“Only for You”Maintenance Manual

Foreword Catalog
This Manual is prepared for the technical
Item Group No.
personnel authorized for the maintenance of
“Only for You”car to assist them in achieving General Items GI

the effective and proper maintenance. Engine Maintenance MA

In order to ensure the satisfaction of users, Engine Overview EM
the special technical personnel for “Only for
Engine Mechanical System EM
You” car are required to provide warm
service and proper maintenance. For this Engine Electrical System EE

purpose, it is very important for the Engine Control System EMS

maintenance personnel to fully understand Gearbox MT
this Manual. Also, this Manual should be put
Clutch CL
in such a place convenient for reading and
Front Suspension FSU
reference at any time.
All the content in this Manual, including Rear Suspension RSU
figures and technical parameters, are latest Brake System BR
by the issue date. However, when the
Anti-lock Brake System ABS
maintenance is affected due to the
Power Steering System PS
improvement of products, JAC will issue a
technical bulletin or provide supplementary Inner & Outer Trimmings EI

volumes. So, it is important to pay attention Central Controller BCM

to and collect the updated information Door Lock Control System BL
concerned.
Lighting and Illumination LT
JAC reserves the rights to change, add or
improve the design. Without the previous Reversing Radar BCR

approval of the issuer, no part of this Manual Safety Restraint System SRS
is allowed to be copied or amended.
Using any non-original fitting out of JAC or
unqualified oil/fuel may damage the car.
 Error Reporting and Suggestion
For any error found in this Manual or any suggestion, please contact JAC in form of letter or
fax for error reporting and suggestion, addressed as follows:
JAC Sedan Marketing Company
Address: No.282 Danxia Road, Taohua Industrial Park, Hefei City, Anhui Province
Post Code: 231202

For contact purpose, please prepare the following information:

□ Your name
□ Name of special maintenance center
□ TEL and FAX of special maintenance center
□ Vehicle model
□ VIN of your car
□ Descriptions concerned
□ Necessary information
□ Any applicable electronic information and part identification number

JAC will respond in the following form:

□ Transferring your question to the related maintenance engineer;
□ Consulting with the related maintenance engineer;
□ Providing you with the answer within 10 workdays

Any question you are interested is welcomed by JAC Sedan Marketing Company!
24-hour Service Hotline: 400-888-9933
Website: www.jac.com.cn
 GI-1

General Matters
Summary
This manual introduces all the procedures required by service operation, covering
the following 5 items:
— Dismantlement/installation
— Disassembly/assembly
— Replacement
— Check
— Adjustment
The simple operations that can be executed by observing the vehicle are omitted in
this manual.

Service Procedure
Check and Adjustment
The check and adjustment procedure is divided into several steps.
The key positions to be checked and adjusted and their procedures are illustrated in
details.

Repair Procedure
1． Most of the repair procedures begin with a summary illustration, which clearly
shows for you the subassemblies and their coordination, and describes the visual
inspection for spare parts.
2． All the dismantlement/reassembly procedures that require the systematic
operations are illustrated in details.
3． For the consumables, tightening torque, fuel, engine oil and sealant, this manual
gives marks for all of them. In addition, the special tools or the equivalent tools
necessary in practice are illustrated clearly at the preceding section of each chapter.
4． The illustration for procedure steps involves serial numbers. The technical
illustration indicates the main steps and the positions of spare parts concerned.
Occasionally, the key or extra information of specific procedure may be listed in the
technical illustration for reader’
s reference.

How to Use This Manuel

The Only for You Maintenance Manual comprises four volumes, namely engine, chassis,
body and electric appliance, and circuit overhaul.
Each volume covers the dismantlement/reassembly, working principle and
troubleshooting for Only for You car of current model. Such information is coordinated
when this manual is issued.
Also, both the detailed content and index are provided at the preceding section of each
volume, from which you can find the content you want quickly and easily.
 GI-2

Information of Vehicle Nameplate

The Vehicle Identification Number (VIN)
is located at the right shroud of engine
hatch.

Vehicle Identification Number

Just as shown in the following figure, the Vehicle Identification Number (VIN) is composed
of three sections, totaling 17 character places without anyone empty as stated in
GB16735 Standard.
Of which, the first section is the world manufacturer identifier (WMI), the second is the
vehicle description section (VDS), and the last is the vehicle indication section.
 GI-3

①, ②, and ③ Characters — — code of Anhui Jianghuai Automobile Co., Ltd.: LJI

④ Character — — vehicle type
Type
Code Vehicle Type
2 Passenger vehicle
6 Passenger car and class III chassis

⑤ Character — — type of vehicle

body
Type

Code Type of Vehicle Body

A Front engine car and class III chassis
F Three-compartment sedan

⑥ Character — — max. gross weight (kg)

Code Max. Gross Weight (kg)

A >2,000~3,500
K >1,000~2,000

⑦ Character — — length of car, bus and chassis (m)

Code Length of Car, Bus, and Chassis (m)

1 >3~4
2 >4~5
3 >5~6

⑧ Character — — type and rated power of engine (kw)

Code Engine Rated Code Engine Rated

Type Power Type Power
C Diesel >60~90 1 Petrol ≤70
D Diesel >90~115 2 Petrol >70~90
E Diesel >115~135 3 Petrol >90~110
F Diesel >135~165 4 Petrol >110~130

⑨ Character — — inspection place

 GI-4

⑩ Character — — year code as specified uniformly in the world

⑾ Character — — code of marking location of assemblage factory

Code Code of Marking Location of

Assemblage Factory
7 General Assembly I of Car Manufacture
Company
4 General Assembly I of Car Manufacture
Company

⑿~⒄ Characters — — sequence number

It stands for the serial number of vehicle production. This number is arranged annually
based on the vehicle category of the same series produced in the assemblage factory. If
the number is not long enough for such places, the left places may be occupied by “0”.
The VIN system for current vehicle category is shown as follows:

VIN
1~3 4 5 6 7 8 9 10 11 12~17
Place
Type
Type Length and
Max. Production
Vehicle Vehicle of of Car Rated
WMI Gross Inspection Year Assemblage Sequence
Category Type Vehicle and Power
Weight Number
Body Bus of
Engine
Depending
C-class on
LJI 2 F K 2 2 4
Vehicle Production
Plan
Depending
on
SRV LJI 6 A A 2 2 4
Production
Plan
 GI-5

Using of Lifter
It is very dangerous to lift the vehicle in wrong method, for during the incorrect lifting, the
vehicle may slide down from the lifter, resulting in serious injury or fatal accident. To
avoid such accident, the vehicle should be lifted according to the regulations.
1. Place the four outriggers of lifter at the four supporting points of vehicle;
2. Adjust the outriggers to proper angles;
3. Lift the vehicle to a proper height and check if the supporting is firm or not;
4. Lift the vehicle to the wanted height and apply the safety device.

Attention:
When lifting or lowering the vehicle, make sure there is no object or working
personnel under the vehicle.

Vehicle Supporting and Lifter

The lifting points are shown by arrows in the figure above.

Attention:
1. Don’
t use the jack at the position under the cross rod or the rear suspension
assembly;
2. To avoid the damage of auxiliary beam, always put a piece of cloth on the contact
surface of the jack so as to prevent the coating from erosion due to damage;
3. Don’
t support the vehicle by using only one jack, and always use the safety post;
4. Don't try to lift one side of the vehicle by placing a jack in the middle section between
front and rear wheels, which may cause the permanent damage of vehicle body.
 GI-6

Protection of Vehicle
Before the working, make sure the vehicle is equipped with “four-piece set”, including seat
cover, steering wheel cover, gearshift lever cover, and foot mat. Always cover the engine
hatch fender with the protective pad when opening the engine hood for the overhaul of
engine.

Precautions for Welding

Various electrical parts are mounted on the
vehicle. In order to prevent such parts
suffering from too high current during the
welding, the following procedure should be
executed:
1. Screw the ignition switch to "Lock"
position.
2. Cut off the battery wire.

3. Earth the welding equipment carefully,

with the earthing position nearby the
welding area.
4. Cover the surrounding equipment around
the welding area properly to protect them
from solder.

Towing Vehicle
If the vehicle needs to be towed, please contact the special after-sales service center of
JAC car or the professional towing service company.
Attention:
① Don’
t permit any passenger in the vehicle being towed;
② Don’
t tow the vehicle with a speed above the safety speed or the specific road speed
limit;
③ Don’
t use the damaged part that has not fully and firmly fixed on the vehicle for
towing;
④ Any nonobservance of the precautions above may cause injury.

Use the Wheel Lifter to Drag Your Vehicle

1. Switch on the danger warning flash lamp.
2. Turn the ignition key switch to the ACC (accessories) position.
 GI-7

3. Shift the gear to neutral position.

4. Release the parking brake.

Attention:
If it is necessary to tow your vehicle from the rear,
please apply the supporting wheel of towing device
under the front wheel. Never make the front wheel
contact with the ground when towing from the rear. If
the front wheel contacts with the ground, the
gearbox may be damaged seriously.

5. Always make the front wheel away from the

ground in towing.
Attention:
Never use the sling chain type equipment for towing;
Always use the flat truck or wheel lifter for towing.

Emergency Towing
If there is no towing vehicle on the site under emergency, fix a rope onto the emergency
towing hole under the vehicle to tow the trouble vehicle temporarily.

Front Towing Hole

The front towing hole is under the front bumper. A
driver is required in the cab to control the steering
and brake when towing. This towing may be
conducted only on the hard pavement within a
certain distance and at a certain speed, and with
such parts as wheels, axles, driving system,
steering system, and brake system in good running
conditions.
 GI-8

Attention:
In the towing by rope, the vehicle may be damaged.
In order to minimize the damage,
① If there is no other towing equipment, always use the towing hole.
② Tow the vehicle only from its front end.
③ Keep the towing rope away from the bumper.
④ Make sure that both ends of towing rope are fixed onto the towing hole through the
inspection by drawing the towing rope.
⑤ Drive slowly and don’
t apply sharp turning.
Attention:
① In the towing by rope, the towed vehicle may go out of control.
② For any damage of wheel, gearbox, axle, steering system or brake system, don’
t
conduct the towing.
③ Don’
t pull out the key from the ignition switch; otherwise, the steering may be locked
so that the vehicle can’
t travel.

Rear Towing Hook

The rear towing hook is used to tow another
vehicle. It may be used only under emergency (for
example, to tow the vehicle plunged in ditch, thick
snow or mud pit). When the rear towing hook is
used, do make the rope or chain perpendicular
with the towing hook. Don’
t apply the lateral force
to the towing hook, and don’
t start the towing
fiercely in order to avoid damage.
 Engine Volume

Preface

This Benjoy Maintenance Manual is prepared to help the technical service

personnel exactly understand and acquaint him with JAC cars, thus enabling
them to fast and reasonably maintain JAC cars. This Maintenance Manual
consists of four volumes respectively for the engine, chassis, vehicle body &
electric appliance, and circuit overhaul.
The engine volume explicates the 2.0 L4 and 2.4 L4 engine systems integrated
in the Benjoy car and the technical standards for dismantlement & reassembly,
detection, commissioning, and diagnosis of each component.
For replacement of fittings, only the original ones recommended by JAC can
be used. In maintenance, always observe strictly the tightening torque given in
the maintenance manual. If the efficiency of locking device is damaged during
the dismantlement, the replacement with a new one is required.
No part of this Manual may be reproduced or used in any form or by any
means without prior written license; otherwise any infraction will be prosecuted
for.

Compile

July, 2007
 Engine Volume

Contents of Engine Volume

Maintenance of Engine
Operation Flow and Specification for Operation Flow and Specifications for
Maintenance of Engine................ MA-1 Maintenance of Engine’
s Intake System
Lubricating System of Engine.... MA-1 ........................................................MA-17
Engine Belt and Engine Appearance Operation Flow and Specifications for
....................................................... MA-7 Maintenance of Engine’
s Oil Circuit
Operation Flow and Specification for ........................................................MA-22
Maintenance of Cooling System MA-12

Engine Overview (2.0 L4)

Overview ....................................... GI-1 Common Troubles and Causes.... GI-10
Specifications and Parameters .. GI-3 Special Tools.......... ......................GI-11
Tightening Torque............... ........ GI-8

Mechanical System of Engine (2.0 L4)

Precautions .................................. EM-1 Lubrication....................... ............EM-54
Preparations............ ..................... EM-2 Replacement of Engine Oil and Oil
Engine Assembly...................... ... EM-3 Filter...............................................EM-56
Cylinder Compression Pressure Test. Check of Engine Oil Level...........EM-56
....................................................... EM-7 Cooling System. ...........................EM-57
Cylinder Burning Pressure Leakage Coolant..........................................EM-61
Test ................................................ EM-8 Water Pump......................... .........EM-65
Standard Detection Procedure ... EM-10 Radiator and Thermostat............ EM-66
Timing System. ............................ EM-13 Radiator Cover… ..........................EM-69
Oil Pan and Pickup.......... ............ EM-20 Radiator Fan Motor Assembly… ...
Drive Belt.................. .................... EM-22 ........................................................EM-72
Oil Pump and Balancing Shaft. .. EM-26 Thermostat....................................EM-75
Cylinder Head Assembly............. EM-34 Intake System............... ................EM-80
Valve Mechanism ......................... EM-37 Exhaust System............... ............EM-84
Crankshaft Connecting Rod Diagnosis of Common Engine Troubles
Mechanism and Cylinder Body .. EM-43 ........................................................EM-87
Connecting Rod of Piston........... EM-50
 Engine Volume

Engine Overview (2.4 L4)

Overview. ...................................... GI-1 Common Troubles and Causes ..GI-11
Specifications and Parameters .. GI-3 Special Tools........ ........................GI-13
Tightening Torque............. .......... GI-8

Electrical System of Engine

Overview..................... .................. EE-1 Check........... .................................EE-10
Specifications and Parameters .. EE-1 Generator......... .............................EE-15
Tightening Torque.................. ..... EE-2 Storage Battery.............................EE-20
Troubleshooting........................... EE-3 Starting System Overview...........EE-23
Ignition System Overview............ EE-5 Composing Components... .........EE-23
Ignition Coil................ .................. EE-6 Check........... .................................EE-24
Dismantlement and Installation... EE-7 Dismantlement and Installation.....
Ignition Plug Test........ ................. EE-9 ........................................................EE-25
Charging System Overview... ..... EE-10

Engine Control System

Precautions....... ........................... EMS-1 Sensor........................ ................. EMS-39
Preparations.............. ................... EMS-4 DTC P0201, P0202 P0203, P0204 Fuel
Fuel Evaporation and Emission System Injector........................ ................ EMS-45
....................................................... EMS-6 DTC P0230 Oil Pump Relay and Oil
Positive Crankcase Ventilation System Pump.... ....................................... EMS-48
..................................................... EMS-10 DTC P0325, P0670 Knock Sensor
OBD (On-board Diagnosis) System...... ...................................................... EMS-52
..................................................... EMS-12 DTC P0335 Crankshaft Position Sensor
Engine Control Tactics.............. EMS-17 ...................................................... EMS-53
DTC Index............. DTC P0351, P0352 Ignition Coil EMS-55
..................................................... .EMS-2 DTC P0443 Carbon Canister Solenoid
5 Valve... ......................................... EMS-59
Diagnosis System Interface Special for DTC P0480, P0481 Cooling Fan
JAC Car...... ................................. EMS-26 ...................................................... EMS-61
DTC P0105 Intake Manifold Absolute DTC P0500 Speed Sensor ......... EMS-63
Pressure Sensor........................ EMS-27 DTC P0505 Idle Stepper Motor.. EMS-64
DTC P0110 Intake Temperature DTC P0560 Too High System Voltage
Sensor....... .................................. EMS-31 ...................................................... EMS-66
DTC P0115 Water Temperature DTC P0650 Trouble Indicator Light
Sensor....... .................................. EMS-33 ...................................................... .EMS-6
DTC P0120 Throttle Position Sensor 6
..................................................... EMS-36 DTC P1230 Main Relay............... EMS-67
DTC P0130, P0135 P0170 Oxygen DTC P1530 P2000 Air-conditioned
 Engine Volume

Compressor Control.................. EMS-68

DTC P604 ECM ........................... EMS-70
Common Trouble Maintenance Flow
..................................................... EMS-73
 Engine Volume MA-1

Operation Flow and Specification for Maintenance of Engine

Lubricating System of Engine
Ⅰ. Application of Engine Lubricating Oil (Engine Oil)
Engine oil, which plays an important role in the lubrication, rinse, cooling, rust
protection and sealing etc. on the friction surface of engine, is the “blood”of engine.
Choosing the right engine oil can ensure reliable travel of vehicle, abrasion
minimization of parts, economization in fuel consumption and extended life of engine.
So, user shall get the idea of function, specification, number, classification and so on
regarding engine oil, and master how to use such oil.
(I) Classification of Engine Oil
The variety and the specification of engine oil, which is made by adding such
additives as metallic detergent, ashless dispersant, oxidation and corrosion inhibitor,
viscosity index improver, pour point depressant, kilfoam and antirust to the basic oil
composed of refined mineral oil and synthetic oil, are differentiated according to the
performance of basic oil and the quantity of each additive. Presently, API
performance classification method and SAE viscosity classification method of
lubricating oil in USA are recognized and adopted all over the world. China has
established two such national standards as GB/T7631.3-1995 Classification of
Engine Oil and GB/T14906-94 Viscosity Classification of Engine Oil in line with
two engine oil classification methods above, and drew up the quality classification
method and the viscosity classification method of engine oil in our country.
1. Introduction of Engine Oil Quality Grade
API Standard (API=American Petroleum Institute):
This is a standard which comprehensively measures engine oil’
s quality, and
ascending grades of oil quality are listed as follows: SA, SB, SC, SD, SE, SF, SG, SH,
SJ, SL. Presently, Grade SL engine oil possesses the highest quality amongst
worldwide engine oils. Introduction for each grade of engine oil is shown in the
following table.

Low SA In the early 1930s, pure mineral oil not including additive.
SB In the late 1940s, first engine oil including additive, antirust and antioxidant.
(Quality) SC In 1964, providing the protection against high temperature and
low-temperature sediment, abrasion, rust and corrosion.
High SD In 1968, better than SC in performance.
SE In 1972, providing more protection against oxidation, rust, corrosion and
high-temperature sediment.
SF In 1980, better than SE in oxidation stability.
SG In 1989, better than SF in control of engine sediment, engine oil oxidation
and engine abrasion.
SH In 1993, more strict than SG in test program.
SJ In 1996, top-grade engine oil in the world then.
 Engine Volume MA-2

SL In 2002, upgraded version of SJ.

 Engine Volume MA-3

2. Introduction for Viscosity Grade of Engine Oil

SAE Standard (SAE=Society of Automotive Engineers):
This is a standard which measures the viscosity of engine oil, and the viscosity is
classified into the single-viscosity (e.g. SAE40) and the multi-viscosity (e.g.
SAE15W-50). For multi-viscosity, “W”means winter; the smaller the digital in front of
“W”is, the more resistant to low temperature the engine oil is; the bigger the digital in
back of “W”is, the better the retention of high-temperature oil film is.
Presently, a variety of lubricating oils made by normal manufacturers are
differentiated according to these two standards. So, the API grade and SAE grade
are marked on the package housing of their products. Which engine oil to use shall
be found on either user’
s guide for vehicle or the engine housing. For example, in
case of “SF”labeled on the housing of engine, engine oils of grades over or equal to
SF are available. Of course, the higher the grade is, the more expensive the engine
oil is.
II. Check and Replacement for Engine Oil
(I) Maintenance Requirements
1. Expiration of maintenance term specified by manufacturer
2. Oil leakage of engine
3. Blue smoke discharged from engine and engine oil burned
4. Engine oil level beyond specified range
5. Deterioration of engine oil

(II) Maintenance Steps MA00

1. Park the vehicle on the flat road and wait for the
reflux of engine oil by over ten minutes.

2. Open the engine cover, pull out and clean the oil
rule, then insert the oil rule back, pull out the oil
rule again and check the oil level.

3. Get a clean special paper and dribble a drop of oil

on it to check the quality of engine oil.
MA00
(1) Engine oil of poor quality
 Engine Volume MA-4

(2) Engine oil of good quality

MA00

MA00
4. Screw off the cover for adding engine oil.

5. Jack up the vehicle.

MA00
6. Dismount the protective board of crankcase oil
tray.

7. Unscrew the bleeding bolt of crankcase oil MA00

tray.

8. Adjust the upper oil container of oil changing

machine to appropriate height and position,
and make it under the oil bleeding hole.
 Engine Volume MA-5

9. Screw off the bleeding bolt of crankcase oil

MA00
tray to clean it and put it in the proper position. MA00

10. Drain out the engine oil.

11. Replace the seal ring and mount the bleeding bolt MA00
on the crankcase oil tray.

Tightening Torque: 35~45 N·m

12. Put down the vehicle.

13. Fill the engine with proper quantity of engine oil
MA00
from the adding hole.

14. Start the engine and check whether there is

leakage.
15. Stop to take check, and drain/add the oil as the
case may be.
16. After the oil replacement, paste the mark for next oil replacement mileage and date at
the conspicuous place in engine hatch.

(III) Precautions
1. Vehicle shall be parked on horizontal road, when being checked for the oil level.
2. Pay attention to safety during the lifter operation. (Refer to the precautions of lifter.)
3. Replace the old oil with the new one when engine reaches the normal working
temperature (80℃~90℃).
4. In case of some vehicle equipped with magnetic bleeding plug screw on engine oil
disk, iron filings attached on bleeding plug screw shall be removed after the complete
drain of oil.
 Engine Volume MA-6

5. If possible, it is better to use vacuum oil sucking equipment, which can suck old oil
completely at the time of replacing engine oil.
6. Don’
t add excessive oil, otherwise it may lead to high temperature of engine, get into
combustion chamber for burning to increase the emission leads to the failure of
three-way catalyst.
7. Adding insufficient oil may lead to low oil pressure, insufficient flow and lubrication and
mechanical abrasion in the presence of high speed.
8. The bleeding bolt shall be tightened according to the specified tightening torque so as
to avoid the slipped thread.
9. Replace seal ring again when mounting bleeding bolt every time.
10. Wipe up the bleeding bolt and its circumference by dishcloth or paper towel when
mounting it.
11. The selected type of engine oil shall be right.
12. Remind owner of the mileage or time for next maintenance.
13. Establish maintenance archives.

