 2Ω. － In case of being larger than the specified value, replace S82 windshield wiper/washer switch. 8. Turn S82 windshield wiper/washer switch to a low-speed position, and test whether the resistance between signal terminals 3 and 5 is lower than 2Ω. － In case of being larger than the specified value, replace S82 windshield wiper/washer switch. Windshield wiper motor 6. Turn the ignition switch to OFF position, and disconnect wiring harness connector of M75 windshield wiper motor. 7. Install a jumper wire with 25A fuse between control terminal 5 and 12V voltage. Install a jumper wire between ground terminal 4 and ground. 8. Confirm that M75 windshield wiper motor is running under a low-speed mode. － In case that M75 windshield wiper motor is not running under a low-speed mode, replace M75 windshield wiper motor. 9. Install a jumper wire with 25A fuse between control terminal 6 and 12V voltage. Install a jumper wire between ground terminal 4 and ground. 10. Confirm that M75 windshield wiper motor is running under a high-speed mode. － In case that M75 windshield wiper motor is not running under a high-speed mode, replace M75 windshield wiper motor. Service Instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Replacement of windshield wiper motor Relay replacement Replacement of switches for windshield wiper and washer Refer to “Control module reference”, so as to replace, set up and program body control module
Body system 4-145
4.8.4 Service Instruction 4.8.4.1 Replacement of windshield washer nozzle hose
15AJ0406001
Replacement of windshield washer nozzle hose Figure No. Part Name Preparation procedure 1. Open the hood. 2. Removing the engine hatch isolation pads. See "Engine compartment cover vibration isolator replacement". 3. Remove the right front wheel cover gasket. See "Front Wheel Cover Replacement". 1 Windshield washer nozzle 2 3
Windshield Washer Nozzle Hose Clamp (Quantity: 9) Windshield Washer Nozzle Hose Procedure Disconnect from the nozzle
Body system 4-146
4.8.4.2 Replacement of windshield washer nozzle
12a0406002
Replacement of windshield washer nozzle Figure No. Part Name Preparation procedure Open the hood. Removing the engine hatch isolation pads. See "Engine compartment cover vibration isolator replacement". Disconnect the windshield washer nozzle and hose connection. 1 Windshield washer nozzle
Body system 4-147
4.8.4.3 Replacement of windshield washer reservoir filler neck
15AJ0406002
Replacement of windshield washer reservoir filler neck Figure No. 1
2
Part Name Windshield washer fluid reservoir filler neck screws quantity:1) Warning: Refer to “Warning on relevant tightening”. Tightening torque 4±0.5 N. m Windshield washer fluid reservoir filler pipe Procedure Disconnect the filler pipe from the reservoir
Body system 4-148
4.8.4.4 Replacement of windshield washer fluid reservoir
15AJ0406003
Replacement of windshield washer fluid reservoir Figure No. Part Name Preparation procedure 1. Remove the front bumper fascia. Refer to “Replacement of front bumper fascia”. 2. Remove the washing fluid reservoir filler neck. See "wash fluid reservoir filler pipe replacement." 3. Disconnect the windshield washer fluid reservoir water. Windshield washer fluid reservoir mounting screws (Quantity:4) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 7±1 N. m 2 Windshield washer fluid reservoir
Body system 4-149
4.8.4.5 Replacement of windshield washer pump
15AJ0406004
Replacement of windshield washer pump Figure No.
Part Name
Preparation procedure Remove the front bumper cover assembly. Refer to “Replacement of front bumper cover assembly”. 1
Windshield washer pump
2
Seal ring of windshield washer pump
Body system 4-150
4.8.4.6 Replacement of air inlet grille
14BT0406005
Replacement of air inlet grille Figure No.
Part Name
Preparation procedure open the hood 1 2 3
Windshield wiper arm mounting nut cover (quantity:6) Windshield wiper arm retaining nut (Qty: 2) Warning: Refer to “Warning on relevant tightening”. Tightening torque 18±2 N. m Windshield wiper arm
Body system 4-151
4.8.4.7 Replacement of front windshield wiper arm
15AJ0406005
Replacement of front windshield wiper motor Figure No. Part Name Preparation procedure 1. Disconnect the battery negative line. See "Battery Disconnection and Connection". 2. Remove the upper mounting plate trim assembly. See "Replacing the upper mounting plate trim assembly". Mounting screws for windshield wiper motor (quantity: 3) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 7±1 N. m Windshield wiper motor 2 Procedure Pull out the wiper motor from the connecting rod
Body system 4-152
4.8.4.8 Replacement of front windshield wiper motor and gear lever
14BT0406006
Replacement of front windshield wiper arm Figure No. Part Name Preparation procedure 1. Remove the windshield wiper arm. See "Windshield wiper arm replacement". 2. Remove the upper mounting plate trim assembly. See "Replacing the upper mounting plate trim assembly". Windshield wiper connecting rod mounting nut (Qty: 4) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 9 ± 1 N. m 2 Windshield wiper connecting rod)
Body system 4-153
4.8.4.9 Replacement of combination switch wiper and washer
12a0406001
Replacement of combination switch wiper and washer Figure No.
Part Name
Preparation procedure 1. Disconnect the battery negative line. See "Battery Disconnection and Connection". 2. Remove the steering column upper trim cover. Refer to “Replacement of steering column upper trim cover”. 3. Remove the steering column lower trim cover. Refer to “Replacement of steering column lower trim cover”.
combination switch wiper and washer 1
Procedure Disconnect the electrical connector.
Body system 4-154
4.8.4.10 Replacement of rear windshield wiper arm
14BT0406007
Replacement of windshield wiper arm Figure No. 1 2
3
Part Name Rear windshield wiper arm cover Mounting nut for rear windshield wiper arm (quantity: 1) Warning: Refer to “Warning on relevant tightening”. Tightening torque 7±1 N. m Windshield wiper arm
Body system 4-155
4.8.4.11 Replacement of rear windshield wiper motor
14BT0406008
Replacement of rear windshield wiper motor Figure No. Part Name Preparation procedure 1. Disconnect the battery negative line. See "Battery Disconnection and Connection". 2. Remove the rear windshield wiper arm. See "Replacing the rear windshield wiper arm". 3. Remove the tailgate trim. See "Replacement of the tailgate trim." Mounting screws for rear windshield wiper motor (quantity: 3) Warning: Refer to “Warning on relevant tightening”. 1 Tightening torque 7±1 N. m 2 Rear windshield wiper motor
Body system 4-156
4.8.4.12 Replacement of rear windshield wiper blade
15AJ0406006
Replacement of rear windshield wiper blade Figure No.
Part Name
1
Rear windshield wiper blade Procedure 1. Lift the wiper arm, turn the blade to a right angle to separate it.
Body system 4-157
4.8.4.13 Replacement of front windshield wiper blade (boneless wiper)
14BT0406009
Replacement of front windshield wiper blade (boneless wiper) Figure No.
1
Part Name Front windshield wiper blade Procedure Lift the wiper arm, turn the blade to a right angle, Press down the clips at the same time, along the direction of the wiper arm, wiper blade down exit Check the degree of fit between the wiper strip and the windshield.
Body system 4-158
4.8.4.14 Replacement of front windshield wiper strips (boned wiper) Disassembly procedure 1. Turn the wiper arm over. 2. Lever the mounting end of the strip, extract the wiper strip from the bracket. Installation procedure 1. Put the strip in the wiper strip bracket along the groove. 2. Put down the wiper arm. Check the fit degree of the wiper strip and windshield. 13AH-0802004
4.8.4.15 Replacement Front windshield wipers wiper (bone wiper) Disassembly procedure 1. Turn the wiper arm over, and turn the wiper blade to a right angle. 2. At the same time of pressing the clamping piece, remove the wiper blade along the wiper arm. 3. Remove the wiper strip bracket.
13AH-0802005
Installation procedure 1. Put the wiper blade into the wiper arm hook and insert a clip into it. 2. Put down the wiper arm. 3. Check the fit degree of the wiper strip and windshield.
Body system 4-159
4.8.5 Description and operation 4.8.5.1 Description and operation of wiper/ washer system Units for wiper/ washer system Wiper/ washer system is composed of the following electrical units: Windshield wiper relay Windshield washer solvent pump relay Windshield washer solvent pump Windshield wiper motor Windshield wiper/washer switch Body control module Front windshield wiper system There is a self-stop device in the front windshield wiper circuit, which is composed of a gear on worm and a cam disc for the purpose of temporarily maintaining a complete circuit in case of switch off. Wiper system is driven by a permanent magnet motor. Front windshield wiper motor is installed on the dash panel, directly connecting to the front windshield wiper connecting rod. There are two gears for the front windshield wiper motor speed with intermittent operation. Wiper switch is a constituent part of the wiper/washer switch. Front windshield wiper is operated by the control rod at the right side of the steering column. Front windshield washer system Front windshield washer system is composed of washer solvent reservoir, washer solvent pump, hose, nozzle and wiper/ washer switch. Front windshield washer solvent reservoir is installed on the rear of the left front wheel tank mud flap. A washer solvent pump is connected to washer solvent reservoir, the pump makes the washer solvent pass through the hose and transport to the two nozzles installed on the hood. Washer switch is a constituent part of the wiper/washer switch. Front windshield washer is operated by the control rod at the right side of the steering column. Rear windshield wiper system The rear windshield wiper is directly controlled by wiper/washer switch. For the vehicles equipped with rear window wiper, the body control module decides the operating mode of the rear window wiper/washer system by monitoring the multiplexed output of the rear window wiper/washer switch.
Rear window wiper /washer switch Use the reference ground signal received from BCM. The body control module provides switch battery pull-up voltage for the received output signal of rear window wiper/washer switch. When the rear window wiper switch provides an access to the reference ground signal, all input signals of body control module are regarded as start. By monitoring the voltage, the body control module decides how to control the rear window wiper motor relay and rear window washer relay. When the body control module starts the output and provides battery voltage to the relay coil, the relay
powers on to allow the battery voltage to pass through the rear window wiper relay’s switch contact, and the fuse is to provide the control input to the rear window wiper motor. And then the motor will continuous operating at low speed. The stop of rear window wiper motor is automatic and is not under the control of body control module. When body control module stops its output, rear window wiper motor relay switch contact is reconnected to the ground, the wiper will conduct dynamic braking. Internal stop switch and circuit of rear window wiper will maintain the operation of motor until the wiper arm returns to the stop position. Rear and front windshield washer system The rear windshield wiper is directly controlled by wiper/washer switch. When the body control module detects that the rear window wiper/washer switch has started the instantaneous washing switch, driving output at the high level side providing battery voltage of rear window washer pump relay coil will be started. It makes the relay power on and then connect the battery supply to washer pump motor. Body control module will start continuous low-speed windshield wiper as mentioned above. Body control module software will attempt to detect whether the rear window washer switch is clamped. If the output of rear window washer motor relay starts continuously for 10 seconds or above, the rear window washer switch will be detected as clamping. Upon detection, body control module will conduct fail soft to make the control state of rear window wiper to not start. It will make the operation of the system similar to the state of stopping instantaneous washing control.
Body system 4-160
Blank
Chapter 5 Brake system Contents Hydraulic brake system ..................................1 Specification ......................................................1 Tightening torque specification .........1 Specification of brake system ...........1 Schematic and wiring diagram ..........................2 Schematic diagram of brake warning system ...............................................2 Parts location diagram .......................................2 Hydraulic Brake System Locating Diagram (ABS) ..................................2 Hydraulic Brake System Locating Diagram (Non-ABS)Error! Bookmark not defined. Exploded view of brake pedal bracket assembly ...........................................3 Diagnostic information and procedure ...............4 Diagnosis of Hydraulic brake system 5 Diagnosis of brake boosting system .8 Brake judder .................................... 11 Noise on brake system ...................12 Braking force is uneven - deviation .13 The front and rear brake are uneven ............................................14 The brake pedal stroke is too long ..15 Brake pedal is too hard ...................17 Brake is stuck ..................................18 Brake system is slowly released .....19 Draining of brake fluid .....................20 Diagnosis of disc brake system ......21 Malfunction of brake warning lamp .24 Diagnosis of Hydraulic Brake System ............................................26 Road test of vehicle brake system ..29 Check on external leakage of brake system .............................................30 Internal leakage test of brake system .............................................30 Visual inspection to operation of hydraulic brake component .............31 Check of brake pipe and hose ........32 Maintenance guide ..........................................33 Check and filling of brake fluid ........33 Check of vacuum booster ...............34 Hydraulic brake system exhausting 34 Replacement of brake fluid reservoir ..........................................35 Brake master cylinder replacement 36 Replacement of brake lamp switch .37 Replacement of brake pedal ...........38 Replacement of vacuum booster. ...39 Replacement of vacuum hose of vacuum booster ...............................41 Replacement of brake pipe for master cylinder (ABS) .................................42
Replacement of front brake pipe (ABS) .................................................... 43 Replacement of Brake Pressure Regulating Valve Pipe（ABS） ...... 44 Front brake pipe replacement - right （ABS）.......................................... 45 Front brake pipe replacement – left （ABS）.......................................... 46 Replacement of master cylinder brake pipe (non-ABS) ............................... 47 Replacement of brake pressure Regulation valve pipe (non-ABS) ... 48 Replacement brake pressure regulator valve (non-ABS) .............. 49 Front brake pipe replacement - right (non-ABS) ....................................... 50 Front brake pipe replacement – Left (non-ABS) ....................................... 51 Proportional Valve Replacement (Non-ABS) ...................................... 52 Replacement of front brake hose ... 53 Replacement of rear brake hose .... 54 Rear brake hose replacement – Brake Disc ................................................. 55 Free play stroke inspection of brake pedal ............................................... 56 Description and operation ............................... 57 Hydraulic brake system .................. 57 Brake boosting system ................... 57 Brake system fault warning lamp .... 57 Disc Brake ...................................................... 58 Specification .................................................... 58 Disc brake parameters.................... 58 Tightening torque ............................ 58 Parts location diagram .................................... 59 Detailed diagram of disc brake ....... 59 Diagnostic information and procedure ............ 60 Disc brake makes abnormal sound 60 Service instruction ........................................... 61 Replacement of front brake caliper assembly ......................................... 61 Replacement of rear brake caliper assembly - disc type ....................... 62 Inspection of brake calipers ............ 64 Replacement brake pad.................. 65 Brake pad test ................................. 66 Run-in of brake pad and brake disc 66 Replacement of front brake disc ..... 67 Replacement of rear brake disc - disc type ................................................. 68 Brake disc thickness measurement 69 Brake disc thickness deviation measurement .................................. 69 Brake disc surface and wear
制动系统 5-2 inspection ........................................70 Measurement of rear face run-out of brake disc assembly........................70 Replacement of dust guard plate ....72 Description and operation ...............................73 Disc brake .......................................73 Special tools ....................................................73 Special tools ....................................73 Drum brake .....................................................74 Specification ....................................................74 Drum brake parameters ..................74 Tightening torque ............................74 Parts location diagram .....................................75 Exploided view of Drum brake ........75 Diagnostic information and procedure .............76 Drum brake diagnostic starting point ................................................76 Drum brake symptoms ....................76 Brake drum surface and wear inspection ........................................77 Inspection of drum brake parts .......78 Inspection of drum brake adjustment parts ................................................78 Service instruction ...........................................79 Gap adjustment of drum brake .......79 Replacement of rear drum brake ....80 Rear drum brake surfacing .............81 Adjustment of rear drum brake .......82 Replacement of rear brake shoe .....83 Check of rear brake shoe ................86 Run-in of brake shoe and drum brake ...............................................86 Replacement of rear brake cylinder 87 Replacement of rear brake assembly .........................................89 Description and operation ...............................90 Drum brake .....................................90 Drum brake gap self-adjuster ..........90 Special tools ....................................90 Parking brake .................................................91 Specification ....................................................91 Tightening torque ............................91 Parts location diagram .....................................91 Parking brake system location map 91 Diagnostic information and procedure .............92 Park brake is unable to remain braking mode or release ..............................92 Service instruction ...........................................93 Check and adjust parking brake mechanism – Drum Brake ..............93 Parking brake adjustment – Disc Brake ...............................................94 Replacement of parking brake mechanism ......................................95 Replacement of parking brake lamp mechanism ......................................96 Replacement of parking brake cable assembly .........................................97 Description and operation ...............................99 Parking braking system ...................99 Parking brake lamp .........................99
Anti-locking brake system (Bosch system) ......................................................... 100 Specification .................................................. 100 Tightening torque .......................... 100 Schematic diagram and circuit diagram ........ 101 ABS system circuit diagram .......... 101 Parts location diagram .................................. 102 Location diagram of anti-lock brake system........................................... 102 Diagnostic information and procedure .......... 103 No code fault repair ...................... 104 Random fault maintenance ........... 104 DTC C109904 ............................... 105 DTC C00A000, C00A200, C00A400, C00A600 ....................................... 106 DTC C00A100, C00A300, C00A500, C00A700 ....................................... 107 DTC C003200, C003500, C003800, C003B00 ....................................... 108 DTC C001004, C001104, C001404, C001504, C001804, C001904, C001C04, C001D04 ..................... 109 DTC C007208 ............................... 110 DTC C109504 ............................... 111 DTC C002004 ............................... 112 DTC C006B06 .............................. 112 DTC C121308 ............................... 114 DTC C121343 ............................... 114 DTC C121408 ............................... 115 DTC C121443 ............................... 115 DTC C121208 ............................... 116 DTC C100004 ............................... 116 DTC C101008 ............................... 117 DTC C100104 ............................... 117 DTC U000104 ............................... 118 DTC U000500 ............................... 118 DTC U000700 ............................... 119 DTC U100104 ............................... 119 DTC C190004 ............................... 120 DTC C190104 ............................... 121 DTC C003108, C003408, C003708, C003A08 ....................................... 122 DTC C00A900, 00AA00, C00AB00, C00AC00 ...................................... 123 Service instruction ......................................... 124 Replacement of ABS control module .......................................... 124 Replacement of ABS bracket assembly ....................................... 126 Front wheel speed sensor replacement .................................. 127 Rear wheel speed sensor replacement .................................. 129 Description and operation ............................. 131 Anti-lock brake system.................. 131 ABS control module ...................... 131 Wheel speed sensor ..................... 131 Warning lamp of anti-lock brake system........................................... 131
Brake system 5-1
Hydraulic brake system Specification Tightening torque specification Application
Specification (N.m)
Nut - brake master cylinder connected to vacuum booster
20±3
Oil pipe joint - front brake pipe connected to brake master cylinder
16±2
Oil pipe joint - front brake pipe connected to ABS Control Module
16±2
Nut - brake bracket connected to vacuum booster
19±3
Nut - brake bracket connected to body
19±3
Oil pipe joint - brake pipe connected to height sensor and braking proportioning control valve
16±2
Oil pipe joint - front brake hose connected to brake caliper
16±2
Oil pipe joint - rear brake hose connected to brake pressure modulator valve intermediate pipe
16±2
Oil pipe joint - rear brake hose connected to brake pipe at rear axle
16±2
Specification of brake system Specification of brake system Application Body Brake booster and master cylinder Front brake Rear brake Brake fluid reservoir Park brake
Function Vacuum booster, hydraulic drive and diagonal pipeline Single-chamber vacuum booster, dual-chamber tandemtype brake master cylinder Caliper disc brake Drum brakes or disc brakes With brake fluid level warning device Sling cable-type and hand operated for rear wheel parking brake
Brake system 5-2
Schematic and wiring diagram Schematic diagram of brake warning system Refer to “Chapter 8 Circuit diagram of instrument cluster”
Parts location diagram Hydraulic Brake System Locating Diagram (ABS)
13AH-0501002
Figure 1. Brake Master Cylinder Reservoir 7. Front Brake Pipe 2. Brake Booster Vacuum 8. Front Brake Pipe 3. Brake Master Cylinder Assy 9. Left Front Brake Pipe 4. Brake Master Cylinder 10. Right Rear brake Pipe 5. Right Front Brake Pipe 11. Left Rear brake Pipe 6. Anti-Lock Brake System (ABS) Control Module ________________________________________________________________________________________
Brake system 5-3
Exploded view of brake pedal bracket assembly
13AH-0501003
Figure 1. Brake pedal bracket 2. Brake pedal bolt 3. Brake pedal pivot bushing 4. Sleeve 5. Brake pedal assy 6. Pedal pad 7. Clutch pedal assy
8. 9. 10. 11. 12. 13. 14.
Clutch pedal bolt Return spring Washer Nut (M8) Washer Nut (M10) Brake pedal bracket assy
________________________________________________________________________________________
Brake system 5-4
Diagnostic information and procedure Diagnosis starting point System Diagnostics Start by referring to the "Notes and Actions" section of the system. When the vehicle fails, refer to the "Description and Operation" to become familiar with the system function to help determine the correct diagnostic procedure. Check out the following “Description and operation” : ● Hydraulic brake system ● Brake boosting system ● Brake system fault warning lamp Visual /routine inspection Visual /routine inspection shall be firstly conducted in case of vehicle failure. The items of inspection are as follows: ● Visible or accessible parts of the system for any visible damage ● Whether installed after sales parts that may cause a system failure ● Parts that have unusual loosenes ● Brake fluid level and condition ● Vacuum booster Common symptoms Corresponding symptoms will be shown in case of vehicle failure. The common symptoms are shown as follows: ● Brake warning failure indicator ● Brake judder ● Noise of brake system ● Brake uneven ● Brake pedal stroke is too wide ● The brake pedal is hard ● The brake is stuck ● The brake system is slowly released ● Draining of brake fluid
Brake system 5-5
Diagnosis of Hydraulic brake system Diagnosis of Hydraulic brake system Step Operation Yes No Definition: This diagnosis table is only used for diagnosing the parts of hydraulic brake system to guarantee that the hydraulic brake system can be operated normally. Please also check another tables of guidance with appropriate symptoms, according to the situation to other brake system diagnosis table for diagnosis. 1 Is there any “Brake symptom list” in this table? Go to Step 2 Check and adjust the level of brake fluid in brake master cylinder. Refer to “Brake 2 reservoir filling”. Go to step 3 Go to step 4 Did the level of hydraulic brake fluid is too low? 1. Check whether the brake fluid has the following conditions showing that it is contaminated: · For layering of brake fluid, it shows that there are two kinds of oil fluid. - Spiral shaped – the oil-based substance exists - Layering shaped - silica-based substance exists 3 · The color of oil fluid is changed Go to Step 5 Go to Step 6 - Muddy appearance – moisture existed – gray appearance / there is suspended particle, dirt, iron rust, corrosion and brake dust in the brake fluid. 2. Check the reservoir cap diaphragm and the seal between reservoir and master cylinder are expanded, if so, it means that the brake fluid is contaminated. Whether any above-mentioned situation exists? 1. Check whether the brake fluid has the following conditions showing that it is contaminated: · For layering of brake fluid, it shows that there are two kinds of oil fluid. - Spiral shaped – the oil-based substance exists - Layering shaped - silica-based substance exists 4 · The color of oil fluid is changed Go to Step 5 Go to Step 6 - Muddy appearance – moisture existed – gray appearance / there is suspended particle, dirt, iron rust, corrosion and brake dust in the brake fluid. 2. Check the reservoir cap diaphragm and the seal between reservoir and master cylinder are expanded, if so, it means that the brake fluid is contaminated. Whether any above-mentioned situation exists? 1. Wash hydraulic brake system. 2. In case that layering phenomenon of brake fluid occurs due to being contaminated by oil-based or silica-based fluid, or the reservoir cap diaphragm and seal between reservoir and master cylinder are expanded, the following steps will be executed. Refer to “the indicated procedure”. 2.1. Remove all following parts. Each componen contains contaminated rubber seal /lining. 2.2. Clean hydraulic brake pipe by use of industrial alcohol or equal product. 2.3. Dry brake pipe by use of filtered air free of lubricating oil. 2.4. Repair or replace all following parts. Each component contains contaminated rubber seal/lining. · Replace the reservoir cap diaphragm for brake master cylinder. · Replacement of master cylinder 5 Go to Step 9 — · Brake master cylinder reservoir: Wash the brake master cylinder reservoir by use of industrial alcohol or similar product and dry it with filtered air without lubricating oil, or replace brake master cylinder reservoir when necessary. · Replacement of front brake pipe · Replacement of rear brake pipe · Overhaul of front brake caliper or replacement of front brake caliper assembly · Replacement of rear brake caliper assembly · Replacement of brake pressure modulator valve 3. In case that the brake fluid is not contamined by oil-based fluid, but it is contaminated by water, dirt, rust, corrosion or brake dust, you should replace the diaphragm of brake fluid reservoir which may make the moisture or dust enter the system. 4. Re-fill and exhaust the hydraulic brake system. Refer to “Exhaust of hydraulic brake system”.
Brake system 5-6 Diagnosis of Hydraulic brake system (Continued) Step
6
7 8 9 10 11 12
13
14
15 16
Operation Did the operation and necessary repair or replacement are completely? 1. Check the following parts of hydraulic brake system have hydraulic brake fluid leakage. Repair or replace parts with hydraulic brake fluid leakage. Refer to the corresponding procedure: · The brake fluid reservoir cover for brake master cylinder · Brake master cylinder replacement · Replacement of front brake pipe · Replacement of rear brake pipe · Replacement of brake pipe · Overhaul of front brake caliper or replacement of front brake caliper assembly · Replacement of rear brake caliper assembly · Replacement of brake pressure modulator valve 2. If the above parts of any brake system have been repaired or replaced, the air in hydraulic brake system shall be exhausted. Refer to “Exhaust of hydraulic brake system”. When exhausting air in hydraulic brake system, you should observe the following status: · Air in the system occurs in air bleed valve rather than the repair position (excluding Brake master cylinder replacement or brake press modulator valve) · During exhausting, the hydraulic brake fluid of each axle can flow smoothly and evenly. Did you find and eliminate the problem? Does the air in the system appears in the air bleed valve rather than the repair position (excluding Brake master cylinder replacement or brake press modulator valve)? Is the brake fluid of each axle smoothly and evenly flowing during exhausting? Check the hydraulic function of brake caliper is normal. Refer to “Visual inspection for operation of hydraulic brake parts”. Is the hydraulic function of brake caliper normal? Is the exhaust brake fluid smoothly and evenly through the front axle hydraulic parts? Is the exhaust brake fluid smoothly and evenly through the front axle hydraulic parts? Check the hydraulic function of brake caliper is normal. Refer to “Visual inspection for operation of hydraulic brake parts”. Is the hydraulic function of the brake caliper normal? Confirm whether brake caliper blocks brake fluid, and/or whether its operation is abnormal: 1. Hoist and support the vehicle. Refer to “Vehicle lifting and hoisting”. 2. Remove the tire and wheel assembly. Refer to “Removal and installation of tire and wheel”. 3. Open suspicious brake caliper air bleed valve 4. Use large C-type clamp compression brake caliper piston, observe whether the brake fluid flow is smooth and whether brake caliper piston can move freely. 5. Close brake caliper air bleed valve. Is brake fluid flow smooth, or can brake caliper piston move freely? Repair or replace the abnormal brake caliper assembly. Refer to the corresponding procedure. · Overhaul of front brake caliper or replacement of front brake caliper assembly · Replacement of rear brake caliper assembly Has the repair or replacement been completed? Exhaust air in hydraulic brake system, observe whether air exists in the system and whether the flow of brake fluid of axle is smooth and even during exhausting. Refer to “Exhaust of hydraulic brake system”. Does air exist in the system? Is the brake fluid of each axle smoothly and evenly flowing during exhausting?
Yes
No
Go to Step 7
Go To step 12
Go to Step 19
Go to Step 8
Go to Step 9
Go to Step 10
Go to Step 21
Go to Step 14
Go to Step 13 Go to Step 17
Go to Step 11
Go to Step 15
Go to Step 13
Go to Step 17
Go to Step 14
Go to Step 21
Go to Step 19
Go to Step 16
Go to Step 21
Go to Step 17
Brake system 5-7 Diagnosis of Hydraulic brake system (Continued) Step
17
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21
Operation 1. Check if there is fluid blockage sign such as bend, kink, clamp or damage occurring to the hydraulic brake pipe and flexible brake pipe. Refer to “brake pipe and hose inspection”. 2. Replace all bent, kinked, clamped or damaged hydraulic brake pipe or flexible brake pipe. Refer to the following procedure if necessary: · Replacement of front brake pipe · Replacement of rear brake pipe · Replacement of brake pipe 3. For obvious bend, kink, clamp or damage of hydraulic brake pipe or flexible brake pipe which isn’t found, you should replace the hydraulic brake flexible hose at the blocking position. Did you find and eliminate the problem? Replace brake pressure modulator valve assembly to calibrate the mechanical operation of brake force distribution of rear dynamic wheel in hydraulic brake system. Did you complete the replacement? 1. Check if there is brake fluid leakage of hydraulic brake system parts at seal or connector position which made air enter into the system. 2. Check whether there is recently being repaired sign occurring to the parts of hydraulic brake system to make air enter the system. 3. Repair or replace any parts installed incorrectly or leaking brake fluid. Did you find and eliminate the problem? 1. Check whether there is brake fluid leakage occurring to internal part of brake master cylinder. Refer to “Internal leakage test of brake system”. 2. If internal leakage of brake fluid is found, repair or replace the brake master cylinder. Refer to “Replacement of master cylinder”. Did you find and eliminate the problem? Install or connect the parts removed or disconnected during diagnosis. Did you complete the operation?
Yes
No
Go to Step 21
Go to Step 18
Go to Step 21
Go to Step 21
Go to Step 20
Go to Step 21
Return back to “Symptom List”
Return to “Symptoms List” in case that the hydraulic brake system is normal
Brake system 5-8
Diagnosis of brake boosting system Diagnosis of brake boosting system Step Operation Yes No Definition: This diagnosis table is only used for diagnosing the parts of brake boosting system to guarantee that the brake boosting system can operate normally. Please also check another tables of guidance with appropriate symptoms, according to the situation to other brake system diagnosis table for diagnosis. 1 Is the table transferred from "hydraulic brake symptoms" to this table? Go to Step 3 Go to Step 2 Is it possible to go directly from electrical diagnostics to a possible failure of a Go to Step 5 Go to “Symptom-2 vacuum? hydraulic brake” Check whether brake pedal stroke is appropriate. Refer to “Brake pedal stroke is 3 Go to Step 5 Go to Step 4 too long”. Is the brake pedal stroke within the specified range? 1. Check whether parts of brake pedal system are worn, missed, misplaced, bent Go to Diagnosis of or damaged. Hydraulic Brake · Inspection of brake pedal push rod parts. Systemto check · Check whether the brake pedal bushing is seriously worn or damaged, and whether there is then check whether the brake pedal is misplaced, bent or damaged. Go to Step 5 internal and 4 2. Replace worn, missed, misplaced, bent or damaged brake pedal system external liquid parts. Did you find and replace any of the brake pedal system parts that are leakage and worn, missing, misplaced, bent, or damaged? whether air exists in the hydraulic brake system. Check the vacuum source of engine providing vacuum to the vacuum brake Go to “Engine booster. control diagnostic Go to Step 6 5 Did vacuum read in specified range? information” to check vacuum conditions 6 Check under the condition of cold start, did the condition happen again? Go to Step 7 Go to Step 8 Under the cold start conditions, you should check the power brake booster 7 vacuum and the operation of vacuum pump (if equipped). Refer to “Engine control Go to Step 22 Go to Step 9 system diagnosis”. Did you find and eliminate the problem? During vacuum source test, does one-way valve of vacuum booster operate 8 Go to Step 10 Go to Step 9 normally? Replace one-way valve of vacuum booster. Refer to “Brake booster vacum 9 Go to Step 10 — replacement”. Did you complete the replacement? If the booster with independent vacuum sensor is equipped, you should check 10 whether the grommet of vacuum sensor has crack, cut, corrosion or damage. Go to Step 11 Go to Step 12 Does the grommet of vacuum sensor have any condition listed above? 11 Replace the grommet of vacuum sensor. Did you complete the replacement? Go to Step 12 — 1. If the vehicle is equipped with vacuum sensor, the scan tool shall be mounted. 2. Confirm whether the chassis brake control area or engine control area of power system can obtain vacuum sensor data of brake booster with data 12 display function. Go to Step 13 Go to Step 16
13
Whether the vacuum sensor data can be obtained by scan tool? Execute vacuum booster leakage test by use of scan tool: 1. Loosen the brake pedal. 2. Accelerate the engine to about 3,000 rpm, and then loosen the throttle. Wait for 2-3s, and repeat for one time. 3. Turn off the ignition switch. 4. Turn on the ignition switch. Don’t start the engine. 5. Observe the reading of vacuum sensor on scan tool within 60s, and record it. Note: The vacuum reading will be reduced to about 2.7 KPa when the altitude rises 305m per time.
Go to Step 18
Go to Step 14
Brake system 5-9 Diagnosis of brake boosting system (Continued) Step
14
15
16
17
18
Operation 6. Determine the vacuum leakage rate. Maximum allowable vacuum leakage rate with the specification: 10KPa, Is the vacuum leakage rate within 60 seconds within the specified allowable range? 1. Exhaust completely vacuum reserve by stepping brake pedal for several times or dismantling the one-way valve of vacuum booster. 2. Separate master cylinder from vacuum brake booster. Don’t disconnect any brake pipe. Refer to “Brake master cylinder replacement”. 3. If there is a vacuum seal at the backside of master cylinder, you should check whether the seal is damaged and is placed on the correct position of master cylinder. Replace vacuum seals when necessary. 4. Carefully re-install master cylinder to brake booster. Refer to “Replacement of master cylinder”. Has the operation completed? Execute vacuum booster leakage test by use of scan tool: 1. Loosen the brake pedal. 2. Accelerate the engine to about 3,000 rpm, and then loosen the throttle. Wait for 23s, and repeat for one time. 3. Turn off the ignition switch. 4. Turn on the ignition switch. Don’t start the engine. 5. Observe the reading of vacuum sensor on scan tool within 60s, and record it. Note: The vacuum reading will be reduced to about 2.7 KPa when the altitude rises 305m per time. 6. Determine the vacuum leakage rate. Maximum allowable vacuum leakage rate with the specification: 10KPa, Is the vacuum leakage rate within 60 seconds within the specified allowable range? 1. Separate master cylinder from vacuum brake booster. Don’t disconnect any brake pipe. Before dismantling the master cylinder, exhaust vacuum completely through dismantling one-way valve or stepping brake pedal for several times. Refer to “Brake master cylinder replacement”. 2. If there is a vacuum seal at the backside of master cylinder, you should check whether the seal is damaged and is placed on the correct position of master cylinder. 3. If the vacuum seal as a part of booster is equipped, you should check whether the seal is damaged. Does the vacuum seal have any condition listed above? 1. If the vacuum seal is equipped at the backside of master cylinder, you should replace vacuum seal when necessary. Guarantee that the seal is placed on correct position during installation. 2. If the vacuum seal needed to be replaced is equipped, and the seal is a part of booster, the booster assembly must be replaced. 3. Carefully re-install master cylinder to brake booster. Refer to “Brake master cylinder replacement”. Did you complete the replacement? Conduct vacuum booster functional test: 1. If it is still separated, you should re-install the master cylinder on the booster. Refer to “Brake master cylinder replacement”. 2. If the engine starts after the master cylinder is re-installed on the booster, the following steps shall be conducted: Stop the engine, step on the brake pedal for several times to exhaust vacuum reserve completely. 3. Step on the brake pedal with moderate force.
Yes
No
Go to Step 15
—
Go to Step 22
Go to Step 21
Go to Step 17
Go to Step 18
Go to Step 18
—
Go to Step 21
Go to Step 19
Brake system 5-10 Diagnosis of brake boosting system (Continued) Step
19
20
21
22
Operation 4 Start the engine, and observe the operating conditions of pedal. 5. Obvious vacuum leakage was observed. The brake pedal gets down slightly and maintained. Whether the sound of vacuum leakage in brake pedal area was heard? Is the brake pedal slightly lowered and maintained at the position after the engine is started? Conduct vacuum booster leakage function test: 1. Loosen the brake pedal. 2. Accelerate the engine to about 3,000 rpm, and then loosen the throttle. Wait for 2-3 seconds, and repeat it. 3. Turn off the ignition switch. 4. Wait for 60s. 5. Step on the brake pedal twice, to check whether there is vacuum reserve on the vacuum booster. Observe pedal force. · The joint of two pedals shall be provided by the boosting force. · The boosting force will decrease gradually after the second joint. Whether the joint of two pedals has vacuum boosting force? Replace vacuum booster. Did you complete the replacement? All dismantled or disconnected parts during installation or connection diagnosis period. Did you complete the operation?
Yes
No
Go to Step 20
Go to Step 21
Go to Step 22
Go to Step 21
Go to Step 22 The brake boosting system returns to “Symptom List” normally.
Brake system 5-11
Brake judder Brake judder Step Operation Yes No Definition: During braking only, feel the fluctuation and judder through brake pedal, steering wheel, seat and floor or in the vehicle. Is the table transferred from "hydraulic brake symptoms" to this table? Go to Step 2 Go to “Symptom1 - hydraulic brake” 1. Check the disc brake system for the following conditions. Go to Step 3 Go to “Symptom· The thickness deviation of disc brake friction surface is too large. - hydraulic brake” · Brake disc Lateral Runout (LRO) friction surface value after final assembly is too large · Hot spots, hot cracks, blue on the friction surface of disc brake; They are caused possibly due to stuck brake · Hyperactive corrosion of disc brake friction surface; including red, grey or black 2 oxidation · Looseness, damage or missing of hardware of brake caliper or friction liner · Bending or damage of brake caliper or installed parts · Wheel / axle flange assembly after the face runout is too large; due to damage or loose or bearing excessive wear. 2. Adjust, repair or replace parts, if necessary. Did you find and eliminate the problem? 1. Install or connect the parts removed or disconnected during diagnosis. Go to Step 2 Normal system 2. Test vehicle on road to confirm normal operation. Refer to “Road test on vehicle brake 3 system”. Is there still fault?
Brake system 5-12
Noise on brake system Noise on brake system Step Operation Yes No Definition: When braking, the vehicle has abnormal noises. After loosening the brake pedal, the vehicle has abnormal noises during moving. Is the table transferred from "hydraulic brake symptoms" to this table? Go to “Symptom 1 Go to Step 2 - hydraulic brake” 1. Check disc brake system for the following conditions. · Lining wear indicator contacts with disc brake · There are debris between disc brake and splash shield or chassis base. Or there are debris between disc brake and lining. · Lining is contaminated · Adding lining after sales · Lining is polished · Lining appears deformation, crack or damage · Lining appears severe wear 2 Go to Step 6 Go to Step 3 · Damage or excessive of hardware of brake caliper or lining · Improper installation, looseness or missing of hardware of brake caliper or lining · There is insufficient lubrication or excessive corrosion on metal-to-metal contact surface · Bend or damage of splash shield or chassis base · The friction surface of disc brake appears hot spots, hot cracks, and blue shade · The friction surface of disc brake is polished · Bend or damage of brake caliper or installed parts 2. Adjust, repair or replace parts, if necessary. Did you find and eliminate the problem? 1. Check the brake boosting system for the following conditions. · There is insufficient lubrication or excessive wear on push rod, pedal pivot or pivot axle bushing 3 Go to Step 6 Go to Step 4 · Pedal push rod, pedal or pedal bracket is bent or damaged · Damage or abnormal operation of vacuum booster or one-way valve 2. Adjust, repair or replace parts, if necessary. Did you find and eliminate the problem? 1. Check the hydraulic brake system for the following conditions. · The piston of brake caliper is abnormal 4 · Brake fluid is contaminated Go to Step 6 Go to Step 5 2. Adjust, repair or replace parts, if necessary. Refer to “Hydraulic brake system diagnosis”. Did you find and eliminate the problem? Check whether parking brake system is normal. Refer to “Symptom--- parking brake”. Go to Step 6 Go to “Symptom5 Did you find and eliminate the problem? - hydraulic brake” 1. Install or connect the parts removed or disconnected during diagnosis. 2. Test vehicle on road to conform normal operation. Refer to “Road test on vehicle brake 6 Go to Step 2 Normal system system”. Is there still fault?
Brake system 5-13
Braking force is uneven - deviation Test description The following number shall be corresponding to the step number in the diagnosis table. 1. For the abnormal operation of parts of suspension system, it may result in instability of vehicle during the operation of brake system. 2. For the abnormal operation of parts of steering system, it may result in instability when following numbers are corresponding to the step numbers in the diagnosis table during the operation of brake system. Braking force is uneven - deviation Step Operation Definition: When braking, vehicles deviate from the right lane. Is the table transferred from "hydraulic brake symptoms" to this table? 1
2
3
4
5
6
1. · · · 2.
Check the hydraulic brake system for the following conditions. Brake pipe or flexible brake pipe is kinked, clamped or damaged Stuck or abnormal operation of brake caliper piston Brake fluid leakage Adjust, repair or replace parts, if necessary. Refer to “Hydraulic brake system diagnosis”. Did you find and eliminate the problem? 1. Check disc brake system for the following conditions. · Lining is contaminated · Lining is polished · Deformation, cracking or damage of lining at one side · Looseness, damage or missing of hardware of brake caliper or friction lining · Incorrect lining at one side · Hot spots, hot cracks, blue shade on the friction surface of disc brake; They are caused possibly due to stuck brake · The friction surface of disc brake is polished · Bend or damage of brake caliper or installed part 2. Adjust, repair or replace parts, if necessary. Refer to “Disc brake system diagnosis” Did you find and eliminate the problem? 1. Check the suspension system for the following conditions. · Tire pressure is incorrect · Joint of suspension parts is loose · Suspension parts appears excessive wear or damage 2. Adjust, repair or replace parts, if necessary. Refer to “General diagnosis of suspension system” Did you find and eliminate the problem? 1. Check the steering system for the following conditions. · The joint of steering parts is loose. · Excessive wear or damage of steering parts 2. Adjust, repair or replace parts, if necessary. Refer to “Symptom--- power steering system”. Did you find and eliminate the problem? 1. Install or connect the parts removed or disconnected during diagnosis. 2. Test vehicle on road to conform normal operation. Refer to “Road test on vehicle brake system”. Is there still fault?
Yes
No
Go to Step 2
Go to “Symptom hydraulic brake”
Go to Step 6
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 6
Go to Step 5
Go to Step 6
Go to “Symptom hydraulic brake”
Go to Step 2
Normal system
Brake system 5-14
The front and rear brake are uneven Braking force is uneven - deviation Step Operation Yes No Definition: During braking or parking, the force sensitivity or binding at the front and rear axles are more obvious. Sensitivity or binding of brake: Too large braking hop force is related to input of brake pedal. Is the table transferred from "hydraulic brake symptoms" to this table? Go to “Symptom 1 Go to Step 2 hydraulic brake” 1. Check hydraulic brake system for the following conditions: · The piston of brake caliper is abnormal · Brake pipe or flexible brake pipe is kinked, clamped or damaged 2 Go to Step 5 Go to Step 3 · Brake fluid leakage 2. Adjust, repair or replace parts, if necessary. Did you find and eliminate the problem? 1. Check disc brake system for the following conditions: · Lining is contaminated · Lining is polished · Lining appears deformation, crack or damage · Lining appears severe wear 3 Go to Step 5 Go to Step 4 · Adding lining after sales · Damage or excessive wear of hardware of brake caliper or lining · The friction surface of disc brake appears hot spots, hot cracks, and blue shade · The friction surface of disc brake is polished 2. Adjust, repair or replace parts, if necessary. Did you find and eliminate the problem? 1. Check the suspension system for the following conditions: · Joint of suspension parts is loose · Suspension parts appear excessive wear or damage Go to “Symptom 4 Go to Step 5 2. Adjust, repair or replace parts, if necessary. Refer to “Starting point of diagnosis – hydraulic brake” suspension system - general diagnosis of suspension system”. Did you find and eliminate the problem? 1. Install or connect the parts removed or disconnected during diagnosis. 2. Test vehicle on road to conform normal operation. Refer to “Road test on vehicle 5 Go to Step 2 Normal system brake system”. Is there still fault?
Brake system 5-15
The brake pedal stroke is too long The brake pedal stroke is too long Step Operation Yes No Definition: In order to meet the strong sense of brake pedal, the brake pedal stroke is much larger than the expected value, i.e., the pedal strong sense cannot be achieved, or the pedal declines slowly or becomes soft. Is the table transferred from "hydraulic brake symptoms" to this table? Go to “Symptom 1 Go to Step 2 hydraulic brake” Check the stroke and feeling of brake pedal when stepping down. Perform the following operation: 1. Step down brake pedal for several times to exhaust reserved vacuum completely. 2. Under the condition of exhausting vacuum completely, step down the brake pedal lightly and stably and maintain for 15s. Observe the stroke and feeling of the pedal. 2 3. Step on the brake pedal lightly and stably, reduce pressure, and then increase Go to Step 3 pressure under the condition of not loosening the pedal incompletely, repeat for several times. Observe the stroke and feel while stepping on the pedal every time. 4. Step on the brake pedal slowly, loosen it and step down the pedal rapidly. Observe the stroke and feel while stepping down pedal every time. Has the inspection of stroke and feel of the brake pedal has been finished? 1. When checking the pedal stroke and feel, you should check whether the hydraulic brake system has the following conditions by observed symptoms. · The pedal feels soft - Air exists in hydraulic system - Brake fluid appears external leakage - Softening, lack of strength or damage of hydraulic hose; Expanding under the pressure · Declivity or closing to the floor of pedal - Poor quality of brake fluid; Too-low boiling point - Brake fluid leaks internally - Brake fluid leaks externally; The function of master cylinder is abnormal 3 Go to Step 8 Go to Step 4 · The pedal is too strong and has slightly decreased; or the pedal is raised after stepping for several times; or the stroke of pedal is different in slow stepping and rapid stepping; or the brake fluid leaks internally; The function of master cylinder is abnormal - Poor quality of brake fluid; Too-low boiling point · After being stepped, the pedal will rebound slowly. - Flexible brake pipe appears internal damage; Prevent the backflow of brake fluid - Stuck brake caliper piston - Brake fluid leaks internally; The function of master cylinder is abnormal 2. Repair or replace parts, if necessary. Refer to “Hydraulic brake system diagnosis”. 3. Re-check the stroke and feel of brake pedal. Did you find and eliminate the problem? 1. Check disc brake system for the following conditions: · Cracking, excessive wear or damage of lining · Cracking, excessive wear or damage of disc brake · Abnormal operation, binding or damage of hardware of brake caliper or lining. 4 Go to Step 8 Go to Step 5 · Looseness or missing of hardware of brake caliper or lining · Brake disc Lateral Runout (LRO) friction surface value after final assembly is too large · Bend or damage of brake caliper or installed parts 2. Adjust, repair or replace parts, if necessary. 3. Re-check the stroke and feel of brake pedal. Did you find and eliminate the problem? Check whether brake pedal stroke is correct. Refer to “Brake pedal stroke is too long”. 5 Go to Step 7 Go to Step 6 Is the brake pedal stroke within the specified range? 1. Check whether parts of brake pedal system are worn, missed, misplaced, bent or damaged. 2. Check whether the brake pedal bushing is stuck, over-worn or damaged, and then, 6 check whether the brake pedal is misplaced, bent or damaged. Go to Step 8 Go to Step 7 3. Replace worn, missed, misplaced, bent or damaged brake pedal system parts. Is any worn, missed, misplaced, bent or damaged parts of brake pedal system found and replaced?
Brake system 5-16 The brake pedal stroke is too long (Continued) Step
7
8
Operation 1. Check brake boosting system for the following conditions: Vacuum leakage or abnormal operation of one-way valve and damage or abnormal operation of brake booster assembly 2. Adjust, repair or replace parts, if necessary. Did you find and eliminate the problem? 1. Install or connect the parts removed or disconnected during diagnosis. 2. Test vehicle on road to conform normal operation. Refer to “Road test on vehicle brake system”. Is there still fault?
Yes Go to Step 8
No Go to “Symptom hydraulic brake”
Go to Step 2 Normal system
Brake system 5-17
Brake pedal is too hard The brake pedal is too hard Step Operation Yes Definition: the brake pedal requires an increase in the driver's input to obtain a good braking or braking distance. 1
2
3
4
5
Is the table transferred from “hydraulic brake symptoms” to this table? 1. Check the brake boosting system for the following conditions: · Vacuum leakage · There is insufficient lubrication, stuck phenomenon or excessive wear on push rod, pedal pivot or pivot axle bushing · Pedal push rod, pedal or pedal bracket is bent or damaged · Damage or abnormal operation of vacuum brake booster 2. Adjust, repair or replace parts, if necessary. Did you find and eliminate the problem? 1. Check the hydraulic brake system for the following conditions: · Stuck brake caliper piston, internal damage of flexible brake pipe. · Prevent the flow of brake fluid · Kinking or damage of flexible brake pipe · Brake fluid leaks internally; Abnormal operation of the master cylinder · Poor quality of brake fluid; Too-low boiling point 2. Adjust, repair or replace parts, if necessary. Refer to “Hydraulic brake system diagnosis”. Did you find and eliminate the problem? 1. Check the disc brake system for the following conditions: · Lining appears severe wear · Polishing, cracking deformation or damage of lining · Lining is contaminated · Binding, damage or excessive wear of hardware of brake caliper or lining · There is insufficient lubrication or excessive corrosion on metal-tometal contact surface · Excessive wear or corrosion of disc brake friction surface · The friction surface of disc brake is polished · The friction surface of disc brake appears hot spots, hot cracks, and blue shade 2. Adjust, repair or replace parts, if necessary. Did you find and eliminate the problem? 1. Install or connect the parts removed or disconnected during diagnosis. 2. Test vehicle on road to conform normal operation. Refer to “Road test on vehicle brake system”. Is there still fault?
Go to Step 2
No
Go to “Symptom - hydraulic brake”
Go to Step 5
Go to Step 3
Go to Step 5
Go to Step 4
Go to Step 5
Go to Step 2
Go to “Symptom - hydraulic brake”
Normal system
Brake system 5-18
Brake is stuck The brake is stuck Step Operation Yes No Definition: the braking system can not be fully released or delayed release; even if not on the brakes, the brake system will block the movement of vehicles. Is the table transferred from “hydraulic brake symptoms” to this table? 1 Go to Step 2 Go to “Symptom - hydraulic brake” 2
3
4
5
6
7
8
9
Whether the vehicle is equipped with adjustable stop lamp switch assembly and/or adjustable cruise control release switch. 1. Check whether the stop lamp switch is correctly adjusted to guarantee the complete loosening of brake pedal. 2. Check whether the cruise control release switch (If equipped) is correctly adjusted to guarantee the complete relief of brake pedal. Did you find and eliminate the problem? Check whether parking brake system is normal. Refer to “Diagnosis of parking brake system”. Did you find and eliminate the problem? 1. Check the disc brake system for the following conditions: · Binding, improper installation or missing of hardware of brake caliper or lining guarantee that the lining and brake caliper can move smoothly. · There is insufficient lubrication or excessive corrosion on metal-tometal contact surface · Lining is bent or damaged · Damage or excessive wear of hardware of brake caliper or lining · Bend or damage of brake caliper or installed parts 2. Adjust, repair or replace parts, if necessary. Did you find and eliminate the problem? 1. Separate the brake booster push rod from the brake pedal. 2. Check brake angle to determine whether the stuck condition of brake still remains. Whether brake angle still has the stuck condition of brake? 1. Check whether the push rod is correctly positioned or damaged. Position or replace the push rod correctly when necessary. 2. Check whether the brake pedal assembly is damage and replace it when necessary. Did you complete the repairment or replacement? 1. For the vacuum boosting system, disconnect vacuum one-way valve from the booster to release vacuum reserve. 2. Separate the master cylinder from the brake booster. Don’t disconnect any brake pipe. 3. Check brake angle to determine whether the stuck condition of brake still remains. Does the brake angle still exist? Replace brake booster assembly. Did you complete the replacement?
Go to Step 7
Go to Step 11
Go to Step 7
Go to Step 11
Go to Step 5
Go to Step 11
Go to Step 6
Go to Step 8
Go to Step 7
Go to Step 11
—
Go to Step 10
Go to Step 09
Go to Step 11
—
Go to Step 11
Go to “Symptom - hydraulic brake”
Go to Step 2
Normal system
1. · · ·
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11
Check the hydraulic brake system for the following conditions. The piston of brake caliper is abnormal Brake fluid is contaminated Flexible brake pipe appears internal damage; Prevent release of brake · General cylinder is damaged or abnormal 2. Adjust, repair or replace parts, if necessary. Refer to “Hydraulic brake system diagnosis”. Did you find and eliminate the problem? 1. Install or connect the parts removed or disconnected during diagnosis. 2. Test vehicle on road to conform normal operation. Refer to “Road test on vehicle brake system”. Is there still fault?
Go to Step 3
Brake system 5-19
Brake system is slowly released The brake system is slowly released Step Operation Yes No Definition: release or return to the brake system slow release of the brake pedal, brake system, a short block of vehicle movement. Is the table transferred from "hydraulic brake symptoms" to this table? Turn to “Symptom - hydraulic 1 Turn to Step 2. brake” 1. Check whether the hydraulic brake system has the following situations: · Abnormal brake caliper piston operation, internal damage of flexible brake pipe. Prevent brake releasing 2 Turn to Step 5. Turn to Step 3. · Brake fluid is contaminated · Master cylinder is damaged or abnormal 2. Adjust, repair or replace part, if necessary. Refer to “Hydraulic brake system diagnosis”. Did you find and eliminate the problem? 1. Check whether the brake boosting system has the following situations: · Clamping, bend or damage of pedal push rod, pedal or brake pedal 3 bracket. Go to Step 5. Go to Step 4. · Damage or abnormal operation of vacuum booster 2. Adjust, repair or replace part, if necessary. Did you find and eliminate the problem? 1. Check whether the disc brake system has the following situations: · Brake caliper component or lining component appears damage or severe wear · Lining is deformed or damaged Turn to “Symptom - hydraulic 4 Go to Step 5. · There is insufficient lubrication or excessive corrosion on metal-tobrake” metal contact surface · Bending or damage of brake caliper or housed part 2. Adjust, repair or replace part, if necessary. Did you find and eliminate the problem? 1. Install or connect the parts removed or disconnected during diagnosis. 2. Test vehicle on road to conform normal operation. Refer to “Road test 5 Turn to Step 2 Normal system on vehicle brake system”. Is the vehicle failure still exists?
Brake system 5-20
Draining of brake fluid Draining of brake fluid Step Operation Yes Definition: the brake fluid level is too low and has nothing to do with the wear of the lining. Is the table transferred from “hydraulic brake symptoms” to this table? 1 Go to Step 2
2
3
4
5
6
1. Check whether the following parts of hydraulic brake system have hydraulic brake fluid leakage: · Connection of flexible brake pipe. Screw and bolt · Pressure joint of flexible brake pipe · Joint of brake pipe · Seals of brake caliper piston · Brake master cylinder reservoir 2. Repair or replace parts, if necessary. Refer to “Hydraulic brake system diagnosis”. Did you find and eliminate the problem? Is the vehicle equipped with vacuum brake booster? 1. Disconnect vacuum one-way valve from the booster to release vacuum reserve. 2. Separate master cylinder from vacuum brake booster. Don’t disconnect any brake pipe. 3. Check whether there is brake fluid leakage at the rear of master cylinder. 4. Check whether there is brake fluid in vacuum brake booster. Is there brake fluid leakage? Replace brake master cylinder and vacuum brake booster. Did you complete the replacement? 1. Install or connect the parts removed or disconnected during diagnosis. 2. Conduct road test for vehicle to guarantee the normal operation. Refer to “Road test on vehicle brake system”. Does the vehicle failure still exist?