(IV) Maintenance Specification

1. Selection of Engine Oil Type (SJ 10W-30)

Petrol & Engine Oil SJ 10W-30

2. Replacement Cycle of Engine Oil
Check the oil on oil rule. Any discoloration shall be unwanted (except for blackening
oil). When engine oil reachs the interval mileage of usage or the oil replacement index,
it is necessary to replace the oil immediately.
3. Tightening Torque of Bleeding Bolt
4. Identification of Engine Oil Level

5. Judgment of Engine Oil Quality

To determine whether the engine oil is metamorphosed, the method of “looking,
smelling, pinching and associating”shall be applied:
① Looking — get little engine oil by oil ruler and dribble the oil on one piece of clean
neutral filter paper (failing the filter paper, the white paper shall be available) and
 Engine Volume MA-7

one piece of plastic paper respectively. After 10mins or so, observe the shape
and gloss. After the diffusion of oil drop on neutral filter paper, the circle ring
appearing around the diffusion spot means the water in the engine oil; and the
more the rings are, the more the water is. In case of much water in engine oil, the
oil drop sampled by the oil ruler appears milky with foam, and vaporizing beads
can be found on the surface of oil ruler when the vehicle is warm. If the upper
color of oil drop on plastic paper goes dark or even loses gloss, this means the
failure of additive in the engine oil.
② Smelling — approach and smell the odor of diffusion spot of engine oil on filter
paper. If the petrol odor is smelt, this means the petrol has mingled with the
engine oil.
③ Pinching — get a drop of engine oil between forefinger and thumb to pinch it.
Particle feeling means many impurities (e.g. mechanical abrasion, dust brought
in engine by air, and the lead oxide particle produced by the burning of leaded
petrol) in engine oil. Spread two fingers, the length of oil thread over 3mm means
the rather high viscosity of engine oil; no slippery feeling at the time of pinching
oil, and the length of oil thread less than 2mm mean that the engine oil is too thin.
④ Associating — associate the recent mechanical troubles of engine with the
phenomenon inferred from “looking, smelling, pinching and thinking”by scientific
analysis and estimate in order to correctly determine whether the engine oil is
degenerative.
 Engine Volume MA-8

III. Replacement for Engine Oil Filter

(I) Requirements for Maintenance MA01
1. Expiration of maintenance term specified by
manufacturer

2. Worsening quality of engine oil

MA01
3. Replacement for engine oil

4. Smudginess of oil circuit or filter

(II) Maintenance Steps

Drain out the old engine oil.
1. Unscrew the engine oil filter with special tools.
2. Screw off the engine oil filter by hand and put it aside.
3. Wipe up the installation place of engine oil filter by dishcloth or paper towel.
Fetch a new engine oil filter and install it into the housing of filter, replace seal ring.
Apply some engine oil to the installation place of new filter and mount the filter in the
engine. Fasten the oil filter in accordance with the specified torque by special tools.
Wipe up the filter and its circumference by clean dishcloth or paper towel. Add engine
oil and check the leakage.

(III) Precautions
1. Installation place of engine oil filter depends
on the model of vehicle. Some vehicles are
dismounted from the top, and others are
dismounted from the bottom.
Apply engine
2. Choose proper special tools when
oil
dismantling or installing the engine oil filter.
3. Apply some engine oil in the interface during
the installation of new engine oil filter.
4. Replace the old seal ring with new one
during the installation of new engine oil filter.

(IV) Maintenance Specification

1. Tightening torque: 12~16 Nm
2. Replacement cycle
 Engine Volume MA-9

Same as engine oil’

s, with the oil filter replaced along with engine oil.

Engine Belt and Engine Appearance

I. Maintenance and Operation Flow of Engine Belt

(I) Maintenance Requirements
1. Routine maintenance

2. Breakage of belt MA01

3. Overhaul of engine

4. Replacement of generator, water pump and so on

MA01

5. Wrong timing of engine

(II) Maintenance Steps

1. Check the appearance of engine belt visually to see whether crazing, abrasion and
shedding are found; replacement is recommended, if anything above is found. Check
the timing belt carefully; if one of the following defects is found, it is necessary to
replace with new belt:
(1) The reverse rubber is hardened, smooth and
inelastic to the extent that no track is left by using the nail to scratch (see the
following figure).

MA01
 Engine Volume MA-10

(2) C MA01 Circular angle at edge

racks appear on the surface of
reverse rubber.
(3) The canvas is tore or separated from the
rubber.

Abnormal abrasion
(Exposed core)

(4) Cracks appear at tooth root.

MA01
(5) Cracks appear on the side face of belt.
Rubber exposed due
(6) Abnormal abrasion appears on the side face
to abraded canvas
of belt
(7) Abnormal abrasion of tooth occurs.
No tooth
Initial stage: it is difficult to recognize
the incompact canvas fiber, the lost
rubber structure, the faded white color
and the canvas structure.
Last stage: the canvas is abraded, the
rubber is exposed, and tooth width is
reduced (see the following figure).
(8) Teeth are lost.

2. It is allowable to strongly press the driving

belt between two belt pulleys by your MA01
thumb to see whether the tension of
driving belt is proper.

3. If tempering and shooting phenomenon

are found in engine, check the timing of
engine belt by the timing lamp.

4. During the replacement of driving belt,

firstly unscrew the fixing bolt of generator
to push the engine towards the cylinder
body in order to make driving belt relax
and take the belt off. If necessary, it is
allowable to rotate the belt pulley while
pulling out the driving belt outwards.
 Engine Volume MA-11

5. Before taking off the driving belt, write

down the circuitous position of installation
for driving belt to avoid the mounting fault.
Carry out the installation according to the
opposite order for dismounting.
6. Align the timing of engine.
 Engine Volume MA-12

(III) Precautions
1. When mounting the driving belt to the belt pulley, it is necessary to check the fitting
conditions between driving belt and belt pulley. If driving belt and belt pulley are in
poor fitting, the life of driving belt may be affected to a great extent. Finally, after the
installation and adjustment have been done, it is required to check whether the driving
belt on belt pulley runs on the same plane. Running on different planes may lead to
the premature damage of driving belt.
Belt pulley

Right
Wron Wrong
2. When adjusting the tension of fan’ s driving belt, unscrew upper and lower fixing bolts
of alternator slightly, and push inwards or pull outwards the whole alternator by a
wrecking bar in order to adjust the tension of driving belt. After the adjustment, it is
required to screw down the fixing bolt firmly. Notice that: never adjust driving belt too
tightly, otherwise the high tension of driving belt may cause the damage upon fan
driving belt and bearing. During the operation, make sure that driving belt is away from
grease, or else grease may cause slide and abrasion to reduce the service life of
driving belt. In case of engine with two driving belts, these two shall be replaced
simultaneously.
3. Adjustment for tension of driving belt depends on the model of vehicle. In case of the
vehicle with automatic adjustment, manual adjustment is not needed. In case of
manual adjustment, it is allowable to move the generator or the oil pump of power
steering device by unscrewing the bolt (nut) with the double offset ring spanner and
the socket spanner.

(IV) Maintenance Specifications

1. After new driving belt runs for 30~60min, its tension shall be checked and adjusted
again according to the method above to prolong its life. It is required to check again
after the vehicle covers 1,000Km; and henceforth, distortion of driving belt shall go
stable.
2. Adjustment and check for timing belt
Check and adjust the timing belt according to the maintenance manual of every model
of vehicle.

II. Cleaning for Engine Appearance

1. Stall the engine.
2. Open the engine hatch cover.
3. Spray the special cleaning agent for engine appearance on the engine body.
4. Clean the engine with a fluffy brush.
 Engine Volume MA-13

5. Take off the cover plate of engine.

6. Cover the ignition plug hole of engine and the ignition coil by a clean towel to keep
water away from ignition system.
7. Clean the cover plate of engine by cleaning agent.
8. Rinse the engine with undefiled water.
9. Spray the engine cleaning agent again to clean the lower place of engine cover plate.
Attention: ensure water away from ignition system while cleaning here.
10. Have the engine dried by compressed air after the cleaning.
11. Start engine to check whether its operating conditions are normal.
12. After the check, wax the outer surface of engine to make it easy to clean next time.

Attention:
1. Pay attention to the water prevention for ignition plug and ignition coil.
2. Heed whether there are crack in fuse box and the relay box.
3. Rinse the engine as seldom as possible to avoid the damage of generator.
4. Be sure to block the air inlet before rinse so as to keep water away.
5. Never rinse the engine by the high-pressure water gun.
6. The long-time rinse is unallowable during the cleaning for engine.
7. The cleaning shall be carried out by special cleaning agent for engine.
 Engine Volume MA-14

Operation Flow and Specification for Maintenance of Cooling

System
I. Application of Anti-freezing Solution
The operating temperature of engine is overhigh and the upper limit value of normal
operating temperature generally exceeds 100℃. In case the cooling system is full of
water and the temperature of engine reaches 100℃, cooling water shall go boiling;
what’ s worse, the boiling water bears causticity engenders scum, which adversely
affects the cooling effect. So the anti-freezing solution, a special cooling agent, is
used in the cooling system.
The major constituent of anti-freezing solution is ethylene glycol, which is provided
with characteristics such as high boiling point and low freezing point. Furthermore,
the additive is plunged into anti-freezing solution to avoid the oxidation of ethylene
glycol (byproduct of high causticity came into being), the corrosion, the foam and so
on.
Anti-freezing solution used by engine possesses the following functions:
1. Exercise a protection against the corrosion influence on components of cooling
system.
2. Prevent the scum and avoid the inferior radiation function of radiator.
3. Make sure that the engine runs within the normal temperature range.
Therefore, the anti-freezing solution of engine must be provided with such
characteristics as freezing protection, boiling prevention, corrosion protection, no
scum and no foam, and independent of seasons and zones. Especially, freezing point
and boiling point are essential indices of anti-freezing solution. At the time of using
the anti-freezing solution, its quality shall be heeded. If the anti-freezing solution is
poor or even fake, it is impossible to achieve the intended effect; what’ s more, the
engine may be damaged due to the corrosion from bad anti-freezing solution.
Coolant is mixed with anti-freezing solution and water according to certain ratio.
Generally, the ratio of anti-freezing solution versus water is 4:6, and the boiling point
and the freezing point of coolant are 106℃ and -26℃ respectively. In case of the ratio
of 5:5, the boiling point is 108℃ and freezing point is -38℃. The effective use life of
anti-freezing solution lasts for 2 years; the anti-freezing solution shall be replaced,
once it is due or the coolant is found too dirty. During the replacement, be sure to
remove the old coolant completely and then add clean water. Drain out the clean
water after the engine has been running at idle speed for a period. Adding new
coolant shall be carried out when the machine is cold.
II. Check for Coolant
(I) Flow and Operation Specifications of Coolant Level Check
1. For the cooling system without expansion tank, it is allowable to open the cover of
radiator to check. The level of anti-freezing solution is required to be about 50~70mm
lower than exhaust hole. (This is for the purpose of avoiding the overflow of
anti-freezing solution due to the increased temperature);
2. For the cooling system with expansion tank, the check shall be done in the presence
of cold vehicle. Make sure that the coolant level shall stay within the specified lineation
(H~L) or (MAX~MIN).
3. Inspection for coolant quantity shall be conducted when the vehicle is cold. The cover
of radiator shall be fastened after the check. Try to use the soft water or the same
 Engine Volume MA-15

paint-proof liquid. Check whether there is leakage before adding.

(II) Flow and Operation Specifications of Coolant Quality Check
1. Quality check: check whether the coolant is deteriorated, turbid and contaminated by
oil; if the fact is positive, replace the coolant.
 Engine Volume MA-16

Illustration:
When the necessary conditions are present, try to carry out the freezing point check
by the freezing point tester to test the concentration of coolant. Adjust the
concentration of coolant according to the testing results.
For testing the freezing point of engine coolant and the capacity of battery, the
refractometer provides a quick and simple testing method. The refractometer is
equipped with the automatic temperature compensation system, which can timely,
precisely and directly read freezing points of ethylene glycol coolant, propylene glycol
coolant and other anti-freezing solution.
DC60 Duo-Chek, Celsius
Specific gravity: 1.100 - 1.400 scale 0.01
Cooling protection:
Ethylene glycol: 0℃ to -48℃
Propylene glycol: 0℃ to -48℃
Graduation plate scale: 3℃
Graduation plate for coolant concentration
Ethylene glycol: 0-70%
Propylene glycol: 0-61%
Refractive index range: 1.3330 - 1.4048
(III) Check for Coolant Leakage
1. Make sure that coolant level has reached the maximum point. Mount the checker of
radiator cap and exert the pressure of 1.6kgf/cm2 to check whether there is leakage in
the radiator hose or the radiator joint.
2. Be sure to mop up the water around the check
position. Don’ t spill coolant when taking out the
tester. When mounting and dismounting tester or
carrying out the test, be careful not to make the
adding port distorted. If leakage is found, relevant
parts shall be maintained or replaced.
III. Replacement for Coolant
(I) Flow and Operation Specifications of
Water Draining
1. Start the engine, turn the air conditioner to the top heating grade, and fully open the
throttle valve of warm-air water box.
2. Shut down the engine, and wait that temperature of engine coolant falls normal
(30℃~40℃).
3. Drain out the engine coolant into the specified recovering container.
4. Do not spill the anti-freezing solution because of the toxic ingredient in coolant. Put
the anti-freezing solution into the special recovering container for the purpose of
professional treatment. In case of accidental
contact, rinse out the anti-freezing solution with
water as soon as possible.
(II) Flow and Operation Specifications of
Water Adding
1. Make sure that draining switch is turned off.
2. Add the engine coolant of specified specification
 Engine Volume MA-17

according to the model of vehicle.

3. Add the coolant till the maximum point mark of
coolant cylinder.
4. Screw down the cover of stock solution tank and make engine operate for 5~7min.
5. Then check the coolant level, and add the coolant till the maximum point mark if
necessary.
(III) Flow and Operation Specifications for Air Discharging of Cooling
System
a) Since the structure of cooling water circulation system in vehicle is complicated and
cooling systems of most vehicles are after the manner of airproof pressurization, the
air found in circulation system may lead to the unfavorable circulation, the poor heat
dispersion, the steep increase in temperature, and finally the boiling.
b) Structures of cooling systems amongst models of vehicles are different, so that ways
of discharging air are various too. The specific operation method shall be based on
the acquaintance with the structure of each model of vehicle and differentiated by the
specific model of vehicle.
c) Air discharging of cooling circulation system:
i. Strictly follow the maintenance steps according to maintenance manual.
ii. Carefully accomplish every discharging step without hurry.
iii. Ensure the complete air discharging.
iv. Start the engine to conduct the test till the start of fan.
v. Carefully check whether there is leakage around the discharging position and
whether the engine temperature is normal.
vi. Especially, examine whether the engine is normal during the increase of engine
temperature.
vii. In case of incomplete air discharging and abnormal temperature, it is necessary
to shut down the engine timely and discharge the air again after the coolant
temperature has been in parallel with the room temperature.
(IV) Check and Maintenance for Coolant
1. Generally, it is enough to judge the conditions of cooling system only by checking the
stock solution tank. It is right when the level of cooling water reaches the horizontal
datum line of cylinder.
2. Take off the cover to check the interior smudginess conditions. In case of poor
maintenance, cooling water shall be black, and sometimes the dirt may be attached at
the bottom of cylinder.
3. Clean the interior of stock solution tank, when replace the cooling water. Take the tank
out and then clean its interior by the brush.
4. It is feasible to drain out the cooling water in a short time by unscrewing the screw under
the cooler.
5. Clean the interior and dash out the dirt by rinsing with tap water. Jack up the rear end
of vehicle to make it easy to drain out the cooling water.
6. Screw down the draining screw after the cleaning, and add the coolant, whose
coolant-water ratio shall be based on the outdoor temperature. Generally, the
coolant-water ratio shall be 4:6.
(V) Use Directions for Anti-freezing Solution
When using anti-freezing solution, pay attention to the following items:
 Engine Volume MA-18

1. Before adding the anti-freezing solution, add the sodium hydroxide solution of 10%
concentration into water tank for the purpose of rinsing and dunking for 30~60min and
then slowly drain the solution out. Later, rinse the water tank for 2~3 times by soft
water to scour off the scum in order to avoid the shedding of scum due to the contact
with anti-freezing solution, which may lead to the blockage of pipeline and the
overheating of engine resulting from the abnormal heat dispersion.
2. Check the cooling system to preclude it from leakage, and then add the anti-freezing
solution.
3. Drain out the cooling water in cooling system, so as to prevent the residual water from
diluting the prepared coolant and avoid the change of freezing point.
4. Prepare the anti-freezing solution of proper solidifying point and using concentration
according to the demand, and top up the water tank.
5. Although the anti-freezing solution is of high boiling point, huge heat capacity, small
evaporation loss and high cooling efficiency, it is shall be noted that the cooling
temperature for engine under anti-freezing solution is 10℃ higher than that under soft
water. At this time, such a phenomenon shall not be regarded as the trouble of engine,
and never open the cover of water tank to prevent the scald due to hot air.
(VI) Other Precautions
1. The anti-freezing solution shall be reserved in plastic drum with cover sealing to keep
foreign bodies away and avoid the volatilization and then deterioration. Keep the
anti-freezing pure and clean.
2. During the maintenance for vehicle, it is required to drain out the anti-freezing solution,
then add it back to water tank and complement the quantity after the deposition.
3. Choose the original and high-grade product of specified brand according to the
requirements of illustration to avoid the sham products. It is unallowable to add
sewage and hard water randomly due to the insufficient anti-freezing solution during
the running of vehicle.
4. For the long-acting anti-freezing solution, it is better to be depurated once a year in
order to avoid the blockage of water way, which may arise from the long-time usage
and the overmuch accumulated foreign body and lead to the overhigh temperature
and power reduction of engine.
5. It is necessary to keep the anti-freezing solution away from human body especially the
eyes because of its toxicity.
6. Generally, the validity period of long-acting anti-freezing solution lasts for 2 years.
Replace the anti-freezing solution as seldom as possible after its adding so as to
reduce the waste; but, it is necessary to frequently check its freezing point, proportion
and appearance; replace the anti-freezing solution timely if the increased proportion,
the thickening, the heightened freezing point, the deterioration, the malodor or the
foaming is found.
7. The replacement of anti-freezing solution shall be carried out when the vehicle is cold. It is
required to drain out the residual anti-freezing solution in the cooling system completely
and clean the water tank by soft water, and then add the anti-freezing solution till the
specified level.
(VII) Selection of Anti-freezing Solution
At the time of selecting the anti-freezing solution, the following items shall be
complied with:
 Engine Volume MA-19

1. Select the freezing point (which is the important index of anti-freezing solution.) of
anti-freezing solution according to the environmental
temperature. Generally, it is preferable that the
freezing point shall be 10℃ lower than the lowest
temperature of local winter;
2. Use the original anti-freezing solution specified by
JAC.
(VIII) Operation Flow and Specifications for
Check and Maintenance of Cooler
1. Check for appearance: check whether the cooling fin
outside the cooler is blocked and whether the cooling blade is inclined.
2. Clean the outer surface of cooler by the compressed air.
3. Repair the inclined part of cooling fin.
The proper cooling is crucial for the normal start of engine. The insufficient or the
overcooling may lead to serious effect. The cooling system of engine automatically
controls the flow of cooling water in big and small circulations by the start and the
shutdown of thermostat, in order to achieve the relative stability of cooling water’ s
temperature.
Insufficient Cooling and Overhigh Temperature of Engine May Give Rise to the
Following Abnormal Phenomena:
The normal cooperating clearance of each moving parts will be disharmonized, which
leads to the increased frictional resistance and the worse abrasion, especially the
movement between piston ring and cylinder wall. Under worse conditions, the burnout, the
seizure, the engine stopping or the cylinder scraping, and the piston or cylinder scoring
will occur. What is worst, the connecting rod will break up the cylinder body.
The lubricating oil will be diluted, the oil films amongst moving parts will be marred, and
the dry or half-dry friction and the accelerated abrasion will be consequently caused.
The air charging volume of engine will be lessened, which reduces the power of engine.
Overcooling for Engine may Lead to the Following Abnormal Phenomena:
The cooling water takes so much heat away that the engine power falls and the power
performance degrades. If the engine is too cold, the abrasion of cylinder will be
deteriorated: when the temperature of cooling water falls to 50℃, the abrasion rises
doubly; when the temperature drops to 30℃, the abrasion grow fivefold. The reason is
that if the temperature is too low, the hydrosphere in mixed gas is easy to condense into
water and react with sulfide in waste air to form the high-causticity acidoid, which can
seriously corrupt the surface of each friction element; meantime, because of cold, it is
easy for the liquid formed by mixed air to get into crankcase to dilute the lubricating oil and
affect the lubrication.
Consequently, it is so important of the cooling system to keep the running temperature of
engine within the optimum range. Generally, when the temperature of cooling water
around cylinder cover is kept at 80℃~90℃, the engine reaches its optimum running
temperature. At this time, power performance and economical efficiency of engine are
best.
Major Factors Affecting Cooling System
Because of the complicated operating conditions of vehicle engine, factors affecting the
cooling system have many phases. In brief, these are such factors as the circulating water
 Engine Volume MA-20

quantity, the heat dispersion efficiency and the air flow. For the optimum cooling
performance of vehicle cooling system, these three factors above shall be kept at certain
quantity and appropriate matching.
Circulating Water Quantity
The circulating water quantity is concerned with not only the structure and rotating speed
of water pump but also the quantity of cooling water and the structure of water flow. The
quantity of cooling water shall be in direct proportion to the power of engine, namely
0.3~0.4 L of cooling water for each kilovolt of power. In addition, the reasonable structure
of water flow may reduce the flow resistance, enhance the circulating water quantity and
achieve the equable cooling of engine cylinders so as to avoid the “dead zone”and the
local hot zone which appear as a result of excessively high temperature on heated parts
(especially the cover of cylinder and the wall of cylinder body).
Heat Dispersion Efficiency
Heat dispersion efficiency is mainly related with water tank. Modern vehicles mostly carry
the tube-strip water tank with pressure cover, which possesses the excellent performance
in heat dispersion. The pressure cover enhances the pressure inside system to make the
cooling water not boil even at 100℃, increases the inside-outside temperature difference
of radiator, heightens the capability of heat dispersion, and reduces the “dead water”
phenomenon which results from no direct contact between cooling water and exterior
environment. This is so-called “enclosed type cooling system”.
Air Flow
Air flow is mainly concerned with the diameter, speed and blade shape of fan, the sealing
of air deflector and the relative position of water tank cover and fan blade. The diameter
and the angle of fan blade greatly affect the air quantity.
Relative position of water tank cover and fan blade: generally, it shall be preferable that
the water tank cover contains 2/3 of longitudinal width of fan impeller. In addition, air flow
is also affected by the radial clearance between water tank cover and fan blade, and a
smaller clearance shall be better. However, because water tank cover and fan are out of
step when the vehicle is running, the clearance value shall be kept within 15mm~20mm;
yet, in the presence of the water tank cover and fan with rigid connection, the clearance of
5mm~6mm shall be better.
Sealing of air guide ring: the sealing of air guide ring may avoid the back flow of air and
the affection against air flow.
Application of Expansion Tank
For the engine with higher compression ratio, especially the diesel engine, the burning air
gets into cooling water easily as a result of high burning pressure, and this may give rise
to the mass foam and the partial vacuum in cooling system (i.e. so-called “cavitation”and
“vapor lock”phenomena) that may result in the sharp reduction of cooling water flow and
the high temperature in engine to badly affect the normal operation of engine. The solution
is to mount expansion tank by locating a still-water chamber (i.e. expansion tank) at the
top position of cooling system. The upper space of expansion tank is connected with
places of cooling system where foam is most easy to accumulate (such as the upper
water chamber of water tank and the cylinder cover), and the lower position is connected
with the water inlet of water pump by the water pipe (inner diameter: approximately
20mm). In this way, the foam in cooling system can be drained out quickly, the pressure
around water inlet of water pump can be enhanced by the still-water pressure inside the
 Engine Volume MA-21

expansion tank, and the possibility of “cavitation”and “vapor lock”will be reduced to a

great extent.
Precautions during Mounting Expansion Tank:
1) Mount the expansion tank with a height as great as possible to form the sufficient
still-water pressure;
2) The level of expansion tank shall be limited to form the enough expansion space,
which is helpful to the discharging of foam. The expansion space shall occupy
1/3~1/2 of the expansion tank’ s capacity.
Factors affecting the cooling effects of cooling system are interrelated, mutually promoting
and restricting. For example, increasing the number of radiating pipe of radiator may
accelerate the circulation of cooling water and enhance the heat dispersion efficiency but
increase the flow resistance of air and affect the air flow. In order to obtain the optimum
effect of cooling system, factors shall be kept in certain proportion and it is unallowable to
stress one side while ignoring other side.
 Engine Volume MA-22