No Turn to “Symptom hydraulic brake”
Go to Step 6
Go to Step 3
Go to Step 4
Go to Step 6
Go to Step 5
Turn to “Symptom hydraulic brake”
Go to Step 6
—
Go to Step 2
Normal system
Brake system 5-21
Diagnosis of disc brake system Diagnosis of disc brake system Step Operation Yes No Definition: This diagnosis table is only used for diagnosing the parts of disc brake system to determine whether the system can operate normally. You will turn to other brake system diagnosis table for diagnosis under the guidance of corresponding symptom table. Is the table transferred from “hydraulic brake symptoms” to this table? Turn to “Symptom 1 Go to Step 2. hydraulic brake” Check whether the brake pad of disc brake has the following conditions visually: Refer to “Check of brake pad”. · The thickness of friction liner is less than the specification. · Uneven or abnormal wear--- edge wear or surface wear. 2 Go to Step 3. Go to Step 12. · Loosening or damage—including parts of brake pad. · Whether there is the sign of foreign matter contamination. Whether any condition is found indicating the fault of brake pad of front or rear disc brake. 3 Is any brake pad of front or rear disc brake polluted? Go to Step 8. Go to Step 4. 4 Is any brake pad of front or rear disc brake uneven? Go to Step 7. Go to Step 5 Is any brake pad of front or rear disc brake or brake pad component 5 Go to Step 7 Go to Step 6 loosening or damaged? 1. Dismantle the worn brake pad of disc brake and check whether there is polishing, loosening, hot spot or damage. 2. Replace the whole set of worn brake pad of disc brake according to 6 Go to Step 12. — the axle. Refer to “Replacement of front disc brake pad” and “Replacement of rear disc brake pad”. Did you complet the checking and replacement? Warning: Support brake caliper with heavy wire or similar tools regardless of whether brake caliper has been separated from its bracket or is still connected with hydraulic flexible brake pipe. If brake caliper isn’t supported by such way, the flexible brake pipe may withstand the weight of brake caliper, resulting in damage and further the leakage of brake fluid. Note: Don’t disconnect hydraulic brake flexible hose from brake caliper. 1. Check whether the brake caliper installing support of disc brake and mounting/ sliding parts have the following conditions: 2. Check whether the brake caliper installing bracket of disc brake and mounting/ sliding parts have the following conditions: 7 Component appears clamping stagnation or stuck Go to Step 12. — Wear, damage or missing of parts. Loosening, bend, cracking or damage of brake caliper installing support. 3. Replace parts as needed. Refer to the following procedure if necessary: Replacement of front brake caliper support Replacement of rear brake caliper support 4. Replace the whole set of worn, uneven, loosen or damaged brake pad of disc brake according to the axle. Refer to “Replacement of front disc brake pad” and “Replacement of rear disc brake pad”. Did you complete the checking and replacement? 1. Check whether the brake caliper and brake pipe of disc brake has the sign of external brake fluid leakage. 2. Replace all parts that have brake fluid leakage. When necessary, refer to the following procedures: Replacement of front brake caliper assembly 8 Go to Step 11 Go to Step 9 Replacement of front brake pipe Replacement of rear brake pipe Replacement of brake pipe Whether it has found and eliminated the leakage source resulting in contamination to brake pad? 1. Check whether the external seal of wheel driving shaft is damaged or has the sign of lubricating grease leakage. 2. Replace the wheel driving shaft seal which is leaking lubricating 9 Go to Step 11 Go to Step 10 grease and may result in brake pad pollution. Whether it has found and eliminated the leakage source resulting in contamination to brake pad?
Brake system 5-22 Diagnosis of disc brake system (Continued) Step
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15
16
Operation 1. Check whether the automatic transmission fluid cooling line (if equipped) has the damage or sign which may result in brake pad pollution or external leakage of brake fluid. 2. Check whether the power steering system hose may result in damage of brake pad pollution and external leakage of brake fluid. 3. Replace all polluted parts on brake pad due to brake fluid leakage. Whether it has found and eliminated the leakage source resulting in contamination to brake pad? 1. Clean the other parts of disc brake system to eliminate contamination mark. Warning: Support brake caliper with heavy wire or similar tools regardless of whether brake caliper has been separated from its bracket or is still connected with hydraulic flexible brake pipe. If brake caliper isn’t supported by such way, the flexible brake pipe may withstand the weight of brake caliper, resulting in damage and further the leakage of brake fluid. Note: Don’t disconnect hydraulic brake flexible hose from brake caliper. 2. Dismantle the corresponding brake caliper of front or rear disc brake from the installing support and support it. Refer to “Brake caliper replacement”. 3. Check whether the brake caliper of disc brake and mounting/ sliding parts have the following conditions: Refer to “Brake caliper inspection”. Component appears clamping stagnation or stuck Deformation, wear, damage or missing of parts. 4. Replace the mounting/ sliding parts of brake caliper when necessary. 5. Replace the whole set of polluted brake pad of disc brake according to the axle. Refer to “Replacement of front disc brake pad” and “Replacement of rear disc brake pad”. Whether the cleaning, check and replacement are completed? Visual inspection of each rear brake disc splash guard/ base plate (if equipped) is exposed to the brake disc. Is there any brake disc splash guard / base plate to contact the brake disc? When necessary, repair or replace splash guard/ base plate of disc brake. Refer to “Replacement of splash guard of disc brake-front”. Did you complete the repairing or replacement? 1. Check the thickness of each disc brake Note: Confirm the following problems, and respectively answer questions to each disc brake. 2. Confirm that whether the surface trimming can be conducted for each disc brake and the minimum thickness requirements of disc brake can be met. Refer to “Thickness measurement of disc brake”. Does the brake disc meet the minimum requirements for surface finishing? Note: Conduct the following checks, and answer the questions of each disc brake respectively. Check whether the thickness deviation of disc brake of disc brake can exceed the maximum allowable value. Refer to “Thickness deviation measurement of disc brake”. Is the brake disc thickness deviation exceeding the maximum allowable value? 1. Check whether each disc brake has the following situation and wear conditions: Refer to “Surface and wear check of disc brake”. Serious rusting or corrosive pitting Cracking or hot spot Became blue seriously Scratches are too deep or excessive exceeding the maximum allowable value. Note: Confirm the following problems, and respectively answer questions to each disc brake. 2. According to the checking results, confirm whether surface trimming is needed for every disc brake. For any above condition occurred to the disc brake, the surface trimming need to be conducted.
Yes
No
Go to Step 11
—
Go to Step 12
—
Go to Step 13
Go to Step14
Go to Step 14
—
Go to Step 15
Go to Step 18
Go to Step 17
Go to Step 16
Go to Step 17
Go to Step 22
Brake system 5-23 Diagnosis of disc brake system (Continued) Step 16
17
18
19
20
21
22
23
24
Operation Does the brake disc need to be trimmed? 1. Conduct surface trimming to the disc brake. Refer to “Surface trimming of disc brake”. 2. Check thickness of disc brake. Refer to “Thickness measurement of disc brake”. Can the brake disc surface finishing and achieve the minimum thickness requirements? Does the brake disc meet or lower than the scrap requirements? Note: Conduct the following checks, and answer the questions of each disc brake respectively. Check whether the thickness deviation of each disc brake can exceed the maximum allowable value. Refer to “Thickness deviation measurement of disc brake”. Whether the thickness deviation of disc brake exceeds the maximum allowable value? 1. Check each disc brake for the following situation and wear conditions: Refer to “Surface and wear check of disc brake”. · Serious rusting, corrosive pitting, cracking or hot spot. · Became blue seriously · Scratches are too deep or excessive · Exceed maximum allowable value Note: Confirm the following problems, and respectively answer questions to each disc brake. 2. According to the checking results, confirm whether replacement is needed for every disc brake. For any above condition occurred to the disc brake, the replacement is needed to be conducted. Whether the disc brake is needed to be replaced? Note: Disc brake lateral runout (LRO) must be measured when replacing the disc brake, so as to ensure the best performance of disc brake. Replace disc brake. Refer to “Replacement of front disc brake” and “Replacement of rear disc brake”. Did you complete the replacement? Note: Conduct the following checks, and answer the questions of each disc brake respectively. Check whether the rear face run-out of each disc brake assembly exceeds the maximum allowable value. Refer to “Measurement of rear face run-out of disc brake assembly”. Whether the rear face run-out of disc brake assembly exceeds the maximum allowable value? Correct the face run-out aiming at each disc brake that its face run-out is confirmed to exceed the maximum allowable value. Refer to “Measurement of rear face run-out of disc brake assembly”. Did you complete the operation? Install or connect the parts removed or disconnected during diagnosis. Did you complete the operation?
Yes
No
Go to Step 22
Go to Step 21
Go to Step 21 Go to Step 21
Go to Step 19 Go to Step 20
Go to Step 21
Go to Step 22
Go to Step 24
—
Go to Step 23
Go to Step 24
Go to Step 24
—
The disc brake system normally returns back to “Symptom table” normally.
—
Brake system 5-24
Malfunction of brake warning lamp The typical reason that ABS warning lamp doesn’t work but no fault diagnostic code is set: · The bulb fails/the lamp holder is loose. · I/P blown fuse · The combination instrument/lamp driver module fails · Electronic brake control module fails · The circuit between combination instrument and electronic brake control module is grounded. Malfunction of brake warning lamp Step 1
Operation Whether “Diagnosis of Starting Point - Hydraulic Brake” is executed?
Yes To Step 2 to “Diagnosis of Starting Point -
No Hydraulic Brake”
1. 2
3 4
5
6
7
8
9
Disconnect the electronic brake control module wiring harness (EBCM) from electronic brake control module. 2. Turn on the Ignition Switch Did the brake warning lamp light up? Replace electronic brake control module. Did you complete the replacement? Check the fuse of combination instrument. Are the contacts of fuse and terminal normal? 1. Replace the blown fuse or repair the loose terminal. 2. Find out the corresponding short-circuit fault which causes fuse blown. Has failure been founded and eliminated? Remove the bulb of brake warning lamp from combination instrument, and check whether the lamp filament is open-circuit or the bad contact is occurred to the lamp holder. Is the lamp holder or bulb normal? Replace the bulb/lamp holder if necessary. Did you complete the replacement? 1. Switch off ignition switch. 2. Check whether the wiring harness of electronic brake control module is still disconnected. 3. Remove the combination instrument assembly from the instrument board. 4. Disconnect the white combination instrument’s wiring harness connector from combination instrument assembly. 5. Keep the engine flame out, and connect the ignition switch. 6. Connect the voltmeter to Terminal 5 of combination instrument wiring harness, and then connect it to body for grounding. Is the voltage within the specified range? Find the reason that the voltage of power supply terminal of combination instrument is too low, and repair it. Has failure been founded and eliminated?
Value
1. 2. 10
Disconnect ignition switch. Disconnect the white combination instrument’s wiring harness connector from combination instrument assembly. 3. Connect the ohmmeter to white Terminal 25 of combination instrument’s wiring harness, and then connect it to the body for grounding. Is the resistance value lower than the specified value?
To Step 3 to Step 4
Normal system To Step 6
To Step 5
Normal system
To Step 8
To Step 7
Normal system 11-14 V
To Step 10
To Step 9
Normal system 2Ω
To Step 12
To Step 11
Brake system 5-25 Malfunction of brake warning lamp(Continued) Step 11 12
Operation Repair the combination instrument and excessive failure of open circuit or resistance. Has failure been founded and eliminated? Replace combination instrument assembly. Did you complete the replacement?
Value
Yes Normal system
Normal system
No
Brake system 5-26
Diagnosis of Hydraulic Brake System Diagnosis of Hydraulic Brake System System diagnostics Step Operation Yes No Definition: this diagnostic chart is only used to diagnose the parts of the hydraulic brake system to determine whether the hydraulic brake system is working properly. You will be under the guidance of the corresponding symptom table, according to the situation to other brake system diagnosis table for diagnosis. Is the table transferred from “hydraulic brake symptoms” to this table? Go to Step 2. Turn to 1 “Symptom hydraulic brake” Check and adjust the level of brake fluid in brake master cylinder. Go to Step 3 Go to Step 4. 2 Is the level of brake fluid too low? 1. Check whether the brake fluid has the following conditions showing Go to Step 5. Go to Step 6. that it is polluted: · Brake fluid appears separation (indicating there are two kinds of fluid) Spiral shaped – existence of oil-based substance Laminated – existence of silFigure-based substance · The color of oil fluid is changed 3 Turbid appearance – existence of water Gray appearance - brake fluid contains suspended particles – dirt, rust, corrosion, and brake dust 2. Check whether the reservoir cap diaphragm and the seal between Brake fluid reservoir and master cylinder are expanded, if it is, show that the oil fluid is polluted. Does any above-mentioned situation exist? 1. Check whether the brake fluid has the following conditions showing Go to Step 5. Go to Step 12. that it is polluted: · Brake fluid appears separation (indicating there are two kinds of fluid) Spiral shaped – existence of oil-based substance Laminated – existence of silFigure-based substance · The color of oil fluid is changed 4 Turbid appearance – existence of water Gray appearance - brake fluid contains suspended particles – dirt, rust, corrosion, and brake dust 2. Check whether the recervoir cap diphragm and the seal between brake fluid reservoir and master cylinder are expanded, if it is, show that the fluid is polluted. Does any above-mentioned situation exist? 1. Wash hydraulic brake system. Go to Step 9. — 2. In case that layering phenomenon of brake fluid is occurred due to being polluted by oil-based or silica-based fluid, or reservoir cap the diaphragm or the seal between brake fluid reservoir and master cylinder are expanded, the following Steps will be executed. Refer to the indicated procedure. 2.1. Remove all following parts. Each part contains the rubber seal / gasket has been contaminated. 2.2. Clean hydraulic brake pipe by use of industrial alcohol or equal. 5 2.3. Dry brake pipe by use of filtered air free of lubricating oil. 2.4. Repair or replace all following parts. Each part contains the rubber seal / gasket has been contaminated. · Brake master cylinder replacement · Replacement of brake fluid reservoir · Replace the brake master cylinder Brake fluid reservoir cap. · Replacement of front brake pipe · Replacement of rear brake pipe · Check front brake caliper assembly.
Brake system 5-27 Diagnosis of Hydraulic Brake System (Continued) System diagnostics Step
Operation Check rear brake caliper assembly In case that the brake fluid is not polluted by oil-based fluid, but it is polluted by water, pollutant, rust, corrosion or brake dust, replace the brake fluid reservoir cap diaphragm which may make the moisture or dust enter the system. 4. Re-fill and exhaust the hydraulic brake system. Refer to “Exhaust of Hydraulic Brake System”. Have operation and necessary repair or replacement completed? 1. Check whether the following parts of brake system have brake fluid leakage. Repair or replace parts with brake fluid leakage. Refer to the corresponding procedure: · Brake master cylinder replacement · Brake master cylinder brake reservoir cap · Replacement of front brake pipe · Replacement of rear brake pipe · Replacement of brake pipe · Check front brake caliper assembly. · Check rear brake caliper assembly. 2. If the above parts of brake system have been repaired or replaced, then exhaust the air in hydraulic brake system. Refer to “Exhaust of hydraulic brake system”. When exhausting air in hydraulic brake system, observe the following status: · Air in the system appears in the position of deflation valve rather than repair position (excluding brake master cylinder replacement) · During exhausting, the brake fluid of each axle can flow smoothly and evenly. Did you find and eliminate the problem? Whether the air in system appears in the position of deflation valve rather than repair position (in addition to the situation on replacing the brake master cylinder)? Whether each axle’s brake fluid is smooth, even in exhausting? Check whether the hydraulic function of brake caliper is working normally. Refer to “Visual check for operation of hydraulic brake component”. Is the hydraulic function of brake caliper working normally? During exhausting, do brake fluid able to flow through hydraulic parts of front axle smoothly and evenly? During exhausting, do brake fluid able to flow through hydraulic parts of rear axle smoothly and evenly? Check whether the hydraulic function of brake caliper is working normally. Refer to “Visual check for operation of hydraulic brake component”. Is the hydraulic function of brake caliper working normally? Confirm whether brake caliper blocks brake fluid or the operation is abnormal: 1. Hoist and support the vehicle. Refer to “Vehicle lifting and hoisting”. 2. Remove the tire and wheel assembly. Refer to “Removal and installation of tire and wheel”. 3. Open suspicious brake caliper deflation valve 4. Use large C-type clamp compress brake caliper piston, observe whether the brake fluid flow is smooth and whether brake caliper piston can move freely. 5. Close brake caliper deflation valve Whether the brake fluid smoothly flows, or whether the brake caliper piston can freely move? Repair or replace the brake caliper with abnormal operation Refer to the corresponding procedure. Brake caliper replacement Whether the repair or replacement has been completed? Exhaust air in hydraulic brake system, observe whether there is air in the system and whether the flow of brake fluid of axle is smooth and even during exhausting. Refer to “Exhaust of hydraulic brake system”. Whether there is air in the system?
Yes
No
· 3.
6
7 8 9 10 11 12
13
14
15
Go to Step 7
Go to Step 12
Go to Step 18
Go to Step 18
Go to Step 9 Go to Step 20
Go to Step 10 Go to Step 14
Go to Step 13
Go to Step 11
Go to Step 17
—
Go to Step 15
Go to Step 13
Go to Step 17
Go to Step 14
Go to Step 20
—
Go to Step 18
Go to Step 16
Brake system 5-28 Diagnosis of Hydraulic Brake System (Continued) System diagnostics Step 16
17
18
19
20
Operation Is each axle’s brake fluid smooth and even while exhausting? 1. Check whether there is brake fluid blockage sign such as bend, kinks, clamp or damage occurred to the hydraulic brake pipe or flexible brake pipe. Refer to “Brake pipe and hose inspection” 2. Replace all bent, twisted, clamped or damaged hydraulic brake pipe or flexible brake pipe. Brake pipe When necessary, refer to the following procedures: · Replacement of front brake pipe · Replacement of rear brake pipe · Replacement of brake pipe 3. For obvious bend, kinks, clamp or damage of hydraulic brake pipe or hose unfound, replace the hydraulic brake flexible hose at the blocking position. Did you find and eliminate the problem? 1. Check whether there is component of hydraulic brake system in the position of sealing element or joint. The brake fluid is leaked, so that the air enters the system. 2. Check whether there is recently being repaired sign occurred to the component of hydraulic brake system to make air enter the system. 3. Repair or replace any component installed incorrectly or leaking brake fluid. Did you find and eliminate the problem? 1. Check whether there is brake fluid leakage occurred to internal part of brake master cylinder. Refer to “Internal leakage test of brake system”. 2. If internal leakage of brake fluid is found, repair or replace the brake master cylinder. Refer to “The Brake master cylinder replacement”. Did you find and eliminate the problem? Install or connect the parts removed or disconnected during diagnosis. Did you complete the operation?
Yes Go to Step 20 Go to Step 20
No Go to Step 17 Go to Step 18
Go to Step 20
Go to Step 19
Go to Step 20
Return back to “Symptom List”
Return to “Symptoms table” in case that the hydraulic brake system is normal
—
Brake system 5-29
Road test of vehicle brake system Pre-examination 1. Conduct visual inspection on whether the touchable brake system component is obviously damaged or leaked, if it is, this may indicate that the vehicle must be sequentially driven after further inspection is completed. 1. Check the fluid level of brake master cylinder Brake fluid reservoir, and adjust it only when necessary under road test of brake system. 2. Check the inflation pressure of tire, and adjust it when necessary. 3. Check the tire tread, to ensure that it is same or extremely similar, particularly for the tire on the same axle. 4. Ensure that the vehicle load is evenly distributed before road test of brake system. Procedure of road test Warning: Test vehicle on the road under the premise of ensuring safety, and abide by all traffic laws. Don’t try any operation which may endanger vehicle control. Violation to the above safety instructions will result in serious personal injury and damage vehicle. 1. Start up and operate engine at idle speed. 2. View whether the brake system warning lamp keeps lights up. 3. In case that the brake system warning lamp keeps lights up, continuous road test of vehicle is prohibited, until the diagnosis and repair are completed. 4. Select the flat, dry, clean and level road or large area that no traffic limitation or barrier exist to the greatest extent, and conduct low-speed road test to the brake system. 5. Park, shift transmission to neutral gear (manual transmission) or parking gear (automatic transmission), and press the brake pedal slightly. Observe the pedal feeling and its stroke. 6. In case that the brake pedal stroke is too long, continuous road test is prohibited, until the repair is completed. 7. Transfer to Step 8 if the brake pedal stroke is not too wide. 8. Loosen and then tread the brake. 9. Shift transmission to forward gear while continuing to press the brake pedal, and then loosen the brake, to make the engine run under idling and leave the parking position. Observe whether brake system is slowly released. 10. Let the assistant to observe the vehicle performance from the exterior, and drive the vehicle at a low speed, and press the brake slightly when the vehicle passes through the front of assistant. Let the assistant to observe the noise situation of brake system from the vehicle side that it is the closest to him, and observe the pedal effort and its stroke at you own.
11. If brake pedal is too hard or its stroke is too long, don’t continue carrying out road test until the repair is completed. 12. Transfer to Step 13 if the brake pedal is not too hard and the pedal stroke is not too long. 13. Drive the vehicle at the same low speed along the opposite direction, and press the brake pedal slightly when passing through the front of assistant. Let the assistant to observe the noise situation of brake system from the vehicle side that it is the closest to him. 14. Drive the vehicle at a low speed, shift transmission to neutral gear (N), however, no brake pedal is trod observe whether there is the phenomenon on sudden reduction of speed, if it is, show that the brake may be blocked. 15. Select the flat, dry, clean and level road that the traffic is not heavy as far as possible, and conduct medium-speed road test to the brake system. 16. Make vehicle drive at a medium speed. Observe whether the vehicle is off tracking or its wheel mark is incorrect when no brake pedal is trod. 17. Continue to drive at a medium speed, meanwhile, press the brake pedal slightly for several times. Observe the pedal effort and its stroke, and observe whether there is noise, pulsation or brake pad age phenomenon occurred to the brake system. 18. If brake pedal is too hard or its stroke is too long, don’t continue carrying out road test until the repair is completed. 19. Transfer to Step 20 if the brake pedal is not too hard and the pedal stroke is not too long. 20. Continue to drive at a medium speed, meanwhile, press the brake by use of medium strength for several times. Observe the pedal effort and its stroke, and observe whether there is judder or uneven brake phenomenon occurred to the brake system – at both sides or the front or the rear. There is slight “Nod” phenomenon occurred to the front of vehicle in case of medium brake strength. 21. If brake pedal is too hard or its stroke is too long, don’t continue carrying out road test until the repair is completed.
Brake system 5-30
Check on external leakage of brake system Warning: Refer to “Warning about irritation of brake fluid”. Warning: Refer to “Warning about impact of brake fluid on paint and electrical component”. 1. The liquid level of brake fluid reservoir shall be firstly checked when checking the external leakage of brake fluid. Although slight reduction of level of brake fluid caused due to wear of brake pad can be deemed as normal phenomenon, if the level is too low, this may indicate that there is brake fluid leakage phenomenon occurred to the hydraulic system. 2. Adjust the level of brake fluid if it is too low. 3. Start up and operate engine at idle speed. 4. Press the brake pedal by use of constant medium strength. In case that the brake pedal gradually declines when treading it, this may indicate that the brake fluid is leaked. 5. Shift ignition switch to OFF position. 6. Conduct visual inspection on whether there is brake fluid leakage, severe corrosion or damage phenomenon occurred to the brake system component. Pay special attention to the joints of all brake pipes and flexible hoses, and ensure that no slightest leakage of brake fluid exists – even if the brake pedal is solid and stable: · Brake pipe to master cylinder joint · All brake pipe joints · Brake pipes · Brake caliper assembly 7. Brake master cylinder brake fluid reservoir around a slight wetting can be regarded as a normal phenomenon, but if there is any brake system parts leakage of brake fluid, it is necessary to immediately pay attention to. Repair or replace these parts if any of the above parts appear signs of brake fluid leakage. After repair or replacement, re check the hydraulic brake system to ensure the normal function.
Internal leakage test of brake system Warning: Refer to “Warning about irritation of brake fluid”. Warning: Refer to “Warning about impact of brake fluid on paint and electrical component”. 1. Start up and operate engine at idle speed. 2. Press the brake pedal slightly by use of stable strength. Observe the pedal feeling and its stroke. 3. Loosen the brake and shift ignition switch to OFF position. 4. Execute the following Steps if the brake pedal feeling is soft, but the brake pedal stroke is not too long. 4.1. Check whether external leakage exists on brake system. Refer to “Check on external leakage of brake system”.
4.2. Exhaust the air in brake system by pressure, so as to clear all air brought in system. Refer to “Exhaust of hydraulic brake system”.
15AH-0504001
5. Execute the following Steps if the brake pedal feeling is not soft, but the brake pedal stroke is too long: 5.1. Loosen the master cylinder to mounting nuts of brake booster. 5.2. Pull out the defined length of master cylinder carefully from brake booster, to check its mounting surface. 5.3. Check whether brake fluid of master cylinder mounting surface on Primary Piston (2) is leaked. 6. In case that any leakage is occurred around Primary Piston (2) of master cylinder, and there is leakage occurred to Main Sealing Element (4) or Auxiliary Sealing Element (3) of primary piston, then the master cylinder needs to overhaul or replace. 7. In case that there is no leakage sign occurred to Primary Piston (2) of master cylinder, exhaust the air in brake system by pressure. Refer to “Exhaust of hydraulic brake system”. 8. In case that the brake pedal feeling is not soft, and the brake pedal stroke is stable and not too wide at first, but it gradually reduces later on, then the master cylinder needs to overhaul or replace as there is internal leakage occurred to the position of Secondary Piston (1) where Main Sealing Element (6) or Auxiliary Sealing Element (5) of secondary piston passes through.
Brake system 5-31
Visual inspection to operation of hydraulic brake component
15AH-0504002
Warning: Refer to “Warning about irritation of brake fluid”. Special Notes: Refer to “Special Notes on Impact of Brake Fluid on Paint and Electrical Component”. 1. Remove the tire and wheel assembly, fix the disc brake by use of wheel nuts with conical surface, and then conduct visual inspection to sealing part of Dust Shield (2) of brake caliper piston to ensure that no brake fluid leaks. 2. In case that there is leakage sign occurred to brake fluid, the brake caliper needs to overhaul or replace. 3. Observe the relative position between Brake Caliper Piston (1) and brake caliper shell when brake system doesn’t work (4). 4. Let the assistant to tread down the brake pedal and loosen it, repeat the above action for several times, meanwhile, observe the working situation of hydraulic brake caliper. ● Observe whether Brake Caliper Piston (1) smoothly and evenly moves during coalescing brake system (5) for each time. ● Observe whether Brake Caliper Piston (1) smoothly and evenly moves during releasing brake system (6) for each time. 5. In case that Brake Caliper Piston (1) doesn’t smoothly and evenly move when coalescing or releasing brake system, the square Sealing Element (3) of piston may be worn or damaged, and the brake caliper assembly may need to overhaul or replace.
Brake system 5-32
Check of brake pipe and hose Warning: Refer to “Warning about irritation of brake fluid”.
15AH-0504003
Warning: Refer to “Warning on influence of brake fluid on paint and electrical parts” 1. Check whether all brake pipes have the following conditions visually: ● Kink ● Incorrect layout ● Fixed part is lost or damaged ● Joints appear leakage ● Severe corrosion 2. In case that the above-mentioned condition is occurred to any brake pipe, the corresponding one or more brake pipe needs to replace. 3. Be sure to support the axle to the driving height correctly, so as to keep the relative position correct between flexible brake hose and chassis. 4. Check whether all the flexible brake pipes have the following conditions visually: ● Kink (1) ● Incorrect layout ● Distortion ● Wear ● Fixed part is lost or damaged ● Joints appear leakage ● Cracking ● Corrosion ● Blister or bulge 5. In case that the above-mentioned condition is occurred to any flexible brake pipe, the corresponding one or more flexible brake pipe needs to be replaced. 6. Press the flexible brake pipe tightly by figures, and check whether there is Soft Point (2) (such phenomenon indicates that there is internal blockage). Check the overall length of each hose. 7. In case that Soft Point (2) is found on any flexible brake pipe, such pipe needs to replace.
Brake system 5-33
Maintenance guide Check and filling of brake fluid Note: Brake fluid will damage the paint surface. If brake fluid overflows carelessly, please immediately wipe off and rush the area with water. Note: In case that the level of brake fluid is too low, the brake fluid level warning lamp will send alarm, and remind to fill the brake fluid.
13AH-0501004
Adjustment procedure 1. Clear the area around brake fluid reservoir cap. 2. Remove the brake fluid reservoir cap and sealing ring. 3. Check the fluid level height of brake fluid reservoir. 4. Fill brake fluid into brake fluid reservoir if necessary, until the level reaches MAX marker. Note: Please make sure to use clean DOT4 brake fluid while supplementing or completely replacing brake fluid. Don’t use the contaminated, otherwise hose and seal may be damaged and leaked, resulting in the loss of braking performance. 5.
Install the brake fluid cap reservoir and sealing ring.
Brake system 5-34
Check of vacuum booster Check procedure 1. Tread down the brake pedal for several times to exhaust the vacuum reserves in vacuum booster after closing the engine. 2. Tread down the brake pedal, and make it stay at the end of stroke. 3. Startup engine 4. Check whether the pedal continues to decline due to generation of boosting force. 5. In case that the brake pedal doesn’t decline, check and repair the vacuum pipe or vacuum booster.
Hydraulic exhausting
brake
system
Note: Exhaust operation must be conducted to hydraulic brake system after servicing such system, so as to ensure the stability of brake performance, and guarantee the traffic safety. Note: Brake fluid will damage the paint surface. If brake fluid overflows carelessly, please immediately wipe off and rush the area with water. Note: Please make sure to use clean DOT4 brake fluid while supplementing or completely replacing brake fluid. Don’t use the contaminated, otherwise hose and seal may be damaged and leaked, resulting in the loss of braking performance. Adjustment procedure 1. Check brake fluid, fill brake fluid into brake fluid reservoir if necessary, until the level reaches MAX marker. 2. Hoist the vehicle to a proper height. 3. Remove the dust shield of exhaust bolt for height sensor braking proportioning control valve (no ABS equipped) or the dust shield of right rear brake exhaust bolt (with ABS equipped). 4. Connect exhaust hose onto exhaust bolt. 5. Immerse the free end of exhaust hose into the dry container with partial clean brake fluid. 6. Loosen the exhaust bolt to release the brake fluid. 7. Tread down the brake pedal to whole stroke stably, which can return independently. 8. Repeat the operation, until no bubble appears in the container, and tighten exhaust bolt to 7-12 N.m (for example, loosening exhaust bolt for loading sensing pressure proportioning valve) or 8-12 N.m (for example, loosening right rear brake exhaust bolt) when the brake pedal stays at the end of lower stroke. 9. Loosen the brake pedal. 10. Remove the exhaust hose from exhaust bolt. 11. Install the dust shield of exhaust bolt for height sensor braking proportioning control valve (no ABS equipped) or the dust shield of right rear brake exhaust bolt (with ABS equipped). 12. Repeat the above exhaust procedure, and exhaust the remaining 3 brakes according to the following sequence. ● Left rear brake ● Right front brake ● Left front brake Warning: In case that the exhaust operation doesn’t conduct according to the above specified sequence, weakening of brake action may be caused. 13. Lower the vehicle 14. Check the brake fluid again, fill brake fluid into brake fluid reservoir if necessary, until the level reaches MAX marker. 15. Check the brake pedal, so as to ensure correct stroke and solid foot feeling during operation. 16. Conduct road test of vehicle, so as to ensure that the brake function is normal.
Brake system 5-35
Replacement reservoir
13AH-0501006
of
brake
fluid
Note: Brake fluid will damage the paint surface. If brake fluid overflows carelessly, please immediately wipe off and rush the area with water. Removal procedure 1. Disconnect the negative electrode of storage battery. 2. Tread down the brake pedal for several times to exhaust the vacuum reserves in vacuum booster. 3. Remove the brake fluid reservoir cap. 4. Take out the brake fluid from brake fluid reservoir. 5. Remove the brake fluid level warning switch. 6. Remove the clamp of clutch hose which is used to connect the brake fluid reservoir, and scrap it. 7. Disconnect clutch hose, and plug the nozzle. 8. Remove the Lock Pin (1) of brake fluid reservoir, and scrap it. 9. Take down brake fluid reservoir (2).
Installation Procedure 1. Remove the new brake fluid reservoir cap. 2. Take down brake fluid reservoir (2). 3. Install Lock Pin (1) of brake fluid reservoir. 4. Remove the plug from the nozzle of clutch hose. 5. Connect the clutch hose onto brake fluid reservoir by use of new clamp. 6. Connect the brake fluid level warning switch. 7. Refuel brake fluid Refer to “Check and refuel of brake fluid”. 8. Install the of brake fluid reservoir cap. 9. Connect the negative electrode of storage battery. 10. Vent hydraulic brake system. Refer to “Venting of hydraulic brake system”.
13AH-0501006
Brake system 5-36
Brake master replacement
cylinder
Note: Brake fluid will damage the paint surface. If brake fluid overflows carelessly, please immediately wipe off and rush the area with water. Removal procedure 1. Disconnect the wiring harness of switch for brake fluid level pilot lamp, and place it aside. 2. Disconnect brake pipe to brake master cylinder joint (1). Cover the joint of brake pipe and plug the nozzle of master cylinder, so as to prevent the brake fluid from draining and polluting the environment. 3. Disconnect clutch hose, and plug the nozzle. 15AH-0501009
4. Remove brake master cylinder nut (1), and scrap it. 5. Remove the brake master cylinder equipped with brake fluid reservoir. 6. Check whether the sealing elements between brake master cylinder and vacuum brake booster are damaged, and replace them when necessary. 7. Remove the lid of brake fluid reservoir. Refer to “Replacement of brake fluid reservoir”. 8. Take down the brake master cylinder.
15AH-0501010
Installation Procedure 1. Install the brake fluid reservoir onto brake master cylinder. Refer to “Replacement of brake fluid reservoir”. 2. Install brake master cylinder on vacuum booster.
15AH-0501009
Warning: Refer to “Warning on tightens”. 3. Install new brake master cylinder nut (1), and tighten the torque of nuts to 20±3 N.m. 4. Install Brake Pipe (1) to brake master cylinder, and tighten the torque of joint to 16±2 N.m. 5. Connect the wiring harness connector pipe clip for switch of brake fluid level pilot lamp. 6. Connect clutch hose. 5. Vent air from brake fluid system. Refer to “Exhaust of hydraulic brake system”.
Brake system 5-37
Replacement of brake lamp switch Removal procedure 1. Disconnect the negative electrode of storage battery. 2. Disconnect Brake Lamp Switch (1) from brake pedal bracket through exerting strength upwards after rotating 90°. 3. Remove Brake Lamp Switch (1) from wiring harness.
15AH-0501030
Installation Procedure 1. Connect Brake Lamp Switch (1) onto wiring harness. 2. Install Brake Lamp Switch (1) on the brake pedal bracket through exerting strength downwards, and then rotate 90° for locking. 3. Connect the negative electrode of storage battery.
15AH-0501030
Brake system 5-38
Replacement of brake pedal Removal procedure 1. Remove Brake Lamp Switch (1). Refer to “Replacement of brake lamp switch”. 2. Remove Lock Pin (2) and Pin roll (3) used for connecting brake pedal and vacuum booster. 3. Remove Torsional Spring (4) of pedal shaft. 4. Remove Nut (5) and Bolt (6) used for pedal shaft. 5. Take down Brake Pedal (7)
15AH-0501035
Installation Procedure 1. Install Brake Pedal (7) onto brake pedal bracket assembly. 2. Install Bolt (6) and Nut (5) used for brake pedal shaft, and tighten the torque of nut to19±3 N.m. 3. Install Torsional Spring (4) of brake pedal. 4. Install Lock Pin (2) and Pin Roll (3) used for connecting brake pedal and vacuum booster. 5. Install brake lamp switch (1). Refer to “Replacement of braking lamp switch”.
15AH-0501035
Brake system 5-39
Replacement of vacuum booster. Reminder: the replacement of the Brake Booster Vacuum might remove Engine Intake Manifold first Note: Brake fluid will damage the paint surface. If brake fluid overflows carelessly, please immediately wipe off and rush the area with water. Removal procedure 1. Remove the brake master cylinder, and refer to “Brake master cylinder replacement”. 2. Remove Lock Pin (1) and Pin Roll (2) used for connecting brake pedal and vacuum booster.
13AH-0501016
3.
Remove Mounting Nut (1) used for booster from double-end stud stretched from the instrument board.
4.
Disconnect Vacuum Hose (1) of vacuum booster, and refer to “Replacement of Vacuum Hose of Vacuum Booster”. Take down Vacuum Booster (2).
13AH-0501017
5.
13AH-0501009
Brake system 5-40
Installation Procedure 1. Locate Vacuum Booster (2) onto the brake pedal bracket. 2. Install Vacuum Hose (1) onto vacuum booster. Refer to “Replacement of Vacuum Hose of Vacuum Booster”.
13AH-0501009
3. Install Fixed Nut (1) for vacuum booster, and tighten the torque of fixed nuts to 19±3 N.m.
13AH-0501017
4. Install Lock Pin (1) and Pin Roll (2) used for connecting brake pedal and vacuum booster. 5. Install brake master cylinder on vacuum booster. Refer to “The Brake master cylinder replacement”. 6. Vent air from brake fluid system. Refer to “Exhaust of hydraulic brake system”.
13AH-0501016
Brake system 5-41
Replacement of vacuum hose of vacuum booster Removal procedure 1. Disconnect the fixed pieces of vacuum hose onto the body pipe clip. 2. Loosen Clamp (1) used for connecting vacuum hose and vacuum booster. 3. Loosen Clamp (1) used for connecting vacuum hose and engine intake manifold. 4. Take down Vacuum Hose (3) of vacuum booster, meanwhile, block the orifice of vacuum booster pipe and orifice of engine intake manifold.
15AH-0501019
Installation Procedure 1. Install Vacuum Hose (3) of vacuum booster onto vacuum booster. 2. Connect Vacuum Hose (3) of vacuum booster onto engine intake manifold. 3. Install Clamp (1) used for connecting vacuum hose and vacuum booster. 4. Install Clamp (2) used for connecting vacuum hose and engine intake manifold. 5. Fix the vacuum hose onto the body pipe clip.
15AH-0501019
Brake system 5-42
Replacement of brake pipe for master cylinder (ABS)
15AH-0501025
Replacement of brake pipe for master cylinder Figure number Part Name Warning: Refer to “Warning about irritation of brake fluid”. Warning: Refer to “Warning about impact of brake fluid on paint and electrical component”. Brake Pipe 1 for master cylinder Warning: Refer to “Warning on tightens”. Procedures 1. Cover or block the connections on ABS control module and brake master cylinder to avoid brake 1 fluid overflowing or being contaminated. Tighten ing Torque 16±2 N.m 2. Execute the venting procedure of brake system. Refer to “Exhaust of hydraulic brake system”. Brake Pipe 2 for master cylinder Warning: Refer to “Warning on tightens”. Procedures 1. Cover or block the connections on ABS control module and brake master cylinder to avoid brake 2 fluid overflowing or being contaminated. Tighten ing Torque 16±2 N.m 2. Execute the venting procedure of brake system. Refer to “Exhaust of hydraulic brake system”.
Brake system 5-43
Replacement of front brake pipe (ABS) Warning: Refer to “Warning about irritation of brake fluid”. Warning: Refer to “Warning about impact of brake fluid on paint and electrical component”. Removal procedure
15AH-0501005
1. Lift the vehicle. 2. Remove front tire & wheel assembly refer to “Removal and installation of tire and wheel”. 3. Disconnect the connector of left front brake pipe (1) from brake pressure modulator valve. 4. Cover or plug the connector of brake pipe and brake pressure modulator valve fluid transfer pipe, to prevent the brake fluid from flowing out or being polluted. 5. Disconnect the left front brake hose from the brake pipe, and cover or plug the connector of brake pipe and the connector of brake pipe, to prevent the brake fluid from flowing out or being polluted. 6. Remove the fixed clip of brake pipe. 7. Remove the brake pipe jacket, pull out the left front brake pipe from engine compartment, and take down the left front brake pipe.
Installation procedure
15AH-0501005
1. Install the left front brake pipe from the engine compartment to make its lower end pass through the brake pipe hole jacket on body, and fix the brake pipe jacket. 2. Take down the plug or cap from connector of brake pipe and oil outlet of brake pressure modulator valve. 3. Fix the connector of left front brake pipe (1) to the brake pressure modulator valve, and tighten the torque of connector to 16 N.m. 4. Connect the left front brake pipe with the connector of brake hose, and tighten the torque of connector to 16 N.m. 5. Make sure that the hose does not contact with any part of the suspension. Check the hose for conditions while turning extremely left and right. If the hose contacts with the suspension, remove hose then fix it. 6. Install the fixed clip of brake pipe. 7. Exhaust the air from hydraulic brake system. Refer to “Exhaust of hydraulic brake system”. 8. Install front tire & wheel assembly. Refer to “Removal and installation of tire and wheel”. 9. Lower the vehicle
Brake system 5-44
Replacement of Brake Pressure Regulating Valve Pipe（ABS）
15AH-0501025
Replacement of Brake Pressure Regulating Valve Pipe（ABS） Figure number Part Name CAUTION: The brake fluid can damage the painted surface. If accidentally spilled, quickly wipe the brake fluid and clean the area with water.
Removal Procedures
1. 2. 3. 4. 5.
6. 1. 2.
Installation Procedures
3. 4. 5.
6.
Lift the vehicle. Disconnect front pressure connector pipe (1) of the brake pressure regulator valve. Disconnect the brake hose from the rear brake hose connection (3). Close the brake pipe connector to prevent brake fluid loss and contamination of the environment. Remove the brake pipe clamp (2) from the brake pressure regulator. Remove the brake pipe from the brake pressure regulator valve. Locate the brake pipe in the brake pressure regulator. Connect the brake pipe from the brake pressure regulator valve to the front pipe coupling (1) of the brake pressure regulator and tighten the joint tightening torque to 16 ± 2 Nm. Install the fixed clamp (2), and fix the brake pipe clamp in the brake pressure regulating valve. Connect the brake pipe to the rear brake hose connection (3) of the brake pressure regulator and tighten the joint with torque to 16 ± 2 Nm. Execute the brake system exhaust procedure. Refer to "Exhaust of Hydraulic Braking System". Lower the vehicle from the lift.
Brake system 5-45
Front brake pipe replacement right（ABS） WARNING: Refer to "WARNING ON RESISTANCE TO BRAKE FLUID". CAUTION: Refer to "Caution on the Effects of Brake Fluid on Paints and Electrical Parts".
15AH-0501011
15AH-0501012
Removal Procedures 1. Lift the vehicle. 2. Remove the front tire and wheel assembly, refer to “Removal and Installation of Tires and Wheels". 3. From the brake pressure regulator, disconnect the right front brake pipe (1). Cover or plug the brake pipe joints and brake pressure regulating valve outlet to prevent the brake fluid loss or contamination of the environment. 4. Disconnect the right front brake pipe clamp (2). 5. Disconnect the front brake pipe from the front brake hose connector (3). 6. Remove the brake pipe clamp (1). 7. Remove the brake pipe jacket, pull the right front brake pipe out of the lower engine compartment, and remove the right front brake pipe. Installation Procedures 1. Install the right front brake pipe from the lower position of the engine compartment, so that the brake pipe passes through brake pipe jacket, and the cover is fixed to the body. 2. Remove the brake pipe stopper or cap. 3. Connect the front brake pipe (1) to the brake pressure regulator and tighten the tightening torque connector to 16 ± 2 Nm. 4. Install the brake pipe clamp (2). 5. Attach the front brake pipe to the front brake hose connector (3) and tighten the torque to 16 ± 2 Nm. 6. Ensure the brake pipe clamp (1). 7. Ensure that the hose does not touch any part of the suspension. Check the condition of the hose at extreme left and extreme right turns. If the hose comes in contact with the suspension, remove the hose then fix it. 8. Drain the air from the hydraulic brake system. Refer to “Exhausting Hydraulic Brake System." 9. Install the front tire and wheel assembly. Refer to “Removal and Installation of Tires and Wheels". 10. Lower the vehicle.
Brake system 5-46
Front brake pipe replacement – left（ABS） WARNING: Refer to "WARNING ON RESISTANCE TO BRAKE FLUID". CAUTION: Refer to "Caution on the Effects of Brake Fluid on Paints and Electrical Parts". Removal Procedures
15AH-0501013
1. Lift the vehicle. 2. Remove the front tire and wheel assembly, refer to “Removal and Installation of Tires and Wheels". 3. From the brake pressure regulator, disconnect the left front brake pipe (1) connector. 4. Cover or block the brake connector and brake pressure regulator valve outlet to prevent brake fluid loss or contamination. 5. Disconnect the left front brake hose from the brake pipe, cover or plug the brake pipe (3) to prevent loss or contamination of the brake fluid. 6. Remove the brake pipe retaining clip (2). 7. Remove the brake pipe jacket, pull the left front brake pipe out of the engine compartment, and remove the left front brake pipe. Installation Procedures
15AH-0501014
15AH-0501013
1. Install the right front brake pipe from the lower position of the engine compartment, so that the brake pipe passes through brake pipe jacket, and the cover is fixed to the body. 2. Remove the stopper fitting and the stopper or cover on the oil outlet of the brake pressure regulating valve. 3. Attach the left front brake pipe (1) fitting to the brake pressure regulator and tighten the torque to 16 ± 2 Nm. 4. Connect the left front brake pipe to the brake hose connector (3) and tighten the joint tightening torque to 16 ± 2 Nm. 5. Ensure that the hose does not touch any part of the suspension. Check the condition of the hose at extreme left and extreme right turns. If the hose comes in contact with the suspension, remove the hose then fix it. 6. Install the brake pipe clamp (2). 7. Drain the air from the hydraulic brake system. Refer to "Exhaust of Hydraulic Braking System". 8. Install front tire and wheel assembly. Refer to “Removal and Installation of Tires and Wheels". 9. Lower the vehicle.
Brake system 5-47
Replacement of master cylinder brake pipe (non-ABS)
15AH-0501025
Replacement of master cylinder brake pipe Figure number Parts Name WARNING: Refer to "WARNING ON RESISTANCE TO BRAKE FLUID". CAUTION: Refer to "Caution on the Effects of Brake Fluid on Paints and Electrical Parts".
1
2
Master cylinder brake pipe 1 CAUTION: Refer to "WARNING ON TIGHTENS". Procedure 1. Cover or block the interface between the ABS control module and the brake master cylinder to prevent brake fluid loss or contamination. Tightening torque 16 ± 2 N · m 2. Execute the brake system exhaust procedure. Refer to "Exhaust of Hydraulic Braking System". Master cylinder brake pipe 2 CAUTION: Refer to "WARNING ON TIGHTENS". Procedure 1. Close or block the interface between the ABS control module and the brake master cylinder to prevent brake fluid loss or contamination. Tightening torque 16 ± 2 N · m 2. Execute the brake system exhaust procedure. Refer to "Exhaust of Hydraulic Braking System".
Brake system 5-48
Replacement of brake pressure Regulation valve pipe (non-ABS) WARNING: Refer to "WARNING ON RESISTANCE TO BRAKE FLUID". CAUTION: Refer to "Caution on the Effects of Brake Fluid on Paints and Electrical Parts".
15AH-0501005
Removal Procedures 1. Lift the vehicle. 2. Disconnect the brake pressure regulator front hose (1) from the brake pressure regulator outlet pipe connector. 3. Detach the front pressure pipe from the clamp (2). 4. Disconnect the brake pressure regulator front pipe from the middle hose connector (1). 5. Block or plug the brake hose connector to prevent brake fluid from draining and contaminating the environment. 6. Detach the front pressure pipe from the clamp (2). 7. Brake pressure regulator valve before the pipe, adjusted to the appropriate angle, removed from the car. Installation Procedures 1. 2.
3.
4.
5. 15AH-0501005
6.
Locate the front brake pressure regulator pipe. Connect the front pressure pipe to the center pipe connection (1) and tighten the joint tightening torque to 16 ± 2 Nm. Install the fixed clamp (2), and fix the front pressure pipe of the brake pressure regulator on the clamp. Connect the brake pressure regulator front (1) to the brake pressure regulator fitting and tighten the joint tightening torque to 16 ± 2 Nm. Execute the brake system exhaust procedure. Refer to "Exhaust of Hydraulic Braking System". Lower the vehicle.
Brake system 5-49
Replacement
brake pressure regulator valve (non-ABS)
15AH-0501025
Figure Parts Name number CAUTION: The brake fluid can damage the painted surface. If accidentally spilled, quickly wipe the brake fluid and clean the area with water. Removal 1. Lifting vehicles. Procedures 2. Disconnect the brake hose from the front of the brake pressure regulator valve (1). 3. Disconnect the brake hose from the rear brake hose connector (3). 4. Cover the brake pipe joints to prevent the brake fluid loss and contaminate of the environment. 5. Remove the pipe in the brake pressure regulator from the retaining clip (2). 6. Remove the pipe from the brake pressure regulator valve. Installation 1. Locate the pipe in the brake pressure regulating valve (1) and tighten the joint Procedures tightening torque to 16 ± 2 N · m. Connect the brake pressure regulator valve to the front of the brake pressure regulator valve (1). 2. Install the fixed clamp (2), and fix the pipe in the brake pressure regulating valve on the clamp. 3. Connect the pipe to the rear brake hose connection (3) of the brake pressure regulator and tighten the joint tightening torque to 16 ± 2 Nm. 4. Perform brake system exhaust procedure. Refer to "Exhaust of Hydraulic Braking System". 5. Lower the vehicle.
Brake system 5-50
Front brake pipe replacement right (non-ABS) WARNING: Refer to "WARNING ON RESISTANCE TO BRAKE FLUID". CAUTION: Refer to "Caution on the Effects of Brake Fluid on Paints and Electrical Parts".
15AH-0501011
15AH-0501012
Removal Procedures 1. Lifting vehicles. 2. Remove the front tire and wheel assembly, refer to “Removal and Installation of Tires and Wheels". 3. From the brake pressure regulator, disconnect the right front brake pipe (1). Cover or plug the brake pipe joints and brake pressure regulating valve outlet to prevent the brake fluid loss or contamination of the environment. 4. Disconnect the right front brake pipe clamp (2). 5. Disconnect the front brake pipe from the front brake hose connector (3). 6. Remove the brake pipe clamp. 7. Remove the brake pipe jacket, pull the right front brake pipe out of the lower engine compartment, and remove the right front brake pipe. Installation Procedures 1. From the lower part of the engine compartment, install the right front brake pipe, until brake pipe through the jacket hole, fixed sheath to the body. 2. Remove fitting stopper or cover. 3. Connect the front brake pipe (1) to the brake pressure regulator and tighten the tightening torque connector to 16 ± 2 Nm. 4. Install the brake pipe clamp (2). 5. Attach the front brake pipe to the front brake hose connector (3) and tighten the joint tightening torque to 16 ± 2 Nm. 6. Fixed brake pipe clamp. 7. Ensure that the hose does not touch any part of the suspension. Check the condition of the hose at extreme left and extreme right turns. If the hose comes in contact with the suspension, remove the hose then fix it. 8. Drain the air from the hydraulic brake system. Refer to "Exhaust of Hydraulic Braking System". 9. Install front tire and wheel assembly. Refer to “Removal and Installation of Tires and Wheels". 10. Lower the vehicle.
Brake system 5-51
Front brake pipe replacement – Left (non-ABS) WARNING: Refer to "WARNING ON RESISTANCE TO BRAKE FLUID". CAUTION: Refer to "Caution on the Effects of Brake Fluid on Paints and Electrical Parts".
15AH-0501013
15AH-0501014
15AH-0501013
Removal Procedures 1. Lifting vehicles. 2. Remove the front tire and wheel assembly, refer to “Removal and Installation of Tires and Wheels". 3. From the brake pressure regulator, disconnect the left front brake pipe (1), (3) connector clamp. 4. Cover or block the brake pipe joints and brake pressure regulating valve outlet to prevent the brake fluid loss or contamination. 5. Disconnect the left front brake hose from the brake pipe, cover or block the brake pipe connector and the brake pipe connector to prevent brake fluid loss or contamination. 6. Remove the brake pipe retaining clip. 7. Remove the brake pipe jacket, pull the left front brake pipe out of the engine compartment, and remove the left front brake pipe.
Installation Procedures 1. From the lower part of the engine compartment, install the right front brake pipe, until brake pipe through the jacket hole, fixed sheath to the body. 2. Remove the fitting stopper and the block or cover on the oil outlet of the brake pressure regulating valve. 3. Attach the left front brake pipe (1) fitting to the brake pressure regulator and tighten the joint tightening torque to 16 ± 2 Nm. 4. Connect the left front brake pipe to the brake pipe soft fitting (3) and tighten the joint tightening torque to 16 ± 2 Nm. 5. Ensure that the hose does not touch any part of the suspension. Check the condition of the hose at extreme left and extreme right turns. If the hose comes in contact with the suspension, remove the hose then fix it. 6. Install the brake pipe retaining clip. 7. Drain the air from the hydraulic brake system. Refer to "Exhaust of Hydraulic Braking System". 8. Install front tire and wheel assembly. Refer to “Removal and Installation of Tires and Wheels". 9. Lower the vehicle.
Brake system 5-52
Proportional Valve Replacement (Non-ABS) CAUTION: The brake fluid can damage the painted surface. If accidentally spilled, quickly wipe the brake fluid and clean the area with water.
13AH-0501023
13AH-0501024
Removal Procedures 1. Lift the vehicle on the lift. 2. Disconnect the four brake hose and proportional valve connector pipe. 3. Break four of brake pipe, and use the container to receive the brake pipe out of the brake fluid, while three of brake pipr blocked plug. 4. Remove proportional valve and rear bridge coupling nut (2). 5. Disconnect proportional valve spring. 6. Remove the two bolts connecting the sensor to the body. 7. Separate proportional valve. Installation Procedures 1. Position proportional valve. 2. Install two of stud bolt connected to the body and tighten it to 19-25 N.m. 3. Connect proportional valve spring. 4. Install proportional valve and rear-bridge coupling nut and tighten to 19-25 N.m. 5. Remove the four stoppers. 6. Connect the four brake pipes to the load cell and tighten the three brake pipes to valve connection tubing connector to 14-18 N • m. 7. Lower the vehicle. 8. Fill the brake fluid. Refer to "Brake fluid check and refill". 9. Perform a hydraulic brake exhaust. Refer to "Brake Fluid Exhaust".
Brake system 5-53
Replacement of front brake hose Warning: Refer to “Warning about irritation of brake fluid”. Warning: Refer to “Warning about impact of brake fluid on paint and electrical component”. Removal procedure 1. Lift the vehicle. 2. Remove front tire & wheel assembly by reference to “Removal and installation of tire and wheel”. 3. Disconnect the connector of front brake hose from the front brake pipe. 4. Remove brake pipe fixed clip (1). 5. Remove brake pipe fixed clip (2). 15AH-0501015
6. Disconnect the connector of front brake hose (1) from the front brake caliper. 7. Cover or plug the connector of brake pipe and oil outlet of brake caliper, to prevent the brake fluid from flowing out or being polluted. 8. Take down the front brake hose (2).
15AH-0501018
15AH-0501015
Installation procedure 1. Position the front brake hose (2). 2. Install the connector of front brake hose (1) to the front brake caliper, and tighten the torque of connector to 16 N.m. 3. Connect front brake pipe with the connector of front brake hose, and tighten the torque of connector to 16 N.m.
4. Install brake pipe fixed clip (2). 5. Install brake pipe fixed clip (1). 6. Make sure that the hose does not have contact with any part of the suspension. Check the hose for conditions while turning extremely left and right. If the hose has contact with the suspension, remove hose then fix it. 7. Exhaust the air from hydraulic brake system. Refer to “Exhaust of hydraulic brake system”. 8. Install front tire & wheel assembly. Refer to “Removal and installation of tire and wheel”. 9. Lower the vehicle.
Brake system 5-54
Replacement of rear brake hose Warning: Refer to “Warning about irritation of brake fluid”. Removal procedure 1. Lift the vehicle with lifting machine. 2. Disconnect the oil pipe connector (1) used for connecting rear brake hose and hard pipe of brake pressure modulator valve. 3. Disconnect the oil pipe connector (2) used for connecting rear brake hose and brake pipe of rear brake, and receive the brake fluid flowing out of the brake pipe by use of container. 4. Remove the snap spring (3) of connector used for connecting rear brake hose and body-end support. 5. Remove the snap spring (4) of connector used for connecting rear brake hose and rear axle-end support. 6. Plug the port connecting to rear brake hose. 7. Take down rear brake hose (5). 15AH-0501020
15BL-0504011
Installation procedure 1. Remove the plug of the port connecting to rear brake hose. 2. Position the rear brake hose (5). Note: The rear brake hose shall not have twist or other forms of deformation. 3. Install the snap spring (3) of connector used for connecting rear brake hose and body-end support. 4. Connect the oil pipe connector (1) used for connecting rear brake hose and hard pipe of brake pressure modulator valve, and tighten the tightening torque to 16 N.m. 5. Install the snap spring (4) of connector used for connecting rear brake hose and rear axle-end support. 6. Connect the oil pipe connector (2) used for connecting rear brake hose and rear axle-end brake pipe, and tighten the tightening torque o 16 N.m. 7. Fill brake fluid. Refer to “Inspection and filling of brake fluid”. 8. Exhaust the air of hydraulic brake system. Refer to “Exhaust of Hydraulic Brake System”. 9. Lower the vehicle from lifting machine.
Brake system 5-55
Rear brake hose replacement – Brake Disc
16AH-0501021
WARNING: Refer to "WARNING ON RESISTANCE TO BRAKE FLUID". Removal procedures 1. Lift the vehicle on the lift. 2. Remove the rear brake hose bolts (1). 3. Disconnect the rear brake caliper assembly from the rear brake hose connector (2) and receive the brake fluid from the brake pipe with the container. 4. Remove the rear brake hose from the body end bracket connector retainer (3). 5. Disconnect the rear brake hose (2) from the rear brake hose (1). 6. Plug the connector (4) connected to the rear brake hose. 7. Remove the rear brake hose (2).