Operation Flow and Specifications for Maintenance of Engine’s

Intake System
I. Functions and Elements of Intake System
The air intake system is used for sucking fresh air, and the air intake system of
modern electronic-injection vehicles is complicated. The air filter is mounted in the
front of vehicle and mostly quadrangular. Such an air filter functions to filter and isolate
the filth as dust and impurity and keep air clean. The air flowmeter is mounted behind
and used for metering how much air flows into engine. The computer, according to this
important information, calculates the air-fuel ratio to adjust the oil injection quantity.
The black crinkly plastic pipe is mounted behind the air flowmeter, and the other end
of air flowmeter is connected to the important throttle valve assembly. In the throttle
valve assembly, there is a circular air throttle which is connected with the accelerator
pedal tread by your right foot and the position sensor of air throttle. When you tread
the throttle, the air throttle may automatically open to let more air get into engine and
start the position sensor of air throttle to make computer know how to increase the oil
injection quantity according to the need of driver. The claw-shape intake manifold is
connected to the rear part of throttle valve assembly.
Considering the illustration above, we can recognize the importance of how to
maintain the air inlet system of engine and keep system components in good condition.
Cleaning the carbon deposit becomes the important job of the maintenance, as the
carbon deposit and the failure of throttle valve assembly are inevitably caused by the
backfire during the operation of engine. For the health of engine, we shall not forget to
carry out the check and cleaning for air inlet system regularly.

II. Key Points of Intake System Maintenance

1. Check whether there is air leakage from air filter to intake manifold and whether black
plastic pipes for crucial positions are broken. Especially, the crinkly position shall be
unraveled to check. It is necessary to check whether each adaptor is fastened,
whether each wire adaptor is tightened, whether there is crack and shedding of
vacuum hose and whether there is aging and air leakage in the intake manifold and
the cylinder cushion.
2. Clean the air filter.
3. Rinse the stayguy rotation mechanism outside throttle valve assembly by the cleaning
jet pipe of carburetor to make throttle pedal draw air throttle freely.
4. Take off the black plastic pipe of air throttle assembly. If the carbon deposit or the
black dirty is found in the air throttle, rinse the air throttle by the cleaning jet pipe and
wipe up the dirty by the cloth.

III. Maintenance Requirements

1. Overmuch dust on surface of engine,
2. Quiver of engine at idle speed,
3. Slack running of engine,
 Engine Volume MA-23

4. Carbon deposition of ignition plug and valve, and

5. Expiration of maintenance term specified by manufacture.

IV. Maintenance Steps

1. Stall the engine and open its cover.
2. Blow (by air) or wipe up (by dishcloth) the surface of engine.
3. Disentangle the housing locker of air filter and take out the core.
4. Remove dust and foreign bodies inside the housing by the cleaner.

5. Wipe up the housing of air filter and the intake hose by the clean dishcloth.
6. Check the filter core. Replace the filter core, if it is found very dirty and damaged.
7. Shake and flap the filter core to remove the dust.
8. Uniformly blow off the dust on inner and outer surfaces of core through the bevel
direction from the inside of core by the compressed air.
9. Mount the clean core back to the housing of air filter.
10. Fasten the housing locker of air filter.

V. Precautions
1. It is unallowable to beat or impact the filter core during the operation.
2. If the filter core is damaged, replace it timely. Paper core in normal use shall be
replaced according to the specified interval.
3. Check whether the rubber washer is damaged. If the fact is positive, replace the filter
core and the washer.
4. Mount the filter core carefully. It is unallowable to contact the paper part of filter core
by hand or apparatus. Especially, do not have the filter core contaminated by the oil.
5. Ensure the sealing when mounting the intake pipeline. Special attention shall be given
to the sealing at protective sleeve of intake adaptor.
 Engine Volume MA-24

6. Check the rubber hose connected with air filter carefully during the maintenance.
Replace the rubber hose, if crack or aging upon it are found.

VI. Maintenance Specifications

1. Pressure of compressed air for cleaning shall not be over 5kgf/cm 2.
2. See Maintenance Manual for the recommended replacement cycle of normal
maintenance for air filter.

VIII. Maintenance Flow and Operation Specifications of Air Filter

(I) Maintenance
1. Start the engine and open the cover of engine.
2. Dismount the locker of air filter and take out filter core.
3. Wipe up the housing of air filter by clean dishcloth.
4. Check the contamination conditions of filter core and carry out the cleaning.
5. Replace the cleaned filter core, if it is damaged.
6. Remount the air filter.

(II) Operation Specifications:

1. Check the contamination conditions of air filter core and carry out the cleaning. If the
dry accumulated dust is found in the core and the air compressor is handy, blow off
the dust on inner and outer surfaces of filter core through the bevel direction equably
from the inside of filter core by the compressed air of pressure not over 5kgf/cm2. In
case of no air compressor, tap at filter core by the stem of rotary tool (screwdriver) and
then brush off the outer dirt by the fluffy brush.
Attention:
It is unallowable to beat or impact the filter core during the operation. If the
filter core is damaged during the cleaning, replace it timely. The paper core in
normal use shall be replaced according to the specified interval.
2. For the cleaned filter core, put the lighting into the filter core so as to externally
observe whether there is damage, pinhole or attenuation and check whether the
rubber washer gets marred. Replace the filter core and the washer, if they are
abnormal.
3. Mount the air filter. After the cleaning of filter core, mount every part according to the
reverse order for dismantlement or replace the filter core with new one. Ensure the
dependability of mounting. It is unallowable to contact the paper part of filter core by
hand or apparatus. Especially, do not have the filter core contaminated by the oil.
4. Ensure the sealing (especially the sealing of protective sleeve of intake adaptor) when
mounting the intake pipeline.
5. Check the rubber hose connected with air filter carefully during the maintenance.
Replace the hose, if crack or aging are found.

VIII. Maintenance Flow and Operation Specifications of Intake Pipeline

Mainly check the intake pipeline for the aging of rubber and the shedding of adaptor.
The careless check may lead to the air leakage when the engine is under heavy load
 Engine Volume MA-25

and big vacuum degree.

First, the air not filtered by air filter may get in.
Second, the air leakage may reduce the air flow through the air flowmeter, which
leads to the error of air flowmeter.
Third, the reduced vacuum degree may lead to the metering error of intake pressure
sensor.

IX. Maintenance Flow and Operation Specifications of Air Throttle Body

1. Clean the air throttle body by the compressed air. MA01
2. Dismount the stayguy of air throttle.
3. Dismount the position sensor and the
adaptor of idle speed motor of air throttle.

4. Dismount the intake hose between air filter MA01

and air throttle body.
5. Dismount the air throttle body, and plug the
unraveled intake duct by the clean towel
so as to prevent foreign bodies from falling
into the intake duct.

6. Wipe up the exterior of air throttle body by the clean towel.

7. Rinse pipelines outside air throttle body by the cleaning agent of carburetor, and blow
them by the compressed air.
Rinse the carbon deposition inside valve body by the cleaning agent of carburetor,
and wipe up the valve body by the cleaning paper towel.
8. Rinse the air throttle by the cleaning agent of carburetor, and then check whether the
air throttle can be closed tightly. Clean the air throttle unit by the special cleaning
agent and a brush. Make sure that sediments on surface marked in the figure are all
removed. Carefully wipe up the air conduit on both sides of air throttle disc. Wipe up
edges of air throttle disc. Rinse and check edges of air throttle to make sure that they
are on both sides of air throttle.
Rinse the air throttle unit by the cleaning agent. Check whether there are residual
sediments on the air conduit or the air throttle disc. The residual sediments may lead
to the accumulation of new sediments. Clean the air throttle again, if necessary.
 Engine Volume MA-26

9. Replace the seal gasket or use off-gasket sealant, when remounting the air throttle.
10. Remount the air throttle back into the engine according to the reverse order for
dismantlement.
11. Start the engine and check the stability of running.
Attention:
To prevent the valve body from freezing, the warm water channel is applied to valve body.
Pay attention to the outflow and adding of coolant during the reassembly and
dismantlement.
X. Diagnosis for Vacuum Leakage
Special Tool: Vacuum Gauge
1. The crack or breakage of the vacuum hose results in air leaking into intake manifold to
form the thin air-fuel mixture. When the air-fuel mixture is thinner than normal value,
the idle-speed operation of engine will not be stable. For the fuel injection engine, the
leakage of intake manifold may result in the higher idle speed than the normal value
and the sluggish acceleration of vehicle at low speed. The vacuum leakage in intake
manifold may cause that the air-fuel mixture in other cylinders is thicker than that in
some cylinder, which may misfire at idle speed or low speed. Once the speed of
engine increases, the vacuum in the intake manifold may reduce. Because the
vacuum leakage may not provide too much air, this cylinder stops misfiring.
2. If there is leakage in intake manifold, a vacuum gauge may be connected to the intake
manifold. If the reading of vacuum gauge is low and stable, it is necessary to
periodically check whether the torque of the mounting screw of intake manifold is right.
The looseness of the screw of intake manifold may lead to the leakage between intake
manifold and cylinder cover.
3. The distorted vacuum hose can’
t pass the vacuum to parts, so that they are unable to
work.
 Engine Volume MA-27

Operation Flow and Specifications for Maintenance of

Engine’s Oil Circuit

I. Functions of Engine’
s Oil Circuit System and Recognition for
Elements

Petrol tank

Petrol filter

Electric petrol injection Petrol

Petrol pressure
pump
adjuster

As is shown in the figure above, the fuel system in electric petrol injection system is
composed of the petrol tank, the electric petrol injection pump, the petrol filter, the fuel
pipe, the fuel return pipe, the fuel distribution pipe, the petrol pressure adjuster and
the petrol injector. In addition, the petrol pressure buffer is mounted in some models
of vehicles. The function of fuel system is to provide the pressure fuel for the petrol
injection and inject the fuel into the intake manifold under the control of computer.

II. Key Points of Maintenance for Engine’

s Fuel Circuit
The maintenance for fuel circuit system includes:
1. Cleaning for fuel tank and oil pump screen,
2. Replacement for fuel filter, and
3. Cleaning for fuel injector and so on.
Maintenance for Fuel Tank and Oil Pump Screen
Most troubles of fuel system result from the poor quality of fuel, and fuel quality, road
conditions and driving operation are three major basic reasons giving rise to troubles
of vehicle. For details, the poor quality of fuel makes up over 50%. Because of the
poor-quality fuel and the water and impurity in fuel tank, the fuel tank may get rusty
and engender nigger-brown colloid sediments, which may cause the following
unwanted phenomena: the oil pump give noise when working; the fuel pressure falls;
 Engine Volume MA-28

the idle speed is unstable; and the engine suffers from frequent extinction. For the
purpose of precluding these phenomena, it is required to firstly stop the use of
poor-quality petrol, then check the fuel tank regularly, and clean the tank timely if the
dirt or impurity is found.
Maintenance for Fuel Filter
The poor-quality fuel may cause not only that the screen of oil pump is blocked but
also that before the reach of normal maintenance cycle, too much impurity in fuel filter
leads to the blockage of oil supply, which results in the power fall of vehicle and even
the extinction. Besides the replacement of the fuel filter according to the cycle, check
the acceleration performance of vehicle regularly to judge whether to replace fuel
filter in advance.
Maintenance for Fuel Injector
The operating conditions of fuel injector have a direct effect upon the power and
emission performance of engine. Poor quality of fuel or no maintenance for fuel
injector for a long time is prone to contribute to the poor working conditions of fuel
injector, so much carbon deposition inside the inner cylinder, the quickened abrasion
between cylinder wall and piston ring, the poor acceleration performance, the
unstable idle speed and the emission over standards. The maintenance for fuel
injector is mainly to regularly clean it. Considering the different quality of petrol from
place to place, it is allowable to properly prolong or shorten the maintenance cycle
according to the particular conditions.
4. Periodically check whether there is oil leakage in connectors of oil circuit system.

III. Maintenance Requirements

1. Maturity of specified date, and
2. Dirt found in oil circuit of engine.

IV. Maintenance Steps

1. Shut down the engine, and put back the clamping band around the joint of oil pipe by
the pliers.
2. Dismount the petrol filter from the oil circuit.
3. If any dirt is found, replace the petrol filter with new one.

V. Precautions
1. When replacing the filter, keep the filter away from the naked flame and never
smoking, as the petrol is easy to catch fire.
2. Sometimes there is petrol jetting at the time of dismounting hose, so that it is better to
wrap the joint by the soft cloth.
3. If the insufficient length or the small crack is found in the hose, it is required to replace
the hose with new one.
4. Recover the position of hose and screw down the clamping band after the new filter is
 Engine Volume MA-29

mounted.

VI. Maintenance Specifications

Replacement date for petrol specifications:
Generally, it is necessary to replace the fuel filter after the vehicle has covered
20,000~40,000km.

VII. Replacement Flow and Operation Specifications of Petrol Filter

1. Fuel filter is mounted under the chassis in front of fuel tank.
2. Special attention: when replacing the filter, keep the filter away from the naked flame
and never smoking, as the petrol is easy to catch fire.
3. Loosen the clamping band which fixes the filter on the hose. (If the filter is fixed by
screw, screw off the screw.) Push the clamping band to one side with rotary tools
(screwdrivers), and then take out the clamping band by holding it with hand.
Sometimes the hose is very tight, so it is necessary to dismount it while rotating it
slightly (use pliers, if necessary). Sometimes there is petrol jetting at the time of
dismounting hose, so it is better to wrap the joint by the soft cloth.
4. If the edge of hose is abraded, the abraded part shall be cut away, but make sure that
the length of the part cut away shall not be too long to avoid the insufficient length of
hose. If the insufficient length or the small crack is found in the hose, it is required to
replace the hose with new one. Recover the position of hose and screw down the
clamping band after the new filter is mounted.
5. Wipe up the joint of filter by the dry dishcloth.
6. Apply several drops of clean engine oil on the end of oil pipe joint of filter.
7. Check the quick joint to make sure that the big sleeve of every joint is back to the
original position, and the spring shall be seen within the inner diameter of every quick
joint.
8. Mount the filter on the vehicle according to the right direction.
9. Connect the oil outlet joint to the oil outlet pipe of filter, and compact the joint forcibly
till the spring has been clamped to the right position.
10. Hold the oil pipe of filter tightly and try to pull it outwards so as to make sure that the
quick joint is fixed in place.
11. Mount the oil inlet joint by repeating steps 5 and 6.
12. Screw the fixing screw of filter in accordance with the specified torque.
13. Put down the vehicle and start the engine to check whether there is oil leakage in filter.

VIII. Maintenance Flow and Operation Specifications of Fuel Tank

Vapor Recovery System for Fuel Tank
The sealing of fuel tank and tank cover: it is mainly to test whether the fuel tank and tank
cover is leaked. It is necessary to repair or replace it if the leakage is found.
Check for Fuel Tank
 Engine Volume MA-30

Clean the fuel tank according to the using conditions and check whether the fuel tank is
rusty and engenders the nigger-brown colloid sediments as a result of the water and
impurity in fuel tank. At this time it is necessary to dismount the fuel tank to rinse it
completely.
1. Try to carry out the check when the fuel in tank is little.
2. Carry out the check on the open and ventilating place. In case the check is to be
executed in the workshop, the forced ventilation is required.
3.
Pay attention to fire-prevention, and the fire-fighting instruments are required on the
working site.
4. Dismount the negative pole of battery.
5. Dismount the electronic fuel injection pump,
and observe conditions of fuel tank through
the fixing hole of fuel pump.

Cleaning for Fuel Tank

1. Try to carry out the cleaning when the fuel in

tank is little.
2. Carry out the check on the open and
ventilating place. In case the check is to be executed in the workshop, the forced
ventilation is required.
3. Pay attention to fire-prevention, and the fire-fighting instruments are required on the
working site.
4. Dismount the negative pole of battery.
5. Draw out the residual fuel in fuel tank.
6. Dismount the circuit connection on oil pump. MA02

MA02

7. Disconnect the oil adding pipe, the air pipe, the MA02
flowline, the oil return pipe and the fuel steam
collecting pipe.
8. Disconnect fixing device for fuel tank and
 Engine Volume MA-31

dismount the fuel tank.

9. Dismount fuel injection pump.

10. Clean the fuel tank with the petrol.

Attention:

Never use any other cleaning agent.

11. Mount the fuel tank after the cleaning, and pay attention to the position of each
connecting pipe to avoid the mounting fault.
12. It is required to add oil and give a trial running to vehicle, in order to observe whether
the vehicle runs normally.

IX. Maintenance Flow and Operation Specifications of Oil Pump

1. The maintenance for oil pump mainly refers to the cleaning and replacement for
primary filter screen of oil pump.
2. In case of the pressure test conducted in the system without return oil, when the
pressure is not within the specified range, replace the pressure adjuster.
3. If the fuel pressure is abnormal or the operating noise is too big, replace the oil pump
assembly directly.

X. Specifications
1. The first thing of maintenance for oil pump is to pay attention to fire safety.
2. Fine ventilation and complete fire-fighting equipments in operational environment are
needed.
3. Dismount the negative pole of battery before the operation.
4. Since the oil pump is an assembled part, replace the assembly in case that the pump
works abnormally.

XI. Maintenance Flow and Operation Specifications of Fuel Injector

The maintenance for fuel injector mainly involves carrying out test, cleaning and
maintenance by the fuel injector tester.

Maintenance for Fuel Injector:

1. Dismount the negative wire of battery without the fire on site.
2. Clean the fuel injector, intake manifold and the connecting position between them by
the fluffy brush and the compressed air.
3. Release the oil pressure: loose the connection of induction manifold and oil rail
carefully, hold and absorb the petrol by the towel, and then unravel the oil pipe.

MA02
 Engine Volume MA-32

4. Dismount the oil rail assembly and the fuel injector.

MA02

5. Mount the fuel injector on the tester for testing the operating conditions and analyzing
the status. The use and operation of tester depends on the user’ s manual of specific
model. At the time of mounting fuel injector, seal ring of fuel injector shall be replaced;
and at the time of mounting fuel rail assembly, the seal ring shall be lubricated by the
petrol or Vaseline. After the mounting, start the engine to check whether there is
leakage in the fuel pipeline or of the air intake. If the fact is positive, deal with the
leakage in time.

XII. Cleaning for Fuel System

Maintenance Requirements:
1. Smudge of ignition plug,
2. Viscidity and blockage of fuel injection nozzle,
3. Unstable operation of engine, and
4. Dirty fuel pipeline and unstable fuel pressure.

Maintenance Steps:
1. Open the cover of engine. MA02
2. Find the quick adaptor in fuel circuit, encase
the adaptor by the cloth, and loose the fuel
pipe.
 Engine Volume MA-33

3. Connect the automatic cleaning machine for

fuel circuit to the fuel circuit. Be sure to
MA02
connect the fuel inlet and the fuel outlet pipe
correctly (see the user’ s manual for
equipment).
4. Start the engine and let the fuel get into the oil
storage tank of cleaning machine till 1/3 height
of the tank, and then shut down the engine.
5. Pull out the harness adaptor of fuel injection
pump from the fuel tank.
6. Connect the power wire of automatic cleaning machine of fuel circuit to the battery of
engine.
7. Add the cleaning agent for fuel circuit into the stock solution tank.
8. Switch on the oil pump of cleaning machine, and adjust the pressure (about 2~3 kg).
9. Start engine and keep it running for about half an hour to check the running conditions
of engine.
10. Shut down the engine and the automatic cleaning machine, and lower the pressure in
fuel circuit.
11. Take off the power supply adaptor of automatic cleaning machine.
12. Encase the quick adaptor by the dishcloth, dismount the automatic cleaning machine
pipeline from the fuel circuit, and reconnect the original fuel circuit of vehicle.