Installation procedure
16AH-0501022
1. Remove the connector (4) stopper from the rear brake hose. 2. Locate the rear brake hose (2). CAUTION: The rear brake hose must not be twisted, or otherwise deformed. 3. Connect the rear brake hose (2) to the rear brake hose (1) and tighten to 16 ± 2 N.m. 4. Attach the rear brake hose to the body end bracket connection connector retainer (3). 5. Connect the rear brake caliper assembly to the rear brake hose connector (2). 6. Install the rear brake hose bolts (1) and tighten to 40 ± 5 N.m. 7. Fill the brake fluid. Refer to "Brake fluid check and refill". 8. Perform a hydraulic brake exhaust. Refer to "Brake Fluid Exhaust". 9. Lower the vehicle.
Brake system 5-56
Free play stroke inspection of brake pedal
Free play stroke
front floor
13AH-0501035
Press the brake pedal for three times when the engine stops, so as to eliminate the residual vacuum degree in brake booster, and then press the brake pedal again, until the resistance can be obviously felt (push the booster valve), at this time, the pedal stroke is free play stroke, and the standard value of original state is 10mm. This value will change with the use states of brake system, for example, it will become larger along with more wear of the brake.
Note: The total stroke of the brake pedal is 124mm. The alignment clearance of service brake lamp switch is 0.5-1.5mm.
Brake system 5-57
Description and operation Hydraulic brake system Hydraulic brake system consists of the following parts: ● The brake fluid reservoir provides brake fluid to hydraulic brake system. ● The mechanical input force is converted to hydraulic output force by the brake master cylinder. ● The brake pipe transmits the brake fluid among each component of hydraulic brake system. ● Loading sensing pressure proportioning valve (not ABS) adjusts the brake force according to the load changes. ● ABS control module (ABS) is used to control and adjust the hydraulic pressure of each wheel brake fluid line, so as to reach reasonable allocation of brake force. ● The hydraulic input force is converted to mechanical output force by the brake executive component, so as to realize wheel brake. The input mechanical force is converted to hydraulic pressure through brake master cylinder, and it is adjusted to be hydraulic pressure required by the brake system by pressure balance control device (loading sensing pressure proportioning valve or ABS control module), and then transmitted to the brake executive component through brake pipe, the hydraulic input force is converted to brake force of wheel by the brake component, so as to reach the brake action.
Brake boosting system Brake boosting system consists of the following parts: ● The brake pedal receives the driver’s input force, magnifies and transmits it to the vacuum booster. ● The vacuum booster will utilize vacuum source to reduce the driver’s operating force necessary for treading the brake pedal when receiving the input force of brake system. ● The vacuum pipe provides and maintains vacuum source required by the vacuum booster. The driver’s input force is magnified by the brake pedal, and then transmitted to the brake master cylinder through the boosting action of vacuum booster.
Brake system fault warning lamp The brake system fault warning lamp will light up under the following conditions: ● Ignition switch is on The brake system fault warning lamp will light up at the moment that the ignition switch is on, so as to check whether the indicator normally works. ● Parking brake works The parking brake lamp switch is on when the parking brake handle is lifted for parking brake, and then the indicator on the instrument cluster lights up. The indicator is used to remind the state of parking brake.
●
The level of brake fluid is too low The brake fluid level warning switch will send the signal to the circuit when the level of brake fluid is too low, so that the brake system fault warning lamp will light up to remind that the brake fluid shall be filled.
Brake system 5-58
Disc Brake Specification Disc brake parameters Application
Specification (mm) Front brake
Outer diameter of brake disc
282
Thickness of new brake disc
24
Minimum thickness of brake disc for scrapping Lateral run-out of brake disc (limit)
0.03
Thickness of new brake pad (lining + steel backing of brake pad)
16
Minimum thickness of brake pad for scrapping (lining + steel backing of brake pad)
8
New brake lining thickness
11 Rear brake
Brake disc diameter
271
New brake disc thickness Brake disc minimum scrap thickness
10 8.75
Minimum allowable thickness of the brake disc after trimming
9
Maximum allowable face runout after assembly of the brake disc
0.06
Brake disc maximum allowable scratch depth Brake disc maximum allowable thickness skew New brake pad thickness Brake pad minimum scrap thickness
0.5 0.01 9 1.4
Tightening torque Application Bolt - brake caliper connected to steering knuckle
Specification (N.m)
100±10
Installation of bolt - brake caliper guide rod
40±5
Bolts - Brake hose installation
40±5
Brake system 5-59
Parts location diagram Detailed diagram of disc brake
13AH-0502001
Figure 1. Front brake caliper assembly 2. Dust shield 3. Bleeder screw 4. Brake caliper body 5. Positioning rod 6. Dust shield for positioning pin 7. Front wheel brake piston
8. 9. 10. 11. 12. 13.
Rectangular sealing ring Dust shield for front wheel brake piston Support frame Brake pad Dust guard plate Brake disc / brake rotor
________________________________________________________________________________________
Brake system 5-60
Diagnostic information and procedure Starting point for diagnosis Begin the system diagnosis should refer to “Description and operation” of system. If the vehicle get in trouble, refer to the "description and operation" to be habituate with the function of the system, and help to determine the correct diagnosis procedure. Check out the following “Description and operation” : ● Disc brake Visual inspection/routine inspection Visual inspection/routine inspection shall be firstly conducted in case of vehicle fault. The items of inspection are as follows: ● Whether the visible or easily touchable system component is obviously damaged. ● Whether there is after sales device possibly causing system fault ● Where there is abnormal looseness occurs to the component ● Detection of thickness of brake disc ● Detection of lateral run-out of brake disc ● Detection of brake pad Common symptoms Corresponding symptoms will be shown in case of vehicle fault. The common symptoms are shown as follows: ● Disc brake makes abnormal sound
Disc brake makes abnormal sound Inspection Whether the lateral run-out of brake disc is too large. If the dust guard plate is damaged. If the brake caliper guide rod is loose.
Operation Replace brake disc. Replace dust guard plate. Tighten the brake caliper guide rod.
Instructions: Refer to Chapter “Repair guide” for detailed description on “Operation”.
Brake system 5-61
Service instruction Replacement of caliper assembly
15AH-0501018
front
brake
Note: Brake fluid can damage the paint surface. If brake fluid overflows carelessly, please immediately wipe it off and clean the area with water. Removal procedure 1. Remove front wheel & tire. Refer to “Replacement of wheel and tire”. 2. Disconnect the connector (1) used for connecting the front brake hose (2) and the front brake caliper, plug the connector, and refer to "Replacement of front brake hose". 3. Remove the two bolts (1) connecting the front brake caliper and the steering knuckle. 4. Take down the front brake caliper assembly.
Installation procedure 1. Position the front brake caliper assembly. 2. Install two bolts connecting the front brake caliper assembly and the steering knuckle and tighten the bolt tightening torque to 100±10 N.m. 3. Install the connector (1) used for connecting the front brake hose (2) and the front brake caliper assembly. Refer to “Replacement of front brake hose". 4. Install front wheel and tire. Refer to “Replacement of wheel and tire” 5. Fill brake fluid. Refer to “Inspection and filling of brake fluid”. 6. Exhaust the air of hydraulic brake system. Refer to “Exhaust of hydraulic brake system”. 15AH-0502008
15AH-0501018
Brake system 5-62
Replacement of rear brake caliper assembly - disc type Removal procedures 1. Lifting vehicles. 2. After removing the rear wheels, refer to "Removal and Installation of Tires and Wheels". 3. Remove the rear brake hose (2) inlet fitting to the caliper's bolt (1). 4. Disconnect rear brake hose (2). Block or plug brake calipers and brake pipe, so as not to brake fluid loss and contamination of the environment.
16AH-0501021
5. Disconnect the pull cable from the parking brake (1). Refer to “Replacing parking brake cable".
16AH-0503020
6.
Remove the rear caliper assembly mounting bolt (1) from the rear hub and remove the rear caliper assembly (2).
16AH-0503022
Brake system 5-63 Installation Procedure CAUTION: Refer to "WARNING ON TIGHTENS". 1. Locate the rear caliper assembly (2). 2. Install the rear brake caliper assembly to the rear hub bolts (1) and tighten the bolts to 100 ± 10 Nm.
3. Install the pull cable of parking brake (1). Refer to “Replacing parking brake cable". 16AH-0503022
4. Install the rear brake hose (2). 5. Install the rear brake hose bolt (1) and tighten the bolt tightening torque to 40 ± 5 Nm. 6. Exhaust the air in the caliper. Refer to "Exhaust of Hydraulic Braking System". 7. Install the rear wheels. Refer to “Removal and Installation of Tires and Wheels". CAUTION: Do not operate the vehicle until a firm brake pedal is obtained. Failure to step on the pedals before the vehicle travels could result in personal injury.
16AH-0503020
8. Repeatedly depress the brake pedal so that the brake pad contacts the rear brake disc. 9. Make adjustments to the parking brake, refer to “Adjusting the parking brake". 10. Lower the vehicle.
16AH-0501021
Brake system 5-64
Inspection of brake calipers 1.
2.
3. 4.
Check the brake caliper housing (1) for cracks, severe wear, or damage. If any of these conditions occur, replace the caliper. Check the brake caliper piston dust cover (2) is cracking, rupture, incision, aging or not properly installed in the brake caliper body. If any of these conditions occur, the brake caliper assembly must be overhauled or replaced. Update brake caliper vent cap (3) if lost. Check the exhaust nozzle (2) for clogging.
15BL-0503007
5.
15BL-0503008
Check whether the caliper piston moves smoothly in the caliper hole and reaches the full stroke: The caliper piston moves smoothly and evenly in the caliper hole. If the caliper plunger is jammed or is difficult to move to the end, it may be necessary to overhaul or replace the caliper assembly. Insert the discarded inner brake pad (2) or block into the front of the piston. A large C-clamp (1) is mounted on the caliper (3) and rests against brake pad or block, and then slowly moves the piston in the caliper hole to the bottom.
Brake system 5-65
Replacement brake pad
15AH-0502006
Note: The same axis on the inside and outside the brake pad must also replace the same manufacturer of the same batch of accessories. Removal procedure 1. Remove wheel & tire. Refer to “Replacement of wheel and tire”. 2. Remove the brake caliper guide pin bolt (1). 3. Remove the U-shaped snap spring fixing the brake hose, and remove the hose from the bearing support. 4. Flip down the front brake caliper. Note: After disconnecting the brake caliper, do not tread on the brake pedal, so as not to damage the braking part conditions. 5. Remove brake pad (1) from the caliper bracket.
15AH-0502007
Installation procedure 1. Install the brake pad (1) on the caliper bracket. 2. Flip up the brake caliper and position it. Note: Before installing a new brake pad, be careful to prevent entry of any foreign matters into the caliper cylinder bore. 3. Use silFigure based grease to lubricate the brake caliper guide pin bolts. Note: Do not lubricate the threaded portion of brake caliper guide rod. 4. Install the brake caliper guide pin bolt (1) and tighten to 40±5 N.m. 5. Install wheel and tire. Refer to “Replacement of wheel and tire”. 6. Lower the vehicle 15AH-0502006
Brake system 5-66
Brake pad test Note: At the time of periodic replacement of wheels and tires, detect the brake pad. Inspection procedure 1. Remove the brake pad, and refer to “Replacement of brake pad". 2. Use a vernier caliper to measure the thickness of brake pad. 3. Compare thickness of brake pads and disc brake component specifications, if the value measuremenmt was more than standard value should replace the brake pads.
15AH-0502004
Run-in of brake pad and brake disc Warning: Test vehicle on the road under the premise of ensuring safety, and abide by all traffic laws. Don’t try any operation which may endanger vehicle control. Violation of the above safety instructions will result in serious personal injury and damage the vehicle. To ensure that the friction surface of disc brake system after the repair fits properly, it is a must to run in the brake pad and the brake disc. For re-grinding or replacement of disc brake or replacement of disc brake pad, this procedure must be performed. 1. Choose a section of road that is flat and has small traffic volume or no traffic. 2. Accelerate the vehicle to 48km/h. Note: During the implementation of this step, brake overheating shall be avoided. 3. Step on the brake with moderate or hard force to stop the vehicle. Never cause the brake to be locked. 4. Repeat Steps 2 and 3 until about 20 times of parking operations are completed. During the parking, it shall be ensured that the brake is cooled sufficiently, so that the brake pad and the brake disc are correctly run in.
Brake system 5-67
Replacement of front brake disc Note: The brake discs must be replaced in pairs, unless the brake discs were just replaced and used for less than 1,500km. Removal procedure 1. Lift the vehicle. 2. Under the condition of not disconnecting the brake pipe and the brake caliper, remove the brake caliper assembly; do not use the brake pipe to suspend the brake caliper, use a steel wire with sufficient strength to suspend the brake caliper on the shock absorber spring. Refer to “Replacement of front brake caliper assembly”. 3. Take down the front brake disc (1).
15AH-0502005
Installation procedure 1. Check the brake disc. Refer to “Brake disc surface and wear inspection”. Warning: Refer to “Brake disc surface and wear inspection”. 2. Install the front brake disc (1) on the front wheel hub. 3. Install the front brake caliper assembly. Refer to “Replacement of front brake caliper assembly”. 4. Lower the vehicle from lifting machine.
15AH-0502005
Brake system 5-68
Replacement of rear brake disc disc type Removal procedures WARNING: Refer to "WARNING ON BRAKE DUST" 1. Release the parking brake lever. 2. Lifting vehicles. 3. Remove rear wheels, refer to “Replacing Wheels and Tires"。
15BS-0503019
WARNING: Do not subject the brake tube to the weight of the caliper, which may damage the brake tube. 1. Do not disconnect the brake caliper assembly (2), do not make the weight of the caliper directly on the brake pipe, the use of wire rope hanging brake calipers on the rear frame. Refer to “Replacing the rear brake caliper".
2. 3.
Remove rear brake disc lock screw (2). Remove the rear brake disc (1).
15BS-0503032 Installation Procedure
15BS-0503019
Note: To ensure uniform of braking, even if only one brake disc is defective, the two discs on the coaxial shaft must also be trimmed or replaced in pairs. CAUTION: Refer to "WARNING ON TIGHTENS". 1. Install the rear brake disc (1) on the rear hub, 2. Install the rear brake disk lock screw (2) and tighten the screw torque to 8 Nm. 3. Install the rear caliper assembly (2), refer to “Replacing the rear brake caliper". 4. After installing the rear wheels, refer to “Replacing Wheels and Tires". 5. Tighten the parking brake lever. 6. Lower the vehicle from the lift. 7. Run brake pad and the brake disc, refer to “Braking of brake pad and brake disc".
Brake system 5-69
Brake disc thickness deviation measurement
Brake disc thickness measurement Warning: Refer to “Warning about brake dust”.
Warning: Refer to “Warning about brake dust”. Note: It is required to carry out re-grinding or replacement of the brake disc whose thickness deviation exceeds the maximum allowable value. If the thickness deviation of brake disc exceeds the maximum allowable value, it will result in brake pulsation. 1. If it is unable to contact with the internal friction surface of brake disc, then reposition and support brake caliper with brake pad. Refer to “Replacement of brake pad”. 2. Clean the friction surface of brake disc with industrial alcohol or approved equivalent brake cleaner.
15AH-0502015
1.
2.
3.
4. 5.
6.
7.
If it is unable to contact with the internal friction surface of brake disc, reposition and support brake caliper with brake pad. Refer to “Replacement of brake pad”. Clean the friction surface of brake disc with industrial alcohol or approved equivalent brake cleaner. Use a micrometer (1) with the accuracy reaches micron level or ten thousandth of an inch to measure and record the minimum thicknesses of 4 or more points uniformly distributed on the brake disc circumference. Make sure to measure only inside the friction surface, and the distance between micrometer and the outer edge of brake disc is equal (about 13mm) while measuring every time. Compare the minimum measured thickness and the disc brake component specifications. If the minimum measured thickness of brake disc is higher than the minimum allowable thickness after re-grinding, then re-grinding of brake disc may be carried out based on the conditions of surface and wear. If the minimum measured thickness of brake disc is equal to or less than the minimum allowable thickness after re-grinding, then re-grinding of brake disc cannot be carried out. If the minimum measured thickness of brake disc is equal to or less than the scrapping thickness specifications, then replacement of brake disc is required. Refer to “Replacement of front brake disc”.
15AH-0502015
3.
Use a micrometer (1) with the accuracy reaches micron level or ten thousandth of an inch to measure and record the thicknesses of 4 or more points uniformly distributed on the brake disc circumference. Make sure to measure only inside the friction surface, and the distance between micrometer and the outer edge of brake disc is equal (about 13mm) while measuring every time. 4. Calculate the difference between the maximum and minimum measured thicknesses recorded to obtain the thickness deviation. 5. Compare the measured thickness deviation and the disc brake component specifications. Note: The disc brake lateral runout (LRO) must be measured after the re-grinding or replacement of brake disc, so as to ensure the best performance of disc brake. 6. If the brake disc thickness deviation exceeds the specifications, then re-grinding or replacement of brake disc is required. Refer to “Replacement of front brake disc” or “Re-grinding of brake disc”.
Brake system 5-70
Brake disc surface and wear inspection Warning: Refer to “Warning about brake dust”. 1. If it is unable to contact with the internal friction surface of brake disc, then reposition and support brake caliper with brake pad. Refer to “Replacement of front brake pad” and “Replacement of rear disc brake pad”. 2. Clean the friction surface of brake disc with industrial alcohol or approved equivalent brake cleaner. 3. Check if the following "brake surface conditions" occur to the brake disc friction surface: Serious rust or corrosive pitting. Minor surface rust may be removed by use of a grinding wheel. Serious surface rust or corrosive pitting must be eliminated by re-grinding of brake disc. Refer to “Re-grinding of brake disc”. Crack or hot spot. Become seriously blue. 4. If one or more of the above "brake surface conditions" occur(s) to the brake disc friction surface, then re-grinding or replacement of brake disc is required. Refer to "Replacement of front brake disc" or "Re-grinding of brake disc".
15AH-0502015
5.
6. 7.
Use an appropriate measuring tool (1) with the accuracy reaches micron level or ten thousandth of an inch to measure and record the scratch depths of all grooves on the brake disc friction surface. Compare the scratch depth of groove recorded and the disc brake component specifications. If the scratch depth of brake disc exceeds the specifications or there are too many scratches, then re-grinding or replacement of brake disc is required. Refer to “Replacement of front brake disc” or “Re-grinding of brake disc”.
Measurement of rear face run-out of brake disc assembly Special tools Brake disc re-grinding tool component Wheel hub re-grinding tool component Wheel hub and wheel run-out meter Cone pad of brake disc With respect to the local equivalent tools, refer to "Special tools". Warning: Refer to “Warning about brake dust”. Note: If the disc brake lateral runout (LRO) exceeds the maximum allowable specification, then long-term use will lead to increased brake disc thickness deviation and it is usually 4,800-11,300km. Before checking disc brake lateral runout (LRO), it is a must to check the brake disc thickness deviation. If the thickness deviation of disc brake exceeds the maximum allowable value, it will result in brake pulsation. Refer to “Measurement of brake disc thickness deviation”. 1. Mark the relative positions of the brake discs and wheel studs (if not already marked). Note: When the brake disc is separated from the wheel hub/axle flange, rust or dirt shall be removed from the mating surface of the wheel hub/axle flange and the brake disc. Otherwise, it may cause excessive disc brake lateral runout (LRO), leading to brake pulsation. 2. Check the mating surface of the wheel hub/axle flange and the brake disc to make sure that there are no foreign objects, corrosion, rust or debris. If any of the above conditions occurs to the mating surface of the wheel hub/axle flange or brake disc, then perform the following steps: 2.1. Remove the brake discs from the vehicle. Refer to “Replacement of front brake disc” and “Replacement of rear brake disc”. 2.2. Use the wheel hub re-grinding tool component to thoroughly remove the rust or corrosion from the mating surface of wheel hub/axle flange. 2.3. Use the brake disc re-grinding tool component to thoroughly remove the rust or corrosion from the mating surface of brake disc. 2.4. Clean the friction surface of brake disc with industrial alcohol or approved equivalent brake cleaner. 3. Align the assembly marks made before disassembly to install the brake disc on the wheel hub.
Brake system 5-71 4. Tighten the nuts to the specified torque in the sequence marked * to correctly fix the brake discs. Refer to “Removal and installation of tire and wheel”. 5. If the brake disc has been resurfaced or replaced with new one, then go to Step 14. 6. If the brake disc meets the following conditions, then go to step 10. ● The brake discs conform to the specifications and can be used again. ● The brake disc surface has not been finished. ● The brake disc thickness deviation does not exceed the maximum allowable value.
15AH-0502016
7.
Install wheel hub and wheel run-out meter (1) or equivalent tools on front shock absorber, place the measuring head of dial indicator and make it contact with the friction surface of brake disc in a 90° angle and distant about 13mm from the outer edge of brake disc.
15AH-0502017
8.
Measure and record the rear face run-out of brake disc assembly. 8.1. Turn the brake disc until the reading of dial indicator reaches the minimum value, and then reset the dial indicator.
8.2. Turn the brake disc until the reading of dial indicator reaches the maximum value. 8.3. Mark the highest position relative to the nearest wheel stud or stud. 8.4. Measure and record face run-out. 9. Compare the rear face run-out of brake disc assembly and the disc brake component specifications. 10. If the rear face run-out of brake disc assembly meets the specifications, then go to Step 15. If the rear face run-out of brake disc assembly exceeds the specifications, re-grinding of brake disc is required to ensure accurate parallelism. Refer to “Re-grinding of brake disc”. After brake disc regrinding, go to Step 14. 11. Install wheel hub and wheel run-out meter (1) or equivalent tools on front shock absorber, place the measuring head of dial indicator and make it contact with the friction surface of brake disc in a 90° angle and distant about 13mm from the outer edge of brake disc. 12. Measure and record the rear face run-out of brake disc assembly. 12.1. Turn the brake disc until the reading of dial indicator reaches the minimum value, and then reset the dial indicator. 12.2. Turn the brake disc until the reading of dial indicator reaches the maximum value. 12.3. Mark the highest position relative to the nearest wheel stud or stud. 12.4. Measure and record face run-out. 13. Compare the rear face run-out of brake disc assembly and the disc brake component specifications. 14. If the measured value of rear face run-out of brake disc assembly exceeds the specifications, then it shall make the face run-out meets the specifications. Refer to "Calibration of rear face run-out of brake disc assembly". If the measured value of rear face run-out of brake disc assembly meets the specifications, then install the brake caliper and step on the brake pedal several times so that the brake disc is fixed in place, and then remove the cone pad of brake disc.
Brake system 5-72
Replacement of dust guard plate Removal procedure 1. Remove front wheel & tire. Refer to “Replacement of wheel and tire” 2. Remove front brake disc. Refer to “Replacement of front brake disc”. 3. Remove the front wheel hub component (1). Refer to "Replacement of front wheel hub component". 4. Remove the dust guard plate (2).
15AH-0502018
Installation procedure 1. Install the dust guard plate (2). 2. Install the front wheel hub component (1). Refer to “Front wheel hub component”. 3. Install front brake disc. Refer to “Replacement of front brake disc”. 4. Install front wheel and tire. Refer to “Replacement of wheel and tire”.
15AH-0502018
Brake system 5-73
Description and operation Disc brake The disk brake is floating caliper disc type. The brake caliper is single-cylinder type and fixed by two mounting bolts to the steering knuckle; the brake caliper converts the hydraulic pressure from the hydraulic system to the uniform lateral thrust towards the brake pad under the action of piston; after the inner brake pad receives the thrust from the piston, it moves outwards, meanwhile, the brake caliper body drives the outer brake pad to move inwards, and the inner and outer brake pads act on the brake disc jointly. The friction generated between the brake pad and the brake disc slows down or stops the vehicle.
Special tools Special tools Figure
Tool No. / Description
PT-0008 Dial indicator
PT-0009 Dial indicator magnetic stand
Brake system 5-74
Drum brake Specification Drum brake parameters Application Inner diameter of rear brake cylinder
Specification (mm) 22．22
Inner diameter of new brake drum
240
Maximum inner diameter of brake drum for scrapping
242
Thickness of new brake shoe friction lining
5
Minimum thickness of brake shoe friction lining for scrapping
2
Tightening torque Application
Specification (N.m)
Bolt- rear brake cylinder connected to the rear brake backing plate
9±3
Oil pipe connector- break pipe connected to the rear brake cylinder
16±2
Bolt - rear brake backing plate installation
51±7
Brake system 5-75
Parts location diagram Exploided view of Drum brake
13AH-0503001
Figure 1. Rear brake assembly 2. Rear brake shoe hold down spring washer 3. Rear brake backing plate assembly 4. Rear brake inspection hole plug 5. Rear brake backing plate bolt 6. Rear brake trailing shoe assembly 7. Rear brake cylinder assembly 8. Rear brake leading shoe assembly 9. Rear brake anchor spring 10. Rear brake shoe hold down spring cup 11. Rear brake shoe hold down spring 12. Rear brake drum
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Rear brake adjuster pawl Rear brake shoe pin Stretched spring Rear brake shoe adjuster pawl spring Rear brake adjuster bolt Rear brake adjuster link bracket Rear brake adjuster Rear brake shoe return spring Rear brake shoe adjuster pawl pivot pin Rear brake shoe adjuster actuator washer Actuator adjuster lever
________________________________________________________________________________________
Brake system 5-76
Diagnostic information and procedure Drum brake diagnostic starting point Diagnose the drum brake system from the "Diagnostic starting point - hydraulic brake" in the "Hydraulic brake". Use the "Diagnostic starting point" to determine the correct system diagnostics procedure as well as the location thereof.
Drum brake symptoms Refer to the following symptom diagnosis procedure so as to diagnose the symptoms: ● Not enough braking force ● Uneven braking ● Brake is dragging after the release of pedal ● The brake pedal stroke is too long ● Brake has noise or vibration ● The braking force of parking brake is too weak
Not enough braking force Inspection Serious wear of brake shoe friction lining Fluid on friction lining
Operation Replace the brake shoe friction lining Check whether wheel braking cylinder has leakage, and replace wheel braking cylinder or lining, if necessary. Replace wheel braking cylinder.
Wheel braking cylinder breaks down Self-adjusting function is abnormal
Repair the self-adjusting function.
Uneven braking Inspection Brake shoe return spring is fatigue Wheel braking cylinder breaks down
Operation Replace brake shoe return spring. Replace wheel braking cylinder.
Brake is dragging after the release of pedal Inspection Fluid on friction lining Wheel braking cylinder breaks down
Operation Check whether wheel braking cylinder has leakage, and replace wheel braking cylinder or lining, if necessary. Replace wheel braking cylinder.
The brake pedal stroke is too long Inspection Excessive wear of friction lining Self-adjusting function is abnormal
Operation Replace the friction facing Repair the self-adjusting function.
Break has noise or vibration Inspection Foreign matters attached to the brake drum Brake backing plate bolts are loose Brake drum is damaged
Operation Clean the rear drum brake. Tighten the brake backing plate bolts. Replace brake drum
The braking force of parking brake is too weak Inspection Fluid on friction lining Self-adjusting function is abnormal Parking brake cable is improperly adjusted
Operation Check whether wheel braking cylinder has leakage, and replace wheel braking cylinder or lining, if necessary. Repair the self-adjusting function. Adjust the parking brake cable.
Brake system 5-77
Brake drum surface and wear inspection Warning: Refer to "Warning about clutch dust". At the time of removal of the brake drum, it is a must to thoroughly clean and check the brake drum for cracks, scratches, deep grooves or out of roundness beyond the specified limits. ● Check the inner race. If the inner race is separated from the wheel bearing within the brake drum, then replace the brake drum and wheel bearing assembly. ● Further repair of any cracked brake drum is very unsafe and it is a must to replace. A cracked brake drum is prohibited to be welded. Level the minor scratches. ● Deep scratches or serious scratches will cause excessive wear of brake friction lining, and refinishing of braking surface of brake drum may be required. ● If the brake friction lining is slightly worn but can still be used, but brake drum has grooves, use a fine emery cloth to polish the brake drum, but do not refinish the surface. Removal of all grooves on the brake drum and bulges on the lining will cause excessive loss of metal and lining. Regardless of their existence, fitting the grooves with the bulges can achieve the desired effect of repair. If it is required to replace the brake friction lining, then finish the grooved brake drum. If a grooved brake drum is used in conjunction with a new lining, it will not only lead to lining wear, but also be difficult to provide appropriate braking performance. ● A brake drum out of round is impossible to accurately adjust the brake shoe and is likely to lead to excessive wear of other parts of the brake mechanism. A brake drum out of round will also lead to serious abnormal wear of tire tread and brake pedal pulsation. ● The wear and out of roundness of a brake drum may be accurately measured by use of an internal micrometer with appropriate extension rod. At the time of measurement of wear or radial run-out of brake drum, measure from the inner edge of machined surface to the outer edge thereof at 90 degrees around the brake drum as the spacing. When the radial run-out of a brake drum exceeds the maximum radial run-out, refinish the brake drum.
Inspection procedure 1. Remove the brake drum. Refer to “Replacement of rear brake drum”. 2. Clean the brake drum. 3. Check if the brake drum has any crack or damage.
15BL-0503002 4. Measure the inner diameter of brake drum. Specification For the maximum inner diameter of brake drum, refer to "Specifications of drum brake parts". 5. If the inner diameter of brake drum is higher than the specified value, replace the brake drum. 6. Measure the radial run-out of brake drum. Specification For the maximum radial run-out of rear brake drum, refer to "Specifications of drum brake parts". 7. Install the rear brake drum. Refer to “Replacement of rear brake drum”.
Brake system 5-78
Inspection of drum brake parts Warning: Refer to “Warning about brake dust”.
Inspection of drum brake adjustment parts Warning: Refer to “Warning about brake dust”.
15BL-0503002
1. Visually check if any of the following circumstances occurs to the brake shoe return spring (3) of drum brake system: ● The brake shoe return spring is bent, damaged or cracked at any point of spring (3) ● Severe corrosion of brake drum parts ● Serious stretch, twist or block of brake drum parts ● Damage or leakage of wheel braking cylinder jacket (2) 2. If any of the above-mentioned conditions occurs, replace the brake shoe return spring or wheel braking cylinder. Refer to “Replacement of brake shoe” or “Replacement of rear brake cylinder”.
15BL-0503002
1. Visually check if any of the following circumstances occurs to the actuator spring (3) of the adjuster: ● The spring is bent or cracked at any point of spring ● Severe corrosion ● Omission 2. Visually check if any of the following circumstances occurs to the adjuster assembly (1): ● The adjuster is bent or cracked ● Excessive wear, damage or missing teeth 3. Visually check if any of the following circumstances occurs to the actuator rod of the adjuster: ● The actuator rod is bent or cracked ● Excessive wear occurs to the actuator rod to the surface of the adjuster ● The spring accessory tab is broken ● Omission 4. If any of the above-mentioned circumstances is found, replace the affected part.
Brake system 5-79
Service instruction Gap adjustment of drum brake Note: The drum brake of this vehicle is provided with a self-adjuster without manual gap adjustment of drum brake. Adjustment procedure 1. Step down the brake pedal several times so that the drum brake will automatically adjust the gap.
Brake system 5-80
Replacement of rear drum brake Removal procedure 1. Lift up vehicle with lifting machine. 2. Remove rear wheel and tire. “Replacement of wheel and tire”. 3. Fully release the parking brake lever.
4.
Refer
to
Remove rear drum brake （1）. If the rear drum brake is difficult to remove, please perform the following steps: a) Install two bolts on two threaded holes of the drum brake. b) Equivalent and simultaneously bolt in two bolts until the drum brake is jacked out. c) Remove the two bolts.
15AH-0503004
Installation Procedure 1. Clean the inner surface of rear drum brake. 2. Install the rear drum brake (1).
3. 4. 5. 6.
15AH-0503004
Install rear wheel and tire. Refer to “Replacement of wheel and tire”. Lift down vehicle from lifting machine. Adjust the gap of drum brake. Refer to “Gap adjustment of drum brake”. Check and adjust parking brake mechanism. Refer to “Check and adjustment of parking brake mechanism”.
Brake system 5-81
Rear drum brake surfacing Special tools � Tool parts of surfacing Warning: Before installing the drum brake, check if there are any foreign matters on the working face of bearing within the drum brake, and use industrial alcohol to clean the contact plane between the inner ring and mandrel of drum brake bearing to avoid abnormal wear. Note: Do not repair the drum brake to exclude the following problems: Brake noise (roar/scream) Premature wear of brake friction lining Drum brake surface or shallow corrosion The drum brake is discolored Only when there is any one or more of the following circumstances, then repair the drum brake: The surface of drum brake is severely scratched; for the maximum scratch depth, refer to “Specifications of drum brake parts" The following conditions cause brake judder: Drum brake is not round Corrosion or pitting is deeper than the surface of drum brake 1. Use a caliper to measure the maximum diameter of drum brake. If the diameter exceeds the maximum finishing diameter of drum brake, do not finish the drum brake. Replace drum brake 2. Use a surfacing trimming tool to completely remove the rust from the drum brake flange. 3. Conduct surface trimming to the drum brake. See the brake lathe manufacturer's operating instructions. Note: Improper brake surfacing may cause vehicle parking difficulties. 4. After machining the drum brake, use 120 mesh alumina sandpaper to polish the non-directional brake surface. 5. Use industrial alcohol or suitable brake cleaner to clean the surface of brake.
Brake system 5-82
Adjustment of rear drum brake
15BL-0503008
Required tools Inner and outer diameter caliper Warning: Refer to “Warning about brake dust”. 1. Confirm the parking brake lever is in the fully relaxed state. 1. Remove console box trim to make room to adjust the parking cable. Note: Only use hand tools to loosen or tighten the adjusting nut. 2. Use hand tools to loosen the adjusting nut (1) to the threaded end of cable. 3. Hoist and support the vehicle. Refer to “Vehicle Lifting and Hoisting”. 4. Remove the rear wheels and tires. Refer to “Removal and installation of tire and wheel”. 5. Remove the drum brake. Refer to “Replacement of rear drum brake”.
6. Using a caliper to find the maximum inner diameter of drum brake, and record the caliper measured data. 7. Remove the caliper from the drum brake, then measure the outer diameters at the positions corresponding to the brake shoe and drum brake, and record the value. 8. Calculate the difference between the measurements of inner diameter of drum brake and outer diameter of brake shoe. Compare this value with the value in the drum brake specification table to determine the direction of adjustment.
15BL-0503009
9. Adjust the brake shoe adjuster to a predetermined size. Refer to “Specifications of drum brake component”. 10. Install the rear drum brake Refer to “Replacement of rear drum brake”. 11. Adjust parking brake wire Refer to "Parking brake adjustment". 12. Install the rear tires and wheels. Refer to “Removal and installation of tire and wheel”. 13. Lower the vehicle 15BL-0503010
Brake system 5-83
Replacement of rear brake shoe Removal procedure 1. Lift up vehicle with lifting machine. 2. Remove rear wheel and tire. Refer to “Replacement of wheel and tire” 3. Remove rear drum brake. Refer to “Replacement of rear drum brake”. 4. Remove the tension spring.
13AH-0503005
5.
Repress the brake shoe backing spring and rotate 90°, with pliers to remove.
6.
Remove the small spring of rear brake shoe and the parking brake cable and take the brake out of the shoe and parking brake lever.
13AH-0503006
13AH-0503007
Brake system 5-84
7.
Remove the opening retainer ring with pliers, and remove the parking brake lever from the pinned shaft and the rear brake trailing shoe.
8.
Knock the pinned shaft out of the brake leading shoe and remove the tension spring from the brake shoe hole. Remove the rear brake leading shoe.
13AH-0503008
9.
13AH-0503009
Brake system 5-85 Installation Procedure 1. Clean the surface of brake backing plate. 2. Install the tension spring, and use the pinned shaft to link the brake leading shoe and self-adjuster. 3. Install the brake trailing shoe and the opening retainer ring on the parking brake lever. 4. Connect the brake trailing shoe and brake adjusting bolt. And install the brake shoe on the brake cylinder piston groove.
13AH-0503009
5.
Install the spring connecting the brake leading shoe and the brake trailing shoe. 6. Press down the external spring seat with pliers, rotate the spring seat bar by 90°, and install two spring seat bars, four spring seats and two backing springs. Note: For adjusting bolt assembly, ensure that the end of the side of the structure with a bench is on the outside of brake leading shoe. 7. Install return spring of brake shoe
13AH-0503006
Install the rear drum brake Refer to “Replacement of rear drum brake”. 9. Install rear wheel and tire. Refer to “Replacement of wheel and tire". 10. Lift down vehicle from lifting machine. 11. Adjust the gap of drum brake. Refer to “Gap adjustment of drum brake”. 12. Check and adjust parking brake mechanism. Refer to “Check and adjustment of parking brake mechanism”. 8.
13AH-0503005
Brake system 5-86
Check of rear brake shoe Check procedure Warning: Refer to “Warning about brake dust”. 1. Use a caliper to measure the thickness of brake shoe friction lining. 2. Compare the recorded brake shoe friction lining thickness and the drum brake part specifications. Refer to “Specifications of drum brake component”. Important notes: It is a must to replace the brake shoe and friction lining assembly simultaneously. 3. If the brake shoe friction lining thickness is less than the predetermined value or any defects are found, replace the friction lining. Refer to "Replacement of brake shoe".
Run-in of brake shoe and drum brake
15BL-0503012
After replacing brake shoes, run in the new braking surface. After finishing or replacing drum, run in the new braking surface. Brake 20 times at the speed of 48km/h to polish the new braking surface. Step down the brake pedal with a moderate to hard force. Never cause the brake to be overheated. Special Notes: Avoid emergency brake within the range of 200km after replacement of new brake lining.
Brake system 5-87
Replacement of rear brake cylinder
15AH-0503011
Note: Brake fluid will damage the paint surface. If brake fluid overflows carelessly, please immediately wipe off and rush the area with water. Removal procedure 1. Lift the vehicle. Refer to “Vehicle lifting and hoisting”. 2. Disassemble rear wheels. Refer to “Removal and installation of tire and wheel”. 3. Remove the rear drum brake Refer to “Replacement of rear drum brake”. 4. Remove the rear brake shoe. Refer to "Replacement of brake shoe". 5. Remove the dirt and foreign matters around the wheel brake cylinder braking line inlet, guide rod and bolts. 6. Disconnect brake pipe joint (1) from rear brake cylinder. 7. Plug the opened brake line to prevent brake fluid loss or contamination. 8. Remove the bolts (2) from the rear brake cylinder to the backing plate.
9.
15AH-0503012
Gently knock the brake cylinder (1) out of the backing plate and be careful not to damage the exhaust nozzle and its cap.
Brake system 5-88
Installation Procedure Warning: Refer to “Warning on tightens”. 1. Position the rear brake cylinder (1) on the rear brake backing plate.
15AH-0503012
2. Install the rear brake cylinder to the backing plate bolts (2), and tighten the torque of bolts to 10N.m. 3. Connect rear brake cylinder to brake pipe Joint (1), and tighten the torque of joint to 16 N.m. 4. Install the rear brake shoe Refer to "Replacement of rear brake shoe". 5. Install the rear drum brake Refer to “Replacement of rear drum brake”. 6. Install the rear wheel Refer to “Removal and installation of tire and wheel”. 7. Empty the brake air. Refer to “Exhaust of hydraulic brake system”.
15AH-0503011
Brake system 5-89
Replacement of rear brake assembly Note: Brake fluid will damage the paint surface. If it overflows carelessly, please immediately wipe off and rush the area with water. Special tools ● CH-0002 Half axle puller
13AH-0503013
Removal procedure 1. Lift up vehicle with lifting machine. 2. Remove rear wheel and tire. Refer to “Replacement of wheel and tire”. 3. Remove rear drum brake. Refer to “Replacement of rear drum brake”. 4. Disconnect the brake hard pipe and rear brake cylinder connecting oil pipe joint, and plug the opened brake hard pipe. 5. Disconnect the parking brake cable (1) from the rear brake assembly. Refer to “Replacement of parking brake cable”. 6. Remove the lower half axle assembly. Refer to “Replacement of rear axle shaft assembly”. 7. Remove the four connecting bolts (3) of rear brake plate and rear pivot bushing. 8. Separate the rear brake assembly (2). Installation Procedure 1. Clean the surface of brake backing plate. 2. Position the rear brake assembly (2). 3. Install the four connecting bolts (3) of rear brake backing plate and rear axle and tighten to 51±7N.m. 4. Installation of rear axle shaft assembly. Refer to “Replacement of rear axle assembly”.
AH-0503014
5.
Connect the parking brake cable (1) to the rear brake assembly. Refer to “Replacement of parking brake cable assembly”. 6. Connect the brake hard pipe to the rear brake cylinder and tighten the brake hard pipe and rear brake cylinder connecting oil pipe joint to 16±2N.m. 7. Install the rear drum brake Refer to “Replacement of rear drum brake”. 8. Install rear wheel and tire. Refer to “Replacement of wheel and tire”. 9. Vent hydraulic brake system. Refer to “Venting of hydraulic brake system”. 10. Adjust the gap of drum brake. Refer to “Gap adjustment of drum brake”. 11. Check and adjust parking brake mechanism. Refer to “Check and adjustment of parking brake mechanism”. 12. Lift down vehicle from lifting machine. 13AH-0503013
Brake system 5-90
Description and operation Drum brake The drum brake adopts leading trailing shoe design, and two brake shoes are pressed tightly to the rear brake cylinder piston by the brake shoe back moving spring and brake shoe return spring. When the brake is stepped down, the rear brake cylinder piston pushes outwards two brake shoes to make contact with the drum brake. When the wheel moves forward, the front brake shoe will open within the drum brake open and produce self-energizing force. When the wheel moves backwards, the rear brake shoe produces selfenergizing force. Meanwhile, the parking brake lever is connected to the brake trailing shoe and drives the brake trailing shoe from opening and closing by pulling the parking brake cable.
Drum brake gap self-adjuster A self-adjuster is provided on the drum brake. During the opening of brake leading shoe, the paddles are driven to rotate around the pinned shaft, thereby moving the adjusting seat, to extend the lever assembly controlling gap. When the brake leading shoe is closed, the paddles go back to the original state due to the design of ratchet teeth of adjusting seat, without rotating the adjusting seat, thus enabling automatic adjustment of the gap.
Special tools Figure
Tool No. / Description
CH-0002 Rear axle shaft puller
Brake system 5-91
Parking brake Specification Tightening torque Application
Specifications (N.m)
Bolt - parking brake mechanism is connected to the body
23±6
Bolt - parking brake cable sleeve joint installation
9±3
Bolt - welded members of parking brake cable pipe clip are connected to the steel plate spring assembly
23±3
Bolt - parking brake cable rack is connected to the lower arm assembly
9±3
Bolt - parking brake cable pipe clamp is connected to the vehicle body
9±3
Parts location diagram Parking brake system location map
13AH-0504001
Figure 1. Screw Bolt M4 × 8 2. Parking brake lamp switch
3. 4.
Parking brake cable assembly Parking brake mechanism
________________________________________________________________________________________
Brake system 5-92
Diagnostic information and procedure Starting point for diagnosis Begin the system diagnosis should refer to “Description and operation” of system. If the vehicle get in trouble, refer to the "description and operation" to be habituate with the function of the system, and help to determine the correct diagnosis procedure. Check out the following “Description and operation” : ● Parking brake system ● Parking brake lamp Visual inspection/routine inspection Visual inspection/routine inspection shall be firstly conducted in case of vehicle fault. The items of inspection are as follows: ● Whether the visible or touchable system component is obviously damaged. ● Whether there is after-sales adding device possibly causing system fault ● Where there is abnormal looseness occurred to the component ● Check and adjust parking brake mechanism Common symptoms Corresponding symptoms will be shown in case of vehicle fault. The common symptoms as shown as follows: ● Park brake is unable to remain braking mode or release
Park brake is unable to remain braking mode or release Check Parking brake mechanism damaged. Parking brake cable damage
Operation Replace the parking brake mechanism. Replace the parking brake cable.
Instructions: Refer to Chapter “Maintenance Guidelines” for detailed description on “Operation”.
Brake system 5-93
Service instruction Check and adjust parking brake mechanism – Drum Brake
13AH-0504002
13AH-0504003
Note: Before checking and adjusting the parking brake mechanism, it must be ensured that the rear drum brake gap has been properly adjusted. Check procedure 1. When the parking brake lever is pulled, it should be able to reliably park at the position of any tooth number within a stroke, and when the front button of parking brake lever is pressed, the handle should be able to be smoothly lowered. 2. When the parking brake lever is pulled to the first tooth position, the parking brake lamp should begin to illuminate. After the parking brake lever is lowered down, the parking brake lamp should go off. 3. When the pull acting on the parking brake lever arrives at 400N, it should be ensured that the stroke is 6-9 teeth, or re-adjustment is required. 4. When the parking brake lever is completely lowered down, the rear wheel should be free of dragging, and it should be able to rotate freely, or re-adjustment is required. Adjustment procedure 1. Remove console box trim. Refer to “Replacement of console box trim”. 2. Lift the vehicle to an appropriate height from lifting machine. 3. Fully lay down the parking brake lever. 4. Unbolt the adjustment sleeve outwardly to release the parking brake cable completely. 5. Screw in the adjustment sleeve inwardly until the rear wheel is difficult to turn. 6. Unbolt the adjustment sleeve outwardly in appropriate manner until the rear wheel can rotate freely. 7. Lift up the parking brake lever. 8. Lift down vehicle from lifting machine. 9. Install the console box trim Refer to “Replacement of console box trim”.
Brake system 5-94
Parking brake adjustment – Disc Brake 1. Removed under dashboard, refer to “ Deputy meter end cover replacement." 2. Loosen the adjustment nut at the handbrake. 3. Start the vehicle, press brake pedal 5-10 times, pre-tighten the adjustment nut. 4. Force quickly pull the hand brake 2-3 times. 5. Tighten the adjustment hand brake at the adjustment nut, so that parking brake arm and cable frame clearance range (a) in 1-2mm. 6. Tighten the second handbrake nut and tighten to 17 ± 2 Nm.
16AH-0504009
12a0505005
Brake system 5-95
Replacement of parking brake mechanism Note: For replacement of parking brake mechanism and removal of parking brake cable and other parts, provide anti-slipping protector for the vehicle to avoid any accident. Removal procedure 1. Remove console box trim. Refer to “Replacement of console box trim”. 2. Put down the parking brake lever so that the adjusting nut extends beyond the parking brake pedal bracket. 3. Remove the parking brake adjustment nut (1). Note: Before removing the adjusting nut, record the number of turns of threads at the end of cable to provide reference for installation. 15AH-0504004
4.
Disconnect the connection between parking brake lamp switch and the wiring harness, and refer to “Replacement of parking brake lamp switch".
5.
Remove the bolts (2) connecting the parking brake mechanism and the body. Disconnect the connection between parking brake cable assembly and parking brake mechanism (3). Separate the parking brake mechanism (3).
6. 7.
15AH-0504004
Installation Procedure 1. Position the parking brake mechanism (3). 2. Install the bolts (2) connecting the parking brake mechanism and vehicle body and tighten to 23±6N.m. 3.
4.
Connect the connector pipe clip of parking brake lamp switch and the wiring harness, and refer to "Replacement of parking brake lamp switch".
Connect the parking brake cable assembly and the parking brake mechanism (3). 5. Appropriately lower the parking brake lever. 6. Install the parking brake adjustment nut (1). 7. Check and adjust parking brake mechanism. Refer to “Check and adjustment of parking brake mechanism”. Note: For adjustment sleeve assembly, refer to the records made during the removal until the number of turns of threads at the end of cable before removal is exposed. 8. Install the console box trim trim. Refer to “Replacement of console box trim trim”.
Brake system 5-96
Replacement of parking brake lamp mechanism Removal procedure 1. Disconnect the negative electrode of storage battery. 2. Remove console box trim. Refer to “Replacement of console box trim”. 3. Remove the mounting bolt (1) of parking brake lamp switch.
15AH-0504005
4.
Remove parking brake lamp switch (2) from wiring harness.
Installation Procedure 1. Connect brake lamp switch (2) onto wiring harness. 2. Install bolt of parking brake lamp switch (1). 3. Install the console box trim Refer to “Replacement of console box trim”. 4. Connect the negative electrode of storage battery. 15AH-0504005
Brake system 5-97
Replacement of parking brake cable assembly Removal procedure 1. Release the parking brake lever. 2. Remove console box trim. Refer to “Replacement of console box trim”. 3. Lift up vehicle from lifting machine. 4. Remove the fixing bolts of parking brake cable sleeve joint.
15AH-0504006
5.
Remove the fixed bolts (1) connecting the parking brake cable pipe clamp and vehicle body.
6.
Remove rear drum brake. Refer to “Replacement of drum brake”. Disconnect the parking brake cable from the parking brake lever.
7.
8.
Pull the parking brake cable, press the cable holder into the mounting hole with a bolt driver, and pull the parking brake cable out of the rear brake backing plate.
9.
Disconnect the connection between parking brake cable assembly (2) and parking brake mechanism (1).
15AH-0504007
10. Separate the parking brake cable assembly (2).
15AH-0504008
Brake system 5-98 Installation Procedure 1. Position the cable assembly of parking brake (2). 2. Connect the cable assembly of parking brake (2) and the parking brake mechanism (1)
15AH-0504008
3.
4. 5.
Penetrate the parking brake cable through the rear brake backing plate until the cable holder is installed in place. Connect the parking brake cable to the parking brake lever. Install the drum brake Refer to “Replacement of drum brake”.
6.
Install the fixing bolt (1) connecting the parking brake cable pipe clamp and the vehicle body.
7.
Install the fixing bolt (1) for installation of parking brake cable sleeve joint and tighten to 9±3N.m.
15AH-0504007
8.
Check and adjust parking brake mechanism. Refer to “Check and adjustment of parking brake mechanism”. 9. Install the console box trim Refer to “Replacement of console box trim”. 10. Lift down vehicle from lifting machine.
15AH-0504006
Brake system 5-99
Description and operation Parking braking system The role of parking brake is to stop the vehicle in a reliable manner without slipping. Cooperate with other devices in starting the vehicle on a slope. Also, temporary use may be carried out to park in case of failure of vehicle brake. The parking brake system mainly consists of parking brake mechanism, parking brake cable and drum brake. The driver realizes parking brake by pulling up the parking brake lever. Parking brake cable is driven to tension after lifting parking brake lever, meanwhile, self-locking of parking brake lever can be realized due to setting of pawl device. The balance block in the front end fitting of parking brake cable transmits the tensioning force to two rear parking brake cables evenly. Then the rear parking brake cable controls the brake shoe through pulling the parking brake lever in drum brake, to realize the action of parking brake. The driver can press pawl button to put down the parking brake lever when parking brake needs to release for travelling.
Parking brake lamp The parking brake lamp is set in the vehicle, when the parking brake lever is lifted for parking brake, and then the parking brake lamp switch is connected, and the parking brake lamp on the combination instrument lights up. The parking brake lamp is used to remind the state of parking brake.
Brake system 5-100
Anti-locking brake system (Bosch system) Specification Tightening torque Application
Specifications (N.m)
Oil pipe joint – brake hard pipe connected to ABS control module
16±2
Nut - ABS control module connected to ABS bracket assembly
19±4
Bolt - ABS bracket assembly connected to vehicle body
19±4
Nut - ABS bracket assembly connected to vehicle body
19±4
Installation of bolt – front wheel speed sensor
8±2
Installation of bolt – rear wheel speed sensor
8±2
Bolt – rear wheel speed sensor bracket connected to rear axle
9±3
4 3
B103 Brake lamp switch
2
X51A Fuse block— Instrument panel
1
Electric circuit diagram of data communication
X50A Fuse block— under the engine hood
K17 Electronic brake control module
X90 Install the original ABS data connec tor
Electric circuit diagram of data communication
Brake system 5-101
Schematic diagram and circuit diagram
ABS system circuit diagram
15AH-0505001
Brake system 5-102
Parts location diagram Location diagram of anti-lock brake system
15AH-0505003
Figure 1. Rear wheel speed sensor 3. ABS bracket 2. Front wheel speed sensor 4. ABS control module ________________________________________________________________________________________
Brake system 5-103
Diagnostic information and procedure Starting point for diagnosis Begin the system diagnosis should refer to “Description and operation” of system. If the vehicle get in trouble, refer to the "description and operation" to be habituate with the function of the system, and help to determine the correct diagnosis procedure. Check out the following “Description and operation” :: ● Anti-lock brake system ● ABS control module ● Wheel Speed Sensor ● Warning light of anti-lock brake system Visual inspection/routine inspection Visual inspection/routine inspection shall be firstly conducted in case of vehicle fault. The items of inspection are as follows: ● Whether the visible or touchable system component is obviously damaged. ● Whether there is after-sales adding device possibly causing system fault ● Where there is abnormal looseness occurred to the component Preliminary check Before diagnosis of ABS system, the component which can cause fault of such system and be easy to touch shall be firstly checked, and the fault can be rapidly confirmed through visual inspection and appearance inspection procedure, so that further diagnosis is unnecessary. 1. Ensure that there is tire and hub with recommended size only installed on the vehicle. The figure pattern and depth of coaxial tires must be same. Please refer to vehicle use manual for specific type of tire. 2. Check whether there is leakage occurred to ABS hydraulic regulator, brake pipeline and joint. 3. Check the fuse of ABS system, and confirm that it is not burned and its type is correct. The fuse of ABS system is respectively: ● Fuse of pump motor (40A) ● Fuse of magnetic valve (30A) ● Electronic control component fuse (10A) 4. Check the battery voltage, and check whether the binding post of battery is corrosive or loose. The range of normal working voltage for ABS system is 9.3V–16.8V. 5. Check whether the bonding point of ABS grounding wire is loose, and whether the bonding position is changed. 6. Conduct visual inspection and appearance inspection to the following electrical parts: ● Whether the wiring harness and connector assembly of ABS system relevant component is correctly connected, or damaged through clamping or cutting. ● Whether the wiring harness wiring is too close to the high-pressure or large-current device, such as highpressure voltage or component, generator and motor as well as stereophonic amplifier added after sales. Note: High-pressure or large-current device may make the circuit to generate the induced noise, so as to interfere normal work of circuit. ● ABS component is extremely sensitive to electromagnetic interference (EMI). In case of being suspicious of intermittent fault, check whether the anti-theft device added after sales, lamp or mobile phone is incorrectly installed.
Brake system 5-104
No code fault repair In case that the brake system fails, but there is no fault code saved for ABS, such fault is called as no code fault repair, which is caused by fault of basic brake system in general. For example: ● The brake fluid leaks (too soft brake or too long brake pedal stroke may be caused, and invalid brake may be caused under the severe situation) ● Use poor-quality brake fluid (using poor-quality brake fluid will corrode the internal elements of brake pipeline and ABS hydraulic regulating internal module parts, and invalid brake may be caused under the severe situation) ● There is air in brake pipeline (too soft brake may be caused, even invalid brake may be caused) ● There is blockage in brake pipeline (too hard brake may be caused, even invalid brake may be caused) ● The disc brake is excessively worn (too soft brake or too long brake pedal stroke may be caused) ● The booster fails (too hard or too soft brake or too long brake pedal stroke may be caused, and invalid brake may be caused under the severe situation) ● The brake pipeline is incorrectly connected (the phenomenon on reduction of ABS performance, fishtailing or long braking distance may be caused. Please refer to the identification nearby oil hole on ABS hydraulic regulating module for correct installation method: MC1 represents No. 1 master cylinder oil pipe; MC2 represents No. 2 master cylinder oil pipe; FL represents oil pipe of left front wheel cylinder; FR represents oil pipe of right front wheel cylinder; RL represents oil pipe of left rear wheel cylinder; RR represents oil pipe of right rear wheel cylinder) Note: No power supply to ABS or abnormal interruption of power supply may cause long-time lighting of ABS warning lamp, but no phenomenon of fault code is occurred. Troubleshooting advice: Check the corresponding component aiming at the fault phenomenon, and eliminate the fault according to the vehicle service manual.
Random fault maintenance In electronic system, the problem on instant bad contact may be occurred to electrical loop or place where the signal is input and output, so as to cause accidental fault. The reason on fault generation will spontaneously disappear at times, therefore, the root of problem is not easy to find out. Read the historical fault code by use of diagnostic tester firstly in case of accidental fault, conduct relevant inspection according to fault code, and then simulate fault according to the following mode, and check whether the fault appears again. Serial No.
Possible cause of fault
Simulate fault ● ●
1
In case that vibration becomes the main reason
● ●
● 2
3
In case that temperature becomes the main reason
In case that too high electricity load becomes the main reason
Shake ABSECU connector assembly up, down, left and right in a slight manner Shake ABS wiring harness up, down, left and right in a slight manner Shake sensor up, down, left and right in a slight manner Shake other moving component (such as wheel bearing) in a slight manner
Remarks
In case that the wiring harness is twisted off or cracked due to very tight of pulling, new parts must be replaced. The wiring harness of wheel speed sensor will form temporary open circuit/short circuit along with up and down movement of suspension system when the vehicle moves. Therefore, vehicle driving test must be conducted when checking the sensor wiring harness.