13. Reinsert the harness adaptor of fuel injection pump, and remount the rear seat.
MA02

MA02

14. Start engine to check the leakage of fuel

circuit.
 Engine Volume MA-34

Precautions:
1. Encase the adaptor by the dishcloth before dismounting the fuel pipeline so as to
prevent the fuel from injecting.
2. Smoking and naked flame are forbidden on site.
3. Properly use the automatic cleaning machine.

Maintenance Specifications
1. Test the pressure of fuel system.
2. Add one bottle of cleaning agent.
3. The cleaning time lasts 30min.
 Engine Volume GI-1

Gasoline Engine (2.0 L4)

Overview
HFC4GA3 gasoline engine series refers to the 2.0L multipoint electric injection
four-cylinder gasoline engine of international advanced technology level, which is
independently developed by the Anhui Jianghuai Automobile Co., Ltd. on the basis of the
assimilation of similar products at home and abroad. It may be used as the matched
power for both off road cars and intermediate cars, also as the update power for the
similar imported cars. It is featured by the compact structure and abundant power as well
as the higher performance-price ratio.

Engine Identification Number

The engine identification number is marked right
front side of upper part of cylinder body.

Illustration of Engine Identification Number

Model
Middle
Location Front
Serial Number of Product
Enterprise Number of Code of Technical
Item Displacement
Code Cylinders Type Platform
Places 1 2 3 4 5

The engine model is combined as follows:

HFC 4 G A 3 — 1

1 2 3 4 5 6 7
1. Enterprise Code
HFC — Jianghuai Automobile Co., Ltd.
2. Number of Cylinders
4— 4 cylinders
3. Code of Engine by Fuel Type
G— gasoline engine
4. Technical Platform
A— class A technical platform
 Engine Volume GI-2

B— class B technical platform

C— class C technical platform
D— class D technical platform
5. Engine Displacement
1— gasoline engine, 2.4L
3— gasoline engine, 2.0L
6. Delimiter
Use “— ”as the delimiter to separate the main technical structure characteristics and
the distortion part.
7. Symbol of Structure Characteristic
Symbol Gasoline Engine

Basic type (natural air

1
intake)
The ex-factory code is shown as follows: ☆ 5 3 0 0 0 3 6 9
☆

Year Engine Ex-factory No.

Year
Year Code Year Code Year Code Year Code
2001 1 2009 9 2017 H 2025 S
2002 2 2010 A 2018 J 2026 T
2003 3 2011 B 2019 K 2027 V
2004 4 2012 C 2020 L 2028 W
2005 5 2013 D 2021 M 2029 X
2006 6 2014 E 2022 N 2030 Y
2007 7 2015 F 2023 P 2031 1
2008 8 2016 G 2024 R 2032 2

Engine
Engine Type Code
Gasoline CKD 1
Engine Homemade 3

Ex-factory No.
It is composed of 6 digits as sequence code.
 Engine Volume GI-3

Specifications & Parameters

Model HFC4GA3
Type In-line, double overhead camshafts, 16
valves
Number of cylinders 4
Cylinder diameter×stroke (mm) 85×88
Displacement (L) 2.0
Compression ratio 10:1
Cylinder sleeve type None
Rated rotating speed (r/min) 5,500
Power (KW) 95
Max. torque (N.m) 172
Rotating speed in max. torque (r/min) 3,000-4,500
Idle speed (r/min) 750±30
Full-load min. fuel consumption rate (g/KW.h) 270－280
Engine fuel consumption rate ≤0.15％
Crankshaft rotation direction Anticlockwise
(facing the power input)
Ignition sequence 1－3－4－2
Startup mode Electric startup
Lubrication mode Combination of pressure and splash
Cooling mode Water cooled
Overall dimensions (L×W×H) mm 644.5×689×736.8
Net weight (Kg) 165

Item Specifications & Thresholds

Parameters
General
Type Transverse, double overhead
cams
Number of cylinders 4
Cylinder diameter 85 mm
Stroke 88 mm
Displacement 2.0L
Compression ratio 10:1
Ignition sequence 1-3-4-2
Valve Timing
Intake Valve
 Engine Volume GI-4

Open (BTDC) 18º

Close (ABDC) 54º
Exhaust Valve
Open (BBDC) 56º
Close (ATDC) 8º
Cylinder Head
Manifold mounting surface 0.15 mm 0.3 mm
flatness
Enlarged Dimension for Valve Seat Recovery (Intake)
0.3 mm 35.3-35.325 mm
0.6 mm 35.6-35.625 mm
Exhaust
0.3 mm 33.3-33.326 mm
0.6 mm 33.6-33.625 mm
Enlarged Dimension for Valve Conduit Hole Recovery (Intake and Exhaust)
0.05 mm 12.05-12.068 mm
0.05 mm O.S. 12.25-12.268 mm
0.05 mm O.S. 12.50-12.518 mm
Camshaft
Cam height 35.493 mm 34.993mm
Intake 35.317 mm 34.704mm
Exhaust 35.039 mm 34.704mm
External diameter of journal 26mm
Bearing gap 0.040-0.076 mm
End gap 0.1-0.2 mm
 Engine Volume GI-5

Valve
Valve Length
Intake 109.5 mm
Exhaust 109.7 mm
External Diameter of Valve Rod
Intake 6.565-6.580 mm
Exhaust 6.530-6.550 mm
Bevel Angle 45º-45º5’
Head Thickness of Valve (Edge)
Intake 1.0mm 0.7 mm
Exhaust 1.5mm 1.0 mm
Gap between Valve Rod and Valve Conduit
Intake 0.020-0.047 mm 0.1mm
Exhaust 0.050-0.085 mm 0.15mm
Valve Conduit Length
Intake 45.5 mm
Exhaust 50.5 mm
Maintenance dimension 0.05, 0.25, 0.50 mm
Valve Seat
Contact width of seat 0.9-1.3 mm
Seat bevel angle 44º-44º5’
Maintenance dimension 0.2mm
0.6mm out of tolerance
Valve Spring
Free length 45.82 mm 44.82
Load bearing 25.3kg/40mm
Deflection Less than 1.5º 4º
at assembly height
Cylinder Body
＋0.03
Cylinder diameter 850 mm
Non-roundness and taper of Less than 0.01 mm
cylinder diameter
Top surface flatness of engine Less than 0.05 mm 0.1 mm
block
Piston
External diameter 84．97-85 mm
Clearance of piston and 0.02-0.04 mm
cylinder
Ring Slot Width
 Engine Volume GI-6

No.1 1.22-1.24 mm
No.2 1.51-1.53 mm
Oil ring 2.81-2.83 mm
Maintenance dimension 0.5 mm out of tolerance
Side Gap of Piston Ring
No.1 0.03-0.07 mm
No.2 0.02-0.06 mm 0.1 mm
Oil ring 0.06-0.15 mm
End Gap
No.1 0.25-0.35 mm 0.8 mm
No.2 0.40-0.55 mm 0.8 mm
Side wiper blade of oil ring 0.10-0.40 mm 1.0 mm
Connecting Rod
Camber 0.05 mm
Skewness 0.1 mm
Side gap between big head of 0.10-0.25 mm 0.3mm
connecting rod and
crankshaft
Tension of piston pin 1250±500 kg
External Diameter of Connecting Rod Journal
External diameter of 48-48.015 mm
connecting rod bearing
Oil gap of crankshaft main 0.015-0.048 mm 0.1 mm
bearing
No.1, 2, 4, 5 journal 0.018-0.036 mm
No.3 journal 0.024-0.042 mm 0.1 mm
Crankshaft
External diameter of journal 56.982-57.000mm
Non-roundness of shaft Less than 0.015 mm
journal
Taper of shaft journal Less than 0.005 mm
Axial gap 0.05-0.25 mm 0.25mm
Flywheel
跳动 0.13 mm
Oil pressure in idling ≥80 kPa
[the oil temperature is (11.6 psi)
75-90℃]
Engine Oil Pump
Top Gap
 Engine Volume GI-7

Drive gear 0.16-0.21 mm 0.25 mm

Driven gear 0.18-0.21 mm 0.25 mm
Side Gap
Drive gear 0.08-0.14 mm 0.25 mm
Driven gear 0.06-0.12 mm 0.25 mm
Safety Spring
Free length 46.6 mm
In case of loading [61N] 40.1 mm
Right Balancing Shaft
Front journal diameter 18.467-18.480mm
Rear journal diameter 40.951-40.967mm
Gap
Front 0.020-0.061 mm
Rear 0.050-0.091 mm
Left Balancing Shaft
Diameter of front journal 18.467-18.480mm
Diameter of rear journal 40.951-40.967mm

Front 0.020-0.054 mm
Rear 0.042-0.083 mm
Cooling type With the forced circulation of fan
Capacity of cooling system 7.0L
Thermostat
Type Wax thermostat
Normal opening temperature 82℃
Opening temperature range 80℃-84℃
Full-opening temperature 95℃
Radiator Temperature
Opening pressure of main 107.9±14.7 kpa
valve
Close pressure of main vavle 83.4 kPa
Opening pressure of vacuum -8.86kPa
valve
Air Cleaner
Type Dry type
Filter core Paper filter core
Exhaust Tube
Muffler Resistance muffler
Suspension system Rubber suspension device
 Engine Volume GI-8

Coolant Temperature Sensor

Type Thermosensitive resistance type
Resistance
20℃ 2.45±0.14 KΏ
80℃ 0.3222KΏ

Tightening Torque

Item N.m
Engine support separator bolt 90-110
Engine support nut 60-80
Engine support bolt 60-80
Bolt and nut from engine support to cross beam 55-65
Bolt from front roll stop support to cross beam 40-55
Bolt and nut of front roll stop separator 50-65
Bolt from rear roll stop support to cross beam 50-65
Bolt and nut of front roll stop separator 50-65
Driving shaft support bolt 60-80
Mounting separator bolt of drving shaft 90-110
Air conditioner compressor and support 23-27
Oil pump and support of power steering gear 35-45
Front exhaust pipe and exhaust manifold 30-40
Rocker arm cover bolt 8-10
Center cover bolt 4-5
Camshaft sprocket wheel bolt 80-100
Camshaft bearing cap bolt 19-21
Crankshaft position sensor 10-13
Throttle valve casing seat 15-22
Mounting bolt of air filter 8-10
Damper pulley and crankshaft sprocket wheel 20-30
Cylinder head bolt using new component 63+loosen+20±2+90º+90º
Cylinder head bolt not using new component 20±2+90º+90º
Intake manifold support 18-25
Tension pulley support bolt 23-27
Automatic tensioner bolt 20-27
Tensioner pulley bolt 43-55
Idle gear bolt 30-42
Clamping bolt of front exhaust pipe 20-30
Oil pan (upper and lower) 10-12
Oil pan drain plug 35-45
Engine oil screen 15-22
Lubricating oil pump sprocket wheel nut 50-60
Engine oil pressure switch 8-12
 Engine Volume GI-9

Engine oil filter support bolt 20-27

Lubricating oil pump bolt 15-18
Oil seal cover bolt 10-12
Plug cover 20-27
Front cover bolt 20-27
Driven gear bolt 34-40
Engine cooling pump pulley bolt 8-10
Upper cover of timing belt 8-10
Lower cover of timing belt 8-10
Safety plug 40-50
Flywheel 130-140
Right rear cover of timing belt 10-12
Left rear cover of timing belt (upper) 10-12
Connecting rod cover bolt 20+90º
Crankshaft bearing cap bolt 25+90º
Engine suspension device
M18 25-30
M10 35-55
Engine support bolt 20-25
Engine connecting bolt 8-12
Bolt from engine cooling pump to cylinder body 20-27
Engine coolant temperature sensor 20-40
Engine coolant inlet sealing bolt 10-15
Mounting bolt of air filter 8-10
Mounting bolt (nut) of syntonizer 8-10
Throttle valve casing to intake manifold 15-22
Mounting bolt of intake manifold (M8) 15-20
Mounting nut of intake manifold 30-42
Bolt from pull rod support to pull rod 35-55
Ignition coil bolt 8-12
Power transistor bolt 10-12
Bolt from front exhaust manifold to cylinder body 20-30
Nut from center exhaust pipe to catalyst 30-40
Bolt from center exhaust pipe to main muffler 30-40
Bolt from center exhaust pipe to support 10-15
Bolt from suspension device to engine block 10-15
Bolt from suspension device to main muffler 10-15
Exhaust manifold nut (8) 25-30
Exhaust manifold nut (10) 35-55
Oxygen sensor 40-50
Air cleaner support bolt 10-13
Connecting bolt of exhaust manifold cover and exhaust 12-15
pipe
Oxygen sensor to exhaust manifold 40-50
Front exhaust pipe support bolt 20-30
Main muffler lifting lug support bolt 10-20
 Engine Volume GI-10

Engine oil height meter 12-15

Stud 30-40
Tensioner arm assembly 17-26
Balancing shaft bolt 34-40
Connecting bolt of starter to cylinder body 27-35
Radiator fan motor bolt 8-10
Oil pipe to cylinder body 10-13
 Engine Volume GI-11

Common Troubles and Causes

Trouble Possible Cause Repair

Low pressure of cylinder Damage of cylinder head gasket Replace cylinder gasket
(refer to the engine cylinder Abrasion or damage of piston ring Replace piston ring
pressure measurement method) Abrasion of piston or cylinder Replace piston, or repair or
Abrasion or damage of valve seat replace piston ring or cylinder
body
Replace or repair valve and seat
ring
Fall of engine oil pressure Insufficient height of engine oil Check engine oil
(refer to the engine oil pressure Failure of engine oil pressure Replace engine oil pressure
measurement method) switch switch
Blockage of engine oil filter Replace enigine oil filter
Abrasion of engine oil pump gear Replace engine oil pump gear
or cover or cover
Engine oil diluted Replace engine oil and find out
Failure of engine oil safety valve the causes
(open) Replace engine oil filter support
Too large bearing gap sub-assembly
Replace engine oil pump
assembly
High pressure of engine oil Failure of engine oil safety valve Replace engine oil filter support
(refer to the engine oil pressure (closed) sub-assembly
measurement method)
Excessive vibration of engine Looseness of engine thrust Replace thrust gasket
gasket (front and rear) Retighten
Looseness of engine suspension Check and retighten
Looseness of center components Replace
Damage of engine bracket Replace
assembly
Damage of engine roll stop baffle
Noise in valve Low engine oil pressure Refer to the judgement method
Abrasion or damage of valve rod for the drop of engine oil
or valve conduit pressure
Abrasion or damage of valve seat Replace
Abrasion or damage of hydraulic Replace or repair valve and seat
tappet stem ring
Replace
Noise in connecting rod bearing Insufficient suppluy of engine oil Check the height of engine oil
bush and crankshaft main Thin or diluted engine oil Check and find out the cause
bearing Too large bearing gap Replace
Excessive abrasion of crankshaft Replace or polish
Noise in timing belt Belt tension fails to meet the Adjust the tension of belt
specification Replace timing belt
Damage or abrasion of belt Adjust
Timing belt contacting with timing
protective cover
Low level of coolant Coolant leakage Check and refill to specified
Leakage in radiator level
Water pipe corrupted or cracked Replace radiator assembly
Trouble of radiator cover Replace
Leakage of thermostat seat Replace
component Tighten or replace the
Leakage in engine water pump component assembly
Leakage in cylinder body Tighten or replace sealing
gasket
 Engine Volume GI-12

Replace cylinder body

Blockage of radiator Foreign matter in coolant Clean cooling water passage

Deformation of radiator and replace coolant
Replace radiator
Air leakage in exhaust pipe Looseness of joint Screw down again
Damage of pipeline or muffler Repair or replace
Damage of gasket Replace
Breakdown of exhaust pipe Check and replace
Abnormal noise in exhaust Muffler partion plate separated Replace
system Damage of exhaust pipe lifting lug Check and replace
Pipeline or muffler contacting with Check and rectify
vehicle body Repair or replace
Damage of pipeline or muffler Check and replace
Damage of three-way catalyst

Special Tools
Serial
Name Outline Drawing Code Purpose
No.

For dismounting
Valve engine valve and
1 spring JAC-T1F001 related parts when
compressor there is no need to
take off it

Erector of For mounting the

2 camshaft oil JAC-T1F002 engine camshaft oil
seal seal

Front oil Play the guiding

seal guider role when mounting
3 JAC-T1F003 Guider
of the front oil seal of
crankshaft crankshaft
 Engine Volume GI-13

Erector of
For mounting front
front oil seal Oil seal
4 JAC-T1F004 oil seal of
of Front
crankshaft cover

crankshaft

Pressure rod

Forward mark
For dismounting Forward
Replacer of mark
5 JAC-T1F005 and mounting Guide block
pistion pin
engine piston pin Base

Timing For supporting and

toothed belt fixing the balancing
6 JAC-T1F006
wheel shaft sprocket
stopper wheel

Applied with
relevant mounting
7 Handle JAC-T1F007 Handle
equipment to install
the bearing

Handle
Erector of
For mounting rear Erector of
rear oil seal rear oil seal
8 JAC-T1F008 oil seal of of
crankshaft
of
crankshaft
crankshaft

For dismounting Special

Special sleeve for
dual-gear
and mounging the
9 sleeve for JAC-T1F009
front cover screw of
dual-gear
engine

Erector for
For mounting valve
10 valve oil JAC-T1F010
oil seal
seal
 Engine Volume GI-14

For fixing the

Stopper of flywheel to make
11 JAC-T1F011
flywheel the dismantlment
easy

For dismounting the

Valve
engine valve and
12 spring JAC-T1F012
related parts in
compresor
disassembly

Withdrawal
For dismounting the
13 tool of valve JAC-T1F013
valve conduit
conduit

Erecting of For mounting the oil

balancing seal at the
14 JAC-T1F014
shaft oil balancing shaft of
seal engine

Oxygen For dismounting

15 sensor JJAC-T1F015 and mounting the
spanner oxygen sensor

Erecting for For mounting the oil

16 pulley oil JAC-T1F016 seal of engine’
s
seal timing pulley

Oil pan For dismounting the

17 JAC-T1F017
stripper oil pan
 Engine Volume GI-15

Fuel
For measuring the
18 pressure JAC-T1F018
fuel pressure
gauge
 Engine Volume EM-1

Precautions
Precautions for Discharging Engine Coolant
Precautions for discharging engine coolant and cut fuel pipeline after engine cools down
 Before operation, make sure there is no object that can cause fire or spark in
operation area.
 Release fuel pressure before cutting and disassembling.
 Clog the opening to prevent fuel leaking after cutting the pipeline.
Precautions for Dismantlement and Disassembly
 When the use of special repair tools is specified, please use special repair tools.
Always keep safe in operation, and do not manage it with difficulty or operate against
the instructions.
 Do it with special care and do not damage fitting surface or sliding surface.
 If necessary, use tape or similar objects to seal the opening of engine system to
prevent it against the foreign matters.
 Mark and sort out the dismantled parts to proper positions to facilitate troubleshooting
and important assembling.
 The fundamental rules for unscrewing bolts and nuts are: First unscrew the outermost
one, and then unscrew that at its diagonal position, and conduct on the analogy of
this sequence. If the unscrewing sequence is specified, please operate in the
specified procedures.
Precautions for Check, Repair and Replacement
Thoroughly check the parts before repair or replacement. Check newly-replaced parts in
the same manner and replace them, if necessary.
Precautions for Assembling and Installation
 Use the torque wrench to screw down nuts and bolts.
 The fundamental rules of screwing down bolts and nuts are to screw down the middle
one in the same degree of tightness in multiple steps, then to screw down that in inner
and outer diagonal lines. If the screwing sequence is specified, please operate in the
specified sequence.
 Replace with a new gasket, oil seal or O-ring.
 Thoroughly flush, clean and dry every part. Carefully check if there is blockage in the
engine oil or coolant pipeline.
 Do not damage sliding surface or fitting surface. Thoroughly clear away foreign
matters like cloth scraps or dust etc. Smear the engine oil on sliding surface before
assembling.
 When refilling after discharging the engine coolant, first release the air from pipeline.
 After repair, start engine and increase the rotating speed of engine to check if engine
coolant, fuel, engine oil or tail gas leaks.
Parts Required to be Screwed Down by Specific Angle:
Use the angle wrench to finally screw down the following parts of engine:
① Cylinder head bolts
② Main bearing cap bolts
③ Connecting rod cap nuts
④ Connecting rod cap bolts
 Engine Volume EM-2

⑤ Crankshaft pulley bolts (the angle wrench is not necessary since there are notches for
certain angle screw around bolts)
 Please don’ t screw down according to torque value for final tightening.
 The torque values of these parts are used only for preloading.
 Make sure thread and base surface is clean and is smeared with engine oil.
 Engine Volume EM-3

Preparations
Necessary Materials for Check and Repair
The materials listed in the following table are required in repair of the engine of this type.
So do prepare them timely for use. In addition, use the detergent and lubricating oil of
specified type as possible.
Auxiliary Material Table for Engine Assemblage
No. Name Usage Specifications and Brands
Engine
1 For filling and assemblage SJ 10W-30
oil
Oil pump, water pump, oil pan,
2 Silica gel crankshaft rear oil seal casing, cam LT5699
position sensor support
Lubricating oil pressure switch,
3 Sealant water discharging bolts, fly wheel LT243
bolts
4 Sealant Water temperature sensor LT648
unleaded petrol of 93# and
5 Petrol
above
6 Sealant Double end bolt LT271
Auxiliary Material Table for Cylinder Head Assemblage
Material and
No. Name Assembling Position
Model

Valve head, cam shaft, rocker arm, rocker arm

1 Engine oil SJ 10W-30
shaft, cam shaft oil seal

Sealant
2 LT271 Double end bolt
TB1386D

Ignition plug guide sleeve, cup blank cover of

3 Sealant LT962
cylinder body/head, tube fitting nozzle
 Engine Volume EM-4

Engine Assembly
Dismantlement and Reassembly
Attention:
 Always keep safe in operation before dismantling. Do not manage it with
difficulty or operate against the instructions.
 Please don’t start the operation before the exhaust system and engine coolant
finally cool down.
 Release fuel pressure before dismantling fuel pipeline.
 Set the lifter to support the fixed places of car before dismantling front axle.
 Be careful not to touch other parts when lifting and installing engine.
 Set steel rope on the lifting lug of engine and always keep safe when lifting the
engine.
 If engine part does not include the required item or operation, please refer to
relating chapters.
 Always take out the engine assembly from below the vehicle when dismantling
it.