Heat the parts deemed to be faulted possibly by use of blower
●
Check whether there is cold welding phenomenon by use of cold spray
●
Open all appliance switches, including headlamp and wiper, to make the vehicle power work under a high load
In case that no fault appears again, diagnosis and service must be conducted only when such fault re-appears next time. In a general way, the accidental fault will be gradually evolved as repeatable fault, which can’t spontaneously disappear.
Brake system 5-105
DTC C109904 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle” For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C109904 ： General fault of wheel sensor (exchange of sensors and error of multi-sensor) Run DTC conditions IG ON ECU initialization completed Conditions for setting up DTC Error configuration of internal software, or error configuration of wheel speed integrated IC Multi-channel time stamp of wheel speed sensor is error Test of wheel speed sensor can’t work due to hardware fault (fault of transistor comparator or timer) The power voltage provided to wheel speed sensor by ECU is too low The wheel speed sensors of front shaft are exchanged left and right The wheel speed sensors of rear shaft are exchanged left and right Above one wheel speed sensors simultaneously fail Operation adopted when setting up DTC Close ABS function Condition for clearing DTC Turn OFF to ON after the condition for setting fault code being absent. Receive an instruction for clearing fault code issued by diagnostic tool. Reset ECU after the condition for setting fault code being absent. Reference Information Reference of schematic diagram Schematic diagram of ABS control Reference of connector end view “End View of Parts and Connector” Description and operation Instructions and operation of ABS anti-lock brake system Reference of electrical information Circuit test Repair of connector Test the intermittent fault and bad contact Circuit repair Reference of fault diagnosis tester Refer to “Reference of control module” to obtain the information of fault diagnosis tester. Circuit/system check Drive vehicle straightly until speed reaches up above 8km/h, and diagnosis tester shall be able to obtain wheel speed value of four wheel speed sensors.
Circuit/system test 1. Turn ignition switch to OFF position, disconnect the connector of K17 module and the wiring harness connectors of corresponding wheel speed sensors, and check the relevant circuits for open circuit, short circuit to earth and short circuit to power supply. 2. Check whether the corresponding pin of K17 module accessed by each wheel speed sensor is correct (whether the situation on left and right wheel speed sensors are exchanged exists) 3. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Inspection of Diagnosis and Repair Effect” after completing the diagnostic procedure. Refer to “Reference of control module” to facilitate to replace control module.
Brake system 5-106
DTC C00A000, C00A200, C00A400, C00A600 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle” For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C00A000 ： The cord of left front wheel speed sensor is short-circuit to the ground DTC C00A200：The cord of right front wheel speed sensor is short-circuit to the ground DTC C00A400 ： The cord of left rear wheel speed sensor is short-circuit to the ground DTC C00A600: The cord of right rear wheel speed sensor is short-circuit to the ground Run DTC conditions IG ON ECU initialization completed Conditions for setting up DTC Cord of wheel speed sensor is short circuited to the ground Operation adopted when setting up DTC Close ABS function Enable EBD degrading performance Condition for clearing DTC After the condition for setting fault code being absent and 100 times of ignition cycle Receive an instruction for clearing fault code issued by diagnostic tool. Reference Information Reference of schematic diagram Schematic diagram of ABS control Reference of connector end view “End View of Parts and Connector” Description and operation Instructions and operation of ABS anti-lock brake system Reference of electrical information Circuit test Repair of connector Test the intermittent fault and bad contact Circuit repair Reference of fault diagnosis tester Refer to “Reference of control module” to obtain the information of fault diagnosis tester. Circuit/system check Drive vehicle straightly until speed reaches up above 8km/h, and diagnosis test will obtain wheel speed value of four wheel speed sensors.
Circuit/system test 1. Shift ignition switch to OFF position, disconnect the corresponding wiring harness connector of wheel speed sensor, and measure whether the resistance value between power pin at the end of wiring harness connector and bonding is infinite. Repair relevant wiring harness in case that such value is about 5Ω. 2. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Inspection of Diagnosis and Repair Effect” after completing the diagnostic procedure. Refer to “Reference of control module” to facilitate to replace control module.
Brake system 5-107
DTC C00A100, C00A300, C00A500, C00A700 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle” For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C00A100：The signal line of left front wheel speed sensor is short-circuit to the power source DTC C00A300： The signal line of right front wheel speed sensor is short-circuit to the power source DTC C00A500：The signal line of left rear wheel speed sensor is short-circuit to the power source DTC C00A700 ： The signal line of right rear wheel speed sensor is short-circuit to the power source Run DTC conditions IG ON ECU initialization completed Conditions for setting up DTC The cord of wheel speed sensor is short-circuit to the power source Operation adopted when setting up DTC Close ABS function Enable EBD degrading performance Condition for clearing DTC After the condition for setting fault code being absent and 100 times of ignition cycle Receive an instruction for clearing fault code issued by diagnostic tool. Reference Information Reference of schematic diagram Schematic diagram of ABS control Reference of connector end view “End View of Parts and Connector” Description and operation Instructions and operation of ABS anti-lock brake system Reference of electrical information Circuit test Repair of connector Test the intermittent fault and bad contact Circuit repair Reference of fault diagnosis tester Refer to “Reference of control module” to obtain the information of fault diagnosis tester. Circuit/system check Drive vehicle straightly until speed reaches up above 8km/h, and diagnosis tester shall be able to obtain wheel speed value of four wheel speed sensors.
Circuit/system test 1. Shift ignition switch to OFF position, and disconnect the corresponding wiring harness connector of wheel speed sensor 2. Shift ignition switch to ON position, and measure whether the voltage between signal pin at the end of wiring harness and bonding is zero by use of digital multimeter. Repair relevant wiring harness in case that such voltage value is not zero. 3. Disconnect the wiring harness connector of wheel speed sensor, connect 12V power source and ampere meter in series between two pins of wheel speed sensor’s connector, and connect power-up pin with positive electrode and signal pin with negative electrode of power supply. Slowly turn wheel, and observe whether the reading of ampere meter is within the specified range. If reading fluctuates beyond about 7mA to 14mA, wheel speed sensor is replaced. 4. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Inspection of Diagnosis and Repair Effect” after completing the diagnostic procedure. Refer to “Reference of control module” to facilitate to replace control module.
Brake system 5-108
DTC C003200, C003500, C003800, C003B00 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle” For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C003200：The signal line of left front wheel speed sensor is short-circuit or open-circuit to the ground; Cord appears open circuit fault DTC C003500：The signal line of right front wheel speed sensor is short-circuit or open-circuit to the ground; Cord appears open circuit fault DTC C003800：The signal line of left rear wheel speed sensor is short-circuit or open-circuit to the ground; Cord appears open circuit fault DTC C003B00：The signal line of right rear wheel speed sensor is short-circuit or open-circuit to the ground; Cord appears open circuit fault Run DTC conditions IG ON ECU initialization completed Conditions for setting up DTC The signal line or cord of wheel speed sensor interrupts Operation adopted when setting up DTC Close ABS function Condition for clearing DTC After the condition for setting fault code being absent and 100 times of ignition cycle Receive an instruction for clearing fault code issued by diagnostic tool. Reference Information Reference of schematic diagram Schematic diagram of ABS control Reference of connector end view “End View of Parts and Connector ” Description and operation Instructions and operation of ABS anti-lock brake system Reference of electrical information Circuit test Repair of connector Test the intermittent fault and bad contact Circuit repair Reference of fault diagnosis tester Refer to “Reference of control module” to obtain the information of fault diagnosis tester. Circuit/system check Drive vehicle straightly until speed reaches up above 8km/h, and diagnosis tester shall be able to obtain wheel speed value of four wheel speed sensors.
Circuit/system test 1. Shift ignition switch to OFF position, and disconnect the module connector, disconnect corresponding wiring harness connector of wheel speed sensor 2. Connect the digital multimeter to pins at both ends of cord respectively to measure whether the resistance of cord is within 5Ω. If the measured value of resistance is larger than 5Ω, relevant wiring harness shall be repaired. 3. Connect the digital multimeter to pins at both ends of signal line respectively to measure whether the conductor resistance of cord is within 5Ω. If the measured value of resistance is larger than 5Ω, relevant wiring harness shall be repaired. 4. Measure whether the resistance between signal line and bonding is infinite by use of digital multimeter. Repair relevant wiring harness in case that the measured resistance is less than 5Ω. 5. Disconnect the wiring harness connector of wheel speed sensor, connect 12V power source and ampere meter in series between two pins of wheel speed sensor’s connector, and connect power-up pin with positive electrode and signal pin with negative electrode of power supply. Slowly turn wheel, and observe whether the reading of ampere meter is within the specified range. If reading fluctuates beyond about 7mA to 14mA, wheel speed sensor is replaced. 6. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Inspection of Diagnosis and Repair Effect” after completing the diagnostic procedure. Refer to “Reference of control module” to facilitate to replace control module.
Brake system 5-109
DTC C001004, C001104, C001404, C001504, C001804, C001904, C001C04, C001D04 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C001004：Left front filling valve fault DTC C001104：Left front delivery valve fault DTC C001404：Right front filling valve fault DTC C001504：Right front delivery valve fault DTC C001804：Left rear filling valve fault DTC C001904：Left rear delivery valve fault DTC C001C04：Right rear filling valve fault DTC C001D04：Right rear delivery valve fault Run DTC conditions IG ON ECU initialization completed Conditions for setting up DTC The action test of register in integrated circuit of internal valve drive does not match. The resistance value of valve exceeds the range (too large or too small) Valve defect fed back by valve drive Valve defect fed back by integrated circuit of valve drive The current value of valve doesn’t meet the setting value Detect PWM deviation Operation adopted when setting up DTC Close ABS function Condition for clearing DTC Turn the key from OFF to ON after the conditions for setting up trouble code being absent. Receive an order to erase the trouble code sent by the scan tool. Reset ECU after the conditions for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool.
Circuit/system verification Successively control each solenoid valve with the action test function of scan tool under the shutdown condition, if scan tool prompts Successful Test, the sound of corresponding solenoid valve shall be heard. Circuit/system testing 1. Shift the ignition switch to OFF position, and disconnect module connector. 2. Check whether 25A power supply fuse F1 for battery valve in X50A fuse block is in good condition. The voltages at both ends of fuse shall be about 12V, otherwise, replace the fuse. 3. Test whether the wiring harness between Terminal C2 of X50A fuse block and Terminal 1 of module connector is normal. Repair the wiring harness in case that such section of circuit is open-circuited or short-circuited to the ground. 4. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
Brake system 5-110
DTC C007208 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C007208：Valve group fault (overheat protection, invalid signal and hardware damage) Run DTC conditions IG ON ECU initialization completed Conditions for setting up DTC The supply voltage is instable, or the electric leakage of power supply system is too high Too long action time of control valve is diagnosed (overheat protection) Reading exceeds the range of integrated chip memory address of valve drive when power on. The supply voltage of integrated chip for valve drive is less than threshold value EEPROM is error Operation adopted when setting up DTC Close ABS function Condition for clearing DTC Turn the key from OFF to ON after the conditions for setting up trouble code being absent. Receive an order to erase the trouble code sent by the scan tool. Reset ECU after the conditions for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Successively control each solenoid valve with the action test function of scan tool under the shutdown condition, if scan tool prompts Successful Test, the sound of corresponding solenoid valve shall be heard.
Circuit/system testing 1. Shift the ignition key to OFF position for more than 5 min, and wait for the cooling of each solenoid valve. 2. Check whether the 25A power supply circuit of solenoid valve is normal. If there is short circuit and excessive resistance in the circuit, wiring harness shall be repaired. 3. Read trouble code, and confirm whether trouble code has been erased. 4. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
Brake system 5-111
DTC C109504 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C109504：Valve relay error Run DTC conditions IG ON ECU initialization completed Conditions for setting up DTC The voltage of vale relay is too low The valve relay is short-circuit The valve relay can’t be started, or the chip of feedback circuit is error The valve relay can’t be closed, or the chip of feedback circuit is error Operation adopted when setting up DTC Close ABS function Condition for clearing DTC Turn the key from OFF to ON after the conditions for setting up trouble code being absent. Receive an order to erase the trouble code sent by the scan tool. Reset ECU after the conditions for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Successively control each solenoid valve with the action test function of scan tool under the shutdown condition, if scan tool prompts Successful Test, the sound of corresponding solenoid valve shall be heard. Circuit/system testing 1. Check whether the 25A power supply circuit of solenoid valve is normal. If there is short circuit and excessive resistance in the circuit, wiring harness shall be repaired. 2. Read trouble code, and confirm whether trouble code has been erased. 3. If all circuit tests are normal, K17 module is replaced.
Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
Brake system 5-112
DTC C002004 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C002004：Reflux pump motor fault Run DTC conditions IG ON ECU initialization completed Conditions for setting up DTC Test on motor reversal fails Detect that motor relay is short-circuit Detect that motor relay is overloaded Overheat protection; Operation adopted when setting up DTC Close ABS function Condition for clearing DTC Turn the key from OFF to ON after the conditions for setting up trouble code being absent. Receive an order to erase the trouble code sent by the scan tool. Reset ECU after the conditions for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Circuit/system testing 1. Keep the vehicle still for more than 5 min. 2. Test whether 40A fuse in power supply circuit of motor is normal. 3. Test whether the power supply circuit is opencircuit or short-circuit. 4. Use the action test function of scan tool, and control motor running. - running noise of motor shall be heard. 5. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
DTC C006B06 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C006B06 ： Unreasonable control of ABS (the control time is too long) Run DTC conditions Shift the ignition switch to ON for 60s Vehicle speed is of 60km/h Conditions for setting up DTC There is continuous long-time control over one or more wheel(s) Vehicle dynamic control of front shaft with period larger than 10s continuously ABS emergency brake fault Operation adopted when setting up DTC Close ABS function Condition for clearing DTC Turn the key from OFF to ON after the conditions for setting up trouble code being absent. Receive an order to erase the trouble code sent by the scan tool. Reset ECU after the conditions for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool.
Brake system 5-113 Circuit/system verification Circuit/system testing 1. Increase the vehicle speed to more than 60km/h, and read the 4-wheel speed value by use of scan tool under the condition of no braking The speed values of 4 wheels shall be basically consistent, in case that large difference is found between one wheel speed with the others, corresponding inspection will be conducted to such wheel, to check whether the signal line or power line fails, or check whether the gap between wheel speed sensor and gear ring is within the specified value range (1.15mm for front wheel speed sensor and 0.6mm for rear wheel speed sensor). 2. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
Brake system 5-114
DTC C121308 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C121308：Hardware code error Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC The hardware code saved in EEPROM by ECU is error Operations adopted when setting up DTC Close ABS function Close ESP function Condition for clearing DTC After the condition for setting up trouble code being absent and 100 times of ignition cycle Receive an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Scan tool can be used to read the hardware code saved in ECU. Circuit/system testing 1. Read the hardware code value saved in ECU by use of scan tool. This value shall be complete and within the range supported by this vehicle model (“ABS1” or “ESP1”) 2. In the event of beyond the above range, then replace K17 module. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
DTC C121343 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C121343：The hardware code does not match Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC The hardware code saved by ECU is inconsistent with the hardware code information in configuration code Operation adopted when setting up DTC Close ABS function Condition for clearing DTC After the condition for setting up trouble code being absent and 100 times of ignition cycle Receive an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Scan tool can be used to read the hardware code saved in ECU. Circuit/system testing 1. Enter into the ABS/ESP after-sale online configuration system of scan tool. 2. Input VIN code of this vehicle, log in the after-sale server of SGMW to obtain the online configuration information of this vehicle. 3. Conduct ABS/ESP online configuration of this vehicle again 4. Erase trouble code. 5. Complete online configuration, namely the fault is cleared. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
Brake system 5-115
DTC C121408 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C121408：Vehicle model code error Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC The vehicle model code saved in EEPROM by ECU is error Operation adopted when setting up DTC Close ABS function Condition for clearing DTC After the condition for setting up trouble code being absent and 100 times of ignition cycle Receive an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Scan tool can be used to read the hardware code saved in ECU. Circuit/system testing 1. Read the vehicle model code value saved in ECU by use of scan tool. This value shall be complete and within the range supported by this vehicle model (“CN113”) 2. In the event of beyond the above range, then replace K17 module. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
DTC C121443 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C121443：The vehicle model code does not match Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC The vehicle model code saved by ECU is inconsistent with the vehicle model code information in configuration code Operation adopted when setting up DTC Close ABS function Condition for clearing DTC After the condition for setting up trouble code being absent and 100 times of ignition cycle Receive an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system (ESP - Electronic Stability Program) Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Scan tool can be used to read the vehicle model code saved in ECU. Circuit/system testing 1. Enter into the ABS/ESP after-sale online configuration system of scan tool. 2. Input VIN code of this vehicle, log in the after-sale server of SGMW to obtain the online configuration information of this vehicle. 3. Conduct ABS/ESP online configuration of this vehicle again 4. Erase trouble code. 5. Complete online configuration, namely the fault is cleared. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
Brake system 5-116
DTC C121208 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C121208：Configuration code error Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC The configuration code saved in EEPROM is error Operation adopted when setting up DTC Close ABS function Condition for clearing DTC After the condition for setting up trouble code being absent and 100 times of ignition cycle Receive an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Scan tool can be used to read the configuration code saved in ECU. Circuit/system testing 1. Enter into the ABS/ESP after-sale online configuration system of scan tool. 2. Input VIN code of this vehicle, log in the after-sale server of SGMW to obtain the online configuration information of this vehicle. 3. Conduct ABS/ESP online configuration of this vehicle again 4. Erase trouble code. 5. Complete online configuration, namely the fault is cleared. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
DTC C100004 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C100004：ECU error (hardware and microprocessor error) Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC ECU error is monitored Operation adopted when setting up DTC Close EBD function Condition for clearing DTC Turn the key from OFF to ON after the condition for setting up trouble code being absent. Receive an order to erase the trouble code sent by the scan tool. Reset ECU after the condition for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Circuit/system testing 1. Erase trouble code, reconnect power source, and confirm whether trouble code still exists 2. Replace K17 module. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
Brake system 5-117
DTC C101008 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C101008：ECU error (general software fault) Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC ECU error is monitored Operation adopted when setting up DTC Close ABS function Condition for clearing DTC Turn the key from OFF to ON after the condition for setting up trouble code being absent. Receive an order to erase the trouble code sent by the scan tool. Reset ECU after the condition for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Circuit/system testing 1. Erase trouble code, reconnect power source, and confirm whether trouble code still exists 2. Replace K17 module. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
DTC C100104 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C100104：CAN hardware error Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC CAN hardware error is monitored Operation adopted when setting up DTC Close ABS function Condition for clearing DTC After the condition for setting up trouble code being absent and 100 times of ignition cycle Receive an order to erase the trouble code sent by the scan tool. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system (ESP - Electronic Stability Program) Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Circuit/system testing 1. Erase trouble code, reconnect power source, and confirm whether trouble code still exists 2. Replace K17 module. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
Brake system 5-118
DTC U000104 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC U000104：Fault of CAN BUS OFF Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC Fault of BUS OFF is monitored for 100ms continuously after power on. Operation adopted when setting up DTC Close ABS function Condition for erasing DTC Turn the key from OFF to ON after the condition for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Circuit/system testing 1. Reconnect power source and confirm whether trouble code still exists 2. Replace K17 module. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
DTC U000500 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC U000500：The voltage of CAN bus is too high Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC The voltage is higher than 15.5V Operation adopted when setting up DTC Close ESP function Condition for erasing DTC After the condition for setting up trouble code being absent Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Circuit/system testing 1. Measure whether the voltages at both ends of the battery are not higher than 16V under the condition that the engine is not started Replace the battery in case of being higher than this value. 2. Measure whether the voltages at both ends of the battery are not higher than 16V under the condition that the engine is started Check the engine system in case of being higher than this value. 3. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
Brake system 5-119
DTC U000700 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC U000700：The voltage of CAN bus is too low Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC The voltage is higher than 8.5V Operation adopted when setting up DTC Close ABS function Condition for erasing DTC After the condition for setting up trouble code being absent Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system (ESP - Electronic Stability Program) Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Circuit/system testing 1. Measure whether the voltages at both ends of the battery are not lower than 9V under the condition that the engine is not started Replace the battery in case of being lower than this value. 2. Measure whether the voltages at both ends of the battery are not lower than 9V under the condition that the engine is started Check the engine system in case of being lower than this value. 3. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
DTC U100104 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC U100104：CAN passive error Run DTC conditions IG ON ECU initialization completed System is fault-free Condition for setting up DTC Passive error is monitored for 100ms continuously after power on. Operation adopted when setting up DTC Close ABS function Condition for erasing DTC Turn the key from OFF to ON after the condition for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification Circuit/system testing Reconnect power source and confirm whether network fault still exists Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference” so as to replace control module.
Brake system 5-120
DTC C190004 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C190004：The supply voltage of ECU is too high Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC The supply voltage is higher than the full-load voltage threshold value (16.8V) Operation adopted when setting up DTC Close ABS function Condition for erasing DTC Turn the key from OFF to ON after the condition for setting up trouble code being absent. Receive an order to erase the trouble code sent by the scan tool. Reset ECU after the condition for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification 1. Shift the ignition key to ON position, do no start the engine, use a scan tool to read the internal voltage value of ECU, and measure the voltage values at both ends of the battery with digital multimeter. 2. Start the engine, use a scan tool to read the internal voltage value of ECU, and meanwhile measure the voltage values at both ends of the battery with digital multimeter. Circuit/system testing 1. Do not start the engine, close all external electric equipment, and test whether the battery voltage is within the normal range by use of multimeter. - replace the battery in case that its voltage is higher than 16V. 2. Start the engine, close all external electric equipment, and test whether the battery voltage is within the normal range by use of multimeter. Check whether the engine system has any fault in case that the battery voltage is higher than 16V.
3. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up and programming of control module.
Brake system 5-121
DTC C190104 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Description of DTC DTC C190104：The supply voltage of ECU is too low Run DTC conditions IG ON ECU initialization completed Condition for setting up DTC The supply voltage is lower than the voltage threshold value (7.7V) Operation adopted when setting up DTC Close ABS function Condition for erasing DTC Turn the key from OFF to ON after the condition for setting up trouble code being absent. Receive an order to erase the trouble code sent by the scan tool. Reset ECU after the condition for setting up trouble code being absent. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Test intermittent fault and bad contact Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool. Circuit/system verification 1. Shift the ignition key to ON position, do no start the engine, use a scan tool to read the internal voltage value of ECU, and measure the voltage values at both ends of the battery with digital multimeter. 2. Start the engine, use a scan tool to read the internal voltage value of ECU, and meanwhile measure the voltage values at both ends of the battery with digital multimeter. Circuit/system testing 1. Do not start the engine, close all external electric equipment, disconnect the positive electrode and the negative electrode of the battery, and test whether the battery voltage is within the normal range by use of multimeter. - replace the battery in case that its voltage is lower than 9V. 2. Start the engine, close all external electric equipment, and test whether voltages at both ends of the battery are within the normal range by use of
multimeter. Check whether the engine system has any fault in case that the battery voltage is lower than 9V. 3. Check whether the circuit between Terminal C2 of fuse block X50A and Terminal 1 of module K17 is normal. - check whether situations like the circuit is open circuit, the resistance is too large or it is shortcircuited to the ground exists 4. Check whether the circuit between Terminal 23 of fuse block X50A and Terminal 28 of module K17 is normal. - check whether situations like the circuit is open circuit, the resistance is too large or it is shortcircuited to the ground exists 5. If all circuit tests are normal, K17 module is replaced. Service instruction Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up and programming of control module.
Brake system 5-122
DTC C003108, C003408, C003708, C003A08 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.” Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of DTC DTC C003108：The signal of left front wheel speed sensor does not work (exceeding the range, noise and intermittent), and the line circuit is shorted or open to the ground DTC C003408：The signal of right front wheel speed sensor does not work (exceeding the range, noise and intermittent), and the circuit is shorted or open to the ground DTC C003708：The signal of left rear wheel speed sensor does not work (exceeding the range, noise and intermittent), and the circuit is shorted or open to the ground DTC C003A08：The signal of right rear wheel speed sensor does not work (exceeding the range, noise and intermittent), and the circuit is shorted or open to the ground Conditions for running DTC IG ON ECU initialization completed Conditions for setting up DTC Power line of wheel speed sensor is shorted to ground The signal line of wheel speed sensor is short circuit to the power supply The signal line of wheel speed sensor is short circuit to the ground, or the line is interrupted (power line or signal line) The line of wheel speed sensor fails (accurate fault reason can’t be monitored) The line of wheel speed sensor fails (the power line or signal line is short circuit to the ground, the signal line is short circuit to the power, or the power line or signal line is interrupted) The model of wheel speed sensor is error Exceed the maximum wheel speed Lose the wheel speed signal Detect the wheel speed deviation Interfered by wheel speed signal Operation adopted when setting up the DTC Close ABS function Condition for clearing DTC Turn OFF to ON after the condition for setting up trouble code being absent. Receive an order for clearing trouble code issued by diagnostic tool. Reset ECU after the condition for setting up trouble code being absent.
Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the scan tool information. Circuit/system verification Drive vehicle straightly until speed reaches up above 8km/h, and diagnosis tester shall be able to obtain wheel speed value of four wheel speed sensors. Circuit/system test 1. Turn off the ignition switch, disconnect the connector of K17 module and the wiring harness connectors of corresponding wheel speed sensors, and confirm the relevant circuit is shorted and open to ground and shorted to power supply. 2. Check whether the gap between head of wheel speed sensor and signal wheel is within the required range For front wheel, it is required in 1.15mm; For rear wheel, it is required in 0.6mm. 3. Disconnect the wiring harness connector of wheel speed sensor, connect 12V power supply and ammeter in series between two pins of wheel speed sensor’s connector, and connect power-up pin with positive and signal pin with power negative. Slowly turn wheel, and observe whether the reading of ammeter is within the specified range. If reading fluctuates beyond about 7mA to 14mA, wheel speed sensor is replaced. 4. If all circuits are normal after test, K17 module is replaced. Service instruction Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “Control module reference” to facilitate to replace control module.
Brake system 5-123
DTC C00A900, 00AA00, C00AB00, C00AC00 Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle” For an overview of diagnostic methods, refer to the “policy-based diagnostics.” Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of DTC DTC C00A900：General fault of left front wheel speed sensor DTC C00AA00：General fault of right front wheel speed sensor DTC C00AB00：General fault of left rear wheel speed sensor DTC C00AC00：General fault of right rear wheel speed sensor Conditions for running DTC IG ON ECU initialization completed Conditions for setting up DTC The circuit of wheel speed sensor does not work (accurate fault reason can’t be detected) Operation adopted when setting up the DTC Close ABS function Enable EBD degrading performance Condition for clearing DTC After the condition for setting up trouble code being absent and cycling the ignition for 100 times Receive an order for clearing trouble code issued by scan tool. Reference information Reference of schematic diagram Schematic diagram of ABS control Connector End View Reference “Part connector end view” Description and operation Description and operation of ABS anti-lock brake system Electrical Information Reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the is can tool information. Circuit/System Verification Drive vehicle straightly until speed reaches up above 8km/h, and diagnosis tester shall be able to obtain wheel speed value of four wheel speed sensors. Circuit/system test 1. Turn off the ignition switch, disconnect the connector of K17 module and the wiring harness connectors of corresponding wheel speed sensors, and confirm the relevant circuit is shorted and open to ground and shorted to power supply. 2. If all circuits are normal after test, K17 module is replaced.
Service instruction Execute “Inspection of diagnosis and repair effect” after completing the diagnostic procedure. Refer to “Control module reference” to facilitate to replace control module.
Brake system 5-124
Service instruction Replacement of ABS control module
13AH-0505004
Note: The wet-type ABS control module specifically used after sales shall be selected during replacement, and it only needs to exhaust the hydraulic brake system according to the routine method after replacement (see the chapter of “Exhaust of hydraulic brake system”, the recommended exhaust sequence is: Left rear, left front, right front and right rear). Note: Brake fluid will damage the paint surface. If brake fluid overflows carelessly, please immediately wipe off and clean the area with water. Removal procedure 1. Disconnect the battery negative. 2.
Disconnect the wiring harness connector of ABS control module.
3.
Disconnect the connector of oil pipe connection between brake hard pipe and ABS control module, and receive the brake fluid flowing from brake pipe by use of container. Note: Prevent the foreign matters from falling in the brake hard pipe after removal of such pipe, be unable to change the shape of brake hard pipe sharply, meanwhile, mark the position of mounting hole for each brake hard pipe, so as to refer during installation.
13AH-0505005
4. 5.
15AH-0505006
Loosen two nuts (1) connected between ABS control module and ABS bracket assembly. Separate ABS control module (2) from ABS bracket (shake ABS control module properly by hands, and separate such module from the bracket from down to up).
Brake system 5-125 Installation procedure 1. Locate ABS control module (2). 2. Embed ABS control module into three locating slots of ABS bracket. 3. Tighten two fixed nuts (1) to the 19±4 N.m.
15AH-0505006
4.
Connect the oil pipe connector between brake hard pipe and ABS control module, and tighten to 16±2 N.m. Note: The marker made during removal shall be referred when connecting brake hard pipe to ABS control module, the oil pipe connector must be tightened into ABS control module along the thread, and do not tighten forcibly, otherwise, the sealing at the connector is not tight, and there is oil leakage risk.
13AH-0505005
13AH-0505004
5.
Connect ABS wiring harness to ABS control module.
6. 7.
Connect the battery negative. Exhaust hydraulic brake system, and refer to “Exhaust of hydraulic brake system”.
Brake system 5-126
Replacement of ABS bracket assembly Removal procedure 1. Remove ABS control module (2), and refer to “Replacement of ABS control module”.
15AH-0505006
2. 3. 4.
Remove two bolts (1) connected between ABS bracket assembly and body. Remove one bolt (2) connected between ABS bracket assembly and body. Take down ABS bracket assembly (3).
Installation procedure 1. Locate ABS bracket assembly (3). 2. Install one bolt (2) connected between ABS bracket assembly and body, and tighten its torque to 19±4 N.m. 3. Install two bolts (1) connected between ABS bracket assembly and body, and tighten its torque to 19±4 N.m. 15AH-0505007
4. 5.
6.
15AH-0505006
Install ABS control module (2), and refer to “Replacement of ABS control module”. Fill the brake fluid into its brake fluid reservoir according to the demands. Refer to “Filling of break liquid”. Perform exhaust procedure. Refer to “Exhaust of hydraulic brake system”.
Brake system 5-127
Front wheel speed sensor replacement Removal procedure 1. Disconnect the battery negative. 2. Remove the fuse block (when replacing left front wheel sped sensor), and place it on one side to leave space for removal. Refer to “Replacement of fuse block” 3. Disconnect the connector clip of front wheel speed sensor from wiring harness. 4. 5. 13AH-0505009
6.
7.
8. 9.
Disconnect the connector clip of front wheel speed sensor from clip. Lift up vehicle with lifting machine.
Disconnect the sealing ring connected between front wheel speed sensor and body (pull the wire harness auxiliary down). Move the wiring harness of front wheel speed sensor from upper part of body to its lower part through passing the body hole. Remove the clip connected between front wheel speed sensor and body, and scrap it. Disconnect 4 rubber stop blocks on wiring harness successively.
13AH-0505013
10. Remove mounting bolts (2) for front wheel speed sensor. 11. Separate front wheel speed sensor and its wiring harness (1).
15AH-0505014
Brake system 5-128
Installation procedure Note: Don’t twist wiring harness while installing wheel speed sensors. 1. Locate front wheel speed sensor (1). 2. Install the retaining bolts (2) for front wheel speed sensor, and tighten its torque to 8±2 N.m.
15AH-0505014
3. 4. 5.
6. 7. 8.
Install 4 rubber stop blocks on wiring harness successively into the neck. Fixed the front wheel speed sensor onto body by use of new clip. Move the wiring harness of front wheel speed sensor from lower part of body to its upper part through passing the body hole. Connect the sealing ring used for connecting front wheel speed sensor and body. Lift down vehicle from lifting machine. Connect the connector clip of front wheel speed sensor to clip.
13AH-0505013
9.
Connect the connector clip of front wheel speed sensor to wiring hardness end. 10. Install the fuse block (when replacing the left front wheel speed sensor), and refer to “Fuse block”. 11. Connect the battery negative.
13AH-0505009
Brake system 5-129
Rear wheel speed sensor replacement Removal procedure 1. Disconnect the battery negative. 2. Disconnect the connector clip of rear wheel speed sensor from wiring harness end.
13AH-0505015
3.
Disconnect the connector clip of rear wheel speed sensor from clip.
4. 5.
Lift up vehicle with lifting machine. Disconnect 3 rubber stop blocks on wiring harness successively.
13AH-0505016
13AH-0505017
Brake system 5-130
6.
Remove two bolts used for fixing the wiring harness of wheel speed sensor from the rear axle assembly.
7.
Remove mounting bolts of rear wheel speed sensor.
8.
Separate rear wheel speed sensor and its wiring harness.
13AH-0505018
Installation procedure Note: Don’t twist wire harness while installing wheel speed sensors. 1.
Locate rear wheel speed sensor
3.
Install the fixed bolts of rear wheel speed sensor, and tighten to 8±2 N.m.
4.
Install two bolts used for fixing the wiring harness of wheel speed sensor onto the rear axle assembly, and tighten to 9±3 N.m.
5.
Install 3 rubber stop blocks on wiring harness successively into the clip.
6.
Lift down vehicle from lifting machine.
7.
Connect the connector clip of rear wheel speed
13AH-0505019
sensor onto clip. 8.
Connect the connector clip of rear wheel speed sensor onto wiring hardness end.
9.
Connect the battery negative.
Brake system 5-131
Warning lamp of anti-lock brake system
Description and operation Anti-lock brake system Anti-lock brake system is one active safety device on the vehicle. Its action is to prevent the wheel from
The warning lamp of anti-lock brake system will light up under the following conditions:
up at the moment that the ignition switch is enabled,
locking and sliding during brake, so as to improve directional stability during brake, shorten vehicle brake distance, and make the vehicle brake safer and more effective. Anti-lock brake system is to add wheel speed sensor, ABS control module and ABS control circuit, etc. based on the common brake system. Wheel speed sensor transmits the speed signal collected on the wheel to ABS control module, and such module controls rapid increase or decrease of hydraulic pressure in wheel cylinder through actuator according to the received speed signal, so as to prevent the wheel from locking.
ABS control module ABS control module is control center of anti-lock brake system. Its main task is to continuously monitor and receive the speed signal transmitted from wheel speed sensor, conduct measuring comparison, analysis amplification and distinguishing treatment, and analyze the brake situation of 4 wheels, once the wheel is judged to lock, anti-lock brake control status will be entered immediately, and corresponding order is sent to hydraulic component through internal electronic control component, to prevent the wheel from locking.
Wheel speed sensor Wheel speed sensor is an extremely important constituent part for anti-lock brake system. It can measure the rotation cycles of wheel, and then generate AC signal, to send it to ABS control module.
The warning lamp of anti-lock brake system will light so as to check whether the indicator normally works.
Anti-lock brake system does not work.
The warning lamp of anti-lock brake system will light up when electronic control module detects failure of such system, to remind the driver of failure.
Chapter 6 Diagnostic overview, starting point and programming Contents 6.1 6.1.1
6.1.2
6.2 6.2.1
Programming and setup ................................. 1 Diagnostic information and procedures --control module reference ............................ 1 6.1.1.1 Control module reference ............... 1 Repair guide ... Error! Bookmark not defined. 6.1.2.1 Programming and setup of engine control module (ECM) .................... 2 6.1.2.2 Programming and setup of body control module (BCM) .................... 2 6.1.2.3 Programming and setup of immobilizer module (IMMO) ........... 2 6.1.2.4 Programming and setup of electric power steering (EPS) control module ........................................................ 2 6.1.2.5 Programming system repair ........... 3 Vehicle diagnostic information ....................... 4 Specification ................................................... 4 6.2.1.1 Scan tool information of engine control module….. ............................. 4 6.2.1.2 Scan tool information for body control module….. ............................11 6.2.1.3 Air conditioning system control module scan tool information ....... 14
6.2.1.4
6.2.2
Scan tool information for instrument cluster…... ................ 15 6.2.1.5 Scan tool information for power steering control module .............. 16 6.2.1.6 Scan tool information in the anti-lock brake control module ... 16 Diagnostic information and procedure.. ....... 18 6.2.2.1 Diagnosis based on strategy ...... 18 6.2.2.2 Diagnostic procedure description20 6.2.2.3 Checking of diagnostic system – vehicle …… ................................. 22 6.2.2.4 DTC List...................................... 24 6.2.2.5 Symptom-Vehicle ....................... 33 6.2.2.6 Engine cannot be started ........... 33 6.2.2.7 Engine crankshaft rotates but the engine does not start .................. 33 6.2.2.8 Checking / maintenance system checking.. .................................. 33 6.2.2.9 Diagnostic repair effect test ........ 33 6.2.2.10 Power system DTC type definition .................................................... 34
Diagnostic overview, starting point and programming 6-1
6.1
Programming and setup
6.1.1
Diagnostic information and procedures control module reference
6.1.1.1 Control module reference Control module reference Control module/scan tool information Data link reference Diagnostic system Checking-vehicles Diagnostic trouble code (DTC) List-vehicle Symptom-vehicle Scan tool information for body control module Scan tool information for air conditioning system control module Scan tool information for instrument cluster Scan tool information for object alarm module Scan tool information for power steering control module Immobilizer module Engine control module Power steering control module
Schematic diagram
Schematic diagram of body control system Schematic diagram of heating, ventilation and air conditioning system Schematic diagram of instrument cluster Schematic diagram of object detection system Schematic diagram of power steering system Schematic diagram of immobilizer module Schematic diagram of engine control module Schematic diagram of power steering control system
Service instruction
Replacement of body control module Replacement of heater and air conditioning control device Replacement of instrument cluster Replacement of object alarm module Replacement of power steering auxiliary motor Replacement of immobilizer module Replacement of engine control module Replacement of steering column
Diagnostic overview, starting point and programming 6-2
6.2
Service instruction
6.2.1
Programming and setup of engine control module (ECM)
Preparations for module programming and programming setup Notes: Control module can be programmed with the guidance of the repair procedure or repair communication. Programming the control module at any other time can’t permanently repair the fault reported by the client. Before the programming or the read-in program, the following standards must be met: There is no fault occurring to charging system. All faults of charging system must be repaired before programming the control module. The battery voltage is between 12-16V. If the battery voltage is too low, it must be charged before the control module programming. The battery charger shall not be connected to the vehicle battery. The voltage fluctuation caused by incorrect system voltage or battery charger will affect the programming or cause damages to the control module. Close or disable the following systems which may add loads to the vehicle battery: － Interior lamps － Outside lighting lamps － Heater, ventilation and air conditioning system － Radio － Engine cooling fan, etc. The ignition switch is placed at the correct position. The scan tool prompts that the ignition switches shall be turned on in case the engine is closed. The position of ignition switch shall not be changed during programming, except guided to do so. All the following tools are connected firmly: － Connections of the data link connector (DLC) － Power voltage circuit The wiring harness of tools shall not be interfered during programming. In case of interrupt during the programming, it will affect the control module programming or cause damages to the control module. Replacement of engine control module If the engine control module (ECM) is replaced, the following procedures must be followed: 1. Immobilizer module matching - refer to “Immobilizer module matching”. Re-programming of engine control module If the engine control module requires re-programing, refer to “Programming system repair”. Notes: Execute the following steps after programming, to avoid misdiagnosis: Turn off the ignition switch for 30s. Turn off the ignition switch in case the engine is closed.
Read the historical diagnostic trouble code of all modules by use of scan tool. Clear all historical diagnostic trouble codes.
6.2.2
Programming and setup of body control module (BCM)
Before the body control module (BCM) leaves the factory, the software has been programmed and set up and it meets all functions of controlling vehicles correctly. Replacement of body control module If the body control module (BCM) is replaced, the followings must be followed: Remote-control key matching - refer to “Theft deterrent system remote-control key matching”. Immobilizer module matching - refer to “Immobilizer module matching”. Re-programming of body control module If the body control module requires re-programming, refer to “Programming system repair”. Notes: Execute the following steps after programming, to avoid misdiagnosis: Turn off the ignition switch for 30s. Turn on the ignition switch in case the engine is closed. Read the historical diagnostic trouble code of all modules by use of scan tool. Clear all historical diagnostic trouble codes.
6.2.3
Programming and setup of immobilizer module (IMMO)
Immobilizer module acts as an exciter, makes the key radio frequency transceiver energize and receive the key coding information. Because the immobilizer module software is included in the body control module, after the replacement, the immobilizer module programming or setup has been included in the body control module programming and setup for implementation.
6.2.4
Programming and setup of electric power steering (EPS) control module
The following repair procedure requires programming or setup to complete the repair. Replacement of power steering control module If the power steering control module is replaced, the following procedures must be performed: - Zero learning of the power steering control module: if the power steering control module requires the zero learning again, refer to “Programming system repair”.
Diagnostic overview, starting point and programming 6-3 Re-programming of power steering control module If the power steering control module requires re-programing, refer to “Programming system repair”. Notes: Execute the following steps after programming, to avoid misdiagnosis: Turn off the ignition switch for 30s. Turn on the ignition switch in case the engine is closed. Read the historical diagnostic trouble code of all modules by use of scan tool. Clear all historical diagnostic trouble codes.
6.2.5
Programming system repair
If the control module requires re-programming, please login the after-sales fault diagnosis system (WDS) to enter the “refreshing and matching” function option for corresponding module programming. During the re-programming, you must conduct operation according to the system prompt. Look up the following information to ensure a correct programming protocol. Notes: The control module can be programmed with the guidance of repair procedure or of SAIC-GM-Wuling Automobile repair communication. Programming the control module at any other time can’t permanently repair the fault reported by the client. Before programming repair, it is critical to repair the programming system terminal, MDI/VCI and/or equip the latest software in the scan tool. Due to the time request of controller programming, the battery voltage stability is important during the programming. Any fluctuation, peak, overvoltage or voltage loss will interrupt the programming. Without the above tools, the battery charger can not be connected, except the 12V jumper wire fully charged or the booster components disconnected from the AC voltage power. Before or after the programming, some modules may require to perform another programming/ setup. Some vehicles may require to use the control area network diagnosis module or programming system repair module for programming. Look up the repair information related to these procedures. During the programming, the diagnostic trouble code may be set up. Clear the trouble code upon the completion of programming. Clearing the diagnostic trouble code of the power system may set up the “Checking/maintenance” system status to be “NO”. Before the control module programming, the followings conditions should be met: Vehicle system voltage: - All charging systems work normally. All faults
of charging system must be repaired before programming the control module. - The battery voltage is higher than 12V and lower than 16V. Before the control module programming, the battery must be fully charged. - Close or disable all systems which may load the vehicle battery, taking the following units as an example: Interior lamps Outside lamps Heater, ventilation and air conditioning (HVAC) system Engine cooling fan Radio, etc. The ignition switch is placed at the correct position. The programming system prompts that the ignition switches shall be turned ON in case the engine is closed. The position of ignition switch shall not be changed during the programming, except guided to do so. Guarantee that all tools are firmly connected, including the following units and circuits: － Scan tool Communication wire port Connections of the data link connector (DLC) Supply voltage circuit － MDI/VCI USB, Ethernet or wireless communication port Connections of the data link connector (DLC) The wiring harness of tools shall not be interfered during the programming. In case of interrupt during the programming, it will cause failure of programming or damage of control module. If the programming operation interrupts or fails, then the following steps shall be executed: 1. Do not turn off the ignition switch. Ensure that all the control modules and data link connectors (DLC) are firmly connected and the software repairing the programming system terminal operation is the latest version. 2. Try reprogramming the control module 3. If the control module cannot be programmed all the time, then turn off the ignition switch for one minute at least. 4. Turn on the ignition lock, and try reprogramming the control module. The control module should be programmed. – If the control module cannot be programmed all the time, then replace the control module. After successfully programming the control module, you should ensure that all the steps after programming will be executed; for the correct “Programming and setup” document with regard to the control module in any necessary step, see the “Control module reference”.
Diagnostic overview, starting point and programming 6-4
6.3
Vehicle Diagnostic Information
6.3.1
Specification
6.3.1.1 Scan tool information of engine control module The data list of scan tool of engine control module includes all the engine-related parameters on the scan tool. This list is alphabetized. A given parameter may appear in any data list, and it may appear for multiple times or appear in multiple data lists in some situation so as to combine some relevant parameters. The data list of engine scan tool can be used only after the following matters are confirmed: “Diagnostic system checking – vehicles” has been completed Do not set up diagnostic trouble code (DTC) The vehicle-mounted diagnosis works normally The values of scan tool for the engine which works normally can be used to compare with those of the engine diagnosed. The values in the data list of engine scan tool represent the date values of the engine which works normally. Notes: The scan tool displaying the wrong data cannot be used. Fault of the scan tool should be reported to the manufacturer. The use of the faulty scan tool will result in the misdiagnosis and unnecessary part replacement. This repair manual only involves the following parameters which are used in the diagnostic process. If all the numerical values are within the following typical value scope, see “Symptom – engine control system” to conduct the engine diagnosis.
Diagnostic overview, starting point and programming 6-5 Data parameters of scan tool in the engine control module Parameters
The status of the air conditioning compressor clutch relay
The on / off request status of air conditioning
Accelerator pedal position
Voltage of accelerator pedal position sensor 1
Voltage of accelerator pedal position 2
Ambient atmospheric pressure
On / off status of cooling fan 1
System status
Air conditioning is on or off
Desired value
ON/OFF
Air conditioning is on
ON
Accelerator pedal is not pressed.
0%
Accelerator pedal is completely pressed. Accelerator pedal is not pressed. Accelerator pedal is completely pressed. Accelerator pedal is not pressed. Accelerator pedal is completely pressed.
—
Cooling fan 1 is on
100% 0.75V 4.78V 0.38V 2.39V
70 - 110Kpa
ON/OFF
On / off status of cooling fan 2
Cooling fan 2 is on
ON/OFF
Cylinder fire fault counter
—
0 - 100 counting increments
Times of cylinder 1 fire
—
0 - 50 count increments
Times of cylinder 2 fire
—
0 - 50 count increments
Times of cylinder 3 fire
—
0 - 50 count increments
Times of cylinder 4 fire
—
0 - 50 count increments
Temperature of engine coolant
—
-39 - 143℃
Description Such parameter displays the status of the control circuit of the air conditioning compressor clutch relay. The scan tool displays “OFF (not running)”. “ON (normal)” represents no circuit fault is detected in the current testing period. Such parameter displays the on / off status of the air conditioning. When the scan tool displays “ON” (normal), it expresses no signal fault is tested in the current testing period. Such parameter displays the position and angle of the accelerator pedal calculated by the control module according to the position sensor signal of the accelerator pedal. Such parameter displays the actual voltage in the circuit of the position sensor signal 1 of the accelerator pedal measured by the control module. Such parameter displays the actual voltage in the circuit of the position sensor signal 2 of the accelerator pedal measured by the control module. Such parameter displays the atmospheric pressure. The control module uses the atmospheric pressure sensor input to make up the altitude difference in the fuel control. Such parameter displays the status of the control circuit of cooling fan 1. Scan tool displays “OFF”. ON represents the switch status of fan 1 is normal during its operation. Such parameter displays the status of the control circuit of cooling fan 2. Scan tool displays “OFF”. ON represents the switch status of fan 2 is normal during its operation. Such parameter displays the number of times of all cylinder fire events recorded by the control module Such parameter displays the number of times of fire events of cylinder 1 recorded by the control module Such parameter displays the number of times of fire events of cylinder 2 recorded by the control module Such parameter displays the number of times of fire events of cylinder 3 recorded by the control module Such parameter displays the number of times of fire events of cylinder 4 recorded by the control module Such parameter displays the temperature of the engine coolant obtained according to the input signal from the engine coolant temperature sensor to the control module.
Diagnostic overview, starting point and programming 6-6 Data parameters of scan tool in the engine control module (Continued) Parameters
System status
Desired value
Engine Coolant Temperature Sensor Voltage
—
0.1 - 4.9V
Engine Starting Coolant Temperature
—
-39 - 20℃
Engine speed
Engine start
＞750rpm
Ambient air temperature
—
-20 - 30℃
Air intake manifold pressure
—
60 - 110Kpa
Voltage of intake manifold pressure sensor
—
0.5 - 4.5V
Air intake temperature
—
-20 - 30℃
Voltage of intake temperature sensor
—
0.1 - 4.9V
Air intake volume
—
—
Throttle opening angle
—
5° - 79°
Ignition advance angle
Engine starts
-5° - 25°
Oxygen sensor 1 Voltage
—
0.4 - 0.5V
Oxygen Sensor 2 Voltage
The starting or ignition switch of engine shall be placed in ON position
0.1 - 0.9V
Oil injection time
Engine starts
3 - 9ms
Description Such parameter displays the voltage corresponding to the engine coolant temperature obtained according to the input signal from the engine coolant temperature sensor to the control module. Such parameter displays the relative temperature of the engine coolant temperature sensor when the engine starts Such parameter displays the current speed of the engine Such parameter displays the ambient temperature of the operation condition where the vehicle is parked. Such parameter displays the atmospheric pressure in the intake manifold. Such parameter represents the voltage value corresponding to the pressure in the intake manifold Such parameter represents the gas temperature in the intake manifold Such parameter represents the voltage value corresponding to the gas temperature in the intake manifold Such parameter represents the air flow entering the cylinder in the unit time
Such parameter represents the opening angle of the electronic throttle at certain time (the angle of the throttle is 79° in the full open condition)
Such parameter represents ignition advance angle of cylinder angle at certain time Such parameter displays the output voltage of the heating-type oxygen sensor 1 measured by the control module. Scan tool displays a higher value under the thick fuel mixture, and displays a lower value under the thinner fuel mixture. Such parameter displays the output voltage of the heating-type oxygen sensor 2 measured by the control module. Scan tool displays a higher value under the thick fuel mixture, and displays a lower value under the thinner fuel mixture. Such parameter represents the oil injection time needed by every two rotations of the engine
Diagnostic overview, starting point and programming 6-7 Data parameters of scan tool in the engine control module (Continued) Parameters
System status
Desired value
Oil injection time for cylinder 1
Engine starts
3 - 9ms
Oil injection time for cylinder 2
Engine starts
3 - 9ms
Oil injection time for cylinder 3
Engine starts
3 - 9ms
Oil injection time for cylinder 4
Engine starts
3 - 9ms
Engine idle speed
11 - 28%
Speed of engine 2,500rpm
25 - 40%
Knock control reference voltage for cylinder 1
Engine starts
＜0.01V
Knock control reference voltage for cylinder 2
Engine starts
＜0.01V
Knock control reference voltage for cylinder 3
Engine starts
＜0.01V
Knock control reference voltage for cylinder 4
Engine starts
＜0.01V
Control output
Engine starts
—
Duty ratio of carbon tank control
Engine starts
—
Trip distance
—
—
Battery voltage
—
11 - 16V
Engine load
Description Such parameter represents the oil injection time of cylinder 1 needed by every two rotations of the engine (one stroke) Such parameter represents the oil injection time of cylinder 2 needed by every two rotations of the engine (one stroke) Such parameter represents the oil injection time of cylinder 3 needed by every two rotations of the engine (one stroke) Such parameter represents the oil injection time of cylinder 4 needed by every two rotations of the engine (one stroke) Such parameter displays the engine load calculated according to the input from all the engine sensors to the control module, in the form of percentage. Such parameter is used to display the knock voltage showed on knock sensor. ECU adjusts the ignition advance angle through knock voltage signal to control the knock. Such parameter is used to display the knock voltage showed on knock sensor. ECU adjusts the ignition advance angle through knock voltage signal to control the knock. Such parameter is used to display the knock voltage showed on knock sensor. ECU adjusts the ignition advance angle through knock voltage signal to control the knock. Such parameter is used to display the knock voltage showed on knock sensor. ECU adjusts the ignition advance angle through knock voltage signal to control the knock. Such parameter is used to adjust the air-fuel ratio and amend the closed loop control from time to time. Such parameter is used to display the time interval for the operation of the carbon tank magnetic valve. Such parameter is used to display the specific trip distance of the vehicle Such parameter is used to display the battery voltage
Diagnostic overview, starting point and programming 6-8 Output control of scan tool in the engine control module Output control
Cooling fan relay 1
Cooling fan relay 2
Fault indicator of engine
Air conditioning compressor relay
Carbon tank solenoid valve
Fuel relay
Oil injector control of cylinder 1
Oil injector control of cylinder 2
Description This function controls the cooling fan relay 1. The normal order status of fan relay is “ON/OFF”. Scan tool begins to test in case of meeting the following conditions: The temperature of engine coolant doesn’t exceed the specified scope. Under the correct power supply mode. The engine is not enabled, and the ignition switch is turned on This function controls the cooling fan relay 2. The normal order status of fan relay is “ON/OFF”. Scan tool begins to test in case of meeting the following conditions: The temperature of engine coolant doesn’t exceed the specified scope. Under the correct power supply mode. The engine is not enabled, and the ignition switch is turned on This function controls the malfunction indicator lamp (MIL). The normal order status is “ON / OFF”. When receiving the order of lighting up or going out, the engine control module will make the malfunction indicator light up or go out. This output can also be monitored in the scan tool data parameter “MIL Command”, The system keeps in order status, until scan tool cancels such status. The conditions for the scan tool to conduct the test: Under the correct power supply mode. Fail to start the engine. The ignition voltage is within the specified scope. This function starts the air conditioning compressor relay. The normal order status of air conditioning relay is “ON / OFF”. The air conditioning compressor will power on or power off according to the ON or OFF order. The system keeps in order status, until scan tool cancels such status. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The pressure of the high-pressure side of air conditioning is within the specified scope. The ignition voltage is within the specified scope. Diagnostic trouble code of the air conditioning pressure sensor is not set up. This function starts the carbon tank control valve. The normal control order for the carbon tank control valve is “ON / OFF”, and the carbon tank control valve will work or disconnect according to the ON or OFF order. The system keeps in order status, until scan tool cancels such status. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. The ignition switch is turned on. This function starts the fuel pump relay. The normal control order for the fuel pump relay is “ON / OFF”. The fuel pump relay will work or disconnect according to the ON or OFF order. It will stop automatically and wait for the next control order after the system works. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. The ignition switch is turned on. The order of “OFF” must be conducted after executing the order of “ON”, or ECU control order will be returned, and the next action test may be invalid. This function controls on-off of cylinder 1 oil injection. The normal control order of oil injector of cylinder 1 is “ON / OFF”. The oil injector of cylinder 1 will work or disconnect according to the ON/OFF order. The system keeps in order status, until scan tool cancels such status. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. Engine starts This function controls on-off of cylinder 2 oil injections. The normal control order of oil injector of cylinder 2 is “ON / OFF”. The oil injector of cylinder 2 will work or disconnect according to the ON/OFF order. The system keeps in order status, until scan tool cancels such status. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. Engine starts
Diagnostic overview, starting point and programming 6-9 Output control of scan tool in the engine control module (Continued) Output control
Oil injector control of cylinder 3
Oil injector control of cylinder 4
Ignition control of cylinder 1
Ignition control of cylinder 2
Ignition control of cylinder 3
Ignition control of cylinder 4
Description This function controls on-off of cylinder 3 oil injections. The normal control order of oil injector of cylinder 3 is “ON / OFF”. The oil cylinder of cylinder 3 will work or disconnect according to the ON/OFF order. The system keeps in order status, until scan tool cancels such status. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. Engine starts This function controls on-off of cylinder 4 oil injections. The normal control order of oil injector of cylinder 4 is “ON / OFF”. The oil injector of cylinder 4 will work or disconnect according to the ON/OFF order. The system keeps in order status, until scan tool cancels such status. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. Engine starts This function controls on-off of cylinder 1 ignition to judge whether the ignition system works normally. The normal control order for cylinder 1 ignition is “ON / OFF”. “ON” – ignition starts; “OFF” –ignition stops The system controls on-off of cylinder 1 ignition by “ON / OFF” order. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. The engine fails to start The order of “OFF” must be conducted after executing the order of “ON”, or ECU control order will be returned, and the next action test may be invalid. This function controls on-off of cylinder 2 ignitions to judge whether the ignition system works normally. The normal control order for cylinder 2 ignition is “ON / OFF”. “ON” – ignition starts; “OFF” –ignition stops. The system controls on-off of cylinder 2 ignition by “ON / OFF” order. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. The engine fails to start The order of “OFF” must be conducted after executing the order of “ON”, or ECU control order will be returned, and the next action test may be invalid. This function controls on-off of cylinder 3 ignitions to judge whether the ignition system works normally. The normal control order of cylinder 3 ignition is “ON / OFF”. “ON” – ignition starts; “OFF” –ignition stops. The system controls on-off of cylinder 3 ignition by “ON / OFF” order. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. The engine fails to start The order of “OFF” must be conducted after executing the order of “ON”, or ECU control order will be returned, and the next action test may be invalid. This function controls on-off of cylinder 4 ignitions to judge whether the ignition system works normally. The normal control order of cylinder 4 ignition is “ON / OFF”. “ON” – ignition starts; “OFF” –ignition stops. The system controls on-off of cylinder 4 ignition by “ON / OFF” order. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. The engine fails to start The order of “OFF” must be conducted after executing the order of “ON”, or ECU control order will be returned, and the next action test may be invalid.
Diagnostic overview, starting point and programming 6-10 Output control of scan tool in the engine control module (Continued) Output control
Upstream oxygen sensor heating control
Downstream oxygen sensor heating control
Throttle opening angle control
Intake camshaft control
Idling control
Description This function controls on-off of the upstream oxygen sensor heating to judge whether the operation of the upstream oxygen sensor heating circuit is normal. The normal control order is “ON/OFF”. ON – heating starts; OFF –heating stops; The system controls on-off of the upstream oxygen sensor heater by the “ON / OFF” order. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. Start the engine The order of “OFF” must be conducted after executing the order of “ON”, or ECU control order will be returned, and the next action test may be invalid. This function controls on-off of the upstream oxygen sensor heating to judge whether the operation of the downstream oxygen sensor heating circuit is normal. The normal control order is “ON/OFF”. ON – heating starts; OFF –heating stops; The system controls on-off of the downstream oxygen sensor heater by the “ON / OFF” order. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. Start the engine The order of “OFF” must be conducted after executing the order of “ON”, or ECU control order will be returned, and the next action test may be invalid. This function controls the throttle opening angle to judge whether the throttle is able to work normally. The normal control order is “ON/OFF”. ON – controls opening of the throttle; OFF – control closing of the throttle. The system controls the throttle opening angle to change in the scope of 0-100% by the “ON / OFF” order. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. The order of “OFF” must be conducted after executing the order of “ON”, or ECU control order will be returned, and the next action test may be invalid. The ignition switch is turned on. This function controls the intake camshaft. The normal control order is “ON/OFF”. ON - intake camshaft starts. OFF – the intake camshaft closes. The system controls the intake camshaft by the “ON / OFF” order. Scan tool begins to test in case of meeting the following conditions: Under the correct power supply mode. The ignition voltage is within the specified scope. The ignition switch is turned on. The order of “OFF” must be conducted after executing the order of “ON”, or ECU control order will be returned, and the next action test may be invalid. This function controls the engine revolutions. The normal control order is “ON/OFF”. ON – conduct the engine idle speed control. OFF – recover the engine idle speed. The system conducts the scope adjustment (750 rpm – 2,500 rpm) of the engine idle speed by “ON / OFF” order; if the following conditions are met, the scan tool will begin the test. Under the correct power supply mode. The ignition voltage is within the specified scope. Engine starts
Diagnostic overview, starting point and programming 6-11
6.3.2
Scan tool information for body control module Data parameters of scan tool for body control module
Parameters System status Desired value Definition Operating condition: The ignition switch is turned on; the parking gear of the vehicle is shifted; all the doors are closed. Position lamp switch Scan tool displays: On/Off Low beam lamp switch Scan tool displays: On/Off Headlamp switch Scan tool displays: On/Off High beam switch Scan tool displays: On/Off Switch for left turn lamp Scan tool displays: On/Off Switch for right turn lamp Scan tool displays: On/Off Rear fog lamp switch Scan tool displays: On/Off Hazard warning lamp switch Scan tool displays: On/Off Backup lamp switch Scan tool displays: On/Off Position lamp Scan tool displays: Light/not light Low beam light Scan tool displays: Light/not light High beam lamp Scan tool displays: Light/not light Left turn lamp Scan tool displays: Light/not light Right turn light Scan tool displays: Light/not light Front fog lamp Scan tool displays: Light/not light Rear fog lamp Scan tool displays: Light/not light Backup lamp Scan tool displays: Light/not light Interior lamp Scan tool displays: Light/not light Driver door touch switch Scan tool displays: On/Off Other door touch switch Scan tool displays: On/Off Trunk door touch switch Scan tool displays: On/Off Lock feedback switch Scan tool displays: On/Off Trunk unlocking switch Scan tool displays: On/Off Locking motor Scan tool displays: On/Off Unlocking motor Scan tool displays: On/Off Trunk unlocking motor Scan tool displays: On/Off High-speed switch for front Scan tool displays: On/Off wiper Low-speed switch for front Scan tool displays: On/Off wiper Intermittent switch for front Scan tool displays: On/Off wiper Stop switch for front wiper Scan tool displays: On/Off Intermittent regulating Scan tool displays: On/Off switch for front wiper Front washer switch Scan tool displays: On/Off High-speed motor for front Scan tool displays: On/Off wiper Low-speed motor for front Scan tool displays: On/Off wiper Front washer motor Scan tool displays: On/Off Whether IMMO is locked? Scan tool displays: locked / unlocked Whether PIN is written in Scan tool shows: written/not written Whether SK is written in Scan tool shows: written/not written Whether VOM is written in Scan tool shows: written/not written The key has been matched Scan tool displays: 0/ 1/ 2/ 3/ 4 Whether the key is inserted Scan tool displays: Insert/ Not insert Buzzer Scan tool displays: ON/OFF Parking brake switch Scan tool displays: ON/OFF Electricity saving control Scan tool displays: ON/OFF Left front window lifting Scan tool displays: ON/OFF motor Left front window falling Scan tool displays: ON/OFF motor Right front window lifting Scan tool displays: ON/OFF motor Right front v window falling Scan tool displays: ON/OFF motor
Diagnostic overview, starting point and programming 6-12 Data parameters of scan tool for body control module (Continued) Parameters Left rear window lifting motor Left rear window falling motor Right rear window lifting motor Right rear window falling motor
System status
Desired value
Definition Scan tool displays: ON/OFF Scan tool displays: ON/OFF Scan tool displays: ON/OFF Scan tool displays: ON/OFF
Unlocking relay
Scan tool displays: ON/OFF
Locking relay
Scan tool displays: ON/OFF
The system LED lamp is locked in the instruments
Scan tool displays: ON/OFF
Diagnostic overview, starting point and programming 6-13 Output control of scan tool for the body control module Output control of the scan tool Position lamp switch Low beam lamp switch Headlamp switch High beam lamp switch Switch for left turn lamp Switch for right turn lamp Rear fog lamp switch Hazard warning lamp switch Backup lamp switch Position lamp Low beam lamp High beam lamp Left turn lamp Right turn lamp Rear fog lamp Backup lamp Interior lamp Driver door touch switch Other door touch switches Trunk door touch switch Lock feedback switch Trunk unlocking switch Locking motor Unlocking motor Trunk unlocking motor High-speed switch for front wiper Low-speed switch for front wiper Intermittent switch for front wiper Stop switch for front wiper Intermittent regulating switch for front wiper Front washer switch High-speed motor for front wiper Low-speed motor for front wiper Front washer motor
Instructions Select “on”, and the position lamp will light up Select “on”, and the low beam lamp will light up Select “on”, and the headlamp will light up Select “on”, and the high beam lamp will light up Select “on”, and the left turn lamp will light up Select “on”, and the right turn lamp will light up Select “on”, and the rear fog lamp will light up Select “on”, and the hazard warning lamp will light up Select “on”, and the backup lamp will light up Turn on the switch of the position lamp, and the lamp will light up Turn on the switch of the low beam lamp, and the lamp will light up Turn on the switch of the high beam lamp, and the lamp will light up Turn on the switch of the left turn lamp, and the lamp will light up Turn on the switch of the right turn lamp, and the lamp will light up Turn on the switch of the rear fog lamp, and the lamp will light up Turn on the switch of the backup lamp, and the lamp will light up Turn on the switch of the interior lamp, and the lamp will light up Turn on the driver door touch switch, and the interior lamp will light up Turn on other door touch switch, and the interior lamp will light up Turn on the trunk door touch switch, and the interior lamp will light up Turn on the lock feedback switch, and the interior lamp will light up Turn on the trunk unlocking switch, and the interior lamp will light up If the lock feedback switch is turned off, the vehicle will be locked If the lock feedback switch is turned on, it will be unlocked If the trunk unlocking switch is turned on, the trunk will be open If the high-speed switch of front wiper is turned on, the front wipers will operate in the high speed If the low-speed switch of front wiper is turned on, the front wipers will operate in the low speed If the intermittent switch of front wiper is turned on, the front wiper will operate in the intermittent speed If the stop switch of the front wiper is turned on, the front wiper will not work Be used to control the interval time manually The front washer switch opens, and the front washer motor works If the high-speed switch of front wiper is turned on, the high-speed motor of front wiper will work If the low-speed switch of front wiper is turned on, the low-speed motor of front wiper will operate in the low speed The front washer switch is turned on, and the front washer motor works
Diagnostic overview, starting point and programming 6-14
6.3.3
Air conditioning system control module scan tool information Parameters of the scan tool for the safety airbag control system
System status Operating condition: Turn on the ignition switch Value of the point explosion resistance of the airbag for driver Value of the point explosion resistance of the airbag for co-driver Value of the point explosion resistance of the safety belt pre-tightening for driver Value of the point explosion resistance of the safety belt pre-tightening for co-driver Parameters
Co-driver existence switch
-
Driver safety belt
-
Safety belt for co-driver
-
Preset value
(1.8 - 5.35) ± 0.1Ω (1.5 - 4.56) ± 0.1Ω
Description Display the value of point explosion resistance Display the value of point explosion resistance
(1.5 - 4.56) ± 0.1Ω
Display the value of point explosion resistance
(1.5 - 4.56) ± 0.1Ω
Display the value of point explosion resistance
Exist/not exist Tightened/not tightened Tightened/not tightened
Display the existence status of co-driver Display the tightened status of safety belt Display the tightened status of safety belt
Diagnostic overview, starting point and programming 6-15
6.3.4
Scan tool information for instrument cluster Parameters of scan tool for instrument cluster
System status Operating condition: Turn on the ignition switch The status of the reminder lamp if the driver does not wear the safety belt The status of the reminder lamp if the co-driver does not wear the safety belt Parameters
Preset value
Description
Tightened/not tightened
Display whether the driver wears the safety belt
Tightened/not tightened
Display whether the co-driver wears the safety belt Display whether the high beam lamp is turned on Display whether the left turn lam is turned on Display whether the right turn lamp is turned on Display whether the front fog lamp is turned on Display whether the rear fog lamp is turned on Display whether the position lamp is turned on The reminder lamp will light up if the oil level is lower than the threshold value If any door is not closed, the reminder lamp will light up The reminder lamp will light up when the water temperature is higher than the threshold value The indicator will light up when the key is successfully verified with BCM The indicator will light up when any fault occurs to ABS The indicator will light up when any fault occurs to the airbag Display the current temperature of the engine coolant
The status of high beam lamp
-
Open/not open
The status of the left turn lamp
-
Open/not open
The status of the right turn lamp
-
Open/not open
Front fog lamp
-
Open/not open
The status of rear fog lamp
-
Open/not open
The status of position lamp
-
Open/not open
The status of low oil level indicator
-
Light up/go out
Door touch indicator
-
Light up/go out
High water temperature indicator
-
Light up/go out
Theft deterrent indicator
-
Light up/go out
ABS indicator
-
Light up/go out
Airbag indicator
-
Light up/go out
Displayed value of water thermometer
-
℃
Displayed value of oil level gauge
-
%
Display the current oil level
Displayed value of speedometer
-
0 Km/h
Display the current speed
Displayed value of tachometer
-
0 revolutions/min
Displayed value of odometer
-
Km
Display the total mileage of the vehicle
Subtotal mileage 1
-
Km
Display the subtotal mileage 1
Subtotal mileage 2
-
Km
Display the subtotal mileage 2
MIL indicator
-
Open/not open
EPS red indicator
-
Open/not open
EPS yellow indicator
-
Open/not open
Indicator for the trunk open
-
Open/not open
Indicator for door open warning
-
Open/not open
Display the current rotate speed of engine
Display whether the MIL lamp is turned on Display whether EPS red indicator is turned on Display whether EPS yellow indicator is turned on Display whether the indicator of the trunk open is turned on Display whether the indicator of door open warning is turned on
Diagnostic overview, starting point and programming 6-16 Output control of scan tool for instrument cluster Input and output control
Description
Audible alarm
On/Off
Water temperature indicating control
Increase/decrease
Oil meter indicating control
Increase/decrease
Speed display indicating control
Increase/decrease
Fault indicator control
On/Off
Gear displaying control
Display/close
Side lamp indicator control
On/Off
Indicator control for front fog lamp
On/Off
6.3.5
Scan tool information for power steering control module Parameters of scan tool for power steering control System status
Parameters
Preset value
Description
Operating condition: Turn on the ignition switch Steering wheel angle
-
-
Speed
-
-
Steering wheel torsion
-
-
Fault lamp status
-
-
6.3.6
Display the steering angle of steering wheel Display the supply voltage of wheel EPS Display the steering angle of steering wheel Display the interior temperature of ECU
Scan tool information in the anti-lock brake control module Parameter of scan tool in the anti-lock brake control fault Parameters
System status
Preset value
Description
Operating condition: Turn the ignition switch to ON position Battery voltage
-
0V
Switch of brake lamp
-
Off
Speed
-
0 Km/h
FL front left wheel speed
-
0 Km/h
FR front right wheel speed
-
0 Km/h
RL rear left wheel speed
-
0 Km/h
RR rear right wheel speed
-
0 Km/h
Status of valve relay
-
Off
Status of bump motor
-
Off
Display the working status of bump
-
Not activated
Display the activated status of valve
-
Not activated
Display the activated status of valve
-
Not activated
Display the activated status of valve
-
Not activated
Display the activated status of valve
(AVRR) activated status of inlet valve rear right (EVRR) activated status of inlet valve rear front (AVRL) activated status of outlet valve rear left (EVRL) activated status of inlet valve rear left
Display battery voltage Display whether the brake pedal is depressed Display the real-time speed information Display the real-time information of wheel speed Display the real-time information of wheel speed Display the real-time information of wheel speed Display the real-time information of wheel speed Display the working status of valve relay
Diagnostic overview, starting point and programming 6-17 Parameter of scan tool in the anti-lock brake control fault (Continued) Parameters (AVFR) activated status of outlet valve front right (EVFR) activated status of inlet valve front right (AVFL) activated status of outlet valve front left (EVFL) activated status of inlet valve front left
System status
Preset value
-
Not activated
Display the activated status of valve
-
Not activated
Display the activated status of valve
-
Not activated
Display the activated status of valve
-
Not activated
Display the activated status of valve
Description
Diagnostic overview, starting point and programming 6-18
6.4
Diagnostic information and procedure
6.4.1
Diagnosis based on strategy
the greatest degree. Each box of “Diagnosis based on strategy” is numbered, but it does not need to execute the operations in all boxes for successfully diagnosing the problems reported by the client for repair. The first step of the diagnostic procedure must be “understand and confirm the problem reported by the clients for repairs”. The last step of the diagnostic procedure must be “repair and confirm the repair completion”. For the correct “diagnosis based on strategy”, see the following figure.
When you formulate the action program for each specific diagnosis condition, “diagnosis based on strategy” can provide guidance for you. To follow a kind of similar program for each diagnosis condition can improve the vehicle diagnosis and repair efficiency to
Understand and confirm the problems reported by the client for repair Yes
Inspect the same model of vehicles Client’s misunderstanding of the system – explain the operational condition to the client or see the user’s manual or repair manual. The client is dissatisfied – submit a field product report
The vehicle works normally
No
Pre-checking – appearance and operation
Execute “diagnostic system checking – vehicles”, and confirm which diagnosis category is to be executed
Inspect the relevant communication, memory and preparation information
Current diagnostic trouble code
Symptom – no diagnostic trouble code
Diagnosis not published
Intermittent / historical diagnostic trouble code
Follow the diagnosis of the diagnostic trouble code
Follow the symptom diagnosis
Analyze and formulate the diagnostic program or seek for the technical support
See the following diagnosis details
Confirm the basic cause and then repair and inspect the repair condition
No
Current diagnostic trouble code
Diagnostic overview, starting point and programming 6-19 1.
2.
3.
4.
5. 6.
Understand and confirm the problems reported by the client for repairs: The first part of this step is to understand the condition of client as many as possible. Are some after-sale accessories added in the vehicle? When did the condition appear? Where did the condition appear? How long has this condition lasted? How often does this condition appear? In order to confirm the problems reported by the client for repair, the technicians must be familiar with the normal working condition of the system; to obtain the information required, see the user’s manual or repair manual. The driving condition of the vehicle conforms to the design requirements; such situation exists when the vehicle works normally. The situation described by the client may belong to the normal situations. Under the condition of describing the same situation with the client, compare it with the similar vehicles under the normal running. Explain the result found and the system operation situation to the client. If the client is dissatisfied – submit a field product report. Pre-checking: Conduct the comprehensive visual checking. Look up the historical repair records. Detect whether there is any abnormal sound or abnormal smell. Collect the diagnostic trouble code (DTC) information so as to conduct the effective repair. Execute the “Diagnostic system checking – vehicles” published: Execute the “Diagnostic system checking – vehicles” published, and confirm that the system operation is normal. In this way, the technicians can be guided to adopt the systematic diagnosis program, and confirm which diagnosis category can be executed. Inspect the relevant repair communication, recalling and preparation information (PI). Diagnostic category: 6.1 Current diagnostic trouble code: Conduce the effective repair according to the diagnosis of the diagnostic trouble code specified. Refer to “Diagnostic Trouble Code (DTC) List – vehicles”. 6.2 Symptom – no diagnostic trouble code: Select the corresponding symptom for diagnosis. Complete repair according to the diagnostic steps or suggestions. Refer to “Symptom – vehicles”. 6.3 Diagnostic procedure not published: Analyze the problems reported for repair. Formulate the diagnostic program. The schematic diagram of repair manual will be beneficial to the system power, ground,
7.
8.
input and output circuits. You can also confirm the position where the contact is connected with other multiple circuits. Look up the position of the parts, and confirm whether the parts, connectors or wiring harnesses are exposed to the extreme temperature or humidity environment and whether they will be exposed to the road anti-freezing salt or other corrosive battery acid liquor, engine oil or other oil liquid. Utilize the circuit diagram, description and operation as well as the system circuit description. 6.4 Intermittent / historical diagnostic trouble code: The intermittent fault does not occur continuously, is hard to reappear and only occurs when the conditions are met. In the general condition, the intermittent fault is resulted in by the electric connector and wiring harness fault, units fault, electromagnetism / radio frequency interference, driving condition or the after-sale equipment added. The following methods / tools are beneficial to position and repair of the intermittent fault or historical diagnostic trouble code. Combine the professional knowledge and the available repair information. Judge the symptoms and conditions described by the client in the Confirmation Form of Client Reporting for Repair. Follow the suggestions in “Intermittent fault and bad contact test”. Use the equipped scan tool with the data capturing function, digital multimeter or J 42598. Find the basic cause of the fault, and then repair and inspect the repair condition: Execute “Diagnosis and repair effect checking”, and conduct repair and inspect whether the vehicle operation is correct after finding the basic cause of the fault. Confirm that diagnostic trouble code or symptom has been eliminated, and it is possible to carry out road test on vehicle. Re-inspect the warranty problem of client: If technician fails to find problem, re-checking can be carried out when necessary. Reconfirm the warranty problem of client again. Problem may be intermittent fault or normal condition.
Diagnostic overview, starting point and programming 6-20
6.4.2
Diagnostic procedure description
Description of diagnostic trouble code The diagnostic trouble codes diagnosed in this procedure are described. If appropriate, it is necessary to write out the diagnostic trouble code number with symptom description and fault description. Diagnostic information of fault Fault diagnosis information table can identify all circuits constituted into electric sub-system and relevant circuit fault. The table lists the diagnostic trouble codes and symptoms related to all circuit fault modes. The information can be used to diagnose electrical faults or as quick visual reference to indicate how different symptoms and diagnostic trouble codes are reflected in the subsystem undergoing diagnosis. Although all diagnostic trouble codes and symptoms are reflected in this table, it is unable to indicate that they can be diagnosed by a same procedure.
The followings are brief descriptions about all 16 kinds of procedures included in the diagnostic procedure. Diagnostic description Here, you can find the link of “Diagnostic system checking - vehicle”. Because this procedure can avoid misdiagnose of other integrated systems, it shall be firstly executed before executing other diagnostic procedures. Here, you can find the link of “Diagnosis based on strategy”. Here, you can find the descriptions about how to diagnose vehicle by relevant technicians. Here, you can find the link of “Descriptions about diagnostic procedure”. Such information is brief descriptions about all 16 kinds of procedures included in the diagnostic procedure.
List for engine coolant temperature (ECT) procedure Circuit Engine coolant temperature sensor signal Engine coolant temperature reference low voltage
Short circuit to the ground P011716
P011817
Short circuit to the power supply P011817
-
-
-
Open circuit
Signal performance P011629 -
List for engine coolant temperature procedure Circuit
Short circuit to the ground
Open circuit
Short circuit to the power supply
+140℃
-30℃
-30℃
-
-30℃
-
Operating condition: Engine starts Operation scope of parameters: -30℃ to +140℃ Engine coolant temperature signal Low-level reference voltage
If short circuit occurs to B+, the inside part of engine control module will be damaged.
Diagnostic overview, starting point and programming 6-21 Circuit/system description Circuit / system description determines how circuit / system works normally. Conditions for running DTC Conditions for running diagnostic trouble code, which confirm that some condition must occur prior to running fault diagnosis. Conditions for setting up DTC Conditions for setting up diagnostic trouble code, which confirm that some conditions must occur in the event of diagnosis failure and when the diagnostic trouble code is to be set up. Operation adopted when setting up the DTC Operation for setting up diagnostic trouble code, which refers to default operation for confirming control module to set up diagnostic trouble code. Condition for clearing DTC Condition for clearing DTC, which confirms the condition that must be met in order to clear diagnostic trouble code. Diagnostic assistance Diagnosis assistance is a kind of suggestion, and gives other explains about the fault diagnosis. It also provides the special information to technicians to find and repair vehicle fault. Reference information Reference information includes the links for providing other information to diagnosis procedure. For example: Schematic diagram reference Connector end view reference Description and operation Electrical information reference Type reference of diagnostic trouble code Scan tool reference Specialty tools required Circuit/System Verification For the diagnosis form, any one of three diagnosis types is not forced to be executed by the technician (circuit/system checking, circuit/system test and units test). However, first execution of circuit/system checking is beneficial to confirm whether the vehicle fault currently exists. This type can guide technicians to enter into another diagnosis procedure which shall be firstly executed; for example, diagnostic trouble code with higher priority. Circuit / system checking is an incoherent procedure, outlines how to confirm one system or one system terminal is running normally. Vehicle shall be kept intact and tested as one complete system in the checking process. The checking can help technicians determine whether fault is current fault or intermittent fault. If fault is determined as intermittent fault, technicians can use the links in the “Reference of electric information”. “Test the intermittent fault and bad contact”. If appropriate, technicians shall be able to confirm that fault occurs in input circuit – signal occurs in output circuit – control. Technicians require determining whether the system works normally in the confirmation result, or whether further diagnosis is needed in circuit/system test and/or units test.
Circuit/system testing For the diagnosis form, any one of the three diagnosis types is not forced to be executed by the technician (circuit/system verification, circuit/system testing and component test). However, execution of circuit/system verification at first is beneficial to confirm whether the vehicle fault currently exists. Circuit / system testing is carried out step by step in order to allow technicians to carry out each test step in order until fault is diagnosed. If the results of test step numbered are obtained, the next test step numbered is continuously carried out based on the normal process. If the results of test step numbered are not obtained, the maintenance arrow after the test (-) points to the operation to be performed. Disruptive diagnosis is performed to determine system fault. Harness connector of system is disconnected from the module or component to test the function of single circuit. Module or component is used for helping to confirm circuit function. If the checking isn’t passed, the maintenance step (-) will point to the circuit fault requires to be tested. For example, short circuit to voltage, short circuit or open circuit to ground, or the resistance is too large. When single circuit fault is inspected, technicians shall also carry out terminal checking, such as the connecting surface and terminal tension of harness and component/module. Additionally, technicians can use the links in the “Electrical information reference”: “Test intermittent fault and bad contact” or “Circuit test”. Control module and component will be diagnosed at the time of performing these test steps. Control module or component shall always be retested prior to the replacement. For example, all components and modules are reconnected and system is retested to confirm that fault still remains prior to the replacement of module or component. Component test For the diagnosis form, any one of the three diagnosis types is not forced to be executed by the technician (circuit/system verification, circuit/system testing and component test). However, execution of circuit/system verification at first is beneficial to confirm whether the vehicle fault currently exists. Component test is able to provide static and / or dynamic component test. These tests are used to confirm whether components are working normally to avoid unnecessary replacement. Test modules in this category are not provided. In most situations, modules are used to confirm the harness circuit in the category of circuit / system testing, and modules shall always be retested prior to the replacement. Service instruction “Repair guide” provides the link of “Diagnostic repair effect test”. Such link describes how to confirm the vehicles to be repaired. Here is the list of all links of "Repair or replacement procedures". Repair effect test When additional information other than "Diagnostic repair effect test" is required, the "Repair effect test" describes how to test the vehicle repair
Diagnostic overview, starting point and programming 6-22
6.4.3
Checking of diagnostic system–vehicle
Diagnostic description Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle”. For an overview of diagnostic methods, refer to the “policy-based diagnostics.”. Proceed to implement “Checking of diagnostic system” until a specific diagnostic or repair procedure is implemented following the instruction. After the repair is completed, carry out "Diagnostic repair effect test", to confirm that the customer repair issues have been eliminated. The premise to perform the diagnostic procedures in this manual is to assume that the following functions of various aspects are consistent with the design conventions: 12V battery is fully charged, and the wire is clean and secure. Refer to "Battery checking/test". Fuse is not open. Refer to "Power distribution diagram" and "Electrical center logo view". The ground circuit at the customer repair area is clean, secure and at the correct position. Refer to "Ground distribution diagram" and "Harness wiring diagram". All connections/connectors at the fault area are completely in place. Refer to “Part connector end view”. No aftermarket equipment will affect the system operation. Refer to “Checking of aftermarket accessories”. Scan tool is energized. Refer to "Scan tool is not energized". Checking of diagnostic system 1. Confirm the customer repair issues - understand and confirm the customer repair issues. Inspect if the visible system components have obvious damage or fault that results in such fault. 2. Refer to maintenance communication - inspect relevant maintenance communication, recall/regional operations and preliminary information. 3. Mechanical system fault) — Confirm that this symptom is not caused by the mechanical system fault alone. － If the symptom is caused only by the mechanical system fault, refer to "Symptoms - vehicle". 4. Vehicle power test - place the ignition switch at the ON position and make sure that the vehicle is energized. － If the vehicle is not energized, refer to "Power mode mismatch". Note: Unless specified in the diagnostic procedures, do not clear any DTC. If a DTC is associated with the power system, then select "Capture information" to save the "Freeze fault state/fault record" on the scan tool. 5. Control module communication and DTC checking - Use a scan tool, perform the "Vehicle DTC information" function and confirm that at least one control module is in communication with the scan tool.
Record the following information on the maintenance order: All control modules that do not communicate. All DTCs (including symptom bytes) and control module that has set DTC. － If the scan tool cannot communicate with the control module of any vehicle, then refer to "Data link reference". 6. Internal performance fault of control module Make sure that no DTC for internal hardware performance of control module is set. － Refer to “List of diagnostic trouble code (DTC) Vehicle” in case that any one diagnostic trouble code of this type is set. 7. Control module communication test - Confirm that the vehicle has any control module that does not communicate, refer to "Data link reference". All equipment control modules shall communicate. － If the scan tool cannot communicate with one or more control module(s), then refer to "Data link reference". 8. Communication and power mode fault - Confirm that no control module power mode or communication DTCs are set. － Refer to “List of diagnostic trouble code (DTC) Vehicle” in case that any one diagnostic trouble code of this type is set. Note: The engine may be started during the test. Ensure that the vehicle is not in gear and apply parking brake. Once the starting power mode parameters are observed, the engine shall be immediately shut down. 9. Power mode test - the driver's door is open; when the ignition switch switches at all power modes, observe the "PowerMode" parameters of scan tool. Confirm the current power mode The parameters match the actual ignition switch position. － If the power mode parameters do not match the actual ignition switch position, then refer to "Power mode mismatch". 10. Engine start and running test - Confirm that the engine starts and runs. － If the engine does not start, then refer to "The engine does not start". － If the engine does not run, then refer to "The engine does not run". 11. Look up other DTCs - Confirm that no other DTCs are set. － If other DTC is set, follow the order listed below to carry out diagnosis. Refer to "List of diagnostic trouble code (DTC) - Vehicle". 11.1. Voltage diagnostic trouble code 11.2. Programming, setup, configuration or software performance DTCs 11.3. DTC related components 11.4. DTC related systems 11.5. Other DTCs 12. Emission related checking/maintenance test fault
Diagnostic overview, starting point and programming 6-23 － If this area requires checking and maintenance checking, then confirm that the customer repair issues are not associated with the checking/maintenance test. － If the customer repair issues are associated with the checking/maintenance test, refer to Checking/Maintenance system checking". 13. Symptom diagnosis - Diagnosis of other customer repair issues. Refer to “Symptom – Vehicle”.
Diagnostic overview, starting point and programming 6-24
6.4.4
6.2.2.4 DTC List Engine DTC list
P011629 P011716 P011817 P048013 P048113 P069111 P069212 P069311 P069412 P001178 P001278 P001600 P000A26 P000A29 P002677 P007611 P007613 P007712 P012211 P012312 P0171 P0172 P019716 P019817 P020113 P020213 P020313 P020413 P021900 P022211 P022312 P025A13 P025C11 P025D12 P026111 P026212 P026411 P026512 P026711 P026812 P027011 P027112 P0300F0,P0300F1,P0300F2 P0301F0,P0301F1,P0301F2 P0302F0,P0302F1,P0302F2 P0303F0,P0303F1,P0303F2 P0304F0,P0304F1,P0304F2 P031300 P031881 P032229 P032139 P032500 P032700,P032714 P032800,P032815 P033531 P033629 P0339 P0340 P034129 P044413
Unreasonable fault of engine coolant temperature sensor signal Engine coolant temperature sensor circuit voltage is too low Engine coolant temperature sensor circuit voltage is too high Cooling fan relay control circuit is open (low speed) Cooling fan relay control circuit is open (high speed) Cooling fan relay control circuit is short-circuited to the ground (low speed) Cooling fan relay control circuit is short-circuited to the power supply (low speed) Cooling fan relay control circuit is short-circuited to the ground (high speed) Cooling fan relay control circuit is short-circuited to the power supply (high speed) Intake camshaft moves forwards Intake camshaft moves backwards Intake camshaft position changes Slow operation of intake VVT Operation fault of intake VVT (stuck) Intake crankshaft locking position and unreasonable operation fault Intake VVT circuit is short-circuited or open-circuited to the ground Intake VVT circuit is short-circuited or open-circuited to the ground Intake VVT circuit is short-circuited to the power supply Electronic throttle position sensor 1 signal circuit voltage is too low Electronic throttle position sensor 1 signal circuit voltage is too high offline detection of air ratio closed-loop control self-learning depopulated offline detection of air ratio closed-loop control self-learning is too thick Engine oil temperature exceeds the lower limit Engine oil temperature exceeds the upper limit Cylinder 1 injector control circuit is open Cylinder 2 injector control circuit is open Cylinder 3 injector control circuit is open Cylinder 4 injector control circuit is open Engine speed is too high Electronic throttle position sensor 2 signal circuit voltage is too low Electronic throttle position sensor 2 signal circuit voltage is too high Fuel pump relay control circuit is open Fuel pump relay control circuit is short-circuited to the ground Fuel pump relay control circuit is short-circuited to the power supply Cylinder 1 injector control circuit is short-circuited to the ground Cylinder 1 injector control circuit is short-circuited to the power supply Cylinder 2 injector control circuit is short-circuited to the ground Cylinder 2 injector control circuit is short-circuited to the power supply Cylinder 3 injector control circuit is short-circuited to the ground Cylinder 3 injector control circuit is short-circuited to the power supply Cylinder 4 injector control circuit is short-circuited to the ground Cylinder 4 - injector circuit is short-circuited to the power supply Multi-cylinder misfire occurrence Cylinder 1 misfire occurrence Cylinder 2 misfire occurrence Cylinder 3 misfire occurrence Cylinder 4 misfire occurrence Low fuel level leads to misfire Faulty circuit detection ABS acceleration signal fault or CAN communication failure Speed sensor fault Too many adjustments of missing teeth Knock sensor signal circuit voltage is too low or too high Multiple circuit fault of knock sensor signal terminal (low voltage) Multiple circuit fault of knock sensor signal terminal (high voltage) Missing teeth signal is often lost Missing teeth signal is unreasonable No speed signal is discovered Intake camshaft phase sensor is short-circuited or open-circuited to the ground or the power supply Intake camshaft phase sensor signal is unreasonable Canister control valve control circuit is open
Diagnostic overview, starting point and programming 6-25 Engine DTC list (Continued) P045811 P045912 P050029 P050462 P050623 P050724 P0535 P053716 P053817 P060644 P060645 P060646 P060664 P060665 P060666 P060667 P060692 P060693 P060694 P060695 P061F62 P061F64 P061F68 P064513 P064611 P064712 P068917 P069012 P081D67 P083000 P154534 P154535 P155978 P156400 P157900 P160400 P210126 P210128 P210129 P210174 P210600 P210612 P21064B P210629 P210613 P2122 P2123 P2127 P2128 P213221 P2131 P213322 P213500 P213529 P2138 P214029 P300B00 P003013 P003111 P003212 P003613 P003711 P003812 P00531B P00541B
Canister control valve control circuit voltage is too low Canister control valve control circuit voltage is too high Vehicle speed sensor signal fault Brake switch fault The idle control speed is lower than the target idle The idle control speed is higher than the target idle The voltage of air conditioning temperature sensor is too high The voltage of air conditioning temperature sensor is too low The voltage of air conditioning temperature sensor is too high
Electronic control unit RAM fault and electronic throttle security monitoring function fault
Level 2 security monitoring fault (speed sensor/secure oil cutoff) A/C compressor relay control circuit is open A/C compressor relay control circuit is short-circuited to the ground A/C compressor relay control circuit is short-circuited to the power supply Main relay circuit is open Main relay output voltage is unreasonable Neutral switch fault Clutch pedal switch signal is not correct The deviation between the actual position and the target position of electronic throttle exceeds the limits Electronic throttle self-learning process fault The system voltage does not meet the conditions for self-learning of electronic throttle Electronic throttle self-learning conditions are not satisfied Electronic throttle gain adjustment self-learning fault Electronic throttle mechanical bottom dead center self-learning/spring checking/positional deviation fault
Throttle actuator control system mandatorily uses the restricted power
Electronic throttle pedal position sensor 1 signal voltage low Electronic accelerator pedal position sensor 1 signal voltage is too high Electronic throttle pedal position sensor 2 signal voltage low Electronic accelerator pedal position sensor 2 signal voltage is too high Low input of throttle/pedal position sensor/switch E circuit Electronic accelerator pedal position sensor signal voltage is reasonable High input of throttle/pedal position sensor/switch F circuit Scope/performance fault of Circuit A for throttle/pedal position sensor Scope/performance fault of Circuit A for throttle/pedal position sensor Electronic accelerator pedal position sensor signal voltage is unreasonable Low input of throttle/pedal position sensor/switch D circuit Self-adaptive learning of engine torque control is limited Upstream oxygen sensor heating control circuit is open Upstream oxygen sensor heating control circuit is short-circuited to the ground Upstream oxygen sensor heating control circuit is short-circuited to the power supply Downstream oxygen sensor heating control circuit is open Downstream oxygen sensor heating control circuit is short-circuited to the ground Downstream oxygen sensor heating control circuit is short-circuited to the power supply Upstream oxygen sensor internal heating resistance is unreasonable Downstream oxygen sensor internal heating resistance is unreasonable
Diagnostic overview, starting point and programming 6-26 P010525 P010629
Intake pressure sensor signal does not change Intake pressure sensor is unreasonable
Diagnostic overview, starting point and programming 6-27 Engine DTC list (Continued) P010711 P010812 P011129 P011216 P011317 P013029 P013116 P013217 P013326 P013425 P013426 P013629 P013716 P013817 P0140 P013923 P013924 P042000 P2A0029 P2A0129 P05601C P056216 P056317 P056413 P0567 P057824 P05791C P060100 P060444 P060545 P061055 P070000 P152300 P1609 P161051 P161106 P161306 P161406 P168387 P250333 P250435 P3093 P3094 P3095 U007388 U0074 U0075 U0076 U010187 U0121 U012687 U012987 U014087 U015187 U015587 P05041C P0317 P0321 P2195 P2196 P2270 P2271 P0571 P0650
Intake pressure sensor is short-circuited to the ground Intake pressure sensor is short-circuited to the power supply Intake manifold temperature sensor signal is unreasonable Intake temperature sensor is short-circuited to the ground Intake temperature sensor is short-circuited or open-circuited to the power supply Upstream oxygen sensor circuit signal fault Upstream oxygen sensor signal circuit voltage is too low Upstream oxygen sensor signal circuit voltage is too high Upstream oxygen sensor aging No response from Circuit 1 of upstream oxygen sensor No response from Circuit 1 of upstream oxygen sensor Downstream oxygen sensor circuit signal fault Downstream oxygen sensor signal circuit voltage is too low Downstream oxygen sensor signal circuit voltage is too high Downstream oxygen sensor circuit signal fault Downstream oxygen sensor aging– the signal is too thick or too thin persistently Downstream oxygen sensor aging– the signal is too thick or too thin persistently TWC oxygen storage capacity aging Scope/performance fault of upstream oxygen sensor circuit Scope/performance fault of downstream oxygen sensor circuit Battery voltage signal is unreasonable System battery voltage is too low System battery voltage is too high Cruise circuit fault Cruise control fault Cruise control key (any) stuck or pressed for too long Cruise control signal voltage is unreasonable ECU control module fault EEPROM fault Electronic control unit ROM fault Control module vehicle option error TCU requests MIL light be on Vehicle collision, and airbag pop-out The signal transmitted to ECU from airbag is unreasonable Anti-theft match is not provided by ECM Input of PIN code is incorrect Burglar alarm and key certification fail or are always Busy Burglar alarm certification reply is not received The signal transmitted to ECU from airbag is unreasonable Generator feedback duty cycle signal is too small Generator feedback duty cycle signal is too large Burglar alarm related data is uncoded Incorrect SIM response is received Burglar alarm response is not received within the predefined time Control module communication bus off Relevant diagnosis to CAN communication Relevant diagnosis to CAN communication Relevant diagnosis to CAN communication TCU control module communication node is missing ABS control module communication node is missing ECU and SAS control module communication fault ECU and ABS control module communication fault BCM control module communication node is missing Communication with SRS control module is missing IPK control module communication node is missing Brake switch signal checking fault ABS wheel speed sensor fault / poor detection ABS signal fault Crankshaft upper end point missing signal is not reasonable Upstream Oxygen Sensor Aging - Signals are continuously thicker Upstream Oxygen Sensor Aging - Signal persistently lean Downstream Oxygen Sensor Aging - Signal persistently lean Downstream Oxygen Sensor Aging - Signals are continuously thicker Brake light switch signal circuit failure MIL lamp drive circuit failure
Diagnostic overview, starting point and programming 6-28 P0688 P0704 P1615 P1616 P1617 P1619 P1630 P0501 U0131 U0140 U0151 P000B P0010 P0013 P0015 P0017 P0121 P0221 P0170 P0342 P0343 P0365 P0366 P0367 P0368 P0602 P0627 P0629 P0660 P0661 P0662 P2088 P2089 P2090 P2091 P2177 P2178 P2187 P2188 P1336 P1558 P1565 P1568
Main relay output voltage signal failure The clutch pedal switch signal is not correct Anti-theft matching / communication failure ECM does not perform antitheft matching VIN is not written to the EEPROM (offline) Vehicle speed sensor signal failure Communication with EPS is lost or signal is abnormal Communication with BCM is lost or signal is abnormal Communication with ACU Interrupted Exhaust VVT reaction is slow VVT intake control valve circuit failure VVT Exhaust control valve circuit failure Exhaust VVT is not in the default position at startup Exhaust camshaft and crankshaft relative position is unreasonable The electronic throttle position sensor 1 signal is unreasonable The electronic throttle position sensor 2 signal is unreasonable Off-line detection of air than closed-loop control self-learning unreasonable The intake phase sensor signal circuit voltage is too low The intake-phase sensor signal circuit voltage is too high The exhaust phase sensor is improperly installed Exhaust phase sensor signal is unreasonable The exhaust phase sensor signal circuit voltage is too low Exhaust phase sensor signal circuit voltage is too high Electronic control unit coding failure Oil pump relay control circuit failure Oil pump relay control circuit voltage is too high Variable Inlet Valve Control Circuit Fault Variable inlet control valve control circuit voltage is too low Variable inlet control valve control circuit voltage is too high VVT Inlet control valve circuit voltage is too low VVT Inlet control valve circuit voltage is too high VVT Exhaust control valve circuit voltage is too low VVT Exhaust control valve circuit voltage is too high Excess value of self-learning value (load area) in closed loop than closed loop control The upper limit of self-learning value of empty than ratio closed loop control (middle load area) Upper limit of self-learning value (lower load area) than closed loop control Excess value of self-learning value (lower load area) for empty than ratio closed loop control Electronic throttle safety monitoring Torque limiting effect Electronic throttle opening resistance is too large Electronic Throttle Lower Limit Position Initialization Self - learning Fault Electronic throttle return position is too large
Diagnostic overview, starting point and programming 6-29 Body control module DTC list B111112 B111114 B111212 B111214 B111312 B111314 B111412 B111414 B111500 B111800 B112112 B112114 B112212 B112214 B112312 B112314 B112412 B112414 B110112 B110114 B110311 B110312 B110571 B110771 B11091C B104A11 B104A13 B104A1C B104B11 B104B13 B104B1C B104C01 U000100 U010087 U015587 U030108 U031508 U032308 U100104 U130004 U133508 U150000 U150100 U156200 U156300 U160000 U160141 U015187 U012187 B170100 B170500 B170200 B170600 B170700 B170800
Main driver window lifter rise relay drive is short-circuited to the power supply Main driver side window lifter rise relay drive is short-circuited or open-circuited to the ground Co-driver side window lifter rise relay drive is short-circuited to the power supply Co-driver side window lifter rise relay drive is short-circuited or open-circuited to the ground Left rear driver side window lifter rise relay drive is short-circuited to the power supply Left rear driver side window lifter rise relay drive is short-circuited or open-circuited to the ground Right rear co-driver side window lifter rise relay drive is short-circuited to the power supply Right rear co-driver side window lifter rise relay drive is short-circuited or open-circuited to the ground Co-driver side window lifter switch stuck Main driver side window lifter switch stuck Main driver side window lifter decline relay drive is short-circuited to the power supply Main driver side window lifter decline relay drive is short-circuited or open-circuited to the ground Co-driver side window lifter decline relay drive is short-circuited to the power supply Co-driver side window lifter decline relay drive is short-circuited or open-circuited to the ground Left rear driver side window lifter decline relay drive is short-circuited to the power supply Left rear driver side window lifter decline relay drive is short-circuited or open-circuited to the ground Right rear co-driver side window lifter decline relay drive is short-circuited to the power supply Right rear co-driver side window lifter decline relay drive is short-circuited or open-circuited to the ground Slow-speed wiper relay drive is short-circuited to the power supply Slow-speed wiper relay drive is short-circuited to the ground Quick-speed wiper relay drive is short-circuited to the ground Quick-speed wiper relay drive is short-circuited to the power supply Front wiper motor stalls Rear wiper motor stalls Wiper intermittent gear switch delay exceeds the tolerance Left turn signal drive is short-circuited to the ground Left turn signal drive is open Headlight or rear light fault of left turn signal Right turn signal drive is short-circuited to the ground Right turn signal drive is open Headlight or rear light fault of right turn signal Hazard warning lamp switch stuck High-speed CAN bus is offline Lose communication with engine controller Lose communication with instrument controller High-speed CAN engine management system configuration ID does not match High-speed CAN anti-lock brake system configuration ID does not match High-speed CAN instrument cluster configuration ID does not match High-speed CAN initialization error Volcano software configuration error High-speed CAN airbag diagnostic unit configuration ID does not match Vehicle identification code does not match the other ECU (instrument) Instrument cluster redundancy data synchronization failure Overvoltage Under-voltage Memory chip communication error Saved data verification error Lose communication with airbag controller Lose communication with ABS controller General fault of antenna receiver Base station fault, and communication with ABIC fails Key invalid Anti-theft state is triggered When KL.15 ON, no challenge message is received from EMS within 6S CAN communication fault during the anti-theft certification
Diagnostic overview, starting point and programming 6-30 Electronic power steering control module DTC list U156217 U156316 C162416 C162417 C163023 C163024 C163049 C163038 C164072 C165000 U200541 U200242 U200142 C166000 C166049 C166061 C168000 C169000 U007388 U041581 U041585 U012187 U010087 U040181 U015587 C166654 U014087 C163123 C163124 C163129 C163149 C163138 U014687 C164071 C167162 C167264
The battery voltage is too high The battery voltage is too low Temperature sensor signal is too low Temperature sensor signal is too high TAS T1/T2 signal is persistently too low TAS T1/T2 signal is persistently too high TAS T1/T2 / (T1+T2) signal task is out of range TAS T1 / T2 signal cycle is out of range Motor or its related drive circuit fault Motor position sensor fault ECU Flash checksum error ECU RAM fault ECU EEPROM fault ECU internal power supply related circuit module fault ECU internal circuit fault ECU calculation fault ECU overheat fault ECU relay fault Bus fault Invalid data received from ABS Data received from ABS exceeds the normal range Communication fault with ABS Communication fault with ECM/PCM Invalid data received from ECM Communication fault with IPC ECU does not perform the steering angle offset calibration and RES calibration Communication fault with BCM Angle sensor signal is persistently too low Angle sensor signal is persistently too high Angle signal invalid TAS P/S signal task is out of normal range TAS P/S signal cycle is out of normal range Communication fault with gateway Motor drive circuit fault at the initialization of ECU Main MCU&MCU security parameters do not match During the cross checking of torque commands by two MCUs, the torque values do not match
Instrument control module DTC list U200541 U200142 U156217 U156316 U007488 U014087 U012187 B120100 U010087 U150062 B101062
Flash checksum error EEPROM fault The battery voltage is too high The battery voltage is too low Bus fault Communication fault with BCM Communication fault with ABS SRS indicator fault Communication loss with EMS Vehicle identification code does not match BCM Ignition network fault
Diagnostic overview, starting point and programming 6-31 Anti-lock brake control module DTC list C001013 C001113 C00134B C001413 C001513 C001813 C001913 C001C13 C001D13 C002013 C003102 C003104 C00312F C003212 C003213 C00321D C003402 C003404 C00342F C003512 C003513 C00351D C003702 C003704 C00372F C003812 C003813 C00381D C003A02 C003A04 C003A2F C003B12 C003B13 C003B1D C004008 C004409 C004422 C004429 C00442F C006C55 C110000 C110400 C110704 C110A00 C120001 C120049 C120696 C120793 C121001 C123F16 C123F17 C123F2F U007388
Electromagnetic coil disconnected - Front left isolating valve Electromagnetic coil disconnected - Front left pressure relief valve Temperature of electromagnetic coil is too high Electromagnetic coil disconnected - Front right isolating valve Electromagnetic coil disconnected - Front right pressure relief valve Electromagnetic coil disconnected - Rear left isolating valve Electromagnetic coil disconnected - Rear left pressure relief valve Electromagnetic coil disconnected - Rear right isolating valve Electromagnetic coil disconnected - Rear right pressure relief valve ABS pump motor control fault - Open circuit Left front wheel speed sensor loss fault Left front wheel speed sensor fall-off fault Left front wheel speed sensor instability fault Left front wheel speed sensor short-circuit fault Left front wheel speed sensor open-circuit fault Left front wheel speed sensor power-off fault Right front wheel speed sensor loss fault Right front wheel speed sensor fall-off fault Right front wheel speed sensor instability fault Right front wheel speed sensor short-circuit fault Right front wheel speed sensor open-circuit fault Right front wheel speed sensor power-off fault Wheel speed sensor loss fault - Rear left Wheel speed sensor fall-off fault - Rear left Wheel speed sensor instability fault - Rear left Wheel speed sensor short-circuit fault - Rear left Wheel speed sensor open-circuit fault - Rear left Wheel speed sensor power-off fault - Rear left Wheel speed sensor loss fault - Rear right Wheel speed sensor fall-off fault - Rear right Wheel speed sensor instability fault - Rear right Wheel speed sensor short-circuit fault - Rear right Wheel speed sensor open-circuit fault - Rear right Wheel speed sensor power-off fault - Rear right Brake switch fault Brake pressure sensor "A" circuit fault Brake pressure sensor "A" offset fault Brake pressure sensor "A" non-function fault Brake pressure sensor "A" (master cylinder pressure sensor) signal is unstable Chassis configuration error/vehicle configuration mismatch Ground offset fault Control system close fault Internal sensor initialization fault Microprocessor fault Unknown coil of drain Internal 5V supply voltage fault SPI fault/ECU fault NVRAM fault Valve coil drive short circuit or drain fault System voltage is low System voltage is high System voltage fault CAN bus off fault
Diagnostic overview, starting point and programming 6-32 Airbag control module DTC list B1003 B1004 B1042 B1040 B1044 B1011 B1012 B1021 B1022 B1023 B1024 B1026 B1027 B1028 B1029 B1091 B1092 B1013 B1001 B1025 B102A B10A1 B10A2
Driver airbag error Co-driver airbag error Power supply voltage error Diagnostic lamp/warning lamp error Airbag configuration error The battery voltage is too low The battery voltage is too high Driver airbag is short-circuited to the ground Driver airbag is short-circuited to the power supply Driver airbag resistance is low Driver airbag resistance is high Co-driver airbag is short-circuited to the ground Co-driver airbag is short-circuited to the power supply Co-driver airbag resistance is low Co-driver airbag resistance is high Warning lamp is short-circuited to the ground Warning lamp is short-circuited to the power supply ECU internal error Factory mode Driver's front airbag configuration error Co-driver’s front airbag configuration error Collision output is short-circuited or open-circuited to the ground Collision output is short-circuited to the power supply
Diagnostic overview, starting point and programming 6-33
6.4.5
Symptom-Vehicle
Vehicle body system Symptom - Fixed and movable windows Symptom – Horn Symptom - Lighting Symptom - Rear view mirror Symptom - Vehicle access system Symptom - Wiper/washer system Brake Symptom - Anti-lock brake system Symptom - hydraulic brake Symptom - Parking brake Drive train/axle Symptom - Wheel drive shaft Driver information and entertainment system Symptom – Display screen and instrument Symptom - Entertainment system Symptom - Auxiliary and configurable user control system Engine Symptoms applicable to 1.8L engine - Engine control system Symptom - Engine cooling system Symptom - Engine electrical system Symptom - Engine exhaust system Symptoms applicable to 1.8L engine - Engine mechanical system General information Symptom - squeak and clatter Symptom - Vibration diagnosis and correction HVAC Symptom – Automatic heater, ventilation and air conditioning system Symptom – Manual heater, ventilation and air conditioning system Power supply and signal distribution Symptom - Data communication Symptom - Power socket Symptom - Line system Vehicle roof Symptom – Vehicle roof Security and protection Symptom – Anti-theft module Symptom – Object detection Symptom – Remote function Symptom – Safety belt Symptom - Anti-theft system Seat Symptom - Power seat Symptoms - Seat heating and cooling Steering system Symptom – power steering system Symptoms - Steering wheel and steering column
Suspension system
Symptom –General diagnosis of suspension system Transmission Symptom –Automatic transmission Symptom - Automatic transmission shift lock control system Symptom - Clutch
6.4.6
Engine cannot be started
For the observed symptoms, refer to the following corresponding diagnostic procedures. Electromagnetic coil of starter does not operate Electromagnetic coil of starter operates, but the engine does not start Engine start is low
6.4.7
Engine crankshaft rotates but the engine does not start
For the vehicle inspected and repaired, refer to the following corresponding diagnostic procedures. The "Engine crank rotates but does not run" applicable to 1.8L engine
6.4.8
Checking/maintenance system checking
The vehicle is provided with checking/maintenance (I/M) system checking and test requirements.
6.4.9 1 2
3 4 5
Diagnostic repair effect test
Install all the components or connectors removed or replaced during the diagnosis. Before removing or replacing components or modules perform adjustment, programming or setup procedures based on the needs. Clear the DTC. Shift the ignition switch to OFF position and hold for 60s. If the repair is associated with DTC, reproduce the operation DTC conditions and use "Freeze fault state /fault record" (if applicable) to confirm that DTC will not be set any longer. In case of resetting of DTC or appearance of another DTC, then refer to "DTC list - Vehicle" and perform corresponding diagnostic procedure. Or if repair is associated with the symptoms, reproduce the customer repair fault conditions to verify the effect of repair. If the customer repair issue recurs or another symptom appears, then return to "Symptom - Vehicle" and perform corresponding symptom diagnosis.
Diagnostic overview, starting point and programming 6-34
6.4.10 Power system DTC type definition Emission related DTC Operation adopted when setting up the DTC – Class A When the diagnosis runs but fails to pass, the control module lights up the MIL. Running state at the time that the diagnosis fails to pass is recorded by the control module. The control module saves this information in the "Freeze fault state/Fault record". Operation adopted when setting up the DTC – Class B When the diagnosis runs but fails to pass during the second continuous ignition cycle, the control module lights up the MIL. Running state at the time that the diagnosis fails to pass is recorded by the control module. When the first diagnosis fails to pass, the control module saves this information in the "Fault record". If the diagnosis report fails during the second continuous ignition cycle, then the control module records the running state when the diagnosis fails to pass. The control module writes the running state into the “Freeze fault state” and updates the "Fault record". Conditions for turning off MIL/clearing DTC - Class A or Class B After the diagnosis runs and passes successfully during the 4 continuous ignition cycles, the control module will turn off the MIL. When the diagnosis runs and passes, clear the current DTC (i.e., the DTC that did not pass the last test). If the diagnosis and other emission related diagnoses successfully pass the test in 40 continuous warm-up cycles, then clear the previous DTCs. Turn off the MIL with scan tool and clear DTCs. Non-emission related DTC Operation adopted when setting up the DTC – Class C When the diagnosis runs and fails to pass, the control module saves the DTC information in the memory. MIL is not on. Running state at the time that the diagnosis fails to pass is recorded by the control module. The control module saves this information in the fault record. The driver information center (if equipped) may display a message. Conditions for clearing the DTC – Class C When the diagnosis runs and passes, clear the current DTC (i.e., the DTC that did not pass the last test). If the diagnosis and other non-emission related diagnoses successfully pass the test in 40 continuous warm-up cycles, then clear the previous DTCs. Clear the DTC by use of scan tool.
Operation adopted when setting up the DTC – Class D The control module will perform the default action but DTC will not be saved in the fault record. MIL or emergency vehicle repair indicator is not on. Conditions for clearing the DTC – Class D Clear the DTC by use of scan tool.