Dismantlement Steps:
1. Cut off storage battery and dismantle its support.
2. Release fuel pressure.
3. Discharge coolant and power steering liquid in cylinder body and radiator.
4. Reclaim the refrigerant in refrigerant pipeline.
5. Dismount the following parts around engine assembly:
 Engine cover
 Air filter and air pipeline
6. Cut off wire harness of engine hatch at the side of ECM.

Transmission shift
position EM001

Attention:
In order to keep the wire harness joint clean and
avoid the damage or foreign matter entry, please
use plastic bags or similar objects to cover them
completely.
7. Dismount the following hoses and pipelines
around the engine body:
 Fuel evaporator hose
 Oil supply hose joint
 Brake booster vacuum hose at the side of
engine
 Engine Volume EM-5

8. Dismount gearshift lever connected to

gearbox.

EM002
9. Dismount hydraulic oil tube of clutch.

10. Dismantle refrigerant pipeline from

air-conditioned compressor. (Refer to EM003 Clutch oil duct
“air-conditioner”section for specific
dismantlement steps)

11. Dismount the pressure hose and oil intake

hose on power steering pump. (Refer to
“chassis”section for specific dismantlement EM004
steps)

EM005
Engine Volume EM-6
 Engine Volume EM-7

12. Unscrew the four fixed bolts on the protective

cover of exhaust manifold and take off the EM006
cover.

13. Unscrew the three fixed bolts from front

exhaust pipe to front catalyst and take off from EM007
front exhaust pipe.

14. Lift car and dismantle the connecting rod of EM008

front exhaust pipe and front anti-sway bar.

15. Use quick wrench (ratchet wrench) to EM009

dismount fixed nuts of engine rear suspension.
 Engine Volume EM-8

EM010
16. Dismount fixed bolts of engine left suspension
and the nuts of left suspension support.

Attention:
For safety purpose, before conduct this step, do mount the lifting steel rope to engine
lifting lug.

EM011
17. Dismount fixed bolts of engine right
suspension and the nuts of right suspension
support.

Attention:
For safety purpose, before conducting this step, do mount the lifting steel rope to engine
lifting lug.
EM012

18. Use special lifting truck to put down engine

and gearbox assembly from below the
chassis.

19. Install the lifted engine and gearbox assembly

on engine support, and then separate the
gearbox.

Installment:
Please notice the following cautions and install in the reverse sequence of dismantlement.
 Please do not damage engine mounting gasket and prevent engine oil splashing on
it.
 Make sure all engine installment gaskets are fixed correctly, and then screw down
nuts and bolts as required.
Engine Volume EM-9
 Engine Volume EM-10

Check after Installment:

1. Please check oil/liquid level of engine coolant and engine oil before starting engine. If
it is below the specified level, please fill to the specified level.
2. Turn engine switch to ON position (when engine stops). When oil pressure works on
oil pipe, check if the fuel leaks from the joint.
3. Start the engine, and recheck if fuel leaks from the joint when speeding up engine.
4. Operate engine to check if there is abnormal noise or vibration.
5. Warm up the engine for 15 minutes and make sure there is no leakage of fuel, tail gas
or any oil/liquid (including engine oil and engine coolant).
6. Stop the engine and recheck oil/liquid level (including engine oil and engine coolant)
after the engine cools down for 15 minutes. If necessary, please refill to specified
level.

Cylinder Compression Pressure Test

The results of cylinder compression pressure test may be used to diagnose the following
engine troubles.
Make sure the storage battery has enough power and the engine starter is in good
operation conditions; otherwise the indicated compression pressure may be invalid for
diagnosis.
1. Check the engine oil level, and refill oil if necessary.
2. Drive car until engine gets to normal operation temperature. Choose the roads without
traffic jam or the jam of other types, observe the traffic rules and speed up sharply for
several times through gear shifting.
3. Dismount all ignition plugs from engine. When dismounting them, check if the
electrode indicates some abnormal ignition phenomenon like oil stains, heating,
wetted engine oil etc. Write down the cylinder number of ignition plugs for future
reference.
4. Make sure air throttle fully opens when checking compression pressure.
5. Insert the special tools or equivalent for compression pressure gauge adapter into
ignition plug of first cylinder on the cylinder head.
6. Operate the engine until the gauge indicates the maximum pressure. Write down the
pressure value as compression pressure of first cylinder.
7. Repeat previous steps for all the other cylinders.
8. The compression pressure should not be lower than the given pressure and the
change of compression pressure among all cylinders should not be greater than 25%.
9. If one or more cylinders are not normal and of low compression pressure, repeat
compression pressure test.
10. If abnormal low readings of the same cylinder repeat in the second compression
pressure test, it probably means there are problems in this cylinder or several ones.
The recommended compression pressure is used only as guideline of engine trouble
diagnosis. Do not dismantle the engine to confirm reasons for low compression
 Engine Volume EM-11

pressure except there are troubles inside.

Cylinder Burning Pressure Leakage Test

The burning pressure leakage test provides the accurate methods for determining engine
operation status.
Burning pressure leakage test will check:
 Intake and exhaust valve leakage (wrongly seated);
 Leakage or water leaked into jacket between adjacent cylinders;
 Any reason resulting in the lose of burning/compression pressure.
Caution:
When the system is in thermal status and under pressure, do not dismantle radiator
cover since coolant may cause serious scald.
Check coolant level and fill as required.
Do not install radiator cover.
Start and operate engine until to the normal working temperature, then turn it off.
Use compression air to blow clean the concave place of ignition plug.
Dismount ignition plug.
Dismount engine oil filler cover.
Dismount air filter.
Regulate tester in accordance with manufacturer’
s instructions. Keep air source used for
workshop test at the given pressure.
Execute test procedure on every cylinder according to tester manufacturer’
s instruction.
When testing, listen to know if compression air leaks from air throttle, tail gas tube or
engine oil filler cover. Check the air bubbles in coolant.
The pressure readings of all gauges should be equal and leakage of every cylinder can not
exceed 25%.
Engine Oil Leakage Check:
First conduct a thorough visual check of engine, especially to suspicious leakage area. If
engine oil leakage is not easy to recognize, always observe the following steps:
1. Do not clean or remove oil stains on engine at this time since some solutions may
cause rubber expansion which can block leakage for a moment.
2. Add the solvent coloring agent of engine oil (as recommended by manufacturer); start
engine and let it idling rotate for about 15 minutes. Check the engine oil level to make
sure coloring agent is thoroughly mixed with engine oil, with a color of yellow just like
the yellow under a UV lamp.
3. Use a UV lamp to check if the whole engine has fluorescence coloring agent,
especially in the suspicious leakage area of engine oil. If the engine oil leakage is
found out and determined, repair the engine as required.
4. If no coloring agent is observed, drive the car at different speeds for about 24
 Engine Volume EM-12

kilometers and then repeat the check.

5. If engine oil leakage source is not fully determined, please do the following steps to
continue the air leakage check:
 Cut off the vacuum hose at the cylinder head cover (to refill air) and block or cover the
pipe joint on the cylinder head cover.
 Dismount the PCV valve hose from the cylinder head cover. Cover or block the pipe
joint on the cylinder head cover.
 Connect the air hose with a pressure gauge and adjustor to engine oil level inspector
pipe.
Attention:
Do not make engine assembly undertake a test pressure higher than 20.6kPa.
 When pouring soapsuds to the suspicious leakage position, increase air pressure
slowly from 7 Pascal to max 17.5 Pascal. Regulate the adjustor to proper test
pressure, which can provide the best air bubble for determining the leakage correctly.
If the engine oil leakage is checked and determined, execute the proper repair
according to the trouble.
 If the leakage is at the rear oil seal of crankshaft, refer to this section and check the
rear oil seal for leakage.
6. If the leakage is not found out, cut off the air source. Dismount air hose, all plugs and
blank covers. Install the PCV valve and vacuum hose (to refill air) and go to the next
step.
7. Use the proper solution to clean engine oil in the suspicious position of engine oil
leakage. Drive car for about 24 kilometers at different speeds. Use UV lamp to check if
engine oil leaks.
Attention:
If the engine oil leakage is found at the position from the engine oil level indicator
hose to the cylinder, dismount the indicator hose, clean stud and bearing bearer,
and then reseal it (only applicable to pressure fitting pipe). As for the O-ring
structure pipe, dismount the indicator pipe and replace the O-ring.
Check if there is leakage at rear oil seal:
It is always difficult to determine the engine oil leakage source at rear oil seal, so more
checks are involved. Do the following steps to determine the leakage correctly.
If the leakage happens at the rear oil seal of crankshaft:
1. Cut off storage battery.
2. Lift the car.
3. Dismount the hydraulic converter or clutch cover to check if there is oil stains on the
rear part of cylinder. Use UV lamp to check if there is any leakage of engine oil. If the
leakage exists in this area, dismount the gearbox for further check.
a. The annular spray usually indicates the oil seal leakage or crankshaft damage.
b. If the leakage tends to spread down directly, the possible reasons may be the
penetration of the cylinder body, the cup blank cover of engine oil duct, the bottom
 Engine Volume EM-13

plate to the cylinder body fitting surface, or the oil seal hole. Refer to their
respective repair steps.
4. If no leakage is found out, increase the pressure to crankshaft as previously said.
Attention: Do not exceed 20.6kPa.
5. If no leakage is found out, rotate the crankshaft very slowly to observe if any leakage
happens. If the leakage between crankshaft and oil seal is found out when rotating the
crankshaft slowly, it is probably caused by the damage of crankshaft oil seal surface. If
there are some minor carves or scratches in the oil seal area of crankshaft, rub it out
with emery cloth.
Attention: Be very careful when polishing the crankshaft to remove carves or
scratches. The crankshaft oil seal flange specially processed is used to supplement
the rear oil seal function.
6. If the air bubbles continuously exist when crankshaft rotates, the disassembly is
necessary for further check.
7. After the cause and correction measures are determined, replace the components as
required.
Standard Detection Procedure
Repair for Damage or Abrasion of Thread:
The damage or abrasion of thread (including the fitting thread of ignition plug and
camshaft bearing cap) is repairable. Actually, the repair includes drilling to remove the
worn or damaged thread, tapping out the thread hole with special screw tap (or
equivalent), installing an inset screwed in the thread hole, and then restoring the inner
hole of inset to the original thread size.
Attention:
Make sure the tapped thread hole keeps with the original central line.
Hydrostatic Locking of Engine
When the hydrostatic locking of engine is doubted (for any reason), do the following steps:
Attention:
Do not use starter to rotate the engine; or serious damage could happen.
1. Check air filter, air intake system and air intake manifold to make sure system is dry
and free of foreign matter.
2. Dismount the negative cable of storage battery.
3. When dismounting the ignition plug from engine, put a workshop cloth around it to
receive the oil possibly existed in the cylinder with pressure.
4. After dismounting all ignition plugs, use a protective rod and a box wrench to rotate the
engine crankshaft.
5. Identify the liquids in cylinder (i.e. coolant, fuel, engine oil or others).
6. Make sure all liquids are fully discharged from cylinder. Check if the engine is
damaged (including connecting rod, piston, valve etc.).
7. Repair the engine or its components as required to prevent the same trouble
repeating.
 Engine Volume EM-14

Attention:
Inject about one spoon of engine oil into each cylinder, and rotate the engine to
lubricate cylinder wall to avoid the damage in restarting.
8. Install a new ignition plug.
9. Discharge the engine oil and dismount the engine oil filter.
10. Install a new engine oil filter.
11. Fill the engine oil of given quantity and grade.
12. Connect the negative cables of storage battery.
13. Start the engine and check if there is any leakage.
Shaped Sealing Gasket and Sealant
The sealing gasket is used in many places of engine. The onsite shaped sealing gasket
should be applied carefully to obtain the result as expected. If not specified, do not use
onsite shaped seal gasket, for the size, coherence and position of glue drop are all very
important. If the glue drop is too thin, it may result leakage; if glue drop is too much, it may
overflow, come off and block the oil supply pipeline. The glue drop of correct width is the
foundation to obtain leak-free sealing gasket.
There are many kinds of onsite shaping materials used for engine like the engine RTV
(indoor temperature vulcanized sealant) and GEN II. Every kind has its special property
and can not be used in other places.
Such shaping materials are used to seal sealing components in engine oil. This kind of
sealant is a specially designed black silica rubber inner temperature vulcanized sealant. It
still keeps cohesion and sealing property, even being exposed in engine oil. The moisture
in air can solidify the sealant. This kind of sealant is stored in tube and its service life is
one year. After one year, it can not fully solidify. Do check the expiration date on package
before using.
MAKER: It is a kind of anti-oxygen lining sealant, which may solidify when compacted
between two metal surfaces without air. If it is put in closed tube, it may not solidify. This
kind of anti-oxygen sealant is used between two processing surfaces. Do not use it on
flexible metal flange.
PLATE SEALANT (bottom plate sealant): It is a special (green) anti-oxygen lining sealant
and is specially made to seal the area between bottom plate and cylinder body, and it
never affects bearing gap or the alignment of these components. This type of sealant
solidifies slowly due to the lack of air when it is twisted between two metal surfaces, and
solidifies quickly after heated.
SEALANT (lining sealant): It is a slowly-drying and constant-soft type sealant. It is
recommended for sealing on thread fitting and sealing gasket. It also can prevent the
leakage of engine oil and coolant. It is suitable to the thread connecting parts and
machined parts in different temperatures. It is also used for the engine with the cylinder
head of multi-layer steel pad (MLS). It may prevent corrosion as well.

Usage of Sealant
 Engine Volume EM-15

GasketMaker sealant should be applied on the lining surface with a diameter of 1mm or
smaller. Always smear the sealant around every mounting hole. Too much sealant is easy
to be removed. The component needs to be screwed to the right position within 15
minutes. The locating pin is recommended in installation so as to prevent smeared sealant
move.
The RTV GEN II or ATF RTV lining sealant for engine should be applied in continuous
glue drops with a diameter about 3mm. The sealant should be applied around all mounting
holes continuously. As for the sealing at corners, apply a glue drop of 3.17 or 6.35mm. The
glue drop needs to be applied on the center of lining contacting area. The sealant that
doesn’
t solidify may be removed with workshop cloth. The component should be screwed
to the right position before the sealant at the contacting area solidifies (within 10 minutes).
In the course of installation, it is recommended to use locating pin to prevent the sealant
moving during smearing. When applying lining sealant in aerosol sealant tank, fully smear
the two connecting surfaces and the two sides of lining in even and thin layers before the
installation. The tanked sealant with coating brush may be smeared evenly on sealing
surface. The sealant in aerosol sealant tank should be used for the engine with the
cylinder head of multi-layer steel pad.
 Engine Volume EM-16

Preparations of Engine Seal Gasket Surface

To ensure the engine sealing gasket is sealed well,
the proper surface preparation is required,
especially for the surfaces of engine aluminum
parts and multi-layer steel cylinder head pad.
Never use the following tools or methods to clean
the lining surface. 
① Metal scraper
② Abrasive cloth or abrasive paper to clean
cylinder body and cylinder head
③ High-speed electric tools with abrasive and
steel wire brush

Attention:
The multi-layer steel (MIL) cylinder head pad
needs an abrasion-free sealing surface.
Only use the following articles to clean lining surface:
① Solutions or sealing gasket cleanser in market
② Plastics or wood scraper

Engine Sand Core Blank Cover and Engine Oil Duct Blank Cover
Use a blunt head tool like punch and hammer to knock the lower part of cup blank cover.
Rotate the cup blank cover and hold it tight with pliers or other proper tool to dismount it.

Attention:
Do not knock cup blank cover into the casting. This may result in the throttle of
coolant and serious engine problems.
Thoroughly clean the inside of cup blank cover on the cylinder body or cylinder head.
Make sure original sealant removed. Smear a little glue for installation of stud and bearing
at the inside of blank cover. Make sure no engine oil or grease on new blank cover. Use a
proper blank cover and knock it into the hole until the sharp edge of blank cover enters
into the groove at least 0.5mm. It is not required to wait for sealant to solidify and the
cooling system may be refilled and the car may be used immediately.
 Benjoy Maintenance Manual –Engine Volume EM-17

Timing System
Component Composition Drawing

Timing belt

Upper cover of
timing belt

Engine cooling Generator support

pump

Engine cooling pump pulley

Rear left cover of timing belt

Driving belt (upper)
(air-conditioning, power
steering)
Damper pulley Rear left cover of timing belt (lower)

Balancing shaft sprocket

Camshaft sprocket

Crankshaft sprocket “B”

Timing belt “B”
Tension pulley arm
Tension pulley “B”
Tension pulley
Induction piece
Automatic tension device Idle pulley

Oil pump sprocket

Crankshaft sprocket
Special washer
160--170

Torque: Nm (kg.cm, 1b ft)

 Benjoy Maintenance Manual –Engine Volume EM-18

Dismantlement and Installation

Dismantlement Steps
1. Unscrew the fixed bolts on upper cover of
engine timing belt and take off the upper
cover of timing belt. EM013

EM014

2. Dismount water pump pulley.

EM015
3. Unscrew the fixed bolts of crankshaft belt disc
and take off crankshaft belt disc.

EM016
4. Unscrew the two fixed bolts in the fixed
support of crankshaft position sensor and take
off the crankshaft position sensor.
 Benjoy Maintenance Manual –Engine Volume EM-19

5. Unscrew the fixed bolts on lower cover of

engine timing belt and take off the lower cover EM017
of timing belt.

6. Rotate the engine crankshaft clockwise and EM018

let the 1# cylinder piston up to top dead center
and align the timing mark. Actuate the timing
to observe the hole bolt for determining if
timing is correct.

Attention:
At this time camshaft toothed wheel should
well match timing mark of cylinder head
cover and the locating pin of camshaft EM019
toothed wheel should be at the upper side.

7. Unscrew the two fixed bolts of automatic

tension device and take off automatic tension
device.

8. Take off the loosened timing belt.

Attention:
1. If timing belt needs to be used again, in
order to make sure rotating force direction EM020
is unchanged, mark with an arrow on the
belt according to belt rotation direction.
2. If belt side is as sharp as knife edge, it
means belt side is normal.

9. Dismount fixed bolt of camshaft timing gear

and take off camshaft timing gear.
 Benjoy Maintenance Manual –Engine Volume EM-20

Attention: The two bolts fixing crankshaft position sensor have different
diameters. The lower one has smaller diameter and it is used to adjust the gap
between crankshaft position sensor and signal gear.
Dismantlement of Engine Oil Pump Casing Assembly
10. When dismantling oil pump gear, first
dismount an inspection screw plug at the left EM021
side of engine and then insert a screw driver
with 8mm diameter and insert it for about
60mm to maintain the left balancing shaft.

EM022
11. Dismount the fixed bolts of oil pump gear and
take off engine oil drive gear.

EM023
12. Unscrew the fixed bolts of right balancing
shaft timing gear, unscrew the bolt of
balancing shaft belt tension pulley, take off
eccentric tension pulley. First loosen
secondary belt tension pulley, take off
secondary belt; dismount the bolts for the
toothed wheel of right balancing shaft and
take out the right balancing shaft.

EM024

13. Take off the right balancing shaft driver belt

and dismount right balancing drive gear.
 Benjoy Maintenance Manual –Engine Volume EM-21

14. Take off the crankshaft drive gear and signal EM025
disc.

Check after Dismantlement:

1. Check the camshaft gear, crankshaft gear, tension pulley and idle gear and see if
there is any abnormal abrasion, crack or damage. If any, replace it timely.
2. Check the rotation resistance and motion noise of tension pulley and idle gear. If
abnormal, replace it timely.
3. If there is oil leakage in tension pulley and idle gear, replace it timely.
4. Check the abrasion of tappet head and the damage of tension device. If it is serious,
replace it timely.
5. Measure the exposed height of tension device tappet. If it exceeds standards,
replace tappet.

Standard value: 14.5mm

Use the bench vice to press automatic tension device slowly. If the tappet is easy to
draw back, replace the tension device.
Metal breaker
strip
Caution: EM026
The tension device should be set level on Metal
bench vice. At the same time, pad something breaker strip
under the two sides of tension device to
avoid damage.

Flat washer

Installation:
EM027
1. Install timing gear in crankshaft signal disc,
rotate the crankshaft gear to align it with
timing mark on cylinder body and make sure
1# cylinder piston is at upper dead center.
Benjoy Maintenance Manual –Engine Volume EM-22
 Benjoy Maintenance Manual –Engine Volume EM-23

EM028
2. Install the right balancing shaft gear and align
it to the timing mark on cylinder body.

3. Install the timing belt and eccentric tension

pulley, press the tension pulley with hands
EM029
and then screw down fixed bolts.
Tightening torque: 43~55N•m

Attention:
When installing eccentric pulley, the flange
should be faced to front. When screwing bolts,
do not rotate the balancing shaft; otherwise
belt would be too tight.

EM030
4. Check the tension status of belt: When
pressing the belt with figures, the deflection of
belt should be 5-7mm; when using an
instrument to measure the tension, refer to
the following table.
Measurement Pressure Torque
Range
139mm 0.42kg/Cm2 50— 100N•m
5. Screw down the fixed bolt of right balancing
EM031
shaft gear.
6. Install the signal disc and timing pulley of
crankshaft position sensor.
Attention:
Do not install sensor blade reversely;
otherwise the belt would break off accidentally.
7. Install the dog plate and bolts of crankshaft
timing gear, and screw down bolts.
Tightening torque: 160~170N•m
8. Install the camshaft belt gear, align it to timing mark on cylinder head, and screw
down bolts.
Tightening torque: 80~100N•m
 Benjoy Maintenance Manual –Engine Volume EM-24

Attention:
At this time locating pin of camshaft gear is at the above position.
 Benjoy Maintenance Manual –Engine Volume EM-25

EM032
9． Install the oil pump drive gear and align it
right, use screw driver to clamp the
balancing shaft from inspection hole and
screw down drive gear bolt.
Tightening torque: 50~60N•m

EM033

10．Press the automatic tension device tightly

with the bench vice until the holes on outer
casing align with the holes on plunger, insert
the clips to clamp it, and install tension
device to engine body.
Tightening torque: 43~45N•m

EM034

11. Wrap the belt around such parts in turn as

follows: Crankshaft timing gear --- oil pump
gear --- idle gear --- exhaust camshaft gear ---
intake camshaft gear --- tension pulley.

12. Plug out the retainer pin of automatic tension device, take out the screw driver in
balancing shaft plughole and install the plug screw (with sealant smeared).

13.Rotate the crankshaft for several rounds, check if timing mark is at the right position
and then measure the extending length of top ram of automatic tension device.
Standard value: 5.5~9mm
 Benjoy Maintenance Manual –Engine Volume EM-26

14. Install the lower and upper covers of timing belt and screw down bolt.
(A tightening torque: 8~10N•m, B tightening torque: 8~10N•m)

EM035
15. Install the fixed support of the crankshaft
position sensor and screw down the two fixed
bolts.

Oil Pan and Pickup

Dismantlement and Installation

EM036
Dismantlement Steps:

1. Open the engine oil cover, unscrew the oil bolt

on the oil pan and discharge the engine oil.

Attention:
Put an oil basin under oil drain hole and do not
spill the collected oil onto floor.

EM037

2. Dismount the 19 fixed bolts on the oil pan in

sequence as shown in the figure.

Attention:
There are long and short bolts. (Carefully
Oil seal cover
arrange the bolts by length during EM038
dismantlement).

Torque: 3.0-4.2 kgf.m

 Benjoy Maintenance Manual –Engine Volume EM-27

EM039

3. Dismount the two fixed bolts of pickup and

take off the pickup.

EM040
4. Dismount the four fixed bolts of oil deflector
and take off the deflector.

Installation:
Oil seal cover
1. Clean the gluey remains on the prime coat of EM041

oil pan and then install oil deflector and

pickup.
2. Smear some sealant in the groove at the edge
of oil pan. Screw down the fixed bolts of oil
pan in sequence shown in the figure.
Torque:3.0-4.2 kgf.m

Tightening torque: 10~12N·m

Attention:
The thickness of sealant is 3mm. Install the oil pan well within 15 minutes after
smearing sealant.
 Benjoy Maintenance Manual –Engine Volume EM-28

Driver Belt
Check before Dismantlement: EM042
1. Check if the belt has crack, abrasion or oil
stains. If any, please replace it.
2. Check if the belt is correctly located in the
groove of belt pulley.
3. Check deflection of belt at the middle point of
belt between belt pulleys.
● The check should be conducted after engine
cools down or stops for 30 minutes.
● During measurement, apply a 98N (10Kg) force to mark or check with belt
tensiometer.
● If the deflection exceeds the limit, adjust it.

Adjustment of Tension Methods for Adjusting Belt Tension

Alternator Adjust the adjusting nut of engine

Belt of power steering pump and Adjust the adjusting nut of belt guide
air-conditioned compressor pulley

Dismantlement and Installation

Dismantlement Steps:

1. Unscrew the locking nut of belt tension pulley, then choose the adjusting nut to adjust
the tension, and loosen the driver belt of power steering pump and air-conditioned
compressor.

EM043
2. Take off the driver belt of power steering
pump and air-conditioned compressor.
 Benjoy Maintenance Manual –Engine Volume EM-29

3. Rotate the adjusting nut of generator to adjust

the tension, and loosen the generator driver EM044
belt.

EM045

4. Take off the generator driver belt from

generator pulley.

Installation:
The installation steps are reverse to those
for dismantlement. Check the deflection of
driver belt after installation.

Diagnosis and Test

Visual Diagnosis
EM046
When diagnosing the driver belt, the small lateral EM046
cracks (1) from one ridge to another at the belt
surface are normal, for which the belt is not
required to be replaced; while the cracks (2) (not
lateral ones) along the ridges are abnormal, for
which the belt involved must be replaced. Also, the
belts with serious abrasion or fiber abrasion or the
belts that are polished seriously or become too
thick must be replaced. If the belt has any blister,
surface separation or other unevenness, the belt
should be dismounted for check and replaced as
required.

Noise Diagnosis
The noise generated by the accessory driver belt is most noticeable at idle speed.
Before replacing belt to solve noise problem, check if all accessory driver belt
 Benjoy Maintenance Manual –Engine Volume EM-30

pulley aligns right or is too smooth or if the gap is too large.

 Benjoy Maintenance Manual –Engine Volume EM-31

Diagnosis of Accessory Driver Belt

Problem Possible Cause Measures

Belt ridge 1 Foreign matters are inserted into the 1 Remove foreign matters from the
thickens (one or belt pulley groove. groove of belt pulley and replace belt
more ridges 2 Belt is damaged in installation. 2 Replace belt
separated from
belt)
Abrasion of ridge 1 Belt pulley is not aligned right. 1 Align belt pulley right
or belt 2 Abrasion is caused by environment. 2 Clean belt pulley and replace belt as
3 Pulley rusts. required
4 There is a sharp angle or protrusion 3 Belt pulley rusts
on the top of belt pulley groove. 4 Replace belt pulley and check belt
5 Belt rubber ages. 5 Replace belt
Slipping of belt 1 Belt slips due to the lack of belt 1 Check and replace tension device as
tension. required
2 Belt or pulley is exposed in the 2 Replace belt and clean belt pulley
materials that can decrease the friction 3 Replace damaged component or
(like belt oil, engine oil, and ethylene bearing
glycol). 4 Replace belt
3 The bearing of driven parts is
damaged (resulting in the belt being
blocked).
4 Belt is worn out and hardened after
heated and due to too much slipping.
Longitudinal 1 Belt is wrongly guided into the pulley 1 Replace belt
crack on belt groove. 2 Replace belt
2 The top edge of pulley groove is
worn out of rubber and the core of
draw rope is exposed.
“Jumping”(the 1 Belt tension is not correct. 1 Check/replace tension device as
belt cannot keep 2 Belt pulley is not within the design required
at the correct tolerance. 2 Replace belt pulley
position on belt 3 There is foreign matter in the belt 3 Remove foreign matters from groove
pulley) pulley groove. 4 Align components
4 Pulley is not right aligned. 5 Replace belt
5 The core rope of belt breaks.
Breakdown of 1 Belt tension is not correct. 1. Replace or check/replace tension
belt breaks 2 The core of draw rope is damaged in device as required
(note: Install a belt installation. 2. Replace belt
 Benjoy Maintenance Manual –Engine Volume EM-32

new belt, check 3 The belt is not aligned seriously. 3. Align belt pulley
and resolve 4 The support, belt or bearing is 4. Replace damaged component and
existing damaged. belt
problems)
 Benjoy Maintenance Manual –Engine Volume EM-33

1 Check/replace tension device as

Noise (When the 1 Belt tension is not correct.
required
belt is running, 2 Bearing makes noise.
2 Seek and repair problems
annoying 3 Belt is not aligned right.
3 Belt is not aligned
scream, 4 Belt does not match with the pulley.
4 Install correct belt
cheeping scream 5 Vibration is caused by driven parts.
5 Find out defect follower and repair it
is heard) 6 The even surface of belt separates.
6 Replace belt
Trouble (The
outer fiber 1 Tension protective coat contacts with
around belt is fixed object. 1 Friction status
damaged or 2 Fiber ages due to too much heat. 2 Replace belt
separated from 3 The joint of belt protective coat 3 Replace belt
belt body) breaks.

Rope edge
1 Belt tension is not correct.
trouble (The 1 Check/replace tension device as
2 Belt contacts with fixed object.
elastic part of required
3 One or more pulley is out of
belt edge is 2 Replace belt
tolerance.
partially exposed 3 Replace pulley
4 The adhesion between the elastic
or separated 4 Replace belt
part and rubber is not enough.
from belt body)
 Benjoy Maintenance Manual –Engine Volume EM-34

Oil Pump and Balancing Shaft

Component Composition Drawing

Front bearing

Rear bearing
Right balancing shaft

Gasket

Left balancing shaft

Front cover
Drive gear

Oil pump cover

Driven gear bolt Driven gear

Upper end of crankcase
oil tray
O ring Gasket

Oil pickup

Oil filter

Plug cover Lower end of oil pan

Washer

Oil drain plug

Torque: Nm (kg.cm, 1b.ft)

 Benjoy Maintenance Manual –Engine Volume EM-35

Hydraulic Fluid Type

Overview
Engine Oil and Lubricant
Caution:
The new or used oil is stimulant to skin. Always protect skin from contacting oil for
a long time or many times. The pollution caused by oil burning is bad to health. If
skin contacts oil, use soap and water to clean it thoroughly. Do not use the liquid
that is bad to skin, such as petrol, diesel, diluents or solutions, to clean skin. As for
the waste oil, dispose it properly and do not cause contamination. Contact with the
local distributor or government organization to know local location for recovering
waste oil.
When maintenance is needed, the JAC only recommends using the components,
lubricant and chemical fluid of given brand.
Society of Automotive Engineering (SAE)
American Petroleum Institute (API)
National Lubricating Grease Institute (NLGI)

SAE Viscosity Rate

It is recommended to use SAE 5W-20 and SAE 5W-30
engine oil in all operation temperatures, which can
improve the start ability and fuel economy in the low
temperature. By reading the notice on the engine oil
filler cap, you can acquire recommended information
about engine oil. SAE viscosity rate indicates viscosity
of engine oil. Only use the engine oil with multiple
viscosities like 5W-20 or 5W-30. They are marked with
SAE double viscosity rate and mean viscosity range
from low to high temperature. Choose the engine oil
suitable to temperature range of specific use.

Identification of Oil Container

The standard oil identification mark helps the correct
use of oil. The mark is located on the front label of
plastic bottle and the top of oil tank.

Compound Engine Oil

Many kinds of engine oil are compound or
semi-compound. If choosing the product of this kind,
only use those meeting the SAE viscosity standard.

Gear Lubricant
 Benjoy Maintenance Manual –Engine Volume EM-36

The SAE rate is also suitable to the multigrade universal gear lubricant. The API category
also specifies the usage of lubricant, like API GL-5 and SAE 75W-90.
 Benjoy Maintenance Manual –Engine Volume EM-37

Dismantlement Steps:

1. Rotate the engine to the upper dead center of

1# cylinder piston, and dismount engine timing
belt.
2. Dismount the inspection hole bolt of balancing
shaft at the left side of engine, and then insert
a screwdriver with about 8mm diameter into
about 60mm to clamp the left balancing shaft. EM047

3. Unscrew the fixed bolt of oil pump gear, and EM048

take off the oil pump gear.

4. Dismount the outer cover of left balancing

shaft on the oil pump assembly casing with
special tools, and dismount the fixed bolts
EM049
from left balancing shaft to oil pump driven
gear.

5. Dismount the fixed bolt of right balancing shaft,

dismount the eccentric tension pulley and take
off the driver belt and the right balancing shaft
EM050
gear and shaft.

6. Discharge engine oil and dismount the oil pan.

7. Dismount the fixed bolts of oil pump assembly.

 Benjoy Maintenance Manual –Engine Volume EM-38

8. Dismount the oil pump casing assembly and

EM05
sealing gasket.

EM05

9. Take out the left and right balancing shafts.

EM05

10. Dismount the fixed bolt in oil pump casing and

take off the oil cover and oil pump gear.

Check after Dismantlement:

1. Check if all oil holes of oil pump casing are blocked and clean them if necessary.
2. Check if the front axle box of balancing shaft is worn out, damaged or clamps the
balancing shaft.
3. Check oil if the oil pump casing has crack, aging or other damages, replace it if any.
4. Check if oil seal is worn out, damaged or aged, and replace it if any.
 Benjoy Maintenance Manual –Engine Volume EM-39

5. Mount oil pump gear onto oil pump and rotate gear matched tightly to see if it rotates
well. Check if there is groove abrasion in the fitting surface between oil pump body
and oil pump cover.
6. Mount the oil pump drive gear and driven gear well onto oil pump casing, measure
crest gap of gear.
Reference value: EM054
Drive gear: 0.16-0.21mm
Driven gear: 0.18-0.21mm
Limit value:
Drive gear: 0.25mm
Driven gear: 0.25mm

7. Check the side clearance of oil pump gear.

EM055
Standard value:
Drive gear: 0.08-0.14mm
Driven gear: 0.06-0.12mm

Limit value:
Drive gear: 0.25mm
Driven gear: 0.25mm

Replacement of Balancing Shaft Axle Box

EM056
1. Use special tools to dismount the front
axle box of right balancing shaft from
cylinder body.

Front axle
box
2. Use special tool to dismount the rear axle
box of right balancing shaft from cylinder
EM057
body. Rear axle
box
Benjoy Maintenance Manual –Engine Volume EM-40
 Benjoy Maintenance Manual –Engine Volume EM-41

3. Use special tool to dismount the rear axle

box of left balancing shaft from cylinder EM058
Rearaxis box
Rear
body. At the same time, use special tool to axle
fix the axle box stripper in front of cylinder box

body.

4. Use special tool to mount the rear axle box

of left balancing shaft onto cylinder body.

EM059
Rear
Attention: axle
The rear axle box of left balancing shaft box
does not have oil hole so smear oil on
mounting hole surface of axle box on
cylinder body and outer surface of the rear
axle box during installation.

EM060

5. Use special tool to mount the axle box of

right balancing shaft onto cylinder body.

Attention:
EM061
Make sure the oil hole of axle box aligns
that of cylinder body well. Smear engine oil
on the outer surface of axle box.

6. Use special tool to mount the front axle

box of the right balancing shaft onto Axle
cylinder body. box
Cylinder body
 Benjoy Maintenance Manual –Engine Volume EM-42

Attention:
EM062
Main oil
Make sure the oil hole of axle box aligns distributing
passage
that of cylinder body well.

Installation:
Oil hole

1. Smear engine oil on the oil pump gear and

EM063
align the two timing marks.

2. Mount oil pump casing to the oil pump

casing assembly with bolts.

EM064

3. Mount the left and right balancing shafts to

right position.

EM065
4. Use special tool like the erector of front oil
seal of crankshaft, to mount crankshaft oil
seal to oil pump casing assembly. Oil seal Oil pump
housing
 Benjoy Maintenance Manual –Engine Volume EM-43

5. Use special tool to mount oil pump casing at

the front of crankshaft and smear a thin layer EM066
of engine oil on the surface of the tool to
facilitate the mounting. Mount a new oil
pump casing sealing gasket on oil pump
casing unit and screw down all bolts with the
given torque.

Tightening torque: 20~27N•m

6. Screw the fixed nuts from left balancing shaft

to oil pump driven gear and rotate cover in. EM067
Screw them down with special tool.

7. Insert a screwdriver into the bolt hole at the

left side of cylinder body. Then check if
balancing shaft is at the correct position. EM068
Install the pulley of oil pump drive gear,
replace and screw down the fixed bolts.

8. Mount right balancing shaft drive gear,

eccentric wheel and the timing in crankshaft.
Let gear align with timing mark. Mount right
balancing shaft timing belt to press eccentric
wheel tension belt tight. Screw down fixed
bolts.

9. Align timing marks and mount timing belt.

Pull out screwdriver at the side of cylinder
body and screw the bolts with sealant.
 Benjoy Maintenance Manual –Engine Volume EM-44

Cylinder Head Assembly

Component Composition Drawing
With new component T T: 63 (630,46)+loosening + 20(200,14)+90°+90°

Without new component T T: 20 (200,14)+90°+90°

Cylinder head bolts

Collet
Valve spring upper seat
Collet Washer valve oil seal
Valve spring upper seat Valve spring
Valve oil seal Valve spring lower seat
Valve spring
Intake valve conduit
Valve spring lower seat
Exhaust valve conduit
Cylinder
head

Exhaust valve retainer

Intake valve retainer

Intake valve Exhaust valve

Cylinder head gasket

Cylinder body

Torque: Nm (kg.cm, 1b.ft)

Diagnosis and Test

Cylinder Head Gasket
The leakage of cylinder head gasket is probably located between adjacent cylinders or
between cylinder and adjacent water jacket.
The possible sign of leakage of cylinder head gasket between adjacent cylinders is:
① Engine power loses
② Ignition of engine fails
③ Fuel economy is poor
 Benjoy Maintenance Manual –Engine Volume EM-45

The possible sign of leakage of cylinder head gasket between cylinder and adjacent water
jacket:
① Engine is too hot.
② Coolant loses.
③ Too much steam (white smoke) is in exhaust air.
④ Coolant has foam.
Test of Leakage between Cylinders
To determine if there is leakage of engine cylinder head gasket between adjacent
cylinders, follow the test steps of cylinder compression pressure (for specified operations,
refer to cylinder pressure test section). Leakage of engine cylinder head gasket between
cylinders will cause compression pressure to lower about 50~70%.
Test of Leakage between Cylinder and Water Jacket
Caution:
Be very careful when engine operates after coolant radiator cover is dismounted.
Visual Test Method
When engine is cold, open coolant pressure cover, start engine and warm up it until
thermostat turns on.
If serious leakage of burning pressure/compression pressure exists, bubbles are
noticeable in coolant.
Using method of cooling system tester
Caution:
After cooling system tester is located, pressure will be generated soon. When
engine operates continuously and generates too much pressure, do release it to
safe pressure point. Never let pressure exceed
138 kPa. EM069
Install the cooling system tester or equivalent onto
pressure cover, start engine and observe readings
of pressure gauge of tester. If the pointer of every
pressure gauge of cylinder stroke swings, the
leakage of burning pressure is obvious.
Dismantlement and Installation
Dismantlement Steps:
1. Dismount the fixed bolt of cylinder head cover
and take off cylinder head cover.
EM070
Attention:
Some cup blank covers of oil duct may be
repaired on the cylinder head of engine; while
some require that the affected cylinder head is
taken off from the engine. For any case, only
replace cup blank cover which needs repair.
2. Dismount ignition coil and high-pressure wire.
 Benjoy Maintenance Manual –Engine Volume EM-46

3. Dismount the fixed bolts of valve cover and

EM071
take off valve cover and sealing gasket.

4. Use special tool to dismount cylinder head

Camshaft pulley side
bolt in the following order. EM072

Check after Dismantlement:

1. Carefully check if cylinder head has crack,

damage or leakage. If it has crack, it is
required to replace cylinder head assembly.
2. Completely remove odds, sealing stains and carbon deposit. After cleaning the oil
duct, use compressed air to make oil groove free of blockage.
3. Check the flatness of cylinder head surface. If it exceeds limit, it is required to replace
cylinder head or precisely process this surface.
Cylinder Head Flatness
Standard common difference ---- less than
0.05mm EM073
Maintenance limit --- 0.2mm
4. Check if cylinder gasket has burning, stroke,
damage etc. trouble, and replace it if any.
Attention:
Always replace it with the original cylinder
gasket, otherwise it may cause some troubles
like wrong compression ratio.
Installation:
1. Face the marked side of cylinder gasket to EM074Camshaft pulley side
cylinder head.
2. Carefully align the cylinder head to locating pin
of cylinder body and install it onto cylinder body.
3. Screw down the cylinder head bolts in order to
given torque.
 Benjoy Maintenance Manual –Engine Volume EM-47

Tightening torque:
Used bolts: 20N·m+90°+90°
New bolts: 63N·m+loosening+20N·m+90°+90°
 Benjoy Maintenance Manual –Engine Volume EM-48

Valve Mechanism
Dismantlement and Installation EM075
Dismantlement Steps:

1. Use a wrench to clamp the hexagon fixed

position of camshaft, use a wrench to
dismount the fixed bolt of camshaft toothed
wheel and take off the toothed wheel.

2. Unscrew the fixed bolts of camshaft bearing

cap, then take off camshaft bearing cap, EM076
camshaft, rocker arm and valve clearance
adjustor and arrange them directionally in
order.

3. Use special tool to press valve spring seat,

take off valve clamp lock, do not compress
spring too much, only until clamp lock can
EM077
slip from groove, otherwise valve stem may
wind.

4. If valve clamp lock does not come out when

compressing spring, dismount compression
tool, and put a proper tube on spring seat.
Thus it will not knock valve clamp lock. Put a
wood on the valve head (burning compact of EM078
cylinder head faces to the working station),
then use hammer to knock tube.

5. Reinstall special compression tool to

compress the valve spring, so it is
convenient to get out the clamp lock. After
valve clamp lock is taken out, slowly
unscrew the bolt and dismount the
compression tool.

6. Dismount valve spring seat and valve spring,

and get valve from below.
Benjoy Maintenance Manual –Engine Volume EM-49
 Benjoy Maintenance Manual –Engine Volume EM-50

7. Put every set of valve, valve clamp lock,

valve spring, spring seat in a plastic bag and
mark a number to facilitate restore of original EM079
position.

8. Dismount valve oil seal with pliers.

Attention:
Never repeat using the valve oil seal. EM080

Check after Dismantlement:

1. Valve
Use a brush to clean valve. Check wear and
damage status of every valve B end, replace it if
EM081
necessary. If any end is damaged, repair it. If the
size exceeds limit, it is required to replace valve.

Standard value:
Intake valve: 1.0mm
Exhaust valve: 1.5mm Residual
Maintenance limit:
Intake valve: 0.7mm
Exhaust valve: 1.0mm EM082 Verticality deviation

2. Valve Spring
Free
Check free height of every valve spring, replace
height
spring if necessary. Use a ruler to measure
verticality of every valve spring. If spring exceeds
verticality limit, replace it.
 Benjoy Maintenance Manual –Engine Volume EM-51

Standard value
EM083
Free length: 48.82mm
Load: 25.3kg/40mm
Verticality deviation: 1.5°or smaller
Maintenance limit:
Free height: 44.82mm
Verticality deviation: 4°

3. Valve Conduit EM084

Check the gap between the valve stem and
valve conduit. If it exceeds limit, use a new
valve conduit with enlarged size to replace the Valve
old one. The gap between valve stem and stem
valve conduit is: Stem
diameter
Standard value: Stem internal diameter
Intake valve: 0.020-0.047mm
Exhaust valve: 0.050-0.085mm
Maintenance limit:
Intake valve: 0.1mm EM085
Cutter
Exhaust valve: 0.15mm Guide bar

Repair of Valve Retainer:

1. Check if valve conduit wears out through Exhaust valve Intake valve seat
seat
rectification. Replace the worn duct and then
rectify the seat.
2. Use the valve seat guide rod and reamer to EM086
Intake valve

rectify valve seat.