Chapter 7 Drivetrain Contents 7.1 Propeller shaft ..................................................... 1 7.1.1 Specification .......................................................... 1 7.1.1.1 Torque specifications ............................. 1 7.1.1.2 Grease and Lubricant type ..................... 1 7.1.2 Component location diagram ................................ 2 7.1.2.1 Exploded view of propeller shaft ............ 2 7.1.3 Diagnostic information and procedure ................... 3 7.1.3.1 Abnormal sound of propeller shaft ......... 3 7.1.3.2 Vibration of propeller shaft ..................... 3 7.1.4 Maintenance guidelines ......................................... 4 7.1.4.1 Propeller shaft bending test ................... 4 7.1.4.2 Replacement of propeller shaft assembly ................................................ 4 7.1.4.3 Drive shaft support bracket welded assembly replacement ........................... 5 7.1.5 Description and operation ..................................... 6 7.1.5.1 Propeller shaft ........................................ 6 7.1.6 Special tools .......................................................... 6 7.2 Rear drive axle ..................................................... 7 7.2.1 Specification .......................................................... 7 7.2.1.1 Differential parameters ........................... 7 7.2.1.2 Torque specifications ............................. 7 7.2.1.3 Grease and lubricant type ...................... 7 7.2.2 Component location diagram ................................ 8 7.2.2.1 Exploded view of differential .................. 8 7.2.2.2 Exploded view of main gear reducer/differential ................................. 9 7.2.3 Diagnostic information and procedure................. 10 7.2.3.1 Abnormal sound of differential (the faster the speed is, the greater the sound is) ............................................... 11 7.2.3.2 Abnormal sound of differential (sharp change of speed or uphill) .................... 11 7.2.3.3 Abnormal sound of differential (turning) ............................................................. 11 7.2.3.4 The differential and gear reducer cage generate heat ....................................... 11 7.2.3.5 The differential gear oil leaks ............... 11 7.2.4 Maintenance guidelines ....................................... 12 7.2.4.1 Inspection and filling of differential gear oil ................................................. 12 7.2.4.2 Replacement of differential gear oil ..... 12 7.2.4.3 Replacement of differential assembly (semi-detached coil spring rear suspension) .......................................... 13 7.2.4.4 Replacement of rear axle shaft assembly (Drum Brake) ....................... 16 7.2.4.5 Replacement of rear axle shaft assembly (Disc Brake) ......................... 17 7.2.4.6 Replacement of rear axle shaft oil seal 18 7.2.4.7 Replacement of assembly of differential gear reducer ....................... 19 7.2.4.8 Replacement of differential bearings ... 20 7.2.4.9 Replacement of connecting flange assembly .............................................. 22
7.2.4.10 Replacement of Drive pinion gear oil seal ....................................................... 23 7.2.4.11 Replacement of Drive pinion gear outer bearing ......................................... 24 7.2.4.12 Replacement of front bearing adjustment shim for drive pinion gear ... 25 7.2.4.13 Replacement of adjustment shim for rear bearing of Drive pinion gear .......... 25 7.2.4.14 Replacement of rear axle shaft bearing assembly. ................................. 26 7.2.4.15 Replacement of rear drive axle cage .... 27 7.2.4.16 Gearing inspection and adjustment of ring gear and drive pinion gear ............. 28 7.2.4.17 Inspection on backlash in circular tooth of gear pair of gear reducer ......... 29 7.2.4.18 Inspection on backlash in circular tooth of gear pair of differential ............. 29 7.2.5 Description and operation .................................... 30 7.2.5.1 Rear drive axle ...................................... 30 7.2.6 Special tools ......................................................... 31
Drivetrain 7-1
7.1
Propeller shaft
7.1.1
Specification
7.1.1.1 Torque specifications Application position
Specification (N.m)
Bolt - Propeller shaft connected to differential
53±8
Bolt - Propeller shaft drive shaft support bracket welded assembly connected to the body
40±5
Bolt - Propeller shaft support connected to the drive shaft support bracket welded assembly
40±5
7.1.1.2 Grease and Lubricant type Application Spider bearing race Bearing race and yoke race
Specification 7022 Automobile High Grade Grease or Lithium-based High Penetrating lubricant
Drivetrain 7-2
7.1.2
Component location diagram
7.1.2.1 Exploded view of propeller shaft
15AJ0701001
figure 1. Yoke assembly-propeller front shaft spline 2. Spider assembly 3. Spacer-propeller shaft cross member 4. Propeller shaft tube assembly 5. Bearing seal 6. Propeller shaft support bearing
7. 8. 9. 10. 11. 12.
Propeller shaft support bearing case Bearing seal Propeller shaft support bracket welded assembly Yoke-end of front propeller shaft Bearing locknut Yoke-proppeler shaft differential
Drivetrain 7-3
7.1.3
Diagnostic information and procedure
Starting point for diagnosis Begin the system diagnosis should refer to “Description and operation” of system. If the vehicle get in trouble, refer to the "description and operation" to be habituate with the function of the system, and help to determine the correct diagnosis procedure. Check out the following “Description and operation”: Transmission shaft Visual inspection/routine inspection Visual inspection/routine inspection shall be firstly conducted in case of vehicle fault. The items of inspection are as follows: Visible or accessible parts of the system for any visible damage Whether installed aftermarket parts that may cause a system failure Components that have unusual loosenes Bend inspection of propeller shaft Common symptoms Corresponding symptoms will be shown in case of vehicle fault. The common symptoms as shown as follows: Abnormal sound of propeller shaft Shimmy of propeller shaft
7.1.3.1 Abnormal sound of propeller shaft Inspection Whether the spider is worn or damaged. Whether spider lubrication is sufficient. If any spline teeth within the sliding yoke is damaged. Whether the holding bracket of propeller shaft is loose. Whether the connection between propeller shaft and differential is loose. Whether the connection between weldment for support stand and weldment for holding bracket is loose.
Operation Replace the spider Lubricate the spider and replace the spider when necessary. Replace propeller shaft assembly. Tighten the weldment for holding bracket of propeller shaft. Tighten the connection between propeller shaft and differential. Tighten the connection between weldment for support stand and weldment for holding bracket.
Instructions: Refer to Chapter “Maintenance Guidelines” for detailed description on “Operation”.
7.1.3.2 Vibration of propeller shaft Inspection Whether the propeller shaft is out of balance. Whether the propeller shaft is bent. Whether the spider is worn or damaged. Whether the drive shaft support bracket welded assembly of propeller shaft is loose. Whether the connection between propeller shaft and differential is loose. Whether the connection between weldment for support stand and weldment for holding bracket is loose. If resonance occurs to the propeller shaft.
Operation Replace propeller shaft. Replace propeller shaft. Replace the spider Tighten the weldment for holding bracket of propeller shaft. Tighten the connection between propeller shaft and differential. Tighten the connection between weldment for support stand and weldment for holding bracket. Replace propeller shaft.
Instructions: Refer to Chapter “Maintenance Guidelines” for detailed description on “Operation”.
Drivetrain 7-4
7.1.4
Maintenance guidelines
7.1.4.1 Propeller shaft bending test Special tools Dial indicator PT-0008 Magnetic stand for dial indicator PT-0009
16AJ0701002
Check procedure 1. Remove the propeller shaft assembly. See "Propeller Shaft Assembly". 2. Position the propeller shaft on the bench. 3. Select three points on the propeller shaft and use a micrometer to measure the runout errors of three points. Runout error should not be less than 0.5mm. If it exceeds the value, correction and rebalance should be made, and replace the propeller shaft assembly if necessary.
7.1.4.2 Replacement of propeller shaft assembly Disassembly procedure 1. Lift up vehicle with lifting machine. 2. Use a jack to support appropriately the propeller shaft. 3. Remove the bolt connecting the propeller shaft support bracket welded assembly and the body.
16AJ0701003
Notes: Disconnect the propeller shaft and differential, and mark the relative positions of flange yoke and differential flange for reference during the installation. 4.
16AJ701004
Use an open-end wrench to fix the bolts connecting the propeller shaft and the differential, remove 4 bolts, and hold the rear section weldment of propeller shaft with hand.
Drivetrain 7-5
5. 6. 7. 8.
16AJ0701005
Pull the sliding yoke of drive shaft from transfer case output shaft The propeller shaft assembly. Move away the jack. Plug the sliding yoke of propeller shaft and gearbox output shaft with cover plug.
Installation Procedure 1. Remove the blanking cap plugged sliding yoke of propeller shaft and transfer case output shaft. 2. Insert the sliding yoke of driving shaft into the gearbox output shaft. 3. Position propeller shaft assembly 4. Use a jack to support appropriately the propeller shaft support bracket welded assembly and hold with hands the rear section of weldment of the propeller shaft. Notes: Place the relative positions of the propeller shaft flange yoke and the differential flange at the marking made at the removal. 5.
6.
7. 8.
Install 4 bolts connecting the propeller shaft and the differential, use an open-end wrench to secure the bolt, install four nuts and tighten to 53±8N·m. Install the bolts connecting the propeller shaft support bracket welded assembly and the body, and tighten to 40±5N·m. Move away the jack. Lift down vehicle from lifting machine.
7.1.4.3 Drive shaft support bracket welded assembly replacement Disassembly procedure 1. Remove the propeller shaft assembly. Refer to “Replacement of Propeller Shaft Assembly”. 2. Remove two bolts connecting the drive shaft support bracket welded assembly and the drive shaft support bracket welded assembly. 3. Separate the drive shaft support bracket welded assembly. 15AJ0701006
Installation Procedure 1. Position the drive shaft support bracket welded assembly. 2. Install two bolts connecting the drive shaft support bracket welded assembly and holding bracket and tighten to 40±5N·m. 3. Install the propeller shaft assembly. Refer to “Replacement of Propeller Shaft Assembly”.
Drivetrain 7-6
7.1.5
Description and operation
7.1.5.1 Propeller shaft The propeller shaft consists of universal shaft of spider, shaft tube and intermediate support, the front section is connected by the output shaft between spline or gearbox or transfer case and the rear end is connected by the flange plate and the differential. It is used to transfer smoothly the power from the gearbox to the main gear gear reducer under the circumstance of change of relative location between transmission and rear drive axle. It is required that the propeller shaft must be able to deliver the highest torque at a low gear generated by the engine, but also withstand the high-speed rotation necessary for high-speeding of running of the vehicle
7.1.6
Special tools Figure
Tools no./description
PT-0008 Dial indicator
PT-0009 Magnetic stand for dial indicator
Drivetrain 7-7
7.2
Rear drive axle
7.2.1
Specification
7.2.1.1 Differential parameters Application
Value
Final ratio
4.3（B15）
7.2.1.2 Torque specifications Application position
Specification
Plug - Refueling plug installation
50±10
Plug - Drain plug installation
60±10
Bolt - Propeller shaft connected to differential
53±8
Bolt - Upper arm assembly connected to the differential
84±12
Bolt - Lower arm assembly connected to the differential
115±15
Nut – Rear absorber connected to differential
40±10
Bolt - Rear brake backing plate installation
51±6
Oil pipe fitting - Brake pipe connected to the rear brake cylinder
16±2
Bolt- Rear brake cylinder to the rear brake backing plate
9±3
Nut - Main gear reducer housing connected to the differential assembly
17±3
Bolt – Ring gear mounting
75±5
Bolt - Differential bearing cap connected to the main gear reducer housing
50±5
Bolt - Stopper installation
4.5±1
Nut - Drive pinion gear lock
(N.m)
225±25
7.2.1.3 Grease and lubricant type Application Gear oil for differential Gear oil filling volume for differential
Specification API Grade GL-5 (SAE 75 W/90) 1.8±0.1L
Drivetrain 7-8
7.2.2
Component location diagram
7.2.2.1 Exploded view of differential
16AJ0702001
figure 1. Rear axle shaft bearing retainer 2. Rear wheel speed sensor retainer (ABS) 3. Rear axle shaft bearing 4. Rear axle shaft washer 5. Rear wheel spindle retainer 6. Rear wheel bolt 7. Rear axle shaft 8. Rear axle shaft seal 9. Rear axle shaft drive pinion oil baffle 10. Rear axle housing bolt
11. Drain plug gasket 12. Drain plug assembly 13. Special bolt 14. Washer 15. Nut 16. Ventilation plug 17. Rear axle housing oil filler plug gasket 18. Rear axle housing oil filler plug 19. Rear axle shaft assembly 20.Load-sensing proportional valve bracket (non-ABS)
Drivetrain 7-9
7.2.2.2 Exploded view of main gear reducer/differential
16AJ0702002
figure 1. Ring gear 2. Adjusting nut 3. Differential bearing 4. Differential bearing cap bolt M10x50 5. Diffrential bearing lock cap 6. Differential cage 7. Bolt 8. Adjusting shim 9. Differential side gear 10. Cylindrical pin 11. Pinion gear 12. Side gear thrust washer
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Drive pinion gear Adjusting shim (II) Drive pinion gear rear bearing Pinion gear bearing spacer Adjusting shim (III) Drive pinion gear outer bearing Drive pinion gear oil seal Drive pinion gear lock nut Differential case Dust seal Connecting flange
Drivetrain 7-10
7.2.3
Diagnostic information and procedure
Starting point for diagnosis Begin the system diagnosis should refer to “Description and operation” of system. If the vehicle get in trouble, refer to the "description and operation" to be habituate with the function of the system, and help to determine the correct diagnosis procedure. Check out the following “Description and operation”: Rear drive axle Visual inspection/routine inspection Visual inspection/routine inspection shall be firstly conducted in case of vehicle fault. The items of inspection are as follows: Visible or accessible parts of the system for any visible damage Whether installed aftermarket parts that may cause a system failure Components that have unusual loosenes Inspection of differential gear oil Active and ring gear meshing inspection Inspection on backlash in circular tooth of gear pair of gear reducer Inspection on backlash in circular tooth of gear pair of differential Common symptoms Corresponding symptoms will be shown in case of vehicle fault. The common symptoms as shown as follows: Abnormal sound of differential (the faster the speed is, the greater the sound is) Abnormal sound of differential (sharp change of speed or uphill) Abnormal sound of differential (turning) The differential and gear reducer cage generate heat The gear oil of differential leaks
Drivetrain 7-11
7.2.3.1 Abnormal sound of differential (the faster the speed is, the greater the sound is) Inspection Whether the differential bearing is loose.
Operation Repair and replace the differential bearing, if necessary.
Whether the backlash in circular tooth of gear pair of gear reducer is too large.
Adjust the backlash in circular tooth of gear pair of gear reducer.
Instructions: Refer to Chapter “Maintenance Guidelines” for detailed description on “Operation”.
7.2.3.2 Abnormal sound of differential (sharp change of speed or uphill) Inspection Whether the backlash in circular tooth of gear pair of gear reducer is too large.
Operation Adjust the backlash in circular tooth of gear pair of gear reducer.
Instructions: Refer to Chapter “Maintenance Guidelines” for detailed description on “Operation”.
7.2.3.3 Abnormal sound of differential (turning) Inspection Whether the differential gear pair backlash is too large. Whether the rear axle shaft gear or keyway is damaged. Whether the wheel bearing is loose or worn.
Operation Adjust the differential gear pair backlash in circular tooth. Replace the differential assembly Replace wheel bearing.
Instructions: Refer to Chapter “Maintenance Guidelines” for detailed description on “Operation”.
7.2.3.4 The differential and gear reducer cage generate heat Inspection Whether the bearing pre-tightening degree is too high. Whether the gear pair backlash in circular tooth is too large. Whether the differential gear oil is insufficient. Whether the type of differential gear oil is correct. Whether plug of differential is blocked.
Operation Adjust the bearing pre-tightening degree Adjust the differential gear pair backlash in circuit tooth. Fill differential gear oil. Replace differential gear oil. Repair and replace the differential plug, if necessary.
Instructions: Refer to Chapter “Maintenance Guidelines” for detailed description on “Operation”.
7.2.3.5 The differential gear oil leaks Inspection Whether the oil seal of rear axle shaft is damaged Whether the oil seal of Drive pinion gear is damaged. Whether differential gear oil is filled too much.
Operation Replace the rear axle shaft oil seal. Replace the oil seal of Drive pinion gear. Adjust filling volume of the differential gear oil
Instructions: Refer to Chapter “Maintenance Guidelines” for detailed description on “Operation”.
Drivetrain 7-12
7.2.4
Maintenance guidelines
7.2.4.1 Inspection and filling of differential gear oil Adjustment procedure 1. Lift up vehicle with lifting machine. 2. Clean the peripheral area of differential fill plug. 3. Remove the fill plug.
Oil drain hole plug
Fluid filler plug 16AJ0702003
4.
Inspect the liquid height of differential gear oil, of which the level of gear oil shall be parallel to the bottom of mounting hole for filling plug, and not lower than 6mm. 5. Fill gear oil into differential if necessary, until the level reaches the correct position. Notes: Please use the recommended gear oil when adding or completely replacing the differential gear oil. 6. Install the filling plug, and tighten to 50±10 N.m. 7. Lift down vehicle from lifting machine.
7.2.4.2 Replacement of differential gear oil
15AJ0702004
Adjustment procedure 1. Lift up vehicle with lifting machine. 2. Clean the peripheral area of drain plug for differential. 3. Remove the drain plug, and patch3 the gear oil flowed from differential by use of large container. 4. Install the drain plug, and tighten to 60±10 N.m. 5. Clean the peripheral area of filling plug of differential. 6. Remove the filling plug. 7. Fill gear oil into differential until the level reaches the correct position. Notes: Please use the recommended gear oil when adding or completely replacing the differential gear oil. 8. Install the filling plug, and tighten to 50±10 N.m. 9. Lift down vehicle from lifting machine.
Drivetrain 7-13
7.2.4.3 Replacement of differential assembly (semi-detached coil spring rear suspension) Notes: Brake fluid will damage the paint surface. If brake fluid overflows carelessly, please immediately wipe off and rush the area with water.
16AJ0701004
16AJ0702005
Disassembly procedure 1. Lift up vehicle with lifting machine. 2. Remove rear wheel and tire. Refer to “Replacement of Wheel and Tire”. 3. Disconnect the rear brake hose connected with differential. Refer to “Replacement of Rear Brake Hose”. 4. Disconnect the assembly of hand brake cable. Refer to “Replacement of Assembly of Hand Brake Cable”. 5. Disconnect rear wheel speed sensor (if equipped). Refer to “Rear Wheel Speed Sensor”. 6. Support propeller shaft assembly by use of hydraulic lifting equipment. 7. Use an open-end wrench to fix the bolts connecting the propeller shaft and the differential, remove 4 nuts and then 4 bolts. Notes: Disconnect the connection between propeller shaft and the differential, and mark the relative positions of flange yoke and differential flange for reference during the installation. 8. Support the differential assembly to a proper height by use of hydraulic lifting equipment. 9. Remove the lateral connecting rod assembly. Refer to “Replacement of Lateral Connecting Rod Assembly”.
10. Remove the nuts used for connecting rear absorber and differential. 11. Disconnect the connection between rear absorber and differential.
12. Remove the nuts while fixing the bolts used for connecting lower arm assembly and differential by use of open-end wrench, and then remove the bolts. 13. Disconnect the connection between lower arm assembly and differential. 14. Separate the rear spiral spring. 15. Remove the upper and lower cushion rubbers from the rear spring.
16AJ0702006
Drivetrain 7-14
16. Remove the nuts while fixing the bolts used for connecting upper arm assembly and differential by use of open-end wrench, and then remove the bolts. 17. Disconnect the connection between upper arm assembly and differential.
16AJ0702007
18. Lower the hydraulic lifting equipment, and separate the differential assembly.
Installation Procedure 1. Support differential assembly by use of hydraulic lifting equipment. 2. Lift the hydraulic lifting equipment, and position the differential assembly.
15AJ0702008
3. 4.
16AJ0702007
Connect upper arm assembly and differential together. Install bolts connecting the upper arm assembly and the differential, use an open-end wrench to secure the bolt, install nuts and tighten to 80±10N·m.
Drivetrain 7-15
5. 6. 7.
8.
16AJ0702006
16AJ0702005
16AJ0701004
Install the upper and lower cushion rubbers for the rear spring. Position the rear spiral spring. Connect lower arm assembly and differential together. Install bolts connecting the lower arm assembly and differential, use an open-end wrench to secure the bolt, install nuts and tighten to 115±15N·m.
9. Connect rear absorber and differential together. 10. Install the nuts used for connecting rear absorber and differential, and tighten to 40±10 N.m. 11. Install the lateral rod assembly. Refer to “Replacement of Lateral Rod Assembly”. 12. Move away the hydraulic lifting equipment used to support differential assembly. 13. Install 4 bolts connecting the propeller shaft and the differential, use an open-end wrench to secure the bolt, install four nuts and tighten to 53±7N·m.
Notes: Place the relative positions of the propeller shaft flange yoke and the differential flange at the marking made at the removal. 14. Move away the hydraulic lifting equipment used to support propeller shaft assembly. 15. Connect the rear wheel speed sensor (if equipped). Refer to “Rear Wheel Speed Sensor”. 16. Connect the assembly of hand brake cable. Refer to “Replacement of Assembly of Hand Brake Cable”. 17. Connect the rear brake hose connected with differential. Refer to “Replacement of Rear Brake Hose”. Install the rear wheel and tire. Refer to “Replacement of Wheel and Tire”. 18. Lift down vehicle from lifting machine. 19. Refuel brake fluid Refer to “Check and Refuel of Brake Fluid”. 20. Vent hydraulic brake system. Refer to “Venting of Hydraulic Brake System”.
Drivetrain 7-16
7.2.4.4 Replacement of rear axle shaft assembly (Drum Brake) Special tools CH-0002 rear axle shaft puller Disassembly procedure 1. Lift up vehicle with lifting machine. 2. Remove rear wheel and tire. Refer to “Replacement of Wheel and Tire”. 3. Remove brake drum. Refer to “Replacement of Brake Drum”.
16AJ0702009
16AJ0702010
16AJ0702011
4.
Remove 4 bolts from rear brake backing plate while fixing the nuts by use of open-end wrench.
5.
Remove the rear axle shaft assembly from differential by use of special tool CH-0002.
Installation Procedure 1. Install the rear axle shaft assembly in place. 2. Release the rear brake suspending on vehicle. 3. Install 4 bolts for rear brake backing plate while fixing the nuts by use of open-end wrench, and tighten to 51±6 N.m. 4. Install brake drum. Refer to “Replacement of Brake Drum”. 5. Install the rear wheel and tire. Refer to “Replacement of Wheel and Tire”. 6. Lift down vehicle from lifting machine.
Drivetrain 7-17
7.2.4.5 Replacement of rear axle shaft assembly (Disc Brake) Special tools CH-0002 rear axle shaft puller
1. 2. 3.
4. 5. 16AJ0503019 6. 7.
8.
Disassembly procedure Lift up vehicle with lifting machine. Remove rear wheel and tire. Refer to “Replacement of Wheel and Tire”. Remove hand brake bracket plate from the rear axle. Remove brake hose from the rear brake hose and remove the brake tube mounting bracket.
Remove brake caliper mounting bolts and remove caliper. See "Replacing the brake caliper". Remove the brake disc While securing the nut with an open-end wrench, remove the four rear brake shoe bolts and pull out the brake shoe. Remove the axle assembly from the rear axle using the special tool CH-0002.
Installation Procedure
1. 2. 3.
15AJ0702011
Install the axle assembly and install it in place. Install the brake shoe on the shaft. Secure the nuts with an open-end wrench and attach the four rear brake bottom plate bolts and fasten to 51 ± 6 Nm. 4. Install the brake disc. See "Brake Disc Replacement". 5. Install the caliper. See "Replacing the brake caliper". 6. Install the rear brake tube mounting brackets and connect the rear brake soft tube. 7. Install the parking cable bracket to the rear axle bracket bracket. 8. Install the rear wheels and tires. See "Replacing Wheels and Tires". 9. Lower the vehicle on the lift. 10. Fill the brake fluid, see "Checking and filling the brake fluid". 11. Vent the brake line. Refer to "Brake Fluid Exhaust". 12. Check and replenish the rear axle oil.
Drivetrain 7-18
7.2.4.6 Replacement of rear axle shaft oil seal Special tools PT-0107 oil seal removal tool CH-0031 rear axle shaft oil seal mounting tool Disassembly procedure 1. Remove the rear axle shaft assembly, and refer to “Replacement of rear axle shaft assembly”. 2. Remove the rear axle shaft oil seal by use of special tool PT-0107.
16AJ0702012
Installation Procedure Notes: The oil seal shall be coated with lubricating grease well before installation, so that the oil seal can be installed better. 1. Install the rear axle shaft oil seal by use of special tool CH-0031. 2． Install the rear axle shaft assembly, and refer to “Replacement of rear axle shaft assembly”.
16AJ0702013
Drivetrain 7-19
7.2.4.7 Replacement of assembly of differential gear reducer
16AJ0702014
Disassembly procedure 1. Lift up vehicle with lifting machine. 2. Remove rear wheel and tire. Refer to “Replacement of Wheel and Tire”. 3. Drain gear oil for differential Refer to “Replacement of Gear for Differential”. 4. Remove the propeller shaft assembly. Refer to “Replacement of Propeller Shaft Assembly”. 5. Remove the rear axle shaft assembly. Refer to “Replacement of Rear Axle shaft Assembly”. 6. Support the assembly of differential gear reducer by use of hydraulic lifting equipment. 7. Remove 8 nuts used for connecting main gear reducer cage and differential cage assembly according to the object. 8. Lower the hydraulic lifting equipment, and separate the differential gear reducer assembly.
Installation Procedure 1. Clean the sealant from the interface flange of differential cage assembly, and coat new semi-dry sealant. 2. Support the assembly of differential gear reducer by use of hydraulic lifting equipment. 3. Hoist the hydraulic lifting equipment, and locate the differential gear reducer assembly. 4. Install 8 nuts used for connecting main gear reducer cage and differential cage assembly, and tighten to 27±3 N.m. 5. Move away the hydraulic lifting equipment used to support differential gear reducer assembly. 6. Install the rear axle shaft assembly. Refer to “Replacement of Rear axle shaft Assembly”. 7. Install the propeller shaft assembly. Refer to “Replacement of Propeller Shaft Assembly”. 8. Fill differential gear oil. Refer to “Replacement of Differential Gear Oil”. 9. Install the rear wheel and tire. Refer to “Replacement of Wheel and Tire”. 10. Lift down vehicle from lifting machine.
Drivetrain 7-20
7.2.4.8 Replacement of differential bearings Special tools PT-0017 extractor CH-0036 differential bearing removal tool Disassembly procedure 1. Remove the assembly of differential gear reducer. Refer to “Replacement of Assembly of Differential Gear reducer”. 2. Remove 2 mounting bolts from bearing lock cap. 3. Remove 2 bearing lock cap.
16AJ0702015
Notes: Mark the screwing status of regulating nuts before removing, so as to refer during installation. 4. Remove 2 regulating nuts. 5. Remove 4 bolts used for connecting 2 bearing caps and main gear reducer cage. Notes: Make the pairing mark firstly before removing the bearing cap, so as to refer during installation. 6. Remove 2 bearing caps.
16AJ0702016
7. 8.
16AJ0702017
Lever out the differential, ring gear and differential bearing component by use of stick. Remove the differential, ring gear and bearing component of differential. See "Differential Assembly".
Drivetrain 7-21
9.
Remove 2 differential bearings by use of special tools PT-0017 and CH-0036.
16AJ0702018
16AJ0702019
Installation Procedure 1. Press 2 differential bearings into differential assembly by use of special tools CH-0036. 2. Inspect differential bearing backlash in circular tooth. Refer to “Inspection and Adjustment of Differential Bearing Backlash in Circular Tooth”. 3. Position the ring gear. 4. Install 10 mounting bolts for ring gear, and tighten to 75±5 N.m. 5. Position the differential, ring gear and differential bearing component. Notes: Position the bearing cap correctly according to the mark made during removal. 6. Position 2 bearing caps. 7. Install 4 bolts used for connecting 2 bearing caps and main gear reducer cage, and tighten to 50±5 N.m.
Notes: Assemble the regulating bolts to the mark status made during removal. 8. Install 2 regulating nuts.
16AJ0702016
Drivetrain 7-22
9. Position 2 bearing lock cap. 10. Install 2 mounting bolts for bearing lock cap, and tighten to 4.5±1 N.m. 11. Install the assembly of differential gear reducer. Refer to “Replacement of Differential Gear reducer Assembly”.
16AJ0702015
7.2.4.9 Replacement of connecting flange assembly Special tools CH-0005 flange holder Disassembly procedure 1. Remove the assembly of differential gear reducer. Refer to “Replacement of Assembly of Differential Gear reducer”. 2. Fix the connecting flange by use of special tool CH-0005.
16AJ0702020
16AJ0702021
3.
Remove the lock nuts from Drive pinion gear, and scrap it. 4. Remove gasket. Notes: Make the position mark firstly before removing the connection flange, so as to refer during installation. 5. Separate the connecting flange assembly. Installation Procedure Notes: Position the connecting flange assembly according to the mark made during removal. 1. Position the connecting flange assembly. 2. Install the gasket. 3. Install new lock nuts for drive pinion gear, and tighten to 225±25 N.m, refer to “Rear Drive Axle – Specification – Fasteners Torque” for specific torque. 4. Remove Special Tools CH-0005 5. Install the assembly of differential gear reducer. Refer to “Replacement of Assembly of Differential Gear reducer”.
Drivetrain 7-23
7.2.4.10 Replacement of Drive pinion gear oil seal Special tools CH-0029 differential oil seal mounting tool CH-0005 flange holder Disassembly procedure 1. Remove the assembly of connecting flange(2). Refer to “Replacement of Assembly of Connecting Flange”(3). 2. Remove the oil seal of Drive pinion gear.
16AJ0702022
Installation Procedure 1. Coat the lubricating grease in lip and groove of new Drive pinion gear oil seal 2. Install new Drive pinion gear oil seal by use of special tool CH-0029, and make the oil seal lip inward. 3. Install the assembly of connecting flange. Refer to “Replacement of Assembly of Connecting Flange”. 4. Inspect the differential gear oil. Refer to “Inspection and Filling of Differential Gear Oil”.
16AJ0702023
Drivetrain 7-24
7.2.4.11 Replacement of Drive pinion gear outer bearing Special tools CH-0012 differential front bearing outer ring mounting tool Disassembly procedure 1. Remove the assembly of differential gear reducer. Refer to “Replacement of Assembly of Differential Gear reducer”. 2. Remove the assembly of connecting flange. Refer to “Replacement of Assembly of Connecting Flange”. 3. Remove the oil seal of Drive pinion gear. Refer to “Replacement of Oil Seal of Drive pinion gear”. 4. Remove the differential, ring gear and bearing component of differential. Refer to “Replacement of Bearing of Differential”. 16AJ0702024
5. 6. 7. 8.
Pad the end of ring gear by use of plank, and knock out its component downward. Remove the inner ring from front bearing of Drive pinion gear. Remove adjusting shim and spacer bush from front bearing of Drive pinion gear. Remove the outer ring from front bearing of Drive pinion gear by copper bar.
16AJ0702025
16AJ0702026
Installation Procedure 1. Install outer ring for front bearing of Drive pinion gear by use of special tool CH-0012. 2. Install the adjustment shim of front bearing of Drive pinion gear. 3. Install Drive pinion gear. 4. Install the inner ring from front bearing of Drive pinion gear. 5. Install the differential, drive pinion gear and differential bearing component. Refer to “Replacement of Bearing of Differential”. 6. Install new Drive pinion gear oil seal by use of special tool CH-0029. 7. Install the flange assembly. Refer to “Replacement of Assembly of Connecting Flange”. 8. Install the assembly of differential gear reducer. Refer to “Replacement of Assembly of Differential Gear reducer”.
Drivetrain 7-25
7.2.4.12 Replacement of front bearing adjustment shim for drive pinion gear
16J0702027
Disassembly procedure 1. Remove the front bearing of Drive pinion gear. Refer to “Replacement of Drive pinion gear outer bearing”. 2. Remove adjustment shim from front bearing of Drive pinion gear. Installation Procedure 1. Select the shim with the thickness same to the replaced shim, and install it onto the Drive pinion gear. 2. Install the Drive pinion gear outer bearing. Refer to “Replacement of Drive pinion gear outer bearing”. 3. Use and install new oil seal. 4. Install the connecting flange, fasten it by use of new lock nuts, and tighten to 200±25 N.m. 5. Detect the starting torque. The starting torque shall be within the scope of 0.6-0.9, and use the shim with other thickness to replace in case of being exceeded, in order to meet the requirements.
7.2.4.13 Replacement of adjustment shim for rear bearing of Drive pinion gear
16AJ0702028
16AJ0702029
Disassembly procedure 1. Remove the rear bearing of Drive pinion gear. Refer to “Replacement of Rear Bearing of Drive pinion gear”. 2. Remove the adjustment shim from the rear bearing of Drive pinion gear. Installation Procedure 1. Select the shim in proper thickness via using the shim with thickness same to the replaced shim or following the calculation method in Step 2, and install the Drive pinion gear. 2. Measure Distance H between central line of differential bearing and end face for rear bearing hole of Drive pinion gear as well as Height B of rear bearing, and then calculate the thickness of adjustment shim according to the actual mounting distance A of Drive pinion gear (label on the small end face of Drive pinion gear, in case that such end is not labeled, it will be just the theoretical value 92mm) D=H-B-A。 3. Install the rear bearing for drive pinion gear. Refer to “Replacement of Rear Bearing of Drive pinion gear”.
Drivetrain 7-26
7.2.4.14 Replacement of rear axle shaft bearing assembly. Special tools CH－0002 rear axle shaft removal tool CH－0034 rear axle shaft bearing removal tool
16AJ0702031
Disassembly procedure 1. Lift and support the vehicle properly. Refer to “Vehicle Lifting and Hoisting” in “General Information”. 2. Remove the assembly of left and right rear wheels and tires. Refer to “Replacement of Wheel and Tire Assembly”. 3. Remove rear axle shaft assembly. Refer to “Replacement of Rear axle shaft Assembly”. Notes: The protective plate must be installed at the front of press machine when removing the haft shaft bearing by use of press machine, to prevent the personnel injury due to collapse. 4. Remove the bearing by use of special tool CH－ 0034. 5. Inspect the rear axle shaft, and replace the rear axle shaft assembly in case that there is obvious damage or bending to journal.
16AJ0702032
Installation procedure 1. Install the bearing cap, rear axle shaft spacer, bearing and adapter sleeve into the rear axle shaft according to the figure’s sequence. 2. Install the bearing by use of special tool CH－ 0034. 3. Install rear axle shaft assembly. Refer to “Replacement of Rear axle shaft Assembly”. 4. Install the assembly of left and right rear wheels and tires. Refer to “Replacement of Wheel and Tire Assembly”. 5. Lower the vehicle
16AJ0702033
Drivetrain 7-27
7.2.4.15 Replacement of rear drive axle cage
16AJ0702031
Disassembly procedure 1. Lift and support the vehicle properly. Refer to “Vehicle Lifting and Hoisting” in “General Information”. 2. Remove the assembly of left and right rear wheels and tires. Refer to “Replacement of Wheel and Tire Assembly”. 3. Remove differential assembly Refer to “Replacement of Differential Assembly”. 4. Remove the left and right rear axle shafts. Refer to “Replacement of Rear axle shaft Assembly”. 5. Remove the differential gear reducer assembly. Refer to “Replacement of Assembly of Differential Gear reducer”. 6. Replace the rear driving axle cage.
Installation Procedure 1. Install the differential gear reducer assembly. Refer to “Replacement of Assembly of Differential Gear reducer”. 2. Install the left and right rear axle shafts. Refer to “Replacement of Rear axle shaft Assembly”. 3. Install differential assembly Refer to “Replacement of Differential Assembly”. 4. Install the assembly of left and right rear wheels and tires. Refer to “Replacement of Wheel and Tire Assembly”. 5. Conduct exhausts operation to brake pipeline Refer to “Venting of Hydraulic Brake System”. 6. Lower the vehicle
Drivetrain 7-28
7.2.4.16 Gearing inspection and adjustment of ring gear and drive pinion gear
1. 2. 3. 4.
Small end Tooth surface at the direction of forward motion of ring gear Large end Tooth surface at the direction of astern motion of ring gear
Adjustment procedure 7. Coat red lead powder or paste red lead film on 2-3 tooth surface of ring gear 8. Rotate the ring gear repeatedly, to make the tooth surface coating with red lead powder contact with the Drive pinion gear more than once. 9. Inspect the contact mark of gear
Normal contact
The gear distance between ring gear and drive pinion gear is too far Thicken the adjustment shim installed for drive pinion gear to make the drive pinion gear close to the center of ring gear properly, meanwhile, move the ring gear outward in a proper manner to obtain the appropriate backlash in circular tooth.
The gear distance between ring gear and drive pinion gear is too close Reduce the adjustment shim installed for drive pinion gear to make the Drive pinion gear far to the center of ring gear properly, meanwhile, move the ring gear inward properly to obtain the appropriate backlash in circular tooth.
16AJ0702033
1. 2. 3. 4.
Small end Tooth surface at the direction of forward motion of ring gear Large end Tooth surface at the direction of astern motion of ring gear 16AJ0702034
1. 2. 3. 4.
Small end Tooth surface at the direction of forward motion of ring gear Large end Tooth surface at the direction of astern motion of ring gear 16AJ0702035
Drivetrain 7-29
7.2.4.17 Inspection on backlash in circular tooth of gear pair of gear reducer Special tools Dial indicator PT-0008 Magnetic stand for dial indicator PT-0009
16AJ0702036
7.2.4.18 Inspection on backlash in circular tooth of gear pair of differential
Differential gear pair backlash in circular tooth
Special tools Dial indicator PT-0008 Magnetic stand for dial indicator PT-0009
Measuring terminal
Planetary shaft
Check procedure 1. Make the contact terminal of dial indicator touch the proper position of male face at large end of ring gear. 2. Fix the Drive pinion gear, rotate the ring gear repeatedly, and measure the backlash in circular tooth, of which its standard value is 0.1-0.14mm. Adjust the backlash in circular tooth via regulating nut in case of failure to meet.
Planetary gear
Standard value of number 0.15-0.25mm Limit: 0.40mm
16AJ0702037
Check procedure 1. Embed one wooden wedge between pinion gear and rear axle shaft gear, to make the gear pair fixed without rotation. 2. Make the contact terminal of dial indicator touch the proper position of male face at large end of planetary gear. 3. Rotate the pinion gear repeatedly, measure the backlash in circular tooth, of which its standard value is 0.15-0.25mm, with limit value of 0.40mm, replace the differential assembly in case of exceeding such value.
Drivetrain 7-30
7.2.5
Description and operation
7.2.5.1 Rear drive axle The function and application of rear drive axle are shown as follows: Transmit the engine torque from propeller shaft to wheel via main gear reducer, differential and rear axle shaft, etc., realize reduction of speed and increase the torque. Change the transmission direction of torque via ring gear pair of main gear reducer. Realize differential effect of wheels at both sides via differential, to meet the demands on rotating in different speed by wheels at inner and outer sides.
The rear drive axle mainly consists of main gear reducer, differential, rear axle shaft and drive axle cage, etc. The main gear reducer is the main component in automotive drivetrain to reduce the rotational speed and increase the torque. For differential, it solves the problem on unequal speed of wheels at both sides while steering. The rear axle shaft is used to transmit the driving force reliably. The drive axle cage is basic mounting piece for the main component of drivetrain and driving system.
Drivetrain 7-31
7.2.6
Special tools Figure
Tools no./description
Figure
Tools no./description
CH-0002 Rear axle shaft removal tool
CH-0034 Rear axle shaft bearing removal tool
PT-0107 Rear axle shaft oil seal and intermediate bearing outer ring removal tool
CH-0036 Differential bearing removal tool
CH-0005 Differential flange fixing tool
PT-0017 Puller
CH-0029 Differential oil seal mounting tool
PT-0009 Magnetic stand for dial indicator
CH-0031 Rear axle shaft oil seal installation tool
PT-0008 Dial indicator
Drivetrain 7-32
Blank
Chapter 8 Driver information and entertainment system Contents 8.1 8.1.1 8.1.2
8.1.3
8.1.4
8.1.5
8.2 8.2.1 8.2.2 8.2.3
Mobile phone, entertainment and navigation system .................................................................. 1 Specification .......................................................... 1 8.1.1.1 Torque specification .................................. 1 Schematic and wiring diagram .............................. 2 8.1.2.1 Schematic diagram of radio and tape player/navigation system .......................... 2 Diagnostic information and procedure ................... 4 8.1.3.1 Symptom - entertainment system ............. 4 8.1.3.2 Poor receiver of radio and tape player ..... 4 8.1.3.3 Speaker damage ...................................... 5 Repair guide .......................................................... 6 8.1.4.1 Replacement of entertainment system ..... 6 8.1.4.2 Replacement of analog electronic clock ... 7 8.1.4.3 Replacement of radio and tape player antenna ..................................................... 8 8.1.4.4 Replacement of front side door speaker in entertainment system ........................... 9 8.1.4.5 Replacement of rear side door speaker in entertainment system ............................. 10 8.1.4.6 Replacement of control switch for entertainment system – steering wheel ... 11 Description and operation ................................... 12 8.1.5.1 Description and operation of entertainment system/sound system ...... 12 Display and instrument ..................................... 14 Tightening specification ....................................... 14 8.2.1.1 Torque specification ................................ 14 Schematic and wiring diagram ............................ 15 8.2.2.1 Schematic diagram of instrument cluster 15 Diagnostic information and procedure ................. 17
8.2.3.1 8.2.3.2 8.2.3.3 8.2.3.4 8.2.3.5
Diagnostic information ............................. 17 Symptom – display and instrument ......... 21 Chime doesn’t work ................................. 22 The engine oil pressure indicator fails ..... 23 The fuel gauge is inaccurate or doesn’t work ......................................................... 24 8.2.3.6 Faulty combination meter ........................ 24 8.2.3.7 The trip/reset switch of odometer doesn’t work ......................................................... 25 8.2.3.8 The speedometer and/or the odometer is inaccurate or doesn’t work ...................... 25 8.2.4 Repair guide ......................................................... 26 8.2.4.1 Replacement of the applique of instrument cluster .................................... 26 8.2.4.2 Replacement of instrument cluster .......... 27 8.2.5 Description and operation .................................... 28 8.2.5.1 Description and operation of audio warning .................................................... 28 8.2.5.2 Description and operation of driver information center (DIC) .......................... 29 8.2.5.3 Description and operation of indicator/warning information .................. 29 8.2.5.4 Description and operation of instrument cluster ...................................................... 31 8.3 Auxiliary and configurable user control system ................................................................. 33 8.3.1 Diagnostic information and procedure ................. 33 8.3.1.1 Symptom – auxiliary control system ........ 33 8.3.1.2 Fault of radio control device on the steering wheel ......................................... 33
Driver information and entertainment system 8-1
8.1
Mobile phone, entertainment and navigation system
8.1.1
Specification
8.1.1.1 Torque specification Torque specification Application Fastening screws for entertainment system Fixing screws for analog electronic clock Fastening screws for front side door speaker in entertainment system Fastening screws for entertainment system control switch – steering wheel Fastening screws for rear side door speaker in entertainment system Mounting nuts for entertainment system antenna
Specification (N.m) Metric 2.5±0.5 N.m 2±0.5 N.m 2.5±0.5 N.m 2.5±0.5 N.m 2.5±0.5 N.m 3.25±0.25 N.m
USB socket
Fuse box – instrume nt panel
KR53 Parking lamp relay Radio antenna
S70L Control switch at left side of steering wheel
B16 Backup Lamp Switch
Coil for steering wheel and airbag
Navigati on antenna
Radio
Rear view camera
8.1.2
X50A Fuse box – under hood
Driver information and entertainment system 8-2
Schematic and wiring diagram
8.1.2.1 Schematic diagram of radio and tape player/navigation system Schematic diagram of radio and tape player/navigation system
Speaker – left front door
Speaker – instrument panel at left side
Speaker – right front door
Speaker – instrument panel at right side
Speaker – left rear door
Speaker – right rear door
Radio
Driver information and entertainment system 8-3
Schematic diagram of radio and tape player/navigation system
15AJ0801002
Driver information and entertainment system 8-4
8.1.3
Diagnostic information and procedure
8.1.3.1 Symptom - entertainment system Important notes: The following steps must be completed before using Symptoms List: 1. Execute “Inspection of diagnostic system - vehicle” before adopting “Symptoms List”, to confirm authenticity of the following situation: Does not set up diagnostic trouble code. Control module can communicate through serial data link. 2. Look up system operation, and be familiar with system function. Refer to “Description and operation of radio and tape player/sound system”. Visual /appearance inspection Inspect whether the aftermarket equipment affecting operation of horn exists. Refer to “Inspection of aftermarket accessories”. Inspect whether the touchable or visible system units have obvious damage or fault resulting in such symptom. Intermittent fault The intermittent fault may be caused by electrical connecting fault or wiring harness fault. Refer to “Intermittent fault and bad contact test”. Symptoms List See the symptom diagnosis procedure in the following table to diagnose the symptoms: Speaker fault Poor receiver of radio and tape player
8.1.3.2 Poor receiver of radio and tape player Diagnostic description Execute “Inspection of diagnostic system-vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Circuit/system description The receiver of AM/FM radio and tape player depends on the following units: Antenna for radio and tape player Cable of radio and tape player (feeder line of antenna) Diagnostic help Poor receiver of AM/FM radio and tape player depends on many influence factors, of which some factors may be unrelated to the vehicle. The receiver effect of radio and tape player may become worse in high traffic area or signal blockage channel. The receiver of radio and tape player may be affected by the interior units (not the units of radio and tape player system). Such as after-sales electrical accessories or other units which may cause noise in vehicle electrical system. The colored film pasted on window glass after sales will reduce the receiver effect of radio and tape player, particularly under the condition that there is metal in it.
Reference information Schematic diagram reference Schematic diagram of radio and tape player/navigation system Connector end view reference “Part connector end view” Description and operation Description and operation of radio and tape player/sound system Electrical information reference Circuit test Repair of connector Test the intermittent fault, and repair the circuit with bad contact Circuit/system test Antenna circuit test 1. Turn off the ignition switch, and disconnect the cable of radio and tape player from the A11 antennas radio and tape player and T4M radio and tape player. 2. Insert one copper core cable with length of 3-5m into the interface of antenna of radio and tape player. Turn on radio and tape player to listen to the radio station. -Detect whether the antenna cable and module of radio and tape player are normal in case that the radio station can be received and its tone quality is relatively clear. 3. Connect the cable to T4M radio and tape player antenna again. Test whether the resistance between central terminal of cable of A11 radio and tape player and outer shielding line is infinite. － Replace the antenna cable in case of being less than the specified value. 4. Test whether the resistance between outer shielding line of cable of A11 radio and tape player and ground is less than 10Ω. -Clean the ground surface of antenna in case of being larger than the specified value. Replace T4M radio and tape player antenna in case of no corrosion. 5. Replace A11 radio and tape player in case that all circuits are normal after test. Repair guide Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Replacement of antenna module of radio and tape player Replacement of radio and tape player Replacement of antenna coil of radio and tape player – high-pressure side Replacement of antenna coil of radio and tape player – ground side
Driver information and entertainment system 8-5
8.1.3.3 Speaker damage Diagnostic description Execute “Inspection of diagnostic system - vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Circuit/system description Each audio output channel circuits (+) and (-) of radio and tape player has a DC bias voltage, and such voltage is a half of battery voltage. The voltage measuring value of each audio output channel circuit is about 6.5v (DC voltage) when using digital multimeter. The audio played from sound system is generated from one changing AC voltage, and the value of such changing voltage takes DC bias voltage of the same circuit as center. AC voltage makes the speaker cone move and generate sound. Such voltage is changed along with changes of volume settings of listened audio type, dialogue or music as well as music type and system. The voltage measuring value is about 1V (AC voltage) or lower during low volume and dialogue setting, and the voltage measuring value may be 3V (AC voltage) or slightly higher during music setting. Diagnostic help Improper installation of speaker or looseness of trim may cause buzz or distortion. Inspect whether the corresponding speaker and internal trim around it are proper and fastened for installation. Install the speaker and internal trim around it correctly in case that looseness or improper installation is found. Reference information Schematic diagram reference Schematic diagram of radio and tape player/navigation system Connector end view reference “Part connector end view” Description and operation Description and operation of radio and tape player/sound system Electrical information reference Circuit test Repair of connector Test the intermittent fault, and repair the circuit with bad contact Circuit repair Circuit/system test Antenna circuit test 1. Turn on the ignition switch, open radio and tape player, and disconnect corresponding P19 speaker. 2. Test whether the voltage between terminal of signal circuit and ground is 4-8v. － In case of being lower than the specified scope, test whether the circuit is open / the resistance is too large. Replace A11 radio and tape player in case that the circuit is normal after test. － In case of being larger than the specified scope, test whether voltage is shorted. Replace A11 radio and tape player in case that the circuit is normal after test. 3. Replace P19 speaker in case that the circuit is normal after test.
Repair guide Execute “Diagnosis inspection and repair effect” after the diagnostic procedure is finished. Speaker replacement reference Replacement of radio and tape player
Driver information and entertainment system 8-6
8.1.4
Repair guide
8.1.4.1 Replacement of entertainment system
16BH0801001
Replacement of entertainment system Figure no. Part name Preparation procedure 1. Disconnect the battery negative line. Refer to “Battery disconnection and connection”. 2. Remove the middle of the dashboard trim. Refer to “Replacement of the center trim strip.” Fastening screws for entertainment system (quantity: 4) Warning: Refer to “Warnings on fasteners”. 1 Fastening 2.5±0.5 N.m Entertainment system Procedure 2 Disconnect the electrical connector.
Driver information and entertainment system 8-7
8.1.4.2 Replacement of analog electronic clock
16BH0801002 Replacement of analog electronic clock Figure no. Preparation procedure Remove the instrument panel. Refer to “Replacement of instrument panel”.
1
2
Part name
Setting screws for analog electronic clock (quantity: 3) Warning: Refer to “Warnings on fasteners”. Fastening 2±0.5 N.m Analog electronic clock Procedure Disconnect the electrical connector.
Driver information and entertainment system 8-8
8.1.4.3 Replacement of radio and tape player antenna
15AJ0801004
Replacement of radio and tape player antenna Figure no. Part name Preparation procedure 1. Remove the instrument panel. Refer to “Replacement of instrument panel”. 2. Remove the upper trim plate (right) on front pillar A. Refer to “Replacement of upper trim plate on front pillar A”. 3. Remove the headliner. Refer to “Replacement of headliner”. Mounting nut for radio and tape player antenna (quantity: 1) Warning: Refer to “Warnings on fasteners”. 1 Fastening 3.25±0.25 N.m Mounting washers for radio and tape player antenna 2 Radio and tape player antenna Procedure 3 Disconnect the electrical connector.
Driver information and entertainment system 8-9
8.1.4.4 Replacement of front side door speaker in entertainment system
15AJ0801005
Replacement of front side door speaker in entertainment system Figure no. Part name Preparation procedure 1. Disconnect the battery negative line. Refer to “Battery disconnection and connection”. 2. Remove the front side door decorative panel. Refer to “Replacement of front door trim panel.” Fastening screws for front side door speaker in entertainment system (quantity: 3) Warning: Refer to “Warnings on fasteners”. 1 Fastening 2.5±0.5 N.m Front side door speaker in entertainment system Procedure 2 Disconnect the electrical connector.
Driver information and entertainment system 8-10
8.1.4.5 Replacement of rear side door speaker in entertainment system
15AJ0801006
Replacement of rear side door speaker in entertainment system Figure no. Part name Preparation procedure 1. Disconnect the battery negative line. Refer to “Battery disconnection and connection”. 2. Remove the trim plate of rear side door. Refer to “Replacement of trim plate of rear side door”. Fastening screws for rear side door speaker in entertainment system (quantity: 3) Warning: Refer to “Warnings on fasteners”. 1 Fastening 2.5±0.5 N.m Rear side door speaker in entertainment system Procedure 2 Disconnect the electrical connector.
Driver information and entertainment system 8-11
8.1.4.6 Replacement of control switch for entertainment system – steering wheel
15AJ0801007
Replacement of control switch for entertainment system – steering wheel Figure no. Part name Preparation procedure Disconnect the battery negative line. Refer to “Battery disconnection and connection”. Fastening screws of control switch for entertainment system – steering wheel (quantity: 2) Warning: Refer to “Warnings on fasteners”. 1 Fastening 2.5±0.5 N.m Control switch for entertainment system – steering wheel Procedure 2 Disconnect the electrical connector.
Driver information and entertainment system 8-12
8.1.5
Description and operation
8.1.5.1 Description and operation of entertainment system/sound system For vehicle, its entertainment system has several different kinds of available configuration. To confirm the specific configuration of vehicle, please refer to “Identification label for repaired parts” as well as “Conventional RPO Code List”. The entertainment system in this vehicle is equipped with basic or high-level system. Both basis system and high-level system include one radio and tape player, antenna, antenna feeder line and speaker, and some system also includes one sound amplifier. The difference between high-level system and basic system is that it provides the client with enhanced sound system function. For some function, it may include more speakers, one audio amplifier, programmable equalizer and digital audio broadcasting. Each item listed below will be stated in details later. Operation on circuit of video entertainment system Penal of radio and tape player Antenna system AM/FM receiver Operation of speaker Information on MP3/CD format of MP3/CD radio and tape player (if equipped) Anti-theft system Error information for radio and tape player Control device for steering wheel (if equipped) Auxiliary input jack (if equipped) USB port Operation on circuit of radio and tape player Power supply of radio and tape player The radio and tape player is powered by B+ circuit with fuse. No disperse ignition power circuit is used for power mode of radio and tape player. The main control module under power mode provides system power mode for radio and tape player via serial data information. The main control module under power mode confirms system power mode via processing the power mode information from ignition switch. The serial data power mode supported by radio and tape player includes “Off”, “Accessory”, “Run” and “Crank Request”. One ground is provided to the circuit of radio and tape player via ground to vehicle wiring harness. Ground can also be realized for radio and tape player via shell. Data link communication of radio and tape player Radio and tape player communicates with other modules via serial data. Output of radio and tape player Conduct measurement corresponding to vehicle ground under the condition that the volume is the lowest, and the speaker output (+) and (-) is about a half of battery voltage. Along with increase of volume, voltage changes due to mutual change between positive and negative, to drive the speaker coil or feed to the amplifier.
The light changes in control panel of radio and tape player and brightness of background lamp depends on the serial data information received by radio and tape player. Penal of radio and tape player Radio and tape player panel is an independent unit of radio and tape player. The panel includes radio and tape player control handle and key with all audio functions. In addition, heating, ventilation and air conditioning system cap control module is also one part of panel. The panel communicates with radio and tape player via serial data, and is connected to the radio and tape player directly. One information will be sent to radio and tape player via serial data when the operator changes the radio station or increases volume via rotating the radio and tape player handle. Radio and tape player will adjust it after receiving the information. Contents of monochrome monitor Key/rotary button Indicator status order AM/FM receiver Radio signal The radio and tape player signal is sent from broadcasting station, and then received by antenna. The strength of signal received depends on the following factors: Power output (wattage) of broadcasting station Position of vehicle (or receiver) corresponding to broadcasting tower Barrier between broadcasting tower and receiver Atmospheric conditions Wave band of station broadcast (AM or FM) Antenna type and ground surface AM receiver The frequency scope of AM wave band is lower than FM wave band. Those longer wave bands: Bypass the obstacle Forward along earth surface Ionosphere reflection (jump) The scope of AM frequency is relatively larger due to surface wave. The surface wave is transmitted along the direction of earth surface, and affected by its conductivity. Relatively larger conductivity is equal to relatively little signal loss, therefore, transmission from the water surface is better than that from the land. The scope of AM wave band is 80-320 km (50-200 miles) FM receiver FM wave band has a shorter wave length and higher frequency: Barrier reflection Absorbed by ground Penetrate the ionosphere The broadcasting area of FM wave band is limited in the “Coverage of sight”, which is 40 km (25 miles) in general. However, the signal may be reflected in the non-linear “Shadow” area in the area outside direct sight. The sight influence factors include: Height of broadcasting antenna Height of receiving antenna Terrain and buildings in the transmission path
Driver information and entertainment system 8-13 Operation of speaker The speaker converts electric energy to mechanical energy via permanent magnet and electromagnet, to make the air fluctuate. The electromagnet is energized when the radio and tape player or amplifier (if equipped) transmits the current to speaker coil. The north and south poles will be formed in the coil, which will make the coil and speaker cone move corresponding to permanent magnet. The current transmitted to speaker is AC current (A/C) under rapid change. This makes the speaker cone move toward two directions and generate sound. The voltage applied to both sides of speaker is 1/2 of ignition system when the speaker stops, for example, the volume is the minimum. In this way, the speaker cone can move toward any direction. For information related to MP3/CD format of MP3/CD radio and tape player, the radio and tape player equipped with MP3/CD can play standard audio CD. The user who records music CD by itself shall pay attention to the following matters: Radio and tape player can play CD -R/RW audio only, and can’t record the audio. The standard audio and MP3/WMA file can’t be mixed on the same disk. The player may not play the maximum quantity of files, folders, play lists or sections due to long file, folder, play list name or set or play list of large quantity of files and folders. Auxiliary input jack (if equipped) The remote equipment (such as notebook computer, iPod® and MP3 player) plays the audio signal in this equipment via remote 3.5mm auxiliary stereo socket and USB connector. Radio and tape player detects whether micro audio plug exists via auxiliary socket. Close the mechanical switch when inserting micro audio plug into the auxiliary detection switch. Open the switch when pulling out the plug. This is not audio output; don’t insert the earphone device into the front auxiliary input jack. USB port (if equipped) USB connector uses USB standard 1.1 and 2.0. Such connector supports low-speed (1.5 Mb/s), full-speed (12 Mb/s) and high-speed (480 Mb/s) running.
Driver information and entertainment system 8-14
8.2
Display and instrument
8.2.1
Tightening specification
8.2.1.1 Torque specification Torque specification Application
Specification Metric
Fasteners for trim of instrument cluster
2.5 ± 0.5 N.m
Fasteners for instrument cluster
2.5 ± 0.5 N.m
Driver information and entertainment system 8-15
8.2.2
Schematic and wiring diagram
8.2.2.1 Schematic diagram of instrument cluster
Fuse box – instrument panel
Electric circuit diagram of data communication
Logic
P16 Instrument cluster
Schematic diagram of instrument cluster
15AJ0802001
KR53 Relay parking lamp
X50A Fuse box – under hood
Brake fluid level switch Body control module
Parking brake switch
Generator
Seat belt buckle – driver
Fuse box – instrume nt panel
Engine control module
Engine oil level switch
Instrument cluster
Driver information and entertainment system 8-16 Schematic diagram of instrument cluster (continued)
15AJ0802002
Driver information and entertainment system 8-17
8.2.3
Diagnostic information and procedure
8.2.3.1 Diagnostic information 8.2.3.1.1 DTC U0108 08 Diagnostic description Execute “Inspection of diagnostic system - vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of diagnostic trouble code DTC U0108 08: The information about fuel cannot be communicated Conditions for running diagnostic trouble code Turn on the ignition switch The battery voltage is higher than 7.5 - 18V Conditions for setting up diagnostic trouble code No fuel message is received for 10 consecutive periods Operation adopted when setting up the diagnostic trouble code Fuel indicator is blanking Condition for clearing diagnostic trouble code The detection is normal for 40 continuous operating periods. Receive an order for clearing trouble code issued by diagnostic tool. Reference information Schematic diagram reference Schematic diagram of instrument cluster Connector end view reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical information reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan tool reference Refer to “Control module reference” to obtain the scan tool information. Circuit/system test 1. Inspect whether the ECM and BCM (gateway) have corresponding network faults. Repair guide Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “Control module reference”, so as to replace, set up or program the control module.
8.2.3.1.2 DTC U0116 08 Diagnostic description Execute “Inspection of diagnostic system - vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of diagnostic trouble code DTC U0116 08: The information about water temperature cannot be communicated Conditions for running diagnostic trouble code Turn on the ignition switch The battery voltage is higher than 7.5 - 18V Conditions for setting up diagnostic trouble code No water temperature message is received for 10 consecutive periods. Operation adopted when setting up the diagnostic trouble code Water temperature indicator is blanking Condition for clearing diagnostic trouble code The detection is normal for 40 continuous operating periods. Receive an order for clearing trouble code issued by diagnostic tool. Reference information Schematic diagram reference Schematic diagram of instrument cluster Connector end view reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical information reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan tool reference Refer to “Control module reference” to obtain the scan tool information. Circuit/system test 1. Inspect whether the ECM and BCM (gateway) have corresponding network faults. Repair guide Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure finished. Refer to “Control module reference”, so as to replace, set up or program the control module.
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8.2.3.1.3 DTC U0129 08 Diagnostic description Execute “Inspection of diagnostic system - vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of diagnostic trouble code DTC U0129 08: The information about hand brake switch status can not be communicated Conditions for running diagnostic trouble code Turn on the ignition switch The battery voltage is higher than 7.5 - 18V Conditions for setting up diagnostic trouble code No hand brake message is received for 10 consecutive periods Operation adopted when setting up the diagnostic trouble code The hand brake indicator goes out Condition for clearing diagnostic trouble code The detection is normal for 40 continuous operating periods. Receive an order for clearing trouble code issued by diagnostic tool. Reference information Schematic diagram reference Schematic diagram of instrument cluster Connector end view reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical information reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan tool reference Refer to “Control module reference” to obtain the scan tool information. Circuit/system test 1. Inspect whether the DCU and BCM (gateway) have corresponding network faults. Repair guide Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “Control module reference”, so as to replace, set up or program the control module.
8.2.3.1.4 DTC U0167 08 Diagnostic description Execute “Inspection of diagnostic system - vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of diagnostic trouble code DTC U0167 08: The information about hand brake switch status can not be communicated Conditions for running diagnostic trouble code Turn on the ignition switch The battery voltage is higher than 7.5 - 18V Conditions for setting up diagnostic trouble code No anti-theft message is received for 10 consecutive periods Operation adopted when setting up the diagnostic trouble code The anti-theft indicator lights up Condition for clearing diagnostic trouble code The detection is normal for 40 continuous operating periods. Receive an order for clearing trouble code issued by diagnostic tool. Reference information Schematic diagram reference Schematic diagram of instrument cluster Connector end view reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical information reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan tool reference Refer to “Control module reference” to obtain the scan tool information. Circuit/system test 1. Inspect whether PEPS and BCM (gateway) have corresponding network faults. Repair guide Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “Control module reference”, so as to replace, set up or program the control module.
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8.2.3.1.5 DTC U0199 08
8.2.3.1.6 DTC U0104 08
Diagnostic description Execute “Inspection of diagnostic system - vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of diagnostic trouble code DTC U0199 08: The information about door cannot be communicated Conditions for running diagnostic trouble code Turn on the ignition switch The battery voltage is higher than 7.5 - 18V Conditions for setting up diagnostic trouble code No door information message is received for 10 consecutive periods Operation adopted when setting up the diagnostic trouble code Door indicator goes out Condition for clearing diagnostic trouble code The detection is normal for 40 continuous operating periods. Receive an order for clearing trouble code issued by diagnostic tool. Reference information Schematic diagram reference Schematic diagram of instrument cluster Connector end view reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical information reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan tool reference Refer to “Control module reference” to obtain the scan tool information. Circuit/system test 1. Inspect whether PEPS and BCM (gateway) have corresponding network faults. Repair guide Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “Control module reference”, so as to replace, set up or program the control module.
Diagnostic description Execute “Inspection of diagnostic system - vehicle” before adopting such diagnostic procedure Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of diagnostic trouble code DTC U0104 08: The information about cruise cannot be communicated Conditions for running diagnostic trouble code Turn on the ignition switch The battery voltage is higher than 7.5 - 18V Conditions for setting up diagnostic trouble code No cruise information message is received for 10 continuous operating periods. Operation adopted when setting up the diagnostic trouble code The cruise indicator goes out Condition for clearing diagnostic trouble code The detection is normal for 40 continuous operating periods. Receive an order for clearing trouble code issued by diagnostic tool. Reference information Schematic diagram reference Schematic diagram of instrument cluster Connector end view reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical information reference Circuit test Repair of connector Intermittent fault and bad contact test Circuit repair Scan tool reference Refer to “Control module reference” to obtain the scan tool information. Circuit/system test 1. Inspect whether ECM and BCM (gateway) have corresponding network faults. Repair guide Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “Control module reference”, so as to replace, set up or program the control module.
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8.2.3.1.7 DTC U0073 88 Diagnostic introduction ● Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure ● Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. ● Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of diagnostic trouble code DTC U0073 88: bus off Conditions for running diagnostic trouble code ● Turn on the ignition switch Conditions for setting up diagnostic trouble code No cruise information message is received for 10 continuous operating periods. Operation adopted when setting up the diagnostic trouble code Stop communication Condition for clearing diagnostic trouble code ● The detection is normal for 40 continuous operating periods. ● Receive an order for clearing trouble code issued by diagnostic tool. Reference information Schematic diagram reference Schematic diagram of instrument cluster Connector end view reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical information reference ● Circuit test ● Repair of connector ● Intermittent fault and bad contact test ● Circuit repair Scan tool reference Refer to “Control module reference” to obtain the scan tool information. Circuit/system test Inspect whether CAN bus has corresponding network fault. Repair guide Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “Control module reference”, so as to replace, set up or program the control module.
8.2.3.1.8 DTC U3003 1E Diagnostic introduction ● Execute “Inspection of diagnostic system - vehicle” before adopting such diagnostic procedure ● Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. ● Get overview of each diagnostic category from “Description of diagnostic procedure”. Description of diagnostic trouble code DTC U3003 1E: The working voltage is abnormal. Conditions for running diagnostic trouble code ● Operating voltage＞18V or ＜7.5V. Conditions for setting up diagnostic trouble code Abnormal voltage for one minute Operation adopted when setting up the diagnostic trouble code Condition for clearing diagnostic trouble code ● The detection is normal for 40 continuous operating periods. ● Receive an order for clearing trouble code issued by diagnostic tool. Reference information Schematic diagram reference Schematic diagram of instrument cluster Connector end view reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical information reference ● Circuit test ● Repair of connector ● Intermittent fault and bad contact test ● Circuit repair Scan tool reference Refer to “Control module reference” to obtain the scan tool information. Circuit/system test 1. Inspect whether the supply voltage of battery is normal. 2. Inspect whether power supply circuit of instrument cluster is normal. 3. Replace the instrument cluster module in case that the fault still exists. Repair guide Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “Control module reference”, so as to replace, set up or program the control module.
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8.2.3.2 Symptom – display and instrument Note: the following steps must be firstly completed, and then Symptom Diagnosis List can be used. ● Execute “Inspection of diagnosis system - vehicle” before using Symptom Diagnosis List ● Look up the operation description of system, so as to understand the system function. Refer to the following description and operation: ● Description and operation of instrument cluster ● Description and operation of indicator/warning information ● Description and operation of driver information center (PIC) ● Description and operation of audio warning Visual /appearance inspection ● Inspect whether the aftermarket equipment affecting the work of instrument cluster or audio warning system exists. Refer to “Inspection of aftermarket accessories”. ● Inspect the touchable or visible system units, and view whether it is obviously damaged or failed resulting in such symptom. ● Inspect whether the oil level is correct. Intermittent fault The intermittent fault may be caused by electrical connecting fault or wiring harness fault. Refer to “Intermittent fault and bad contact test”. Symptoms List See the symptom diagnosis procedure in the following table to diagnose the symptoms: Instrument and odometer ● The instrument cluster doesn’t work ● The fuel gauge is inaccurate or doesn’t work ● The stroke/reset switch of odometer doesn’t work ● The speedometer and/or odometer is inaccurate or doesn’t work Indicator ● The indicator for antilock brake system doesn’t work ● The circuit of airbag indicator doesn’t work ● “Fault of brake warning lamp (with antilock brake system)” or “Fault of brake warning lamp (without antilock brake system )” ● Charging indicator doesn’t work ● Door non-closed indicator doesn’t work ● The indicator used for engine oil pressure doesn’t work ● Front fog lamp doesn’t work ● Headlamp doesn’t work ● Indicator showing light doesn’t work ● Diagnosis of fault indicator(MIL) ● Rear fog lamp doesn’t work ● “Circuit for driver safety belt indicator doesn’t work” ● The safety indicator always lights up or blinks ● The safety indicator doesn’t work ● Safety indicator doesn’t work ● The turn signal lamp and/or indicator doesn’t work ● Washer doesn’t work
Driver information center ● The switch for driver information center (PIC) doesn’t work ● The exterior air temperature display is inaccurate or doesn’t work Audio warning Chime sound fails
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8.2.3.3 Chime doesn’t work Diagnostic description ● Execute “Inspection of diagnosis system - vehicle” before using Symptom Diagnosis List ● Look up “Diagnosis based on strategy”, so as to obtain overview of diagnostic method. ● Get overview of each diagnostic category from “Description of diagnostic procedure”. Circuit/system description In case that no radio is equipped, then the radio or chime module will send audio warning. The instrument cluster, body control module (BCM), SRS system sensor and diagnosis module (SDM) or object warning module requests audio warning via signal of “Low-speed CAN bus”. Reference information Schematic diagram reference Schematic diagram of instrument cluster Connector end view reference “Part connector end view” Description and operation Description and operation of audio warning Electrical information reference ● Circuit test ● Repair of connector ● Intermittent fault and bad contact test ● Circuit repair Scan tool reference Control module reference Circuit/system verification Notes: Before executing such diagnosis, ensure that no indicator lights up after executing indicator test by instrument cluster. In case that the indicator lights up after bulb test, the diagnosis to indicator will be executed before such diagnosis. 1. Turn on the ignition switch, open the radio, and adjust the balance and attenuation control of each speaker in radio. -Refer to “Speaker fault” in case that any speaker doesn’t work normally. 2. Turn on the ignition switch, fasten the driver safety belt well, and confirm that the parameter of “Status of driver safety belt” in scan tool is “Fastened” well. -Refer to “Fault of circuit for driver side safety belt indicator” in case of not being fastened well. 3. Turn on the ignition switch, disconnect the switch for headlamp, and confirm that the parameter of “Headlamp engaged switch” in scan tool is “No crank”. -Refer to “Fault of headlamp” in case of not the parameter of “No crank”. 4. Turn on the ignition switch, disconnect the switch of parking lamp, and confirm that the parameter of “Switch for parking lamp” in scan tool is “No crank”. -Refer to “Fault of parking lamp, license lamp and/or tail lamp” in case of not the parameter of “No crank”. 5. Turn on the ignition switch, disconnect the turn signal switch, and confirm that the parameter of “Left turn signal switch” in scan tool as well as the
parameter of “Right turn signal switch” in scan tool is “No crank”. -Refer to “Fault of turn signal lamp and/or indicator” in case of not the parameter of “No crank”. 6. Turn on the ignition switch, loosen the parking brake, and confirm that the parameter of “Parking brake switch” in scan tool is “No crank”. -Refer to “Diagnosis of parking brake system” in case of not the parameter of “No crank”. 7. Turn on the ignition switch, close the door, and confirm all the parameters of the following scan tool are “No crank”. ● Drive side door non-closed switch ● Passenger side door non-closed switch ● Left rear door non-closed switch ● Right rear door non-closed switch -Refer to “Fault of door non-closed indicator” in case of not the parameter of “No crank”. 8. Confirm that the parameter of “Status of inserting key into ignition switch” in scan tool is “No crank” when inserting the key into ignition switch, and confirm that the parameter is “Crank” when pulling out the key from ignition switch. -Replace K9 body control module (BCM) in case that the scan tool parameter doesn’t work normally. 9. Turn on the ignition switch, inspect and confirm that the parameter of “Parking assist chime” is “Crank” when the parking assist system is “Crank”, and the parameter is “No crank” when the parking assist system is “No crank”. -Refer to “Fault of parking assist system” in case that the scan tool parameter doesn’t work normally. 10. Replace A11 radio in case that all parameters are normal after test. Repair guide Execute “Inspection of diagnosis and repair effect” after the diagnostic procedure is finished. Refer to “Control module reference”, so as to replace, set up and program body control module and instrument cluster
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8.2.3.4 The engine oil pressure indicator fails Diagnostic description ● Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic procedure. ● Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. ● Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Circuit/system description The engine oil pressure switch is a normally-closed switch, which can be opened only under the correct engine oil pressure. Engine control module (ECM) shall detect the input of low voltage signal when the ignition switch is in ON position, but the engine doesn’t run. The engine oil pressure switch is on when the engine runs, and the engine control module shall detect an output of high voltage signal Engine control module sends one information to body control module (BCM) through “High-speed CAN bus” when the engine oil pressure is too low. Then body control module sends information to instrument cluster through “Low-speed CAN bus” to request turning on the engine oil pressure indicator. Reference information Reference of schematic diagram Schematic diagram of instrument cluster Connector End View Reference Part connector end view Description and operation Description and operation of indicator/warning information Electrical Information Reference ● Circuit test ● Repair of connector ● Test intermittent fault and bad contact ● Circuit repair Circuit/system verification Shift the ignition switch to ON position, and observe the parameter of “Engine Control Module – Engine Oil Pressure Switch” of scan tool, of which the reading shall be “LOW” when the ignition switch is shifted to ON position and the engine doesn’t run, and the reading shall be “OK” when the engine runs Circuit/system testing 1. Shift the ignition switch to OFF position and disconnect the harness connector of B37 engine oil pressure switch. 2. Shift the ignition switch to ON position, and confirm that the parameter of “Engine Control Module – Engine Oil Pressure Switch” of scan tool is “OK”. -Test whether Terminal 1 of signal circuit is short-circuited to the ground. Replace P16 instrument cluster in case that the circuit test is normal. 3. Install a jumper wire with 3A fuse between Terminal 1 of signal circuit and the ground. Confirm that the parameter of “Engine Control Module – Engine Oil Pressure Switch” of scan tool
is “LOW”. － Test whether the signal circuit is short-circuited or open-circuited to the voltage, or its resistance is too large in case that it is not the specified value. Replace P16 instrument cluster in case that the circuit test is normal. 4. Command the output function of all indicators in instrument cluster to be opened or closed by use of scan tool. The engine oil pressure indicator shall be turned on and off when switching between two kinds of command status. － Replace P16 instrument cluster in case that the engine oil pressure indicator is always turned on or off. 5. Test or replace B37 engine oil pressure switch in case that all circuit tests are normal. Component test Static test 1. Shift the ignition switch to OFF position and disconnect the harness connector of B35 engine oil pressure switch. 2. Test whether the resistance between Signal Terminal 1 and the ground is less than 10Ω when the engine is shut down. I. if it is larger than the specified range, the B35 engine oil pressure switch shall be replaced. 3. Test whether the resistance between Signal Terminal 1 and the ground is infinitely great when the engine runs. I. if it is not the specified range, the B35 engine oil pressure switch shall be replaced. Repair guide ● Execute “Diagnosis inspection and repair effect”. ● Refer to “Control module reference”, so as to carry out replacement, setting up and programming of the engine control module.
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8.2.3.5 The fuel gauge is inaccurate or doesn’t work Diagnostic description ● Execute “Inspection of Diagnostic System Vehicle” before using symptom diagnosis list ● Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. ● Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Circuit/system description Instrument cluster displays the fuel level according to the information from engine control module (ECM). Engine control module transforms the data from fuel level sensor to the fuel level signal. Engine control module sends the fuel level signal to the body control module through “High-speed CAN bus” signal. And then, body control module sends the information to the instrument cluster to display the fuel level through “Low-speed CAN bus” signal. In case that the fuel level is reduced to below 11%, the instrument cluster will light up the indicator indicating that the fuel level is too low. Reference information Reference of schematic diagram Schematic diagram of instrument cluster Connector End View Reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical Information Reference ● Circuit test ● Repair of connector ● Test intermittent fault and bad contact ● Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool Circuit/system verification 1. Shift the ignition switch to ON position, conduct instrument cluster scan test with scan tool to confirm that the fuel level gauge is scanned from the low level to the high level. I. If the fuel level gauge cannot be scanned, the P16 instrument cluster shall be replaced. 2. Scan tool is used to instruct the lighting up and out test of all indicators to confirm the lighting up and out of the indicator indicating that the fuel level is too low. I. If the indicator indicating that the fuel level is too low is always lighted up or out, then the P16 instrument cluster shall be replaced. 3. If the fuel level gauge cannot be scanned and the indicator indicating that the fuel level is too low switches between lighting up and out, the K20 engine control module (ECM) shall be replaced. Repair guide Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up and programming of the instrument cluster.
8.2.3.6 Faulty combination meter Diagnostic description ● Execute “Inspection of Diagnostic System Vehicle” before using symptom diagnosis list ● Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. ● Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Circuit/system description Instrument cluster displays the temperature of engine coolant, vehicle speed and engine speed according to the information from engine control module (ECM). Engine control module sends corresponding information to body control module (BCM) through “High-speed CAN bus” signal. Then body control module sends the information to instrument cluster through “Low-speed CAN bus” signal according to the vehicle requirements, and displays the temperature of engine coolant, vehicle speed and engine speed as well as driving distance with kilometer or mile as unit. Reference information Reference of schematic diagram Schematic diagram of instrument cluster Connector End View Reference “Part connector end view” Description and operation Control module reference Circuit/system verification 1. Shift the ignition switch to ON position, conduct “Instrument cluster scan” test with scan tool to confirm that all the instruments are scanned from the low level to the high level. － If the instrument cannot be scanned, the P16 instrument cluster shall be replaced. 2. Drive the vehicle to confirm the total driving distance displayed on odometer displayer. － Replace P16 instrument cluster in case that no total distance is displayed on the odometer displayer. 3. Replace K20 engine control module in case that all instruments execute scanning and the total distance is displayed on the odometer.
Repair guide Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up and programming of the instrument cluster.
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8.2.3.7 The trip/reset switch of odometer doesn’t work Diagnostic description ● Execute “Inspection of Diagnostic System Vehicle” before using symptom diagnosis list ● Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method. ● Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Circuit/system description Instrument cluster displays the driving distance according to the information from engine control module (ECM). Engine control module transforms the data from vehicle speed sensor to distance signal. Engine control module sends the distance information to the body control module through “High-speed CAN bus” signal. And then, body control module sends the information to the instrument cluster to display the vehicle odometer and trip odometer through “Low-speed CAN bus” signal. After the instrument cluster detects that the trip reset switch is started, press and hold the trip reset switch to reset the trip odometer information to zero. Reference information Reference of schematic diagram Schematic diagram of instrument cluster Connector End View Reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical Information Reference ● Circuit test ● Repair of connector ● Test intermittent fault and bad contact ● Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool Circuit/system verification Shift the ignition switch to ON position, inspect and confirm the display of trip odometer reset by the odometer trip reset switch when pressing the switch. I. If the odometer trip reset switch doesn’t reset the trip odometer, the P16 instrument cluster shall be replaced. Repair guide Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up and programming of the instrument cluster.
8.2.3.8 The speedometer and/or the odometer is inaccurate or doesn’t work Diagnostic description ● Execute “Inspection of Diagnostic System Vehicle” before using symptom diagnosis list ● Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method.
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Provide overview of each diagnostic category in “Description of Diagnostic Procedure”. Circuit/system description Instrument cluster displays the temperature of engine coolant, vehicle speed and engine speed according to the information from engine control module (ECM). Engine control module sends corresponding information to body control module (BCM) through “High-speed CAN bus” signal. Then body control module sends the information to instrument cluster through “Low-speed CAN bus” signal according to the vehicle requirements, and displays the temperature of engine coolant, vehicle speed and engine speed as well as driving distance with kilometer or mile as unit. Diagnostic help If several modules are not the original modules of the vehicle or are not the latest configured correct service parts, the maintenance programming system may not be able to correctly read or recover vehicle odometer values. Comply with the provisions and documents (including vehicle identification) of the government on inaccurate/unknown odometer values. Reference information Reference of schematic diagram Schematic diagram of instrument cluster Connector End View Reference “Part connector end view” Description and operation Description and operation of instrument cluster Electrical Information Reference ● Circuit test ● Repair of connector ● Test intermittent fault and bad contact ● Circuit repair Scan Tool Reference Refer to “Control module reference” to obtain the information of scan tool Circuit/system verification 1. Shift the ignition switch to ON position, conduct “Instrument cluster scan” test with scan tool. If the instrument cannot be scanned, the P16 instrument cluster shall be replaced. 2. Drive the vehicle to confirm the total driving distance displayed on odometer displayer. － Replace P16 instrument cluster in case that no total distance is displayed on the odometer displayer. 3. Replace K20 engine control module in case that all instruments execute scanning and the total distance is displayed on the odometer. Repair guide Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished. Refer to “Control module reference”, so as to carry out replacement, setting up and programming of the instrument cluster.
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8.2.4
Repair guide
8.2.4.1 Replacement of the applique of instrument cluster
16BH0802001
Replacement of the applique of instrument cluster Figure no. 1
2
Part name Fasteners for the applique of instrument cluster (quantity: 2) Warning: Refer to “Warning on relevant fasteners”. Fastening 2.5±0.5 N.m Applique of instrument cluster Procedure After dismantling the fastening screws for the applique of instrument cluster, dismantle the applique of instrument cluster with small flat blade tools.
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8.2.4.2 Replacement of instrument cluster
16BH0802002 Replacement of instrument cluster Figure no. Part name Preparation procedure 1. Disconnect the battery negative line. Refer to “Battery disconnection and connection.” 2. Dismantle the instrument cluster. Refer to “Replacement of instrument cluster”. Fasteners for instrument cluster (quantity: 3) Warning: Refer to “Warning on relevant fasteners”. 1 Fastening 2.5±0.5 N.m Instrument cluster Procedure 2 Disconnect the electrical connector.
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8.2.5
Description and operation
8.2.5.1 Description and operation of audio warning Audio warning reminds the driver to pay attention to the problems of certain system or serious vehicle fault. The radio sends audio warning through loudspeaker. The radio receives audio warning request through serial data circuit. If the radio receives several audio warning requests, the warning with the highest priority will be sent firstly. For vehicle without radio, the buzzer module will send audio warning and receive audio warning request through serial data circuit. Radio or buzzer module can buzz. Warning of unfastened seat belt Buzzer generator in the radio starts the audio warning for fastening the seat belt according to the request of body control module (BCM). Body control module sends serial data information to buzzer generator to instruct the buzzer to send multi-pulse sound of gong. In case of the following circumstances, the warning beep for fastening seat belt will be sent and the indicator for fastening seat belt will be lighted up. ● Shift the ignition switch to ON position. ● The sensing and diagnosis module of the airbag system detects that the seat belt of the driver is not fastened and the signal is low level. The sensing and diagnosis module sends serial data information to the body control module to indicate the seat belt status. The instrument cluster receives serial data information from body control module assembly to indicate the seat belt status of the driver. If the seat belt has been fastened when shifting the ignition switch to ON position, the buzzer will not voice. If the seat belt has been fastened when the buzzer is about to voice, the buzzer will stop voicing. If the seat belt is not fastened when shifting the ignition switch to ON position for the first time, the buzzer will not voice. Warning of lamp open The buzzer generator will light up the lamp according to the warning request of body control module. Body control module sends serial data information to buzzer generator to instruct the buzzer to send multi-pulse sound of gong. In case of the following circumstances, the warning beep for lamp open will be sent: ● Shift the ignition switch to OFF position. ● Body control module confirms that the door at the driver side is open and the signal circuit is low level. ● Body control module confirms that the headlamp switch is in the position of parking lamp or headlamp. Warning for inserting the key into the ignition switch Buzzer generator starts the audio warning for inserting the key into the ignition switch according to the request of body control module. Body control module sends serial data information to buzzer generator to instruct the buzzer to send multi-pulse sound of gong. In case
of the following circumstances, the warning beep indicates that the key has been inserted into the ignition switch will be sent. ● Shift the ignition switch to OFF position Body control module confirms that the door at the driver side is open and the signal circuit is low level. Warning of door open According to the warning request of body control module, the buzzer generator sends the audio warning of door open. Body control module sends serial data information to buzzer generator indicating that the frequency of buzzer is medium frequency and lasting for some time. In case of the following circumstances, the warning beep of door open will be sent, and corresponding indicator of door open on the driver information center will be lighted up: ● Body control module detects that the doors (Door at the driver side, door at the passenger side, left rear door, right rear door and tail door) are open, and the signal circuit is low level. Instrument cluster also receives serial data information indicating that the door is in unclosed status from the body control module. ● Do not put the vehicle into Parking gear. Body control module receives serial data information indicating the gear from engine control module/body control module. Object detection Buzzer generator sends object detection audio warning according to the request of object warning module. When the object is within the measuring range of the sensor, ultrasonic pulse will be reflected and received by adjacent sensor. The sensor will transform the signal to voltage signal and send it to object warning module. And the object warning module will assess the sensor signal received. Once the object is within the measuring range, the object warning module will send a message to the buzzer generator to send audio distance signal. Other warnings The following warnings all have information of corresponding instrument cluster indicator or driver information center. ● Turn signal indicator—the buzzer generator starts audio warning according to the request of body control module. Buzzer generator will generate two different kinds of buzzing. One is corresponding to the turning off of turn signal lamp, and the other is corresponding to the turning on of turn signal lamp. ● “Fault of reverse assist system, rear bumper cleaning” information---the buzzer generator starts audio warning according to the request of body control module. Body control module sends serial data information to the buzzer generator. Refer to “Description and Operation of Indicator/Warning Information”.
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8.2.5.2 Description and operation of driver information center (DIC) Install another display screen at the lower part of instrument cluster. Its task is to provide additional information, such as odometer or DTC/warning information. Refer to “Description and Operation of Indicator/Warning Information”. Trip/fuel information menu ● Trip A ● Trip B ● Fuel range ● Average speed Fuel range The information shows, after the last time that the storage battery is connected to the instrument cluster, the estimated value of vehicle driving mileage under the current fuel efficiency and fuel level conditions. The following equations shall be used to calculate fuel range: Fuel rang = driving distance/fuel used ● Driving distance = accumulated driving distance since the last reset ● Fuel used = accumulated value of transported fuel since the last reset Engine control module (ECM) sends the fuel range value to the instrument cluster. The instrument cluster receives the serial data information about fuel information. When the ignition switch is in OFF position, the fuel range value remains unchanged. Fuel range value displayed cannot be reset. When the fuel range is lower than the pre-set value, it will display “Low”. Average speed shall be calculated according to the following equations. Average speed= driving distance at average speed/time for driving at average speed ● Driving distance = accumulated driving distance since the last reset ● Time for turning the ignition switch to ON position = accumulative time for connecting ignition switch since the last reset.
8.2.5.3 Description and operation of indicator/warning information Instrument cluster indicator Symbol
Reference
Anti-lock brake system: Description and operation of anti-lock brake system
Airbag: Description and operation of airbag
Brake warning indicator. The signal control way for the hand brake switch and the brake fluid level switch of this vehicle model is different; refer to relevant schematic diagrams of the instrument cluster for details.
Charge: Description and operation of charging system
Driver information and entertainment system 8-30 Instrument cluster indicator (continued) Symbol
Reference According to the test results of the engine control module (BCM), the instrument cluster displays that the engine oil pressure is too low through the indicator. The engine control module monitors the engine oil pressure switch/sensor signal circuit to confirm the engine oil pressure. The engine control module sends the engine oil pressure information to body control module (BCM) through serial data circuit. Instrument cluster receives the serial data information from the body control module and requests to display the engine oil pressure of engine control module. When the instrument cluster detects that the engine oil pressure is too low, light up the indicator indicating that the engine oil pressure is too low.
Instrument cluster indicator (continued) Symbol
Reference
Indicator indicating excessively high water temperature: Description of coolant temperature sensor
Position indicator: Description and operation of exterior lighting system
Engine fault indicator: L2B, LBH or 2HO: Description of engine control module
Fasten seat belt: Description and operation of seat belt system
Rear fog lamp: Description and operation of exterior lighting system Front fog lamp: Description and operation of exterior lighting system
Indicator of engine anti-theft system: Description and operation of anti-theft module High beam: Description and operation of exterior lighting system
Driver information and entertainment system 8-31 Instrument cluster indicator (continued) Symbol
Reference
Turn signal: Description and operation of exterior lighting system
Door open: Description and operation of power door lock
EPS fault warning lamp: Fault of indicator for electronic power steering system (EPS)
Fuel level Indicator indicating that the fuel level is too low: Description of fuel system
Front passengers fasten the seat belt Description and operation of seat belt system
Too low engine oil level--- add oil When the engine control module detects that the engine oil level is too low from the engine oil level sensor/switch, the driver information center will display the information of too low engine oil level--- add oil. The engine control module sends high-speed CAN bus information to the body control module. At this time, body control module assembly will send low-speed CAN bus information to the instrument cluster to request the driver information center to display the information of too low engine oil level--- add oil. Too low oil pressure—stops the engine When the engine control module detects that the engine oil pressure is too low from the engine oil pressure sensor/switch, the driver information center will display the information of too low oil pressure--stop the engine. The engine control module sends high-speed CAN bus information to the body control module. And then, the body control module will send low-speed CAN bus information to the instrument cluster to request the driver information center to display the information of too low oil pressure—stop the engine.
8.2.5.4 Description and operation of instrument cluster Display test When the ignition switch is turned to the ON position, some functions of the instrument cluster will be tested to check whether these functions are normal. The following circumstances appear when the ignition switch is turned to the ON position: ● The indicator of anti-lock brake system is lighted up for a moment. ● The indicator of storage battery is lighted up for a moment. ● The indicator for door open is lighted up for a moment. ● The indicator indicating that the fuel level is too low is lighted up for a moment. ● The indicator indicating that the oil pressure is too low is lighted up for a moment. ● The seat belt indicator is lighted up for a moment. ● The airbag indicator is lighted up for a moment. ● The water temperature indicator is lighted up for a moment. ● The engine fault indicator is lighted up for a moment. ● The EPS fault warning lamp is lighted up for a moment. ● The brake system/EBD warning lamp is lighted up for a moment. ● The indicator of engine anti-theft system is lighted up for a moment. Indicator and warning information Refer to “Description and operation of Indicator/warning information” Engine coolant temperature gauge Instrument cluster displays the engine coolant
Driver information and entertainment system 8-32 temperature confirmed by the engine control module (ECM) Engine control module sends the engine coolant temperature information to the body control module (BCM) through CAN bus signal. And then, the body control module signal sends the information to the instrument cluster to display the engine coolant temperature. If there are the following circumstances, the engine coolant temperature is 40°C (104°F) or lowers by default: ● Engine control module detects the circuit fault of engine coolant temperature sensor. ● Body control module detects the loss of serial data communicating with engine control module. ● Instrument cluster detects the loss of serial data communicating with body control module. Fuel level gauge Instrument cluster displays the fuel level according to the information from engine control module. Engine control module transforms the data from fuel level sensor to the fuel level signal. Engine control module sends the fuel level signal to the body control module through “High-speed CAN bus” signal. And then, body control module sends the information to the instrument cluster to display the fuel level through signal. In case that the fuel level is reduced to below 11%, the instrument cluster will light up the indicator indicating that the fuel level is too low. If there are the following circumstances, the fuel gauge shows no fuel by default. ● Engine control module detects the circuit fault of fuel level sensor. ● Body control module detects the loss of serial data communicating with engine control module. ●
Instrument cluster detects the loss of serial data communicating with body control module. Speedometer Instrument cluster displays the vehicle speed according to the information from engine control module. Engine control module sends the vehicle speed information to the body control module through “High-speed CAN bus” signal. And then, the body control module sends the vehicle speed information to the instrument cluster through signal according to the requirements of vehicle. The vehicle speed is displayed with kilometer or mile as unit. If there are the following circumstances, the speedometer displays 0 Km/h by default: ● Body control module detects the loss of serial data communicating with engine control module. ● Instrument cluster detects the loss of serial data communicating with body control module. Tachometer Instrument cluster displays the engine speed according to the information from engine control module. Engine control module transforms the data from engine speed sensor to engine speed signal. The engine control module sends the engine speed information to the body control module through signal. And then, the body control module sends the information to the instrument cluster to display the engine speed. If there are the following circumstances, the tachometer displays 0 r/min by default: ● Engine control module detects the circuit fault of
engine speed sensor. Body control module detects the loss of serial data communicating with engine control module. ● Instrument cluster detects the loss of serial data communicating with body control module. Display screen of driver information center Install another display screen at the middle-lower part of instrument cluster. Its task is to provide additional information. ●
Driver information and entertainment system 8-33
8.3
Auxiliary and configurable user control system
8.3.1.2 Fault of radio control device on the steering wheel Diagnostic description
Execute “Inspection of Diagnostic System Vehicle” before adopting such diagnostic
8.3.1
Diagnostic information and
procedure.
procedure
Look up “Diagnosis Based on Strategy”, so as to obtain overview of diagnostic method.
Provide overview of each diagnostic category in
8.3.1.1 Symptom – auxiliary control system
Circuit/system description
Important notes: The following steps must be
Radio control switch on the steering wheel A set of
completed before using Symptom List:
resistance values are corresponding to each switch.
“Description of Diagnostic Procedure”.
Execute “Inspection of Diagnostic System -
When pressing down a switch, a certain voltage drop
Vehicle” before using “Symptom List”, to confirm the
will be generated on the resistance corresponding to
authenticity of the following situation:
the switch. Corresponding module can identify the
DTC is not set up.
selected switch and start corresponding function.
Communication can be realized by control module
Conditions for running DTC
through serial data link.
The battery voltage is between 9-16V.
Look up system operation, and get familiar with
Shift the ignition switch to ON position.
1.
2.
system function. Refer to “Description and operation of
Diagnostic help
steering wheel control system”.
control.
Visual inspection/appearance inspection
Inspect whether the aftermarket equipment may
The diagnosis is used for steering wheel audio
Before diagnosing the steering wheel control,
affecting the operation of horn exists. Refer to
make sure that the main control operation of
“Inspection of aftermarket accessories”.
relevant components is normal.
Inspect whether the easily touchable or visible
For the failure of single switch function, the
system components have obvious damage or fault
questionable switch shall be tested. Refer to
that causes such symptom.
“Component test”.
Intermittent fault
Reference information
The intermittent fault may be caused by electrical
Reference of schematic diagram
connection fault or harness fault. Refer to “Test
Schematic diagram of radio/navigation system
intermittent fault and bad contact”.
Connector End View Reference “Part connector end view”
Symptom List
Description and operation
Refer to the symptom diagnosis procedure in the
Radio control switch on the steering wheel reproduces
following table to diagnose the symptoms: Refer to
the main control functions of relevant components
“Description and operation of steering wheel control
through instantaneous contact switch and a group of
system”.
series resistance network. A series of control switches are set on the steering wheel. Steering wheel radio switch controls the increase and decrease of the sound, radio search, system switch and mute through A11 radio module.
Driver information and entertainment system 8-34
Electrical Information Reference
whether the signal circuit is short-circuited to the
Circuit test
ground.
Repair of connector
Test intermittent fault and bad contact
Circuit repair
6.
If all circuit tests are normal, then test or replace A22 steering wheel radio switch. Component test
Component test
Circuit/system testing
Static test
1.
4.
Shift the ignition switch to OFF position, and disconnect X3 harness connector at X85 steering column spring coil.
2.
Disconnect the harness connector of X85 radio control switch.
5.
Test the resistance between the terminals of X85
Shift the ignition switch to ON position and test
radio control switch.
whether the voltage between the positive interface
I. If the measured resistance value of any single
side of reference voltage circuit terminal 1 (X3)
switch is not within the range of specified
and the ground is higher than 5V.
resistance value, the control switch at the right
In case of being lower than the specified value,
side of A22 steering wheel shall be replaced.
test whether the reference voltage circuit is short-circuited or open-circuited to the ground, or
Minimum
Maximum
resistance value
resistance value
Volume up
1,951 ohm
1,959 ohm
Volume down
99 ohm
101 ohm
Search up
7,614 ohm
7,766 ohm
Search down
4,248 ohm
4,332 ohm
test whether the signal circuit is short-circuited or
Mode
12,435 ohm
12,685 ohm
open-circuited to the voltage, or the resistance is
Audio mute
23,622 ohm
24,098 ohm
too large. Replace A11 radio in case that the
Answer/call
53,718 ohm
54,802 ohm
circuit test is normal.
Switch not
-
-
the resistance is too large. Replace A11 radio in
Function switch
case that the circuit test is normal. 3.
Test whether the voltage between reference voltage circuit terminal and signal circuit terminal is higher than 5V. In case of being lower than the specified value,
4.
Shift the ignition switch to OFF position, and
pressed
disconnect X1 harness connector at A11 radio. 5.
Test whether the resistance between the signal circuit terminal of steering column spring coil of X85 airbag system and the ground is infinitely
Repair guide Execute “Diagnosis inspection and repair effect” after diagnostic procedure finished.
great. -In case of being less than the specified value, test
“Replacement of radio control switch—steering wheel”
Replacement of radio
Chapter 9 Engine Contents 9.1
Engine control and fuel system-1.5L (L2B) ...... 1
9.1.3.26 DTC P1336 P1545 P1558 P1559
9.1.1 Specification .......................................................... 1
P1564 P1565 P1568 P1579 P1604
9.1.1.1
Table of temperature and resistance ..... 1
P2106 ................................................... 37
9.1.1.2
Torque specification ............................... 2
9.1.3.27 DTC P0219 ........................................... 79
9.1.2 Schematic and wiring diagram .............................. 3
9.1.3.28 DTC P0317 ........................................... 80
9.1.2.1
Schematic diagram of engine control
9.1.3.29 DTC P0321 ........................................... 81
system .................................................... 3
9.1.3.30 DTC P0133 P0420 P2195 P2196
9.1.3 Diagnostic information and procedure ................. 12 9.1.3.1
P2270 P2271 ........................................ 82
DTC P000A P000B P0010 P0012
9.1.3.31 DTC P0571 ........................................... 83
P0013 P0015 ....................................... 12
9.1.3.32 DTC P0606 ........................................... 84
9.1.3.2
DTC P0016 P0017 ............................... 13
9.1.3.33 DTC P0650 ........................................... 85
9.1.3.3
DTC P0030 P0031 P0032 P0036
9.1.3.34 DTC P0688 ........................................... 86
P0037 P0038 P0053 P0054 ................ 14
9.1.3.35 DTC P0704 ........................................... 87
9.1.3.4
DTC P0105 P0106 P0107 P0108 ........ 15
9.1.3.36 DTC P1523 P1683 ............................... 88
9.1.3.5
DTC P0111 P0112 P0113 ................... 16
9.1.3.37 DTC P1615 P1616 P1617 .................... 89
9.1.3.6
DTC P0116 P0117 P0118 ................... 17
9.1.3.38 DTC P1619 ........................................... 90
9.1.3.7
DTC P0121 P0122 P0123 P0221
9.1.3.39 DTC P1630 ........................................... 91
P0222 P0223 ....................................... 18
9.1.3.40 DTC P2122 P2123 P2127 P2128
9.1.3.8
DTC P0130 P0131 P0132 P0134
P2138 ................................................... 92
P0136 P0137 P0138 ............................ 19
9.1.3.41 DTC P0501 ........................................... 93
DTC P0170 P0171 P0172 ................... 20
9.1.3.42 DTC UO121 .......................................... 94
9.1.3.10 DTC P0201 P0202 P0203 P0204 ........ 21
9.1.3.43 DTC U0131 U0140 U0151 ................... 95
9.1.3.9
9.1.3.11 DTC P0261 P0262 P0264 P0265 P0267 P0268 P0270 P0271 ................ 22
9.1.4 Repair guide ......................................................... 96 9.1.4.1
Fuel pressure release procedure ......... 96
9.1.4.2
Cleaning of fuel system ........................ 96
9.1.4.3
Replacement of fuel filter (1.5L) ........... 97
9.1.4.4
Drain fuel tank ...................................... 99
P0365 P0366 P0367 P0368 ................ 24
9.1.4.5
Replacement of fuel tank .................... 100
9.1.3.14 DTC P0444 P0458 P0459 ................... 25
9.1.4.6
Replacement of fuel tank fuel pump
9.1.3.12 DTC P0300 P0301 P0302 P0303 P0304 ................................................... 23 9.1.3.13 DTC P0340 P0341 P0342 P0343
9.1.3.15 DTC P0480 P0481 P0692 P0694 ........ 26
module ................................................ 102
9.1.3.16 DTC P0506 P0507 ............................... 27
9.1.4.7
Replacement of fuel level sensor ....... 104
9.1.3.17 DTC P0537 P0538 ............................... 28
9.1.4.8
Replacement of fuel conveying pipe
9.1.3.18 DTC P0560 P0562 P0563 ................... 29 9.1.3.19 DTC P0602 P0604 P0605 ................... 30 9.1.3.20 DTC P0627 P0629 ............................... 31 9.1.3.21 DTC P0645 P0647 ............................... 32
(1.5L) .................................................. 105 9.1.4.9
Replacement of fuel return pipe – fuel pump to fuel filter (1.5L) ..................... 106
9.1.4.10 Replacement of fuel conveying pipe of
9.1.3.22 DTC P0660 P0661 P0662 ................... 33
fuel filter (1.5L) .................................... 107
9.1.3.23 DTC P0327 P0328 ............................... 34
9.1.4.11 Replacement of canister assembly .... 108
9.1.3.24 DTCP 2088 P2089 P2090 P2091 ........ 35
9.1.4.12 Replacement of engine control module109
9.1.3.25 DTC P2177 P2178 P2187 P2188 ........ 36
9.1.4.13 Replacement of intake air temperature sensor ................................................ 110
9.1.5.3
Description of electronic throttle ......... 136
9.1.5.4
Description of coolant temperature
9.1.4.14 Replacement of positive crankcase ventilation pipe ................................... 111 9.1.4.15 Replacement of front and rear oxygen
sensor ................................................. 136 9.1.5.5
Description of canister solenoid valve 136
9.1.5.6
Description of camshaft position
sensors ............................................... 112 9.1.4.16 Replacement of accelerator pedal
sensor ................................................. 136 9.1.5.7
position sensor ................................... 113
Description of crankshaft position sensor ................................................. 136
9.1.4.17 Replacement of air filter ..................... 114
9.1.5.8
Description of intake pressure sensor 136
9.1.4.18 Replacement of air filter inlet duct ...... 115
9.1.5.9
Description of intake air temperature
9.1.4.19 Replacement of air filter outlet duct ... 116
sensor ................................................. 136
9.1.4.20 Replacement of air filter element ....... 117
9.1.5.10 Description of oxygen sensor ............. 136
9.1.4.21 Replacement of intake pressure
9.1.5.11 Description of VVT system ................. 137
sensor ................................................ 118
9.1.5.12 Description of knock sensor ............... 137
9.1.4.22 Replacement of knock sensor ............ 119
9.1.6 Special tools and equipment .............................. 138
9.1.4.23 Replacement of ignition coil ............... 120 9.1.4.24 Inspection of spark plug ..................... 121 9.1.4.25 Replacement of spark plug ................ 123 9.1.4.26 Replacement of evaporative emission canister purge solenoid valve ............ 124 9.1.4.27 Replacement of injector ..................... 125 9.1.4.28 Replacement of crankshaft position sensor ................................................ 126 9.1.4.29 Replacement of camshaft position sensor ................................................ 127 9.1.4.30 Replacement of camshaft phase actuator solenoid valve ...................... 128 9.1.4.31 Replacement of coolant temperature sensor ................................................ 129 9.1.4.32 Replacement of intake manifold regulator valve actuator (for VGIS) .... 130 9.1.4.33 Replacement of intake manifold regulator valve actuator solenoid valve (for VGIS) ........................................... 131 9.1.4.34 Replacement of engine oil pressure switch ................................................. 132 9.1.4.35 Replacement of throttle body assembly 133 9.1.4.36 Replacement of evaporative emission canister purge pipe............................. 134 9.1.5 Description and operation ................................. 135 9.1.5.1
Description of intake system .............. 135
9.1.5.2
Description of crankcase ventilation system ................................................ 135
9.1.6.1
Special tools ....................................... 138
Engine control and fuel system-1.5 L (L2B) 9-1
9.1
Engine control and fuel system-1.5L (L2B)
9.1.1
Specification
9.1.1.1 Table of temperature and resistance Table of temperature and resistance (approximate values) Engine coolant temperature
Intake air temperature
(ECT) sensor (Ω)
(IAT) sensor (Ω)
212
177
187
90
194
241
246
80
176
332
327
70
158
467
441
60
140
667
603
50
122
973
837
45
113
1188
991
40
104
1459
1180
35
95
1802
1412
30
86
2238
1700
25
77
2796
2055
20
68
3520
2500
15
59
4450
3055
10
50
5670
3760
5
41
7280
4651
0
32
9420
5800
-5
23
12300
7273
-10
14
16180
9200
-15
5
21450
9200
-20
-4
28680
15080
-30
-22
52700
25600
-40
-40
100700
45300
℃
℉
100
9-2 Engine control and fuel system-1.5 L (L2B)
9.1.1.2 Torque specification Application
Specification Metric
Engine oil pressure switch
27±3
Bolts for engine control module
8±2 N·m
Front oxygen sensor assembly
50±10 N·m
Rear oxygen sensor assembly.
50±10 N·m
Bolts for intake air pressure sensor
10±2 N·m
Bolts for knock sensor
20±5 N•m
Coolant temperature sensor
20±2 N·m
Bolts for camshaft position sensor
10±2 N·m
Bolts for camshaft position actuator solenoid valve
10±2 N·m
Bolts for crankshaft position sensor
10±2 N·m
Bolts M6 for intake manifold tuning valve actuator
8±1 N•m
Bolts M4 for intake manifold tuning valve actuator
2.5 N•m
Ignition coil retaining bolt
10±1 N·m
Fuel rail retaining bolt
15±2 N.m
Spark plug
20±5 N•m
Bolts for throttle body
10±2 N·m
Accelerator pedal retaining bolt
10±1 N·m
Fuel filter retaining bolts
9±3 N·m
Bolt assembling unit - fuel tank
22±3 N·m
Bolt assembling unit - fuel bump
4±1 N•m
Clip retaining bolt
9±2 N·m
Installation bolts for silencer thermal baffle
7±1 N•m
Bolt assembling unit - carbon tank assembly
9±3 N·m
发动机控制和燃油系统-1.5 L（L2B）9-3
9.1.2
Schematic and wiring diagram
9.1.2.1 Schematic diagram of engine control system
Ignition Main Relay
Fuse Box – Engine Compartment
Combination meter
Electrical Circuit Diagram Communication Data
Engine Control Module
Schematic diagram of engine control system (Power, Ground, Serial, & Indicator)
9-4 Engine control and fuel system-1.5 L (L2B) Schematic diagram of engine control system
Manifold Absolute Pressure Sensor
Intake Air Temperature Sensor
Engine Coolant Temperature Sensor
Engine Control Module
(intake pressure sensor, intake air temperature sensor, coolant temperature sensor)
Engine control and fuel system-1.5 L (L2B) 9-5
Throttle Body
Engine Control Module
Accelerator Pedal Position Sensor
Schematic of the engine control system (accelerator pedal position sensor, electronic throttle control)
Ignition Main Relay
Heating type Oxygen Sensor
Fuse Box – Engine Compartment
Intake Manifold Control Solenoid Valve
EVAP discharge solenoid purge valve
Engine Control Module
9-6 Engine control and fuel system-1.5 L (L2B) Schematic of the engine control system
(Oxygen sensor, VIM valve, carbon canister solenoid valve)
Ignition Coil 1
Ignition Main Relay
Fuse Box – Engine Compartment
Ignition Coil 2
Ignition Coil 3
Engine Control Module
Ignition Coil 4
Engine control and fuel system-1.5 L (L2B) 9-7
Schematic of the engine control system (Ignition Coil)
Intake valve solenoid to execute camshaft position
Ignition Main Relay
Fuse Box – Engine Compartment
Intake valve solenoid to execute camshaft position
Intake Camshaft Position Sensor
Exhaust Camshaft Position Sensor
Engine Control Module
9-8 Engine control and fuel system-1.5 L (L2B) Schematic of the engine control system (Camshaft position sensor, VVT valve)
Fuel Injector 1
Ignition Main Relay
Fuel Injector 2
Fuel Injector 3 Fuel Injector 4
Fuel Pump Relay
Fuel Pump & Oil Level Sensor
Fuse Box – Engine Compartment
Engine Control Module
Engine control and fuel system-1.5 L (L2B) 9-9
Schematic of the engine control system
(Fuel control - fuel injector, fuel pump, oil level sensor)
9-10 Engine control and fuel system-1.5 L (L2B) Schematic of the engine control system
Ignition Switch
Vehicle Speed Sensor
Fuse Box – Engine Compartment
Clutch Pedal Position Sensor
Crankshaft Position Sensor
Knock Sensor
Engine Control Module
(Vehicle speed sensor, knock sensor, crankshaft position sensor, clutch switch)
Ignition Main Relay
High Speed Cooling Fan Relay
Cooling Fan Motor
Low Speed Cooling Fan Relay
Engine Control Module
Fuse Box – Engine Compartment
Engine control and fuel system-1.5 L (L2B) 9-11
Schematic of the engine control system (Cooling Fan)
9-12 Engine control and fuel system-1.5 L (L2B) The
9.1.3
Diagnostic information and
operations
are
conducted
when
setting
diagnostic trouble codes
procedure
Fault codes P000A P000B P0010 P0012 P0013 P0015 are stored in the internal storage.
Failure of all potential functions.
9.1.3.1 DTC P000A P000B P0010 P0012 P0013 P0015
Do not light up the fault lamp.
Diagnostic description
Circuit test
Before proceed to this diagnostic procedure,
Repair of connector
please
Intermittent fault and bad contact test
inspection--vehicle”
Circuit repair
Look up the “Diagnosis based on strategy” for
Type reference of diagnostic trouble code
overview of diagnostic methods.
Power system diagnostic trouble code (DTC) type
“Description of diagnostic procedure” provides the
definition
overview for various diagnostic categories.
Reference of scan tool
implement
“Diagnosis
system
Circuit information reference
Description of fault diagnosis
Refer to “Control modules reference” to obtain scan
DTC P000 intake VVT responds slowly
tool information.
DTC P00B exhaust VVT responds slowly
Circuit/system verification
DTC P0010 VVT intake control valve suffers from
1.
whether fault codes related to VVT are set up.
circuit fault DTC P0012 intake VVT is not at the default position
2. 3.
Use the scan tool to read the engine water temperature and judge whether it is in the normal
circuit fault
range.
DTC P0015 exhaust VVT is not at the default position during start
Detect whether the engine fault lamp lights up in the instrument panel.
during start DTC P0013 VVT exhaust control valve suffers from
Start the engine and use the scan tool to detect
—
30—120℃。
The conditions for operating diagnostic trouble
Circuit/system test
codes
1.
Start the engine and use the scan tool to erase the
Ignition voltage is in 9V-16 V
existing fault codes. Stop the engine immediately
Start the engine
after starting it and then start it again. Use the scan
Conditions for setting diagnostic trouble codes
tool to read fault codes and detect whether they
Engine oil temperature (30℃-130℃)
reappear.
Water temperature (30℃-120℃)
Engine speed (600-4,800) r/min
intake/exhaust VVT control valve, connect with the
There are huge difference between practical angle
battery and start the engine. Use the scan tool to
and targeted angle of VVT.
detect whether fault codes reappear.
2.
3.
Disconnect the battery negative, replace the
If all circuits are normal after test, you should replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-13
3.
9.1.3.2 DTC P0016 P0017
are installed at the correct positions.
Diagnostic description
Circuit/system test
Before proceed to this diagnostic procedure, please
Detect whether the camshaft and the crankshaft
implement
“Diagnosis
1.
system
Turn on the ignition switch and use the scan tool to erase the fault codes P0016 and P0017. Stop the
inspection--vehicle”
engine immediately after staring it and then power
Look up the “Diagnosis based on strategy” for
it again. Next, use the scan tool to read the fault
overview of diagnostic methods.
codes and detect whether P0016 and P0017
“Description of diagnostic procedure” provides the
reappear.
overview for various diagnostic categories.
2.
Replace sensors at the crankshaft or camshaft
Description of fault diagnosis
positions and make the ignition key energize. Then,
DTC P0016 intake camshaft and crankshaft installation
use the scan tool to detect whether fault codes
position is not aligned.
reappear.
DTC
P0017
exhaust
camshaft
and
crankshaft
installation position is not aligned. The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
The ignition switch is turned on.
Conditions for setting diagnostic trouble codes The learning value and the setting value between the crankshaft and the camshaft are more than 13KW or less than -13KW. The operations for setting diagnostic trouble codes
Fault code P0016 and P0017 are stored in the internal storage.
The fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Reference of scan tool Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether fault codes related to the intake camshaft and the exhaust camshaft are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
3.
If all circuits are normal after test, you should replace engine control module.
9-14 Engine control and fuel system-1.5 L (L2B) storage.
9.1.3.3 DTC P0030 P0031 P0032 P0036 P0037 P0038 P0053 P0054
Failure of all potential functions.
Fault lamp light up
Diagnostic description
Circuit information reference
Before proceed to this diagnostic procedure,
Circuit test
please
implement
“Diagnosis
system
Repair of connector
inspection--vehicle”
Intermittent fault and bad contact test
Look up the “Diagnosis based on strategy” for
Circuit repair
overview of diagnostic methods.
Type reference of fault diagnosis code
“Description of diagnostic procedure” provides the
Power system diagnostic trouble code (DTC) type
overview for various diagnostic categories.
definition
Description of fault diagnosis
Fault diagnosis reference
DTC P0030 upstream oxygen sensor heating control
Refer to “Control modules reference” to obtain scan
circuit does not work
tool information.
DTC P0031 upstream oxygen sensor heating control
Circuit/system verification
circuit voltage is too low
1.
Start the engine and use the scan tool to detect
DTC P0032 upstream oxygen sensor heating control
whether faults related to oxygen sensor heater
circuit voltage is too high
control circuit are set up.
DTC P0036 downstream oxygen sensor heating
2.
control circuit does not work DTC P0037 downstream oxygen sensor heating
Detect whether the engine fault indicator lights up in the instrument panel.
3.
Use the scan tool to read the value of the oxygen
control circuit voltage is too low
sensor voltage and judge whether it is in the
DTC P0038 downstream oxygen sensor heating
specified range.
control circuit voltage is too high
—
Rear oxygen sensor 0.1-0.9V
DTC P0053 upstream oxygen sensor heating internal
—
Front oxygen sensor: 0.4-0.8V
resistance value is unreasonable
Circuit/system test
DTC P0054 upstream oxygen sensor heating internal
1.
Turn on the ignition switch, erase fault code with
resistance value is unreasonable
scan tool, stop the engine immediately after
The conditions for operating diagnostic trouble
starting it, and power it on again, read the fault
codes
code with scan tool to detect whether the fault
Ignition voltage is in 9V-16 V
codes reappear.
Turn on the ignition switch.
2.
Conditions for setting diagnostic trouble codes
Detect whether the oxygen sensor heating circuit is shorted/open to the ground.
ECU hardware circuit automatically detects.
—
If so, you should replace the relevant circuits.
The operations for setting diagnostic trouble codes
—
If not, you should replace oxygen sensor.
3.
If all circuits are proved to be normal after test, you
Fault codes P0030 P0031 P0032 P0036 P0037 P0038 P0053 P0054 are stored in the internal
should replace the engine module.
Engine control and fuel system-1.5 L (L2B) 9-15
Circuit/system verification
9.1.3.4 DTC P0105 P0106 P0107 P0108
1.