3. After rectification, carefully grind valve and Exhaust valve

valve seat with grinding paste.

Benjoy Maintenance Manual –Engine Volume EM-52
 Benjoy Maintenance Manual –Engine Volume EM-53

Replacement of Valve Retainer: 0.3— 0.6mm

EM087 0.3mm
Valve:

New hole
1. Thoroughly clean and check valve. Replace
valves which are burned, wound, or have Cut
Used hole
crack.
2. Check gutter.
0.15— 0.3m
3. Check valve conical surface.
4. Measure valve stem.
5. Cut valve retainer from inside to replaced
size and thin wall thickness and then replace EM088
valve retainer.
6. Re-hole valve-seat hole until to enlarged
valve retainer diameter. Valve
stem
7. At front of fitting valve retainer, heat valve
head until to 250℃ or cool valve retainer in Stem diameter

liquid NOx, to prevent from bruising cylinder

Stem internal diameter
head seat hole.
8. Screw down fixed bolt of cylinder in order.

EM089
Contact width of valve retainer: 0.9~1.3mm

Replacement of Valve Conduit

Cylinder head
1. Use special tool to press used valve conduit
Cylinder guide
out from cylinder head base. Grind new
valve conduit hole to match it with valve.

EM090 Intake Exhaust

2. Use special tool to press in valve conduit and

press it from the top of cylinder head. Be
careful that the lengths of intake and
exhaust conduits are different.
 Benjoy Maintenance Manual –Engine Volume EM-54

3. After pressing and installing valve conduit,

EM091
install valve, check if it can slide smoothly.

Valve
stem seal

Installation:
1. Clean every spare part, and lubricate the
Valve spring seat
rotating and moving parts.

EM092 Spring
Enamel-plating upper seat
2. Use special tool to press new valve oil seal side

to given position.

Spring
Seal rod
3. Smear oil on every valve, insert valve into
conduit. Do not use too much strength to
Spring seat
insert valve into valve oil seal. After inserting,
check if valve can slide smoothly.

4. When installing valve spring, face the end EM093

with paint to valve spring upper seat.

5. Use special tool or proper tool to press

spring and install clamp lock. After installing
valve, make sure if clamp lock is correctly
installed.

EM094
Camshaft pulley side
6. Clean sealing surface connecting cylinder
body and cylinder head.

7. Check cylinder gasket mark and install the

gasket with marked side facing cylinder
head.

8. Screw down fixed bolt of cylinder in order.

 Benjoy Maintenance Manual –Engine Volume EM-55

Illustration:
When checking the above components, for any abrasion, it is recommended to
replace the cylinder head assembly.
Hydraulic Tappet
Diagnosis and Test
Diagnosis of Hydraulic Tappet Noise
The correct noise diagnosis is on the foundation of finding out the noise. It may be difficult
sometimes to find out tappet noise. At last original wrong judgment may occur. Refer to
the tappet noise table to determine possible tappet noise source and the possible source
which causes wrong judgment.
Refer tappet noise table for possible cause and measures of tappet noise.
Tappet Noise Table
Possible Cause Measures
Engine oil level is too high or too low. It Check and correct engine oil level.
may cause the aired oil to enter tappet
and make it soft.
The rotating time after repairing cylinder It is necessary to rotate in low speed up to
head is not enough. one hour to facilitate discharging air
completely from valve system. During this
period, shut down engine and re-start it
after several minutes. Repeat it several
times after engine meets normal working
temperature.
Air is left in tappet (after rotating for one a) Install tappet to cylinder head, at the
hour). same time, check if tappet becomes soft.
Press down rocker part of tappet. If tappet
is normal, it feels hard. It is easy to touch
the base if tappet is very soft.
b) If tappet is still soft, replace with new
tappet/rocker arm assembly.
Engine oil pressure is low. a) Check and correct engine oil level.
b) Check engine oil pressure.
c) Check if gap between bearings is too
much and correct it if it is.
d) Check if oil pump wears out.
Oil to cylinder head is blocked by scraps. Check if cylinder head oil groove and
cylinder head gasket locating device are
blocked. Clean or replace them if
necessary.
Valve conduit wears out. Measure valve conduit and replace valve
 Benjoy Maintenance Manual –Engine Volume EM-56

with enlarged size and oil seal.

Air enters the oil because oil pump Check the induction pipe, and replace it, if
induction pipe breaks or has crack. necessary.
Tappet is damaged as it absorbs scraps. Clean scraps from engine and replace
tappet.
 Benjoy Maintenance Manual –Engine Volume EM-57

Crankshaft Connecting Rod Gear and Cylinder Body

Component Composition Drawing

Fly wheel

Fly wheel
Support of Crankshaft baffle
rear oil seal rear oil seal

Adaptive disc

Adaptive disc
Crankshaft
bushing

Upper bearing bush

Thrust plate

Crankshaft

Lower bearing
bush
Thrust plate
Main bearing cap
 Benjoy Maintenance Manual –Engine Volume EM-58

Main Bearing Bush

1. Choose bearing bush according to crankshaft mark or color code (refer to the
following table). If they can’
t be recognized, measure crankshaft journal diameter and
choose suitable bearing to match them.
Diameter of
Crankshaft Journal Cylinder Body Bearing Bush
Bearing Hole
Recognition Recognition Recognition
Range Diameter of Journal
Mark Mark Mark
0 1
49.994
1 1 1 2
~50.000
2 3
0 2
49.988
2 2 1 3
~49.994
2 4
0 3
49.982
3 3 1 4
~49.988
2 5

5th main journal

4th main journal
3rd main journal
2nd main journal Rate Marks of Crankshaft Journal
1st main journal Rate Mark
I 1
II 2
III 3
 Benjoy Maintenance Manual –Engine Volume EM-59

Main Journal Rate of Cylinder Body

Rate Mark
0 0
I 1
II 2

2. The recognition mark of hole diameter of

bearing bush is carved at the shown position.
Always choose and install the bearing
according to these marks.

3. Choose bearing bush from the above table on

the basis of recognition marks in the first and
Without With
second steps. trough trough

Lower main bearing bush Upper main bearing bush

(1st, 2nd, 3rd, 4th, 5th) (1st, 2nd, 3rd, 4th, 5th)
For example,
A. If the measured journal is 50.000mm, then it
belongs in the first category of the above
table.
B. If the recognition mark of hole diameter of cylinder body bearing bush is 1, choose the
bearing bush with recognition mark 2.
4. There is groove in all upper bearing bushes and there is no groove in lower bearing
 Benjoy Maintenance Manual –Engine Volume EM-60

bush.
 Benjoy Maintenance Manual –Engine Volume EM-61

Dismantlement and Installation

Dismantlement Steps:
1. Dismantle engine timing system, cylinder head part, oil pan part, fly wheel, front
cover and oil pump assembly part.
2. Dismantle rear baffle plate and rear oil seal.
3. Unscrew bolts of piston connecting rod big end casing, take down casing of
connecting rod big end and push piston out of cylinder top.

Attention:
Mark on piston connecting rod casing to make sure right position and direction in
the next installation. Forbid using steel or hard article to knock connecting rod
bearing part when pushing connecting rod piston, to prevent damage or
deformation.

4. Unscrew and dismount crankshaft main bearing cap bolts in order, dismount bearing
cap and crankshaft, then arrange bearing bush in order according to engine body
serial number.

Check after Dismantlement:

1. Crankshaft
Check the damage, uneven wear and
crack of crankshaft main journal and
connecting rod journal, at the same time
check oil hole. Check the braze corner and
external diameter of crankshaft journal.
Standard Value:
Main journal external diameter: 56.982— 57.000mm
Connecting rod journal external diameter:
44.980— 45.000mm
2. Bearing Bush
Carefully check if every bearing bush of main
bearing and connecting rod bearing has the peel,
melt, scuffing action or improper contact. If any,
replace the bearing bush.

Measure Oil Film Gap

Oil film gap is got from measuring and comparing crankshaft main journal external
diameter and bearing bush internal diameter.
Standard Value:
The 1st, 2nd, 4th, 5th main bearing bushes of crankshaft: 0.018~0.036mm
The 3rd main bearing bush of crankshaft: 0.024~0.042mm
 Benjoy Maintenance Manual –Engine Volume EM-62

Connecting bearing bush: 0.015~0.048mm

Limit: 0.1mm
Usage of Plastic Gauge:
Usually we use plastic gauge to measure oil film gap. First clear away the oil, grease or
other foreign matter on bearing bush and main journal, put in a plastic gauge with the
same width as the main bearing bush, put it horizontal to journal and avoid oil hole.
Install crankshaft, main journal and main bearing cap and screw to the given torque.
During this process, don’
t rotate crankshaft. Dismount main bearing cap, measure its
width at the widest place according to the stains left on plastic gauge. If the measured
oil film gap exceeds limit, it is necessary to replace bearing bush or choose bearing
bush with lessened size.

When installing new crankshaft, always use

bearing bush with standard size. If standard oil
film gap is not met after replacing bearing bush, it
is necessary to grind main journal and connecting
rod journal to lessened size. At the same time,
choose bearing bush with corresponding size.
3. Oil Seal
Check if front and rear oil seal has damage or surface wear and replace them if any.
4. Main Bearing Cap
After the main bearing cap is installed, make sure
crankshaft can rotate smoothly and the axial
clearance is correct. If the axial clearance
exceeds limit, replace bearing bush.
Standard value: 0.05~0.25mm

5. Fly Wheel
Check if fly wheel and the contact surface of
clutch plate has damage or wear, if serious,
replace fly wheel.
Check the separation gap of fly wheel and clutch contact surface and the limit is 0.13mm.
Check if fly wheel ring gear has damage, crack or wear. If necessary, replace ring gear.

6. Cylinder Body
① Check if cylinder hole has scratch, rust or
corrosion.
② Measure cylinder hole in A and B direction in the
figure with cylinder hole gauge.
Position 1: The 1st compression ring
Position 2: The central position of cylinder hole
 Benjoy Maintenance Manual –Engine Volume EM-63

Position 3: The end position of cylinder hole

③ If cylinder hole exceeds cylindricality requirements, or cylinder wall suffered serious
wear or damage, the cylinder hole should be rebored and reground. Then install
enlarged piston and piston ring.
Standard value:
Cylinder hole: 86.5+0.03mm
Cylindricality of cylinder hole: Max 0.01mm
④ If there is a fillet on the surface of cylinder
body, use machine tool to process it. The
operation size and mark of piston are:
Identical mark: 0.50 mm
Size: 0.50 0. S.
⑤ Re-bore the cylinder hole, and make sure
there is special designed oil gap between enlarged piston and cylinder hole, and
make sure all used piston has the same increase. The standard measuring method of
piston external diameter is to measure the diameter of 23mm up to the end of flexible
skirt section.
Oil gap between piston and cylinder hole: 0.02~0.04mm
⑥ Check engine top level. If it exceeds limit, process it to minimum or replace it.
Standard value: Flatness of engine body: Max 0.05mm
Limit: Flatness of engine body top: 0.1mm
Attention:
When installing cylinder head, it is acceptable that wear quantity is less than
0.2mm.
⑦ Boring cylinder hole
The enlarged piston should be selected based on the maximum cylinder hole.
Identical mark: 0.50
Size: 0. 50mm
Attention:
Piston size is carved at piston top.
⑧ Measure the external diameter of piston in use, and then calculate new cylinder hole
size. New cylinder hole size= piston external diameter+0.02~0.04mm (oil gap
between piston and cylinder hole) -0.02 (ground residual)
Attention:
TO prevent cylinder hole deformation as temperature increases, drill, hole, grind
cylinder hole in ignition order.
⑨ Inspect gap between piston and cylinder hole.
Attention: Without groove With groove

When drilling cylinder body, process the

four cylinders together, but not only one is
processed.
 Benjoy Maintenance Manual –Engine Volume EM-64

Lower bearing
Installation: bush
Without groove Upper bearing
bush

1. Install a main bearing bush with groove at

engine body side (upper bearing bush).
2. Install a main bearing with no groove at
Thrust bearing (central one)
main bearing bush side (lower bearing
bush).
3. Install thrust plate.
 Benjoy Maintenance Manual –Engine Volume EM-65

4. Smear the lubricating oil on main journal Oil seal Oil

support separation
and connecting rod journal. Then install film

crankshaft.

5. Install the main bearing cap and make sure

Oil
the arrow mark faces to engine. The hole
Oil pan surface
number on cap should be correct.

6. Screw down the main bearing cap stud with

the given torque (25Nm+90°).

7. Rotate crankshaft and make sure that

crankshaft rotates freely. And check axial
clearance of crankshaft.

8. Use special tool to install newly replaced oil

seal in oil seal support.

Attention:
Always replace a new one after dismounting oil seal. When installing oil seal in oil
seal support, make sure oil hole in oil seal faces down.

9. Install new oil seal support gasket and oil

seal support device.
Tightening torque: 10~12N·m

10. Install rear baffle plate to engine body. Install

fly wheel assembly and screw down fly
wheel bolt.
Standard torque: 130~140N·m
 Benjoy Maintenance Manual –Engine Volume EM-66

Piston Connecting Rod

Component Composition Drawing

1st piston ring

2nd piston ring

Oil ring

Piston

Piston pin

Bolt
Connecting rod

Upper bearing bush

Lower bearing bush

Connecting rod bearing cap

Plastic lock bolt

Torque: Nm (kg.cm, 1b.ft)

 Benjoy Maintenance Manual –Engine Volume EM-67

Dismantlement and Installation

Dismantlement Steps:
1. Dismount fixed bolt from connecting rod Dismantlement
EM095 device
bearing cap to crankshaft. Take down lower
bearing bush and arrange directionally in
order. Support
frame
2. Push connecting rod and take out piston from
upper part of cylinder, take out upper bearing Support fork

bush and arrange it directionally in order.

3. Arrange connecting rod bearing cap and
connecting rod directionally in order.
4. Use special tool to press out piston pin.
5. Use piston ring caliper to take off piston ring.

Check after Dismantlement:

Piston and Piston Pin
1. Check if every piston has scratch, abrasion or other damages. Replace the piston if
any and replace piston ring together with the piston. Check installation of piston pin in
the hole. In room temperature, the piston pin should be pushed smoothly in pin hole
with hand.
2. Measurement of piston ring side clearance EM096
Measure piston ring side clearance like shown in
the figure. If the measurement value exceeds
the limit, replace with a new piston ring and then
measure its side clearance. If side clearance still
exceeds limit, then replace piston and piston ring
at the same time. If side clearance is within limit,
only replace piston ring.
Piston ring side clearance standard value:
Press down ring with piston
1st piston ring: 0.03— 0.07mm
2nd piston ring: 0.02— 0.06mm EM097
Oil ring: 0.06— 0.15mm
3. Piston ring end clearance
Put piston ring in cylinder hole of engine body, use
piston to gentle push piston ring down to correct
position. Use gauge to measure end clearance. If
End clearance
it exceeds limit, replace piston ring.
Piston ring end clearance standard value:
1st piston ring: 0.25— 0.35 mm
2nd piston ring: 0.40— 0.55 mm
Oil ring film loop: 0.10— 0.40mm
 Benjoy Maintenance Manual –Engine Volume EM-68

Limit value of piston ring end clearance:

2nd piston ring: 0.8mm
Oil ring film loop: 1.0mm
4. Connecting rod
Check wears status of connecting rod. If there is damage in installation surface,
replace connecting rod.
Installation:
EM098
1. Install bushing ring of piston oil ring.
2. Install upper film loop and lower film loop of
piston oil ring.

EM099
Attention:
When installing upper film loop, first put one Internal braze
corner kind
end of film ring between piston groove and
bushing ring, then press a part of film loop
down, as shown in the figure, to install it into Lower cut kind
the groove. When installing film loop, do not
use the piston ring tension device. Install the
lower film loop with the above method.

3. Smear lubricating oil around piston and

EM100
piston ring, then use piston tension device to Upper film Top piston ring
ring end end
install it into secondary piston ring and top
piston ring.
Engine
front

Secondary piston Lower film

ring end and ring end
4. Use special tool to install piston pin, bushing ring
tension end
connecting rod, and piston together and be
careful with front and rear directions.
EM101
5. Use piston ring compression device to press
Engine
piston ring tight, install piston and piston ring
body
into engine body. number

Cut
 Benjoy Maintenance Manual –Engine Volume EM-69

6. Make sure the forward recognition marks on

piston and connecting rod point to the front
end of engine.
7. When installing casing of connecting rod big
end, make sure the connecting rod and big
end casing mark are located at the same
side.

Screw down connecting rod nut (upper tightening torque 20Nm+90°).

8 Check connecting rod side gap.
EM102

Standard value: 0.10~0.25mm

Limit: 0.4 mm
 Benjoy Maintenance Manual –Engine Volume EM-70

Lubrication

Intake camshaft hole

Intake hydraulic tappet hole

Cylinder head return port

Oil distributor
Exhaust hydraulic tappet hole

Exhaust camshaft hole

Left balancing shaft front

hole

Piston pin hole Left balancing shaft rear

sleeve hole

Right balancing shaft rear

sleeve hole
Big end shaft hole of connecting
rod
Right balancing shaft
front sleeve hole

Crankshaft main bearing

hole
Cylinder head return port
Crankshaft main bearing
hole
Crankshaft main bearing
hole

Front Main oil groove Engine oil pressure Rear

switch
Pressure
pressurerelief
valve
Oil filter reducing
Oil pump

Oil pickup

Oil pan

Overview
The lubricating system is the type of full flow filtration and pressure supply. Oil pump is
installed on engine cylinder body. The rotor in oil pump is driven by crankshaft. An oil
catcher is used to decrease oil shake in high speed of engine so as to increase power.
Engine oil is pumped from oil pan by rotor-type oil pump directly connecting to crankshaft.
Oil pressure is controlled by safe valve installed at the inner side of oil pump casing. Refer
to the following table for oil pump lubricating passage.

From To From To
Oil pump Oil pump seat (inlet) Main oil distributing 1 Crankshaft main
passage at the bearing
Oil filter seat (inlet) Oil filter center of cylinder 2 Left cylinder head＊
Oil filter Oil filter (outlet) body 3 Right cylinder head
＊
Oil filter (outlet) Oil groove at the right side Crankshaft main Connecting rod
of cylinder body bearing bearing
Oil groove at the right Oil groove and oil cooling Left cylinder head Left cylinder head
side of cylinder body device at the rear part of
cylinder (some models)
 Benjoy Maintenance Manual –Engine Volume EM-71

Oil groove at the rear Main shaft passage at the Right cylinder head Right cylinder head
part of cylinder body center of cylinder body
There is an oil limiter on the hot plate of cylinder head to control the oil flow of cylinder head.
From To

Inlet passage of right cylinder head (inlet side of Rear part of cylinder head ＊ oil groove and
cylinder head) accumulator
Rear part of cylinder head ＊ oil groove and 1 Oil groove of exhaust camshaft
accumulator 2 Oil groove of intake camshaft
Left exhaust camshaft oil groove 1 Left-intake camshaft journal
2 Valve hydraulic tappet and rocker arm
nd
3 Left camshaft (the 2 ) drive chain tensioner＊
＊
Left intake camshaft oil groove 1 Left intake camshaft journal
2 Valve hydraulic tappet and rocker arm
＊When oil flows to the rear part of cylinder head, oil flows through oil groove to an accumulator in the
center of cylinder head and the accumulator is closed by a shrunk-in core plug, which has a small
measurement hole. The oil flows down to the two oil grooves by a 45-degree angle through
accumulator, one passage is at intake side of cylinder head and the other at exhaust side.
＊＊2nd camshaft drive chain tensioner is the last component to receive oil from left cylinder head.
Right cylinder head inlet passage and Oil groove behind cylinder head and accumulator
accumulator＊ ＊
Right exhaust camshaft oil groove 1 Right exhaust camshaft journal
2 Valve hydraulic tappet and rocker arm
nd
3 (The 2 ) camshaft drive chain tensioner
st
4 1 timing drive chain tensioner of right cylinder
head＊＊
Right inlet camshaft oil groove 1 Right inlet camshaft journal
2 Valve hydraulic tappet and rocker arm
＊When oil flows to the rear part of cylinder head, oil flows through oil groove to an accumulator in the
center of cylinder head and the accumulator is closed by a shrunk-in core plug, which has a small
measurement hole. The oil flows down to the two oil grooves by a 45-degree angle through
accumulator, one passage is at intake side of cylinder head and the other at exhaust side.
＊＊Timing (the 1st) drive chain tensioner is the last component to receive oil from right cylinder.

Diagnosis and Test

Check Engine Oil Pressure
1. Dismount oil pressure switch①.
2. Install oil pressure test gauge assembly.
3. Start engine and monitor gauge readings.

Attention:
If oil pressure is zero at idle speed, never operate the engine in 3,000 rpm.
4. Oil pressure (when engine is in working temperature): Minimum value under basic
idle speed is 34.5 kPa, and 300~724 kPa at 3,000rpm.
5. If oil pressure is zero at idle speed, stop engine and check if compression safe valve
is blocked at open position or oil pickup is blocked.
6. Dismount oil pressure tester assembly, and install oil pressure switch after finishing
testing.
 Benjoy Maintenance Manual –Engine Volume EM-72

Replacement of Engine Oil and Filter

Caution:
New or used oil is stimulant to skin. Always protect skin from contacting with oil for
a long time or many times. Pollution caused by internal burning may be detrimental
to health. If skin contacts oil, use soap and water to clean it thoroughly. Never use
petrol, diesel, diluents, and solution to clean skin. These may cause health
problems. As for the waste oil, dispose it properly. Do not cause contamination.
Check the usage mileage and time interval of oil
and filter described in maintenance periodic table. EM103
When replacing engine oil

1. Operate engine until temperature is up to

normal.
2. Lift and support car on safe station. ⑵
3. Put a proper drain pan under crankshaft oil ⑴
drain hole (2).
4. Dismount the drain plug (2) from the oil pan
and discharge oil into the pan. Check if the EM104
thread of drain plug (2) is lengthened or has 1
other damage. If any, replace drain plug (2)
and lining.
5. Dismount oil filter (1).
6. Install drain plug (2) to oil pan.
2
7. Install new oil filter 1.
8. Put down car and dismount oil filler cap1. Fill
crankshaft tank with oil of given type and
quantity. EM105
9. Install oil filler cap1.
10. Start engine and check if there is leakage.
1
11. Stop engine and check oil level 2.