Diagnostic description
whether fault codes related to the intake pressure
Before proceed to this diagnostic procedure, please
implement
“Diagnosis
system
sensor are set up. 2.
inspection--vehicle”
Start the engine and use the scan tool to detect
Detect whether engine fault indicator in the instrument panel lights up.
Look up the “Diagnosis based on strategy” for
3.
Use the scan tool to read the value of the intake
overview of diagnostic methods.
pressure sensor voltage and judge whether it is in
“Description of diagnostic procedure” provides the
the specified range.
overview for various diagnostic categories.
—
0.18-4.8V
Description of fault diagnosis
Circuit/system test
DTC P0105 intake pressure sensor signal has no
1.
fluctuation (freeze) DTC
P0106
intake
Turn on the ignition switch, erase fault code with scan tool, stop the engine immediately after
pressure
sensor
signal
is
starting it, and power it on again, read the fault
unreasonable
code with scan tool to detect whether the fault
DTC P107 intake pressure sensor signal circuit voltage
codes reappear.
is too low
2.
Disconnect the battery negative and disconnect
DTC P0108 intake pressure sensor signal circuit
the intake pressure sensor patch plug. Then detect
voltage is too high
whether sensor control circuit is shorted to the
The conditions for operating diagnostic trouble
ground/power supply.
codes
—
If so, you should replace the circuit.
Ignition voltage is in 9V-16 V
—
If not, you should replace the intake pressure
The ignition switch is turned on.
sensor.
The conditions for setting up diagnostic trouble codes The value of the intake pressure sensor voltage is always more than 4.8V or less than 0.18V. The operations for setting diagnostic trouble codes
Fault codes P0105P0106P0107P0108 are stored in the internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of fault diagnosis code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information.
3.
If all circuits are normal after test, you should replace engine control module.
9-16 Engine control and fuel system-1.5 L (L2B) 3.
9.1.3.5 DTC P0111 P0112 P0113
whether it is in the specified range.
Diagnostic description
Use the scan tool to read the inlet temperature and
—
-43-139.5℃
Before proceed to this diagnostic procedure,
Circuit/system test
please
1.
implement
“Diagnosis
system
Turn on the ignition switch, erase fault code with
inspection--vehicle”
scan tool, stop the engine immediately after
Look up the “Diagnosis based on strategy” for
starting it, and power it on again, read the fault
overview of diagnostic methods.
code with scan tool to detect whether the fault
“Description of diagnostic procedure” provides the
codes reappear.
overview for various diagnostic categories.
2.
Disconnect the battery negative and disconnect
Description of fault diagnosis
the intake temperature sensor patch plug. Then
DTC P0111 intake temperature sensor signal is
detect whether the sensor control circuit is shorted
unreasonable
to the ground/power supply.
DTC P0112 intake air temperature sensor signal circuit
—
If so, you should replace the circuit.
voltage is too low
—
If not, you should replace the intake temperature
DTC P0113 intake temperature sensor signal circuit
sensor.
voltage is too high
3.
The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
The ignition switch is turned on.
The conditions for setting up diagnostic trouble codes The intake temperature is more than 139.5℃ or less than -43℃. The operations for setting diagnostic trouble codes
Fault codes P0111P0112P0113 are stored in the internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether
fault
codes
related
to
the
intake
temperature sensor are set up. 2.
Detect whether the engine fault indicator lights up in the instrument panel.
If all circuits are normal after test, you should replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-17
sensor are set up.
9.1.3.6 DTC P0116 P0117 P0118
2.
Diagnostic description
instrument panel lights up.
Before proceed to this diagnostic procedure, please
implement
Detect whether engine fault indicator in the
“Diagnosis
3.
system
Use the scan tool to read the intake temperature and judge whether it is in the specified range.
inspection--vehicle”
—
Look up the “Diagnosis based on strategy” for
Circuit/system test
overview of diagnostic methods.
1.
-44.25-142.5℃ Turn on the ignition switch, erase fault code with
“Description of diagnostic procedure” provides the
scan tool, stop the engine immediately after starting
overview for various diagnostic categories.
it, and power it on again, read the fault code with
Description of fault diagnosis
scan tool to detect whether the fault codes
DTC P0116 engine coolant temperature sensor signal is
reappear.
unreasonable
2.
Disconnect the battery negative and disconnect the
DTC P0117 engine coolant temperature sensor signal
engine coolant temperature sensor patch plug.
circuit voltage is too low
Then detect whether the sensor control circuit is
ETC P0118 engine coolant temperature sensor signal
shorted to the ground/power supply.
circuit voltage is too high
—
If so, you should replace the circuit.
The conditions for operating diagnostic trouble
—
If not, you should replace the engine coolant
codes
Ignition voltage is in 9V-16 V
Start the engine
The conditions for setting up diagnostic trouble codes The coolant temperature is more than 142.5℃ and less than -44.25℃. The operations for setting up diagnostic trouble codes
Fault codes P0116P0117P0118 are stored in the internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain Scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether fault codes related to coolant temperature
temperature sensor. 3.
If all circuits are normal after test, you should replace engine control module.
9-18 Engine control and fuel system-1.5 L (L2B)
9.1.3.7 DTC P0121 P0122 P0123 P0221 P0222 P0223 Diagnostic description
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Before proceed to this diagnostic procedure,
Circuit repair
please
Type reference of diagnostic trouble code
implement
“Diagnosis
system
inspection--vehicle”
Power system diagnostic trouble code (DTC) type
Refer to the “Diagnosis based on strategy” for
definition
overview of diagnostic methods.
Fault diagnosis reference
“Description of diagnostic procedure” provides the
Refer to “Control modules reference” to obtain scan
overview for various diagnostic categories.
tool information.
Description of fault diagnosis
Circuit/system verification
DTC P0121 electronic throttle position sensor 1 signal
1.
Start the engine and use the scan tool to detect
is unreasonable.
whether fault codes related to the electronic
DTC P0122 electronic throttle position sensor 1 signal
throttle position sensor are set up.
circuit voltage is too low
2.
DTC P0123 electronic throttle position sensor 1 signal circuit voltage is too high
Detect whether engine fault indicator in the instrument panel lights up.
3.
DTC P0221 electronic throttle position sensor 2 signal
Use the scan tool to read the throttle position sensor voltage and judge whether it is in the
is unreasonable
specified range.
DTC P0222 electronic throttle position sensor 2 signal
—
circuit voltage is too low
Circuit/system test
DTC P0223 electronic throttle position sensor 2 signal
1.
0.245-4.746V Turn on the ignition switch, erase fault code with
circuit voltage is too high
scan tool, stop the engine immediately after
The conditions for operating diagnostic trouble
starting it, and power it on again, read the fault
codes
code with scan tool to detect whether the fault
Ignition voltage is in 9V-16 V
codes reappear.
Start the engine
2.
Disconnect the battery negative and disconnect
Conditions for setting diagnostic trouble codes
the throttle position sensor patch plug. Then detect
The value of the electronic throttle position sensor
whether the sensor control circuit is shorted to the
voltage is more than 4.746V or less than 0.245V.
ground/power supply.
The operations for setting up diagnostic trouble
—
If so, you should replace the circuit.
codes
—
If not, you should replace throttle position sensor.
3.
If all circuits are normal after test, you should
Fault codes P0121 P0122 P0123 P0221 P0222 P0223 are stored in the internal storage.
Fault lamp light up
replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-19
9.1.3.8 DTC P0130 P0131 P0132 P0134 P0136 P0137 P0138 Diagnostic description
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Before proceed to this diagnostic procedure,
Circuit repair
please
Type reference of fault diagnosis code
implement
“Diagnosis
system
inspection--vehicle”
Power system diagnostic trouble code (DTC) type
Look up the “Diagnosis based on strategy” for
definition
overview of diagnostic methods.
Fault diagnosis reference
“Description of diagnostic procedure” provides the
Refer to “Control modules reference” to obtain scan
overview for various diagnostic categories.
tool information.
Description of fault diagnosis
Circuit/system verification
DTC P0130 upstream oxygen sensor signal is
1.
Start the engine and use the scan tool to detect
unreasonable
whether the fault codes related to oxygen sensor
DTC P0131 upstream oxygen sensor signal voltage is
are set up.
low
2.
DTC P0132 upstream oxygen sensor signal circuit voltage is too high
Detect whether engine fault indicator in the instrument panel lights up.
3.
DTC P0134 upstream oxygen sensor circuit signal fails
Use the scan tool to read the oxygen sensor voltage and judge whether it is in the specified
DTC P0136 downstream oxygen sensor signal is
range.
unreasonable
—
Front oxygen sensor: 0.4-0.8V
DTC P0137 downstream oxygen sensor signal voltage
—
Rear oxygen sensor: 0.1-0.9V
is low
4.
Detect whether the oxygen sensor is worn ，
DTC P0138 downstream oxygen sensor signal circuit
corroded, etc.
voltage is too high
Circuit/system test
DTC P0140 downstream oxygen sensor circuit signal
1.
Turn on the ignition switch, erase fault code with
fails
scan tool, stop the engine immediately after
The conditions for operating diagnostic trouble
starting it, and power it on again, read the fault
codes
code with scan tool to detect whether the fault
Ignition voltage is in 9V-16 V
Start the engine
codes reappear. 2.
Disconnect the battery negative and oxygen
Conditions for setting up diagnostic trouble codes
sensor patch plug, detect whether the sensor
The oxygen sensor voltage is always slightly higher or
control circuit is shorted to the ground/power
lower.
supply.
The operations for setting diagnostic trouble codes
—
If so, you should replace the circuit.
Fault codes P0130 P0131 P0132 P0134 P0136
—
If not, you should replace oxygen sensor.
P0137 P0138 are stored in the internal storage.
3.
If all circuits are normal after test, you should
Fault lamp light up
replace engine control module.
9-20 Engine control and fuel system-1.5 L (L2B) instrument panel lights up.
9.1.3.9 DTC P0170 P0171 P0172
3.
Diagnostic description
voltage and judge whether it is in the specified
Before proceed to this diagnostic procedure, please
implement
“Diagnosis
system
range. —
Front oxygen sensor: 0.4-0.8V
inspection--vehicle”
—
Rear oxygen sensor: 0.1-0.9V
Look up the “Diagnosis based on strategy” for
4.
Detect whether the rear oxygen sensor is worn，
overview of diagnostic methods.
Use the scan tool to read the oxygen sensor
corroded, etc.
“Description of diagnostic procedure” provides the
Circuit/system test
overview for various diagnostic categories.
1.
Turn on the ignition switch, erase fault code with
Description of fault diagnosis
scan tool, stop the engine immediately after
DTC P0170 air to fuel ratio closed-loop control
starting it, and power it on again, read the fault
self-learning is unreasonable after offline inspection.
code with scan tool to detect whether the fault
DTC P0171 air to fuel ratio closed-loop control
codes reappear.
self-learning is too lean after offline detection
2.
Disconnect the battery negative and oxygen
DTC P0172 air to fuel ratio closed-loop control
sensor patch plug, detect whether the sensor
self-learning is too rich after offline detection
control circuit is shorted to the ground/power
The conditions for operating diagnostic trouble
supply.
codes
—
Ignition voltage is in 9V-16 V
—
If not, you should replace the rear oxygen sensor.
Start the engine
3.
If all circuits are normal after test, you should
Conditions for setting up diagnostic trouble codes
The catalyst’s oxygen storage capacity exceeds the minimum limit but is less than 0.2.
The speed of the engine is between [1,760, 4,000].
The operations for setting diagnostic trouble codes
Fault codes P0170P0171P0172 are stored in the memory.
Do not light up the fault lamp.
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether the fault codes related to oxygen sensor are set up.
2.
Detect whether engine fault indicator in the
If so, you should replace the circuit.
replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-21
9.1.3.10 DTC P0201 P0202 P0203 P0204 Diagnostic description
2.
instrument panel lights up. 3.
Detect whether the oil nozzle circuit is shorted or
Before proceed to this diagnostic procedure,
open, there is large resistance in the wiring
please
harness, and pins in ECU end or oil nozzle end are
implement
“Diagnosis
system
inspection--vehicle”
Detect whether engine fault indicator in the
contacted poorly.
Look up the “Diagnosis based on strategy” for
Circuit/system test
overview of diagnostic methods.
1.
Turn on the ignition switch, erase fault code with
“Description of diagnostic procedure” provides the
scan tool, stop the engine immediately after
overview for various diagnostic categories.
starting it, and power it on again, use the scan tool
Description of fault diagnosis
to read the fault code and inspect whether the fault
DTC P0201 one-cylinder injector control circuit does
codes reappear.
not work
2.
Disconnect the battery negative, injector patch
DTC P0202 two-cylinder injector control circuit does
plug and detect with the multimeter whether the
not work
voltage between the injector and ground is within
DTC P0172 three-cylinder injector control circuit does
the specified range.
not work
—
3.8-4.5V
DTC P0204 four-cylinder injector control circuit does
3.
Detect whether sensor control circuit is shorted to
not work
the ground/power supply.
The conditions for operating diagnostic trouble
—
If so, you should replace the circuit.
codes
—
If not, you should replace injector controller
Ignition voltage is in 9V-16 V
4.
If all circuits are normal after test, you should
Start the engine
Conditions for setting up diagnostic trouble codes Hardware circuit inspection The operations for setting diagnostic trouble codes
Fault codes P0201P0202P0203P0204 are stored in the internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine use the scan tool to detect whether the fault codes related to injector control circuit are set up.
replace engine control module.
9-22 Engine control and fuel system-1.5 L (L2B)
9.1.3.11 DTC P0261 P0262 P0264 P0265 P0267 P0268 P0270 P0271 Diagnostic description
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Before proceed to this diagnostic procedure,
Type reference of fault diagnosis code
please
Power system diagnostic trouble code (DTC) type
implement
“Diagnosis
system
inspection--vehicle”
definition
Look up the “Diagnosis based on strategy” for
Fault diagnosis reference
overview of diagnostic methods.
Refer to “Control modules reference” to obtain scan
“Description of diagnostic procedure” provides the
tool information.
overview for various diagnostic categories.
Circuit/system verification
Description of fault diagnosis
1.
Start the engine and use the scan tool to detect
DTC P0261 one-cylinder injector control circuit voltage
whether the fault codes related to injector control
is too low; DTCP0262 one–cylinder injector control
circuit are set up.
circuit voltage is too high and DTCP0264 two-cylinder
2.
injector control voltage is too low DTC P0265 two-cylinder injector control circuit voltage
Detect whether engine fault indicator in the instrument panel lights up.
3.
Detect whether the oil nozzle circuit is shorted or
is too high
open circuit, there is large resistance in the wiring
DTC P0276 three-cylinder injector control circuit
harness, and pins in ECU end or oil nozzle end are
voltage is too low
contacted poorly.
DTC P0268 three-cylinder injector control circuit
Circuit/system test
voltage is too high
1.
Turn on the ignition switch, erase fault code with
DTC P0270 four-cylinder injector control circuit voltage
scan tool, stop the engine immediately after
is too low
starting it, and power it on again, read the fault
DTC P0271 four-cylinder injector control circuit voltage
code with scan tool to detect whether the fault
is too high
codes reappear.
The conditions for operating diagnostic trouble
2.
Disconnect the battery negative and injector patch
codes
plug and detect with multimeter whether the
Ignition voltage is in 9V-16 V
voltage between the injector and ground is within
Start the engine
the specified range.
Conditions for setting up diagnostic trouble codes
—
3.8-4.5V
Hardware circuit detection
3.
Detect
The operations for setting diagnostic trouble codes
whether
sensor
control
circuit
is
grounded/shorted to the power supply.
Fault codes P0170P0171P0172 are stored in the
—
If so, you should replace the circuit.
internal storage.
—
If not, you should replace injector controller
Fault lamp light up
4.
If all circuits are normal after test, you should
Circuit information reference
replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-23
9.1.3.12 DTC P0300 P0301 P0302 P0303 P0304
3.
open, and there is large resistance in the wiring harness, and pins in ECU end or oil nozzle end are
Diagnostic description
Detect whether the oil nozzle circuit is shorted or
contacted poorly.
Before proceed to this diagnostic procedure,
Circuit/system test
please
1.
implement
“Diagnosis
system
Turn on the ignition switch, erase fault code with
inspection--vehicle”
scan tool, stop the engine immediately after
Look up the “Diagnosis based on strategy” for
starting it, and power it on again, read the fault
overview of diagnostic methods.
code with scan tool to detect whether the fault
“Description of diagnostic procedure” provides the overview for various diagnostic categories.
codes reappear. 2.
Disconnect the battery negative and injector patch
Description of fault diagnosis
plug and detect with multimeter whether the
DTC P0300 multi-cylinder suffers from fire
voltage between the injector and ground is within
DTC P0301 one-cylinder suffers from fire
the specified range.
DTC P0302 two-cylinder suffers from fire
—
3.8-4.5V
DTC P0303 three-cylinder suffers from fire
3.
Detect whether sensor control circuit is shorted to
DTC P0304 four-cylinder suffers from fire
the ground/power supply.
The conditions for operating diagnostic trouble
—
If so, you should replace the circuit.
codes
—
If not, you should replace injector controller
Ignition voltage is in 9V-16 V
4.
If all circuits are normal after test, you should
Start the engine
Conditions for setting diagnostic trouble codes Hardware circuit detection The operations for setting diagnostic trouble codes
Fault codes P0300P0301P0302P0303P0304 are stored in the internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of fault diagnosis code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether fault codes related to injector control circuit are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
replace engine control module.
9-24 Engine control and fuel system-1.5 L (L2B) P0366 P0367 P0368 are stored in the internal
9.1.3.13 DTC P0340 P0341 P0342 P0343 P0365 P0366 P0367 P0368
storage.
Diagnostic description
Fault lamp light up
Circuit information reference
Before proceed to this diagnostic procedure,
Circuit test
please
implement
“Diagnosis
system
Repair of connector
inspection--vehicle”
Intermittent fault and bad contact test
Look up the “Diagnosis based on strategy” for
Circuit repair
overview of diagnostic methods.
Type reference of diagnostic trouble code
“Description of diagnostic procedure” provides the
Power system diagnostic trouble code (DTC) type
overview for various diagnostic categories.
definition
Description of fault diagnosis
Fault diagnosis reference
DTC P0340 intake phase sensor’s installation position
Refer to “Control modules reference” to obtain scan
is improper.
tool information.
DTC
P0341
intake
phase
sensor
signal
is
unreasonable
Circuit/system verification 1.
Start the engine and use the scan tool to inspect
DTC P0342 intake phase sensor signal circuit voltage
whether fault codes related to phase sensor are
is too low
set up.
DTC P0343 intake phase sensor signal circuit voltage
2.
is too high
instrument panel lights up.
DTC P0365 exhaust phase sensor’s installation
3.
position is improper DTC
P0366
Detect whether engine fault indicator in the
exhaust
Detect whether the phase sensor circuit is short circuit or open circuit, there is large resistance in
phase
sensor
signal
is
the wiring harness, and pins in ECU end or oil
unreasonable
nozzle end are contacted poorly.
DTC P0367 exhaust phase sensor signal circuit voltage
Circuit/system test
is too low
1.
Turn on the ignition switch, erase fault code with
DTC P0368 exhaust phase sensor signal circuit voltage
scan tool, stop the engine immediately after
is too high
starting it, and power it on again, read the fault
The conditions for operating diagnostic trouble
code with scan tool to detect whether the fault
codes
Ignition voltage is in 9V-16 V
Start the engine
codes reappear. 2.
Disconnect the phase sensor patch plug and use the multimeter to detect whether the phase sensor
Conditions for setting up diagnostic trouble codes
circuit is shorted to the ground/power supply.
Hardware circuit detection
—
If so, you should replace the circuit.
The phase signal register value is equal to 255 or
—
If not, you should replace the phase sensor.
0.
3.
If all circuits are normal after test, you should
The operations for setting diagnostic trouble codes
Fault codes P0340 P0341 P0342 P0343 P0365
replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-25
3.
9.1.3.14 DTC P0444 P0458 P0459
control circuit is shorted or open, there is large
Diagnostic description
resistance in the wiring harness, and pins in ECU
Before proceed to this diagnostic procedure, please
implement
“Diagnosis
system
inspection--vehicle”
Detect whether the carbon tank solenoid valve
end or oil nozzle end are contact poorly. Circuit/system test 1.
Turn on the ignition switch, erase fault code with
Refer to the “Diagnosis based on strategy” for
scan tool, stop the engine immediately after
overview of diagnostic methods.
starting it, and power it on again, read the fault
“Description of diagnostic procedure” provides the
code with scan tool to detect whether the fault
overview for various diagnostic categories. Description of fault diagnosis
codes reappear. 2.
Disconnect the carbon tank control valve patch
DTC P0444 carbon tank control valve control circuit
plug and use the multimeter to detect whether the
does not work
control valve circuit is shorted to the ground/power
DTC P0458 carbon tank control valve control circuit
supply.
voltage is too low
—
If so, you should replace the circuit.
DTC P0459 carbon tank control valve control circuit
—
If not, you should replace the carbon tank control
voltage is too high
valve.
The conditions for operating diagnostic trouble
3.
codes
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting up diagnostic trouble codes
Hardware circuit detection
The operations for setting diagnostic trouble codes
Fault codes DTC P0444 P0458 P0459 are stored in the internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of fault diagnosis code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether fault codes related to carbon tank control valve circuit are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
If all circuits are normal after test, you should replace engine control module.
9-26 Engine control and fuel system-1.5 L (L2B)
9.1.3.15 DTC P0480 P0481 P0692 P0694
3.
open, there is large resistance in the wiring
Diagnostic description
harness, and pins in ECU end or oil nozzle end are
Before proceed to this diagnostic procedure, please
implement
“Diagnosis
system
inspection--vehicle”
Detect whether the fan relay circuit is shorted or
contacted poorly. Circuit/system test 1.
Turn on the ignition switch, erase fault code with
Look up the “Diagnosis based on strategy” for
scan tool, stop the engine immediately after
overview of diagnostic methods.
starting it, and power it on again, read the fault
“Description of diagnostic procedure” provides the
code with scan tool to detect whether the fault
overview for various diagnostic categories. Description of fault diagnosis
codes reappear. 2.
Start the engine and use the scan tool to control
DTC P0480 cooling fan relay control circuit does not
connection and disconnection of the fan relay
work (low speed)
switch.
DTC P0692 cooling fan relay control circuit voltage is
—
If fails, you should replace the fan relay.
too high (low speed)
3.
If all circuits are normal after test, you should
DTC P0694 cooling fan relay control circuit voltage is too high (high speed) DTC P0481 cooling fan relay control circuit fails (high speed) The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting up diagnostic trouble codes
Hardware circuit detection
The operations for setting diagnostic trouble codes
Fault codes DTCP0480P0481P0692P0694 are stored in the internal storage.
Fault lamp light up
Reference of circuit information
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Reference of scan tool Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether the fault codes related to the cooling fan relay are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-27
wiring harness, and pins in ECU end or oil nozzle
9.1.3.16 DTC P0506 P0507
end are contacted poorly.
Diagnostic description
please
Circuit/system test
Before proceed to this diagnostic procedure, implement
“Diagnosis
starting it, and power it on again, read the fault code with scan tool to detect whether the fault
overview of diagnostic methods.
codes reappear.
“Description of diagnostic procedure” provides the
DTC P0506 actual idle speed is less than the specified idle speed. DTC P0507 actual idle speed is higher than the specified idle speed. The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting up diagnostic trouble codes Hardware circuit detection
The operations for setting diagnostic trouble codes Fault codes DTCP0506P0507 are stored in the internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of fault diagnosis code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether fault codes related to abnormal idle speed are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
3.
scan tool, stop the engine immediately after
Look up the “Diagnosis based on strategy” for
Description of fault diagnosis
Turn on the ignition switch, erase fault code with
inspection--vehicle”
overview for various diagnostic categories.
1.
system
Detect whether the throttle body control circuit is shorted or open, there is large resistance in the
2.
If all circuits are normal after test, you should replace engine control module.
9-28 Engine control and fuel system-1.5 L (L2B) Circuit/system test
9.1.3.17 DTC P0537 P0538
1.
Diagnostic description
scan tool, stop the engine immediately after
Before proceed to this diagnostic procedure,
starting it, and power it on again, read the fault
please
code with scan tool to detect whether the fault
implement
“Diagnosis
system
inspection--vehicle”
Look up the “Diagnosis based on strategy” for
codes reappear. 2.
temperature sensor circuit is shorted or open to
“Description of diagnostic procedure” provides the
the ground/power supply.
Description of fault diagnosis
—
If so, you should replace the circuit.
—
If
DTCP0537 air conditioning evaporator temperature sensor circuit voltage is too low DTCP0538 air conditioning evaporator temperature sensor circuit voltage is too high The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting up diagnostic trouble codes Hardware circuit detection
The operations for setting diagnostic trouble codes
Fault codes DTCP0537P0538 are stored in the internal storage.
Do not light up the fault lamp.
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of fault diagnosis code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether fault codes related to the air conditioning evaporator temperature sensor are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
3.
Detect whether the air conditioning evaporator
overview of diagnostic methods. overview for various diagnostic categories.
Turn on the ignition switch, erase fault code with
Use the scan tool to read the value of the evaporator temperature sensor voltage and judge whether it is within the specified range. — 0.7-4.8V
not,
you
should
replace
the
evaporator
temperature sensor. 3.
If all circuits are normal after test, you should replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-29
3.
9.1.3.18 DTC P0560 P0562 P0563
judge whether it is within the specified range
Diagnostic description
Use the scan tool to read the battery voltage and
—
7-16V
Before proceed to this diagnostic procedure,
Circuit/system test
please
1.
implement
“Diagnosis
system
Turn on the ignition switch, erase fault code with
inspection--vehicle”
scan tool, stop the engine immediately after
Look up the “Diagnosis based on strategy” for
starting it, and power it on again, read the fault
overview of diagnostic methods.
code with scan tool to detect whether the fault
“Description of diagnostic procedure” provides the
codes reappear.
overview for various diagnostic categories. Description of fault diagnosis DTC
P0560
system
battery
voltage
signal
is
2.
Detect whether the battery is damaged or shorted.
—
If so, you should replace the battery.
—
If not, you should start the engine and wait for a
unreasonable
period to detect whether voltage of the battery has
DTC P0562 system battery voltage is too low
been normal.
DTC P0563 system battery voltage is too high The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting up diagnostic trouble codes
Hardware circuit detection
The battery voltage is less than 2V or more than 17V
The operations for setting diagnostic trouble codes
Fault codes DTCP0560P0562P0563 are stored in the internal storage.
Do not light up the fault lamp.
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether the abnormal fault codes related to the battery voltage are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
3.
If all circuits are normal after test, you should replace engine control module.
9-30 Engine control and fuel system-1.5 L (L2B) Circuit/system test
9.1.3.19 DTC P0602 P0604 P0605
1.
Diagnostic description
scan tool, stop the engine immediately after starting it, and power it on again, read the fault
please
code with scan tool to detect whether the fault
implement
“Diagnosis
system
Look up the “Diagnosis based on strategy” for
codes reappear. 2.
overview of diagnostic methods.
—
If so, you should replace the circuit.
3.
If all circuits are normal after test, you should
work DTC P0604 electronic control unit RAM does not work DTC P0605 electronic control unit ROM does not work The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting up diagnostic trouble codes Hardware circuit detection
The operations for setting diagnostic trouble codes Fault codes DTCP0602P0604P0605 are stored in the internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether fault codes related to the electronic control unit are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
3.
Detect with multimeter whether battery voltage is in the specified range
—
open to the ground / power supply
overview for various diagnostic categories. DTC P0602 electronic control unit coding does not
Detect whether ECU voltage circuit is shorted or
“Description of diagnostic procedure” provides the
Description of fault diagnosis
fault code with
Before proceed to this diagnostic procedure, inspection--vehicle”
Turn on the ignition switch, erase
7-16V
replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-31
Circuit/system test
9.1.3.20 DTC P0627 P0629
1.
Diagnostic description
scan tool, stop the engine immediately after starting it, and power it on again, read the fault
please
code with scan tool to detect whether the fault
implement
“Diagnosis
system
Look up the “Diagnosis based on strategy” for
codes reappear. 2.
overview of diagnostic methods.
— —
If not, replace oil bump relay.
3.
If all circuits are normal after test, you should
DTC P0629 oil pump relay control circuit voltage is too high The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting up diagnostic trouble codes Hardware circuit detection
The operations for setting diagnostic trouble codes Fault codes DTCP0627P0629 are stored in the internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether fault codes related to oil bump rely control circuit are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
3.
shorted or open to the ground/power supply
overview for various diagnostic categories. DTC P0627 oil pump relay control circuit does not work
Detect whether the oil bump relay control circuit is
“Description of diagnostic procedure” provides the
Description of fault diagnosis
fault code with
Before proceed to this diagnostic procedure, inspection--vehicle”
Turn on the ignition switch, erase
Control the connection and disconnection of oil pump relay with scan tool, and detect for normal display
If so, you should replace the circuit.
replace engine control module.
9-32 Engine control and fuel system-1.5 L (L2B) Circuit/system test
9.1.3.21 DTC P0645 P0647
1.
Diagnostic description
scan tool, stop the engine immediately after starting it,
Before proceed to this diagnostic procedure,
and power it on again, read the fault code with scan
please
tool to detect whether the fault codes reappear.
implement
“Diagnosis
system
inspection--vehicle”
control
ground/power supply
or
open
to
the
—
If not, you should replace compressor relay.
3.
If all circuits are normal after test, you should
The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting up diagnostic trouble codes Hardware circuit detection
The operations for setting diagnostic trouble codes Fault codes DTCP0645P0647 are stored in the internal storage. Do not light up the fault lamp.
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification Start the engine and use the scan tool to detect whether fault codes related to the air conditioning compressor relay control circuit are set up. Detect whether engine fault indicator in the instrument panel lights up. 3.
shorted
—
is too high
2.
is
overview for various diagnostic categories.
DTC P0647A/C compressor relay control circuit voltage
1.
circuit
“Description of diagnostic procedure” provides the
not work
Detect whether air conditioning compressor relay
overview of diagnostic methods.
DTC P0645A/C compressor relay control circuit does
2.
Look up the “Diagnosis based on strategy” for
Description of fault diagnosis
Turn on the ignition switch, erase fault code with
Use the scan tool to control the connection and disconnection of air conditioning compressor relay, and detect for normal display
If so, you should replace the circuit.
replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-33
Circuit/system test
9.1.3.22 DTC P0660 P0661 P0662
1.
Diagnostic description
scan tool, stop the engine immediately after
Before proceed to this diagnostic procedure,
starting it, and power it on again, read the fault
please
code with scan tool to detect whether the fault
implement
“Diagnosis
system
inspection--vehicle”
Turn on the ignition switch, erase fault code with
Look up the “Diagnosis based on strategy” for
codes reappear. 2.
Detect whether the variable air duct regulating
overview of diagnostic methods.
valve control circuit is shorted or open to the
“Description of diagnostic procedure” provides the
ground / power supply
overview for various diagnostic categories.
—
If so, you should replace the circuit.
Description of fault diagnosis
—
If not, you should replace variable air duct
DTC P0660 variable air duct regulating valve control
regulating valve.
circuit does not work
3.
DTC P0661 variable air duct regulating valve control circuit voltage is too low DTC P0662 variable air duct regulating valve control circuit voltage is too high The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting up diagnostic trouble codes
Hardware circuit detection
The operations for setting diagnostic trouble codes
Fault codes DTCP0660P0661P0662 are stored in the internal storage.
Do not light up the fault lamp.
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether fault codes related to variable air duct adjusting valve control circuit are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
If all circuits are normal after test, you should replace engine control module.
9-34 Engine control and fuel system-1.5 L (L2B) scan tool, stop the engine immediately after
9.1.3.23 DTC P0327 P0328
starting it, and power it on again, read the fault
Diagnostic description
code with scan tool to detect whether the fault
Before proceed to this diagnostic procedure, please
implement
“Diagnosis
system
codes reappear. 2.
inspection--vehicle”
—
If so, you should replace the circuit.
overview of diagnostic methods.
—
If not, you should replace knock sensor
“Description of diagnostic procedure” provides the
3.
If all circuits are normal after test, you should
Description of fault diagnosis DTC P0327 knock sensor circuit signal voltage is too low DTC P0328 knock sensor circuit signal voltage is too high The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
Start the engine
The engine speed is more than 2,800 rpm
Conditions for setting up diagnostic trouble codes Through hardware circuit detection, voltage signal range is slightly higher or lower. The operations for setting diagnostic trouble codes
Fault codes DTCP0327P0328 are stored in the internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether fault codes related to knock sensor signal circuit are set up.
2.
Detect whether engine fault indicator in the instrument panel lights up.
Circuit/system test 1.
or open to the ground/power supply
Look up the “Diagnosis based on strategy” for
overview for various diagnostic categories.
Detect whether the knock sensor circuit is shorted
Turn on the ignition switch, erase fault code with
replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-35
9.1.3.24 DTCP 2088 P2089 P2090 P2091
intake/exhaust control valve circuit are set up 2.
Diagnostic description
instrument panel lights up.
Before proceed to this diagnostic procedure, please
implement
“Diagnosis
3.
system
Detect with multimeter whether ECU control voltage of VVT control valve is within the specified
inspection--vehicle”
Detect whether engine fault indicator in the
range
Look up the “Diagnosis based on strategy” for
—
overview of diagnostic methods.
Circuit/system test
“Description of diagnostic procedure” provides the
1.
overview for various diagnostic categories.
4.2-4.8V Turn on the ignition switch, erase fault code with scan tool, stop the engine immediately after
Description of fault diagnosis
starting it, and power it on again, read the fault
DTC P2088VVT intake control valve circuit voltage is
code with scan tool to detect whether the fault
too low
codes reappear.
DTC P2089VVT intake control valve circuit voltage is
2.
Detect whether the VVT intake/exhaust control
too high
valve
DTC P2090VVT exhaust control valve circuit voltage is
ground/power supply
circuit
is
shorted
or
open
to
the
too low
—
If so, you should replace the circuit.
DTC P2091VVT exhaust control valve circuit voltage is
—
If not, you should replace the control valve
too high
3.
If all circuits are normal after test, you should
The conditions for operating diagnostic trouble codes
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting diagnostic trouble codes
Through hardware circuit detection, voltage signal range is slightly higher or lower.
The operations for setting diagnostic trouble codes
Fault codes P2088P2089P2090P2091 are stored into internal storage.
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Circuit repair
Type reference of fault diagnosis code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1.
Start the engine and use the scan tool to detect whether
the
fault
codes
related
to
VVT
replace engine control module.
9-36 Engine control and fuel system-1.5 L (L2B)
9.1.3.25 DTC P2177 P2178 P2187 P2188 Diagnostic description
Circuit information reference
Circuit test
Repair of connector
Before proceed to this diagnostic procedure,
Intermittent fault and bad contact test
please
Circuit repair
implement
“Diagnosis
system
inspection--vehicle”
Type reference of fault diagnosis code
Look up the “Diagnosis based on strategy” for
Power system diagnostic fault code (DTC) type
overview of diagnostic methods.
definition
“Description of diagnostic procedure” provides the
Fault diagnosis reference
overview for various diagnostic categories.
Refer to “Control modules reference” to obtain scan
Description of fault diagnosis
tool information.
DTC P2177 air to fuel ratio closed-loop control
Circuit/system verification
self-learning value exceeds the upper limit (middle load
1.
Start the engine and use the scan tool to detect
area)
whether the fault codes related to the air to fuel
DTC P2178 air to fuel ratio closed-loop control
ratio closed-loop control self-learning are set up
self-learning value exceeds the lower limit (middle load
2.
area) DTC P2187 air to fuel ratio closed-loop control
Detect whether engine fault indicator in the instrument panel lights up.
3.
self-learning value exceeds the upper limit (low load
Use the scan tool to read the value of the oxygen sensor voltage and judge whether it is in the
area)
specified range.
DTC P2188 air to fuel ratio closed-loop control
—
Front oxygen sensor: 0.1-0.5V
self-learning value exceeds the lower limit (low load
—
Rear oxygen sensor: 0.4-0.9V
area)
4.
Detect whether the oxygen sensor is damaged,
The conditions for operating diagnostic trouble
oxidized, etc.
codes
Circuit/system test
Ignition voltage is in 9V-16 V
1.
Start the engine
scan tool, stop the engine immediately after
Fuel trim value is not within the range of
starting it, and power it on again, read the fault
0.77-1.23
code with scan tool to detect whether the fault
Air to fuel ratio self-learning startup
Conditions for setting diagnostic trouble codes
Turn on the ignition switch, erase fault code with
codes reappear. 2.
Hardware circuit detection
Detect whether oxygen sensor circuit is shorted or open to the ground/power supply
The operations for setting diagnostic trouble codes
—
If so, you should replace the circuit.
Fault codes DTCP2177P2178P2187P2188 are
—
If not, you should replace oxygen sensor
stored into internal storage.
3.
If all circuits are normal after test, you should
Fault lamp light up
replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-37
9.1.3.26 DTC P1336 P1545 P1558 P1559 P1564 P1565 P1568 P1579 P1604 P2106 Diagnostic description
Fault lamp light up
Circuit information reference
Circuit test
Repair of connector
Intermittent fault and bad contact test
Before proceed to this diagnostic procedure,
Circuit repair
please
Type reference of diagnostic trouble code
implement
“Diagnosis
system
inspection--vehicle”
Power system diagnostic trouble code (DTC) type
Look up the “Diagnosis based on strategy” for
definition
overview of diagnostic methods.
Fault diagnosis reference
“Description of diagnostic procedure” provides the
Refer to “Control modules reference” to obtain scan
overview for various diagnostic categories.
tool information.
Description of fault diagnosis
Circuit/system verification
DTC P1336 electronic throttle security monitoring and
1.
Start the engine and use the scan tool to detect
control torque restricted
whether fault codes related to electronic throttle
DTC P1545 deviation between the actual position of
are set up.
electronic throttle and the target position exceeds the
2.
limit
Detect whether engine fault indicator in the instrument panel lights up.
DTC P1558 opening resistance of electronic throttle is
3.
Use the scan tool to read whether the voltage
too large
value of electronic throttle position sensor is within
DTC P1559 electronic throttle self-learning process
the normal range
does not work
—
Throttle position sensor 1:0.3-2.4V
DTC P1564 system voltage cannot meet the electric
—
Throttle position sensor 2:0.6-4.9V
throttle self-learning condition
4.
Detect whether the throttle body is damaged,
DTC P1565 initialization self-learning at lower limit of
blocked, etc., resulting in abnormal function.
electronic throttle does not work
Circuit/system test
DTC P1568 returning resistance of electronic throttle is
1.
Turn ON the ignition switch, erase fault code with
too large
scan tool, stop the engine immediately after
DTC P1579 electronic throttle self-learning condition
starting it, and power it on again, read the fault
cannot be met
code with scan tool to detect whether the fault
DTC
P1604
electronic
throttle
gain
adjustment
self-learning does not work
codes reappear. 2.
DTC P2106 electronic throttle driving stage does not
Detect whether the throttle position sensor circuit is shorted or open to the ground/power supply
work
—
If so, you should replace the circuit.
The conditions for operating diagnostic trouble
—
If not, you should replace throttle position sensor.
codes
3.
Detect whether the battery voltage is in the normal
Ignition voltage is in 9V-16 V
Start the engine
Conditions for setting diagnostic trouble codes
Hardware circuit detection
The operations for setting diagnostic trouble codes
Fault codes P1336 P1545 P1558 P1559 P1564
P1565 P1568 P1579 P1604 P2106 are stored into internal storage.
range. —
9-16V
4.
If all circuits are normal after test, you should replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-79
9.1.3.27 DTC P0219 Diagnostic description Before proceed to this diagnostic procedure, please implement “Diagnosis system inspection--vehicle” Look up the “Diagnosis based on strategy” for overview of diagnostic methods. “Description of diagnostic procedure” provides the overview for various diagnostic categories. Description & Fault Diagnosis DTC P0219 Engine High Speed The conditions for operating diagnostic trouble codes The ignition voltage is between 9-16 Volts. Start the engine Conditions for setting diagnostic trouble codes Engine speed is higher than 7200rpm The operations for setting diagnostic trouble codes Fault code P0219is stored in the memory Fault lamp light up。 Circuit information reference Circuit Testing Repair the connector Intermittent fault and bad contact test Circuit repair Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1. Start the engine and use the scan tool to detect whether fault codes related to electronic throttle are set up. 2. Detect whether engine fault indicator in the instrument panel lights up. Circuit/system test 1. Turn ON the ignition switch, erase fault code with scan tool, stop the engine immediately after starting it, and power it on again, read the fault code with scan tool to detect whether the fault codes reappear. 2. Check whether the crankshaft position sensor circuit is short-circuited to ground / power supply — If Yes, replace the circuit — If No, replace crankshaft position sensor 3. If all circuits are normal after test, you should replace engine control module.
9-80 Engine control and fuel system-1.5 L (L2B)
9.1.3.28 DTC P0317 Diagnostic description Before proceed to this diagnostic procedure, please implement “Diagnosis system inspection--vehicle” Look up the “Diagnosis based on strategy” for overview of diagnostic methods. “Description of diagnostic procedure” provides the overview for various diagnostic categories. Description & Fault Diagnosis DTC P0317 ABS wheel speed sensor failure / bad road detection ABS signal failure The conditions for operating diagnostic trouble codes The ignition voltage is between 9-16 Volts. Start the engine Conditions for setting diagnostic trouble codes Vehicle speed is less than 5 km/h Fuel cut-off activated Coolant temperature is higher than 64.5 Engine speed range（1520rpm～4000 rpm） The operations for setting diagnostic trouble codes The fault code P0317is stored in the memory. Fault lamp light up. Circuit information reference Circuit Testing Repair the connector Intermittent fault and bad contact test Circuit repair Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1. Run the vehicle and check if the ABS circuit is set up with the diagnostic code. 2. Detect whether engine fault indicator in the instrument panel lights up. Circuit/system test 1. Turn ON the ignition switch, erase fault code with scan tool, stop the engine immediately after starting it, and power it on again, read the fault code with scan tool to detect whether the fault codes reappear. 2. Check whether the signal circuit between the engine control module and ABS is shorted to ground / power supply, - If yes, replace the circuit - If not, replace the ABS module 3. If all circuits are normal after test, you should replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-81
9.1.3.29 DTC P0321 Diagnostic description Before proceed to this diagnostic procedure, please implement “Diagnosis system inspection--vehicle” Look up the “Diagnosis based on strategy” for overview of diagnostic methods. “Description of diagnostic procedure” provides the overview for various diagnostic categories. Description & Fault Diagnosis DTC P0321 High end point of crankshaft is unreasonable The conditions for operating diagnostic trouble codes The ignition voltage is between 9-16Volts. Start the engine Conditions for setting diagnostic trouble codes Jumlah putaran yang terbaca dari gigi acuan >6 The operations for setting diagnostic trouble codes The fault code P0321is stored in the memory. Fault lamp light up。 Circuit information reference Circuit Testing Repair the connector Intermittent fault and bad contact test Circuit repair Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1. Run the vehicle and check if the crankshaft position sensor is set up with the diagnostic code. 2. Detect whether engine fault indicator in the instrument panel lights up. Circuit/system test 1. Turn ON the ignition switch, erase fault code with scan tool, stop the engine immediately after starting it, and power it on again, read the fault code with scan tool to detect whether the fault codes reappear. 2. Detection of crankshaft position sensor signal circuit is ground / power short-circuit, open circuit. — If Yes, replace the circuit — If not，replace crankshaft position sensor 3. If all circuits are normal after test, you should replace engine control module.
9-82 Engine control and fuel system-1.5 L (L2B)
9.1.3.30 DTC P0133 P0420 P2195 P2196 P2270 P2271 Diagnostic description Before proceed to this diagnostic procedure, please implement “Diagnosis system inspection--vehicle” Look up the “Diagnosis based on strategy” for overview of diagnostic methods. “Description of diagnostic procedure” provides the overview for various diagnostic categories. Description & Fault Diagnosis DTC P0133 The upstream sensor is aging DTC P0420 three - way catalytic converter oxygen storage capacity of aging DTC P2195 Upstream Oxygen Sensor Aging - The signal is continuously darker DTC P2196 Upstream Oxygen Sensor Aging - Signal persistently lean DTC P2270 Downstream Oxygen Sensor Aging Signal persistently lean DTC P2271 Downstream Oxygen Sensor Aging - The signal is continuously thick The conditions for operating diagnostic trouble codes The ignition voltage is between 9-16Volts. Start the engine Conditions for setting diagnostic trouble codes Average value of oxygen sensor signal amplitude post from cathalityc is higher than 0.72 The operations for setting diagnostic trouble codes The fault code P0133 P0420 P2195 P2196 P2270 P2271 is stored in the memory. Fault lamp light up。 Circuit information reference Circuit Testing Repair the connector Intermittent fault and bad contact test Circuit repair Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1. Run the vehicle and check if the oxygen sensor is set up with the diagnostic code. 2. Detect whether engine fault indicator in the instrument panel lights up. Circuit/system test 1. Turn ON the ignition switch, erase fault code with scan tool, stop the engine immediately after starting it, and power it on again, read the fault code with scan tool to detect whether the fault codes reappear. — Detection of upstream oxygen sensor signal
— — 2. 3.
circuit is ground / power short-circuit, open circuit. If Yes, replace the circuit If not，replace the oxygen sensor Detection of catalytic converters for damage phenomenon. If all circuits are normal after test, you should replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-83
9.1.3.31 DTC P0571 Diagnostic description Before proceed to this diagnostic procedure, please implement “Diagnosis system inspection--vehicle” Look up the “Diagnosis based on strategy” for overview of diagnostic methods. “Description of diagnostic procedure” provides the overview for various diagnostic categories. Description & Fault Diagnosis DTC P0571 Brake lamp switch signal circuit failure. The conditions for operating diagnostic trouble codes The ignition voltage is between 9-16Volts. Start the engine Conditions for setting diagnostic trouble codes Brake light switch feedback voltage range （0.469V—1.133V） The operations for setting diagnostic trouble codes The fault code P0571is stored in the memory. Fault lamp light up。 Circuit information reference Circuit Testing Repair the connector Intermittent fault and bad contact test Circuit repair Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1. Run the vehicle and check if the brake light switch is set with the diagnostic code 2. Detect whether engine fault indicator in the instrument panel lights up. Circuit/system test 1. Turn ON the ignition switch, erase fault code with scan tool, stop the engine immediately after starting it, and power it on again, read the fault code with scan tool to detect whether the fault codes reappear. 2. The brake light signal detection circuit whether on the ground / power supply short circuit. — If Yes, replace the circuit — If not，replace brake lamp switch assembly 3. If all circuits are normal after test, you should replace engine control module.
9-84 Engine control and fuel system-1.5 L (L2B)
9.1.3.32 DTC P0606 Diagnostic description Before proceed to this diagnostic procedure, please implement “Diagnosis system inspection--vehicle” Look up the “Diagnosis based on strategy” for overview of diagnostic methods. “Description of diagnostic procedure” provides the overview for various diagnostic categories. Description & Fault Diagnosis DTC P0606 Electronic throttle safety monitoring function failure The conditions for operating diagnostic trouble codes The ignition voltage is between 9-16Volts. Star the engine Conditions for setting diagnostic trouble codes ECU internal self-detection electronic throttle safety monitoring module failure The operations for setting diagnostic trouble codes The fault code P0606is stored in the memory. Fault lamp light up。 Circuit information reference Circuit Testing Repair the connector Intermittent fault and bad contact test Circuit repair Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1. Run the vehicle and check if the electronic throttle is set with the diagnostic code 2. Detect whether engine fault indicator in the instrument panel lights up. Circuit/system test 1. Turn ON the ignition switch, erase fault code with scan tool, stop the engine immediately after starting it, and power it on again, read the fault code with scan tool to detect whether the fault codes reappear. 2. Detection of electronic throttle position sensor circuit is ground / power short-circuit, open circuit. — If Yes, replace the circuit — If not, replace the electronic throttle position sensor. 3. If all circuits are normal after test, you should replace engine control module.
Engine control and fuel system-1.5 L (L2B) 9-85
9.1.3.33 DTC P0650 Diagnostic description Before proceed to this diagnostic procedure, please implement “Diagnosis system inspection--vehicle” Look up the “Diagnosis based on strategy” for overview of diagnostic methods. “Description of diagnostic procedure” provides the overview for various diagnostic categories. Description & Fault Diagnosis DTC P0650 MIL lamp drive circuit failure The conditions for operating diagnostic trouble codes The ignition voltage is between 9-16Volts. Star the engine Conditions for setting diagnostic trouble codes Module internal circuit detects a fault line The operations for setting diagnostic trouble codes The fault code P0650is stored in the memory. Fault lamp light up。 Circuit information reference Circuit Testing Repair the connector Intermittent fault and bad contact test Circuit repair Type reference of diagnostic trouble code Power system diagnostic trouble code (DTC) type definition Fault diagnosis reference Refer to “Control modules reference” to obtain scan tool information. Circuit/system verification 1. Run the vehicle and check if the MIL lamp is set up with the diagnostic code 2. Detect whether engine fault indicator in the instrument panel lights up. Circuit/system test 1. Turn ON the ignition switch, erase fault code with scan tool, stop the engine immediately after starting it, and power it on again, read the fault code with scan tool to detect whether the fault codes reappear. 2. Check whether the MIL lamp drive circuit is short-circuited to ground / power supply. — If Yes, replace the circuit — If not，replace meter cluster。 3. If all circuits are normal after test, you should replace engine control module.
9-86 Engine control and fuel system-1.5 L (L2B)
9.1.3.34 DTC P0688 Diagnostic description Before proceed to this diagnostic procedure, please implement “Diagnosis system inspection--vehicle” Look up the “Diagnosis based on strategy” for overview of diagnostic methods. “Description of diagnostic procedure” provides the overview for various diagnostic categories. Description & Fault Diagnosis DTC P0688 Main relay output voltage signal failure The conditions for operating diagnostic trouble codes The ignition voltage is between 9-16Volts. Star the engine Conditions for setting diagnostic trouble codes Check the level voltage signal after the main relay 6 Operation setting when DTC occured Trouble code P0321 is stored in the memory. Fault lamp illuminate. Information Reference Circuit Circuit testing Connector repair Test intermittent faults and poor contact line repair DTC Type Reference Power system Diagnostic Trouble Code (DTC) type definition Fault diagnostic reference Refer to ”Control Module Reference” for information on the diagnostic tool。 Circuit/system check 1. Run the vehicle and check if the trouble code crankshaft position sensor is detected up with the diagnostic tester 2. Check whether the engine fault indicator is illuminate in the instrument panel Circuit/System Test 1. The ignition switch in the ON position, with diagnostic tool clear DTC, turn off immediately after starting the engine and re-power, then read diagnostic trouble code is detected to reproduce. 2. Detection of crankshaft position sensor signal circuit is ground / power short-circuit, open circuit – If yes, replace the circuit – If not，replace the crankshaft position sensor 3. All circuit detects normal, replace the engine control module.
9-82 Engine control and fuel systems -1.2 L（new LMH）
9.2.3.30 DTC P0133 P0420 P2195 P2196 P2270 P2271 Diagnostic instruction Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle” For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Troubleshooting instruction DTC P0133 upstream sensor aging DTC P0420 three - way catalytic converter oxygen storage capacity of aging DTC P2195 Upstream Oxygen Sensor Aging - The signal is continuously darker DTC P2196 Upstream Oxygen Sensor Aging - Signal persistently lean DTC P2270 Downstream Oxygen Sensor Aging Signal persistently lean DTC P2271 Downstream Oxygen Sensor Aging - The signal is continuously thick Run DTC condition Ignition voltage is between 9-16 volts. Engine start. Set DTC condition The mean amplitude of the rear oxygen sensor signal corrected by the critical catalyst model is higher than 0.72 Operation setting when DTC occured Trouble code P0133 P0420 P2195 P2196 P2270 P2271 is stored in the memory. Fault lamp illuminate. Information Reference Circuit Circuit testing Connector repair Test intermittent faults and poor contact line repair DTC Type Reference Power system Diagnostic Trouble Code (DTC) type definition Fault diagnostic reference Refer to ”Control Module Reference” for information on the diagnostic tool。 Circuit/system check 1. Run the vehicle and check if the triuble code oxygen sensor is detected with the diagnostic tool 2. Check whether the engine fault indicator is illuminate in the instrument panel
Circuit/System Test 1. The ignition switch in the ON position, with diagnostic tool clear DTC, turn off immediately after starting the engine and re-power, then read diagnostic trouble code is detected to reproduce. 2. Detection of upstream oxygen sensor signal circuit is ground / power short-circuit, open circuit. – If yes, replace the circuit – If not，replace the oxygen sensor 3. Detection of catalytic converters for damage phenomenon. 4. All circuit detects normal, replace the engine control module.
Engine control and fuel systems -1.2 L（New LMH）9-83
9.2.3.31 DTC P0571
9.2.3.32 DTC P0606
Diagnostic instruction Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle” For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Troubleshooting instruction DTC P0571 Brake lamp switch signal circuit failure Run DTC condition Ignition voltage is between 9-16 volts. Engine start. Set DTC condition Brake lamp switch feedback voltage range（0.469V—
Diagnostic instruction Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle” For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Troubleshooting instruction DTC P0606 Electronic throttle safety monitoring malfunction Run DTC condition Ignition voltage is between 9-16 volts. Engine start. Set DTC condition ECU hardware self learning Electronic throttle safety monitoring malfunction Operation setting when DTC occured Trouble code P0606 is stored in the memory. Fault lamp illuminate. Information Reference Circuit Circuit testing Connector repair Test intermittent faults and poor contact line repair DTC Type Reference Power system Diagnostic Trouble Code (DTC) type definition Fault diagnostic reference Refer to ”Control Module Reference” for information on the diagnostic tool。 Circuit/system check 1. Run the vehicle and check if the trouble code electronic throttle related is detected with the diagnostic tool 2. Check whether the engine fault indicator is illuminate in the instrument panel Circuit/System Test 1. The ignition switch in the ON position, with diagnostic tool clear DTC, turn off immediately after starting the engine and re-power, then read diagnostic trouble code is detected to reproduce. 2. Detection of electronic Throttle position sensor circuit is ground / power short-circuit, open circuit. – If yes, replace the circuit – If not，replace the electronic Throttle position sensor. 3. All circuit detects normal, replace the engine control module.
1.133V） Operation setting when DTC occured Trouble code P0571 is stored in the memory. Fault lamp illuminate. Information Reference Circuit Circuit testing Connector repair Test intermittent faults and poor contact line repair DTC Type Reference Power system Diagnostic Trouble Code (DTC) type definition Fault diagnostic reference Refer to ”Control Module Reference” for information on the diagnostic tool。 Circuit/system check 1. Run the vehicle and check if the trouble code brake lamp switch is detected with the diagnostic tool 2. Check whether the engine fault indicator is illuminate in the instrument panel Circuit/System Test 1. The ignition switch in the ON position, with diagnostic tool clear DTC, turn off immediately after starting the engine and re-power, then read diagnostic trouble code is detected to reproduce. 2. Check whether the brake lamp signal circuit is short-circuited to ground / power supply. – If yes, replace the circuit – If not ， replace the brake lamp switch assembly. 3. All circuit detects normal, replace the engine control module.
9-84 Engine control and fuel systems -1.2 L（new LMH）
9.2.3.33 DTC P0650
9.2.3.34 DTC P0688
Diagnostic instruction Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle” For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Troubleshooting instruction DTC P0650 MIL lamp drive circuit failure Run DTC condition Ignition voltage is between 9-16 volts. Engine start. Set DTC condition Module internal circuitry detects a fault line Operation setting when DTC occured Trouble code P0650 is stored in the memory. Fault lamp illuminate. Information Reference Circuit Circuit testing Connector repair Test intermittent faults and poor contact line repair DTC Type Reference Power system Diagnostic Trouble Code (DTC) type definition Fault diagnostic reference Refer to ”Control Module Reference” for information on the diagnostic tool。 Circuit/system check 1. Run the vehicle and check the trouble code whether MIL lamp is detected with the diagnostic tool 2. Check whether the engine fault indicator is illuminate in the instrument panel Circuit/System Test 1. The ignition switch in the ON position, with diagnostic tool clear DTC, turn off immediately after starting the engine and re-power, then read diagnostic trouble code is detected to reproduce. 2. Check whether the MIL lamp drive circuit is shortcircuited to ground / power supply. – If yes, replace the circuit – If not，replace the meter instrument。 3. All circuit detects normal, replace the engine control module.
Diagnostic instruction Before using this diagnostic program, be sure to perform “Diagnostic System Check - Vehicle” For an overview of diagnostic methods, refer to the “policy-based diagnostics.” The Diagnostics Description provides an overview of the various diagnostic categories. Troubleshooting instruction DTC P0688 Main relay output voltage signal fault Run DTC condition Ignition voltage is between 9-16 volts. Engine start. Set DTC condition Main relay voltage level signal check