Check Engine Oil Level 2

The best time to check engine oil level is after the
engine stops for one night. If engine is working,
wait at least 5 minutes after engine stops before
check oil level 2. Putting car on level ground to
check oil level helps improving the accuracy of oil
level readings. Fill oil at oil filler 1 only when oil
level is at or under “F”mark.
 Benjoy Maintenance Manual –Engine Volume EM-73

Cooling System
Expansion water tank

Water outlet tube Radiator Water inlet Common water

Small circulation passage

Shared passage
Big circulation

Thermostat valve room

Thermostat fully on (>95℃) Water inlet connecting Water pump

tube
Thermostat not fully on (>82℃ and <95℃)

Thermostat off (<82℃)

Throttle valve

Air-warming water outlet branch

Water inlet connecting Cylinder body
branch
Air-warming water Warm air device
outlet tube

Cylinder head

Overview
Cooling system includes:
* Radiator
* Cooling fan
* Radiator pressure cap
* Thermostat
* Coolant recycles system
* Coolant
* Water pump
* Hose and hose clamping band
Engine Coolant
Check
Level Check
• After engine cools down, check if the level of
engine coolant in the fluid reservoir is
between minimum to maximum.
• Adjust engine coolant level if necessary.
 Benjoy Maintenance Manual –Engine Volume EM-74

Leakage Check
● Use a radiator cap tester (universal maintenance tool) and radiator cap tester jointly to
increase pressure to cooling system to check if there is leakage.
Caution:
Please do not dismount radiator cap when Hose joint
engine is very hot. Otherwise high-pressure
engine coolant overflowing from radiator may
cause serious burn.
Attention:
1. If testing pressure exceeds the given Radiator cap
tester
value, it may damage radiator.
2. When engine coolant decreases, please fill
engine coolant to radiator.
Carefully open radiator pressure cap at filler, check coolant level. Press radiator cap to
take it off from locating bump. Clean the inner part of filler, check if the base of seal seat
has concave, crack, paint, dust or weld residual. Check if the hose from radiator to
recycle/overflow tank is blocked. Plug a lead wire through hose and make sure there is no
block. Check the flange at the outer side of radiator filler. If it is damaged, sealing of
pressure cap valve seat and pressure tester will be affected.
Connect pressure tester to the filler.
Use the hand pump of pressure tester to exert a pressure of 124.1 kPa to cooling system.
If the hose is over expanded or swelled, replace it as required. Observe pressure gauge
pointer, and determine cooling system status according to the following rules:
Keeping stable:
If pointer keeps stable up to 2 minutes, it means system does not have serious coolant
leakage. However, internal leakage may exist and it does not occur under common
system testing pressure. If lose or leakage of coolant really exists but cannot be tested,
check if internal leakage occurs or conduct internal leakage test. Refer to “Internal
Leakage Check”section.
Lowering slowly:
It means leakage or seepage is occurring now. Use a flashlight to conduct leakage or
minor leakage check of all joints. Check radiator, hose, gasket edge and heater. Use
sealant to seal small leakage holes. Repair leakage holes and re-conduct pressure check
on system.
Lowering quickly:
It means serious leakage is occurring now. Conduct external leakage check on system. If
leakage is not noticeable, check internal leakage.
Internal Leakage Check
Dismount the drain plug of engine oil pan and discharge little oil. If there is coolant in oil
pan, discharge it first since it is heavier than oil. Another way is to operate engine for a
short time to stir oil. Then take out oil ruler to check if there is any water drop. Also, check
if there is water drop on gearbox ruler in the same way so to check if gearbox cooling
device leaks.
Caution:
When pressure tester is installed on radiator, do not let pressure exceed 145 kPa. If
burning leakage exists, pressure will increase soon. Shake pressure tester to
release pressure. When dismounting pressure tester, if system has pressure, do
 Benjoy Maintenance Manual –Engine Volume EM-75

not rotate pressure tester over half round.

Operate the engine without radiator cap until thermostat turns on. Install pressure tester
on radiator filler. If pressure increases soon, it means burning leakage exists. This is
usually the result of cylinder gasket leakage or engine breaking, repair trouble part as
required.
If the pressure does not increase quickly, then pump the pressure tester until the pointer
points to 124.1 kPa. If the pointer swings, it means compression leakage or burning
leakage occurs in cooling system.
Because the car has catalytic converter, never dismount the ignition plug high-pressure
wire or use short-circuit outside the cylinder to isolate burning leakage.
If the pointer is static, operate engine at high speed for several times to check the
abnormal quantity of coolant or steam. It needs to be discharged through the exhaust tube.
Exhaust tube discharges coolant or steam which may mean there is trouble in cylinder
gasket, engine cylinder body or cylinder head.
Burning Leakage Test— Not with Pressure Tester
Do not waste recyclable coolant. If the coolant is clean, discharge it into clean container
for reuse.
Caution:
When the system is hot or under pressure, do not dismount cylinder body water
drain cock or unscrew radiator water drain cock. Otherwise coolant may cause
serious burning.
Fully discharge coolant to dismount thermostat and dismount accessory driver belt. Fill
little coolant to radiator.
Attention:
To avoid overheat, do not run engine for a long time. Open water drain cock
immediately after testing to avoid coolant boiling.
Start engine and speed up it quickly three times up to about 3,000 rpm. Observe coolant
at the same time. If the gas in engine leaks to cooling system, bubbles will occur in coolant.
If there is no bubble, it means there is no internal gas leakage.
 If some parts and components are found damaged, please repair or replace them.
Replacement of Engine Coolant
Caution:
To avoid burning, please do not replace coolant when engine temperature is very
high.
Use a piece of thick cloth to wrap radiator cap and carefully unscrew it. First rotate
for a quarter round to release pressure in radiator, and then completely unscrew
this cap.
Be careful not to spill engine coolant to driver
belt.
Discharging Engine Coolant
1. Take out seal ring from lower cover.
 Benjoy Maintenance Manual –Engine Volume EM-76

2. Open radiator water drain cock on the base of radiator, then dismount radiator cap.
After fully discharging the engine coolant in system, open water drain cock in cylinder
body.
3. If it is necessary to dismount fluid reservoir, discharge engine coolant and clean fluid
reservoir before re-installation.
4. Check if there is rust, corrosion or discolor in discharged engine coolant. If coolant is
contaminated, please flush engine cooling system.

Refilling Engine Coolant

1. Install the dismounted water drain cocks of fluid reservoir and radiator.
Attention:
Do clean water drain cock and install a new O-ring. If the water drain cock on
cylinder body is plugged out, please plug it in and screw it down.
2. Make sure every hose clip has been screwed down.
3. Fill the coolant to radiator and fluid reservoir to the given level.
4. Install the radiator cap.
5. Warm up engine until thermostat is turned on. The standard warming up time of 3,000
rpm is about 10 minutes.
 Touch radiator hose (below) to feel if there is warm water flowing out so as to
determine if thermostat turns on.
Attention:
Check water thermometer to prevent engine overheat.
6. Stop engine to let its temperature descend below 50 °C.
 Use fan to shorten cooling time.
 If necessary, fill the engine coolant in radiator up to the filler neck.
7. Fill the engine coolant in fluid reservoir up to maximum position.
8. Install radiator cap and repeat steps of 5 to 7 two times or more until engine coolant
level does not go down.
9. Operate the engine and check if leakage occurs in cooling system.
10. Warm up engine to make idle speed of engine is up to 3,000rpm. Check the flow
voice of engine coolant.
 Voice at the heater will be relatively high.
11. If there is still some voice, repeat steps of 5 to 7 to discharge air in cooling system
until engine coolant level does not go down any more.
 Discharge extra coolant in engine.

Flush Cooling System

1. Install the dismounted fluid reservoir and radiator water drain cock.
Attention:
Do clean water drain cock and install a new O-ring. If water drain cock on cylinder
body is plugged off, please plug it in and screw down it.
 Benjoy Maintenance Manual –Engine Volume EM-77

2. Fill water to radiator and fluid reservoir and install radiator cap.
 Cut off joint when engine coolant overflows from heater hose. Then reconnect heater
hose and continue filing with engine coolant.
3. Operate engine and warm it up to normal operation temperature.
4. Speed up engine without load for two or three times.
5. Stop engine and wait until it cools down.
6. Drain the water in system.
7. Repeat the steps of 1 to 6 until clean water flows from the radiator.
Coolant
Overview
Engine Coolant
Ethene ethanediol Mix
Attention:
Do not use normal field equipment to measure relatively dense mix. 100% ethane
ethanediol mix may cause problems.
As for the aluminum cylinder body, cylinder head and water pump, special antiseptic
protection is necessary. Only the anti-icing liquid/coolant, mix with 5 year/160,000km
lifetime (HOAT means filling antiseptic agent into ethyl coolant, i.e., mixing organic
additive technology) specified by JAC are recommended. When it mixes with 50% distilled
water, minus 37°C freezing point is made which makes engine the best cooling effect and
not corrode. If coolant discolors or is contaminated, discharge and flush it, replace it with
new correct mixing coolant.
The required mix of ethane-ethanediol (anti-icing liquid) and water relies on environment
and car working conditions. Under any climate of a year, density of anti-icing liquid must
be at least 44%. If it is lower than 44%, cave corrosion may occur at engine component
and cooling system component may be seriously damaged by corrosion. Density of
anti-icing liquid is 68% when anti-icing ability is strongest which makes the freezing point
of coolant is at minus 67.7℃. The higher anti-icing liquid density is, the lower freezing
point is. However, if density of anti-icing liquid is too high, it may cause engine overheat
since the specific heat of anti-icing liquid is less than that of water.
Usage of 100% ethane-ethanediol may cause additive precipitation to occur in system
because the antiseptic additive in ethane-ethanediol needs water to dissolve. This
precipitation works as heat insulation and causes temperature to ascend to 149℃. Such a
temperature is high enough to melt plastics and to soften soldering tin. The ascent of
temperature will cause the knock of engine. And the freezing point of 100%
ethane-ethanediol is 22℃。
Propene-ethanediol Mix
The range of effective anti-icing temperature of propene-ethanediol mix is less than that of
ethane-ethanediol. The freezing point of the mix of propene-ethanediol and water is minus
32℃。It is 5℃ higher than that of 50% density of ethane-ethanediol. The boiling point of
propene-ethanediol under 96.5 kPa (to prevent engine from boiling in summer) is 125℃
but that of ethane-ethanediol is 128℃. When it is required to use ethane-ethanediol in
cooling system according to the design, usage of propene-ethanediol will result in boiling
or icing at relatively high temperature. The heat transmission property of
propene-ethanediol is poorer than that of ethane-ethanediol which may cause the
 Benjoy Maintenance Manual –Engine Volume EM-78

temperature of cylinder head to ascend in some working conditions.

The mix of propene-ethanediol and ethane-ethanediol may cause all antiseptic unstable
which may damage all components of cooling system. And once ethene-ethanediol
coolant and propene-ethanediol coolant mix in car, regular method which is used to
determine coolant freezing point is not precise any more. The refraction index and specific
gravity of propene-ethanediol and ethane-ethanediol are different.
HOAT Coolant
Caution: Anti-icing liquid is an ethane-ethanediol coolant and it may hurt if swallowed or
breathed in. If swallowed, drink two cups of water to vomit it. If breathed in, move to the
area with fresh air. Find hospital to observe immediately. Do not store it in open or
unmarked container. If contacting with propene-ethanediol, thoroughly clean skin and
clothes. Keep it out of children. Correctly dispose ethanediol coolant, contact with local
distributor or government recycle center. When engine is at working temperature or under
high pressure, do not open cooling system otherwise it may cause injury. When
conducting the maintenance of related engine components, do avoid radiator cooling fan
as it may cause injury.
Attention:
Not recommend using propene-ethanediol coolant as it depreciates anti-icing
protection and antiseptic protection.
Cooling system is designed to use full coolant to cool. Coolant must take away heat from
the cylinder head section near exhaust valve and engine cylinder body metal. Coolant
takes heat to radiator and flat pipe type radiator which may transfer heat to air.
As aluminum made cylinder body, cylinder head and water pump are used, special
antiseptic protection is necessary. Only the anti-icing liquid/coolant, mix with 5
year/160,000km lifetime (HOAT means filling antiseptic agent into ethyl coolant, i.e.,
mixing organic additive technology) specified by JAC are recommended. When it mixes
with 50% distilled water, minus 37°C freezing point is made which makes engine the best
cooling effect and not corrode. If coolant discolors or is contaminated, discharge and flush
it, replace it with a new correct mixing coolant.
Attention: Anti-icing liquid/coolant, mix of 5 year/160,000km lifetime can not be
mixed with any other type of anti-icing liquid. Mixing with coolant other than the
given one will cause engine damage in the guarantee period and deteriorate the
antiseptic protection.
Coolant Property
Required mix of ethane-ethanediol (anti-icing liquid) and water relies on environment and
car working conditions. The property of each mixing coolant is as below:
Pure water: Pure water may absorb more heat than the mix of water and
ethane-ethanediol. This is only for heat transfer. Water may ice at higher temperature and
cause corrosion.
100% ethane-ethanediol: The antiseptic additive in ethane-ethanediol needs water to
dissolve. Without water, additive may precipitate in system. This precipitation works as
heat insulation and cause temperature to ascend to 149℃. Such a temperature is high
enough to melt plastics and to soften soldering tin. Over high temperature will cause the
knock of engine. And the freezing point of 100% ethane-ethanediol is 22℃。
The mix of 50/50 ethane-ethanediol and water is recommended and its freezing point is
minus 37°C. The density of anti-icing liquid must be at least 44% under any climate in a
 Benjoy Maintenance Manual –Engine Volume EM-79

year. If it is lower than 44%, cave corrosion phenomenon will occur and engine parts
corrode. The density of anti-icing liquid is 68% when capability of anti-icing is strongest,
which may prevent coolant from icing at minus 67.7℃. High percent will cause the icing at
higher temperature. And high percent of anti-icing will cause engine overheat as the
specific heat of anti-icing liquid is less than that of water.
Attention:
Do not use normal field equipment to measure relatively dense mix. One hundred
percent ethane-ethanediol mix may cause problems.
Coolant Choose and Additive
As aluminum made cylinder body, cylinder head and water pump are used, special
antiseptic protection is necessary. Only the anti-icing liquid/coolant, the mix with 5
year/160,000km lifetime (HOAT means filling antiseptic agent into ethyl coolant, i.e.,
mixing organic additive technology) specified by JAC are recommended. When it mixes
with 50% distilled water, minus 37°C freezing point is made which makes engine the best
cooling effect and not corrode. If coolant discolors or is contaminated, discharge and flush
it, replace it with a new correct mixing coolant.
Attention:
Do not use the coolant additive that is called to improve engine cooling effect.
Operation Principles
When the coolant flows through engine cylinder, it absorbs heat of engine cylinder body
and then flows to radiator. Cooling radiation plates in the radiator transfer the heat in
coolant into air. In cold days, propene-ethanediol and ethane-ethanediol coolant prevent
the water in cooling system from leaking but ices in the temperature range reflected by the
mixing ratio of coolant and water.
Diagnosis and Test
Coolant Density Test
After filling extra coolant to system or discharge coolant from system, flushing system and
refilling coolant, do check coolant density. When mixed to the freezing point of minus 37°C
to minus 46°C, coolant mix provides the most proper engine cooling and antiseptic
protection. Use hydrometer or refractor to test coolant density.
Hydrometer measures the ethane quantity in mix through measuring mix quantity. The
higher the density of ethane-ethanediol is, the more the float balls are, the better the
anti-icing protection is (up to the maximum 60% of ethanediol content).
Some coolant manufacturers use other types of ethanediol in their coolant formula.
Ethene-ethanediol is the most common new type coolant. However, propene-ethanediol
coolant does not provide the same anti-icing and antiseptic protection and is not
recommended.
Attention:
Do not mix different type coolant otherwise it may seriously deteriorate antiseptic
protection.
First Step Check
Engine cooling system is overheat
Determine which driving status causes it. The following cooling system abnormal loading
may be its causes:
 Long time idle speed
 High environment temperature
 Benjoy Maintenance Manual –Engine Volume EM-80

 Breeze at tail at idle speed

 Slow traffic
 Traffic jam
 High speed or precipitous slope
The driving skills to avoid overheat are:
 When water thermometer is near normal range, shut down air-conditioner for idle
operation.
 Recommend increasing engine rotating speed to get more air.
Recent maintenance or troubleshooting:
Make sure if recent maintenance of car which may affect cooling system is conducted. It
may be:
 Adjust engine (wrong timing)
 Engine accessory driver belt skids
 Brake (possible dragging)
 Replace parts and components. Water pump is improper, or wrong direction of belt
may cause water pump to rotate in reverse direction
 Repair radiator or refilling the cooling system (probably not fully filled or air entering
system)
 Benjoy Maintenance Manual –Engine Volume EM-81

Cooling System Cleaning/Reverse Flushing

Cleaning
Empty cooling system and refill it with water. Operate engine with radiator head installed,
until radiator upper hose heats. Stop engine and drain out the water in system. If the water
is dirty, refill it into system, operate engine and empty system. Repeat the steps until drain
out clean water.

Reverse Flushing
The reverse flushing of cooling system forces water to flow through cooling system. It
blows water in a direction contrary to coolant normal flowing direction with compressed air.
It is usually conducted only when system is very dirty and is partly blocked.

Reverse Flush to Radiator

Cut off the inlet and outlet hoses of radiator. Install a passage of radiator hose to the joint
on the base of radiator, and then plug in a flushing gun. Connect water supply hose and
air supply hose to the flushing gun.

Attention:
Internal pressure of radiator must not exceed 138 kPa, otherwise it may cause
radiator damage.
Fill radiator with water. When filling radiator, apply compressed air at short intervals. At the
interval of applying compressed air, refill radiator. Continue this reverse flushing until
clean water flows from the cooling pipe behind radiator. Find a radiator workshop and
conduct more complete cleaning of radiator.

Reverse Flush to Engine

Empty the cooling system. Dismount thermostat cover and thermostat. Install thermostat
cover. Cut off the hose on radiator and connect a flushing gun to the hose opening. Cut off
the hose under radiator from water pump and lengthen a derived hose to the joint of water
inlet of water pump.

Attention:
In the car installed with control valve of heater coolant, make sure heater control
valve is off (heater is off). This is to prevent the coolant with scale and other
residuals from entering the heater core.
Connect water supply hose and air supply hose to a flushing gun. Fill water to engine.
When filling, apply compressed air at short intervals. At the interval of applying
compressed air, fill in water. Continue flushing until clean water flows from the derived
hose.
Dismount derived hose, flushing gun, water supply hose and air supply hose. Dismount
thermostat cover, install thermostat. Install thermostat cover and new gasket. Refer to
“replacement of thermostat”section. Connect radiator hoses. Use the correct mix of
anti-icing liquid and water to refill cooling system. Refer to “refilling cooling system”
 Benjoy Maintenance Manual –Engine Volume EM-82

section.
Chemical Cleaning
In some conditions, use radiator cleanser before flushing which may soften scale and
other residuals and help flushing.
Water Pump
Component Composition Drawing

Dismantlement and Installation

Dismantlement Steps:
1 Drain out engine cooling water and dismount
Water pump
coolant pump inlet hose. pulley

2 Unscrew the fixed bolts of electric generator and

adjust bolts. Push electric generator upward and
loosen driver belt, and take down driver belt. Electric
generator Crankshaft
3 Dismount water pump pulley bolts and take down pulley pulley
water pump pulley.
4 Dismount electric generator support and tension
pulley of automatic tensioner.
5 Dismount the fixed bolts of water pump casing and take off water pump.
Check after Dismantlement:
1. Check if belt has any crack, aging, damage.
2. Check if water pump has crack, wear, and damage and replace water pump parts if
any.
3. Check if water pump bearing has damage, abnormal noise, and slow rotation and
replace water pump parts if any.
4. Check if sealing parts have leakage and replace water pump parts if any.
5. Check if engine coolant leaks. If any, replace water pump sealing parts.

Installation：

1. Clean engine coolant pump and the surface of cylinder body sealing gasket.
2. Install a new O-ring in chase of the front edge of engine coolant tube then use water
to wet it. Do not use oil or grease.
 Benjoy Maintenance Manual –Engine Volume EM-83

3. Install a new engine coolant pump sealing gasket and a new engine coolant pump
part and screw down bolt with given torque.
Tightening torque: 20~27N·m
4. Install timing belt and timing belt cover.
5. Install engine coolant pump pulley and driver belt. Pull tight electric generator
support.
 Benjoy Maintenance Manual –Engine Volume EM-84

Radiator and Thermostat

Component Composition Drawing

Check:
1. Check if there is foreign matter between cooling fans.
2. Check if cooling fan has damage and repair it if any.
3. Check if radiator has wear, damage, rust or dirt.
4. Check if radiator hose has crack, damage or aging.
5. Check if expansion water tank has damage.

Installation:
1. Fill clean cooling mix to radiator and expansion water pot.
2. Operate engine until coolant is hot enough to turn on thermostat valve, then stop
engine.
3. Take off radiator cap and fill coolant from the radiator filler until to the top end of
expansion water tank.
Attention:
Never open radiator cap when radiator is hot.
Fill with the coolant of given specifications of original manufacturer.
Block of dust, foreign matter on radiator surface may cause water temperature to
increase and it is required to dismount and clean radiator.
 Benjoy Maintenance Manual –Engine Volume EM-85

Dismantlement and Installation

Dismantlement Steps:

1. Cut off grounding wire from battery joint.

EM106

2. Cut off fan motor joint.

EM107

3. Loosen the emission plug of radiator and

discharge coolant.

EM108

4. After making simple marks on radiator hose

EM109
and pipe clamp, loosen upper and lower hose
and overflow device.

5. Dismount the two assembly bolts of radiator.

(one at each side)
 Benjoy Maintenance Manual –Engine Volume EM-86

6. Dismount radiator and fan motor.

7. Dismount radiator fan motor and condenser fan motor from radiator.

Clean
Excellent heat-transfer effect needs a clean radiator cooling fan. If radiator and cooling fan
of air-conditioner has scraps, clean them immediately. After engine cools down, flush
radiator rear part (at engine side) with cold water and compressed air to flush away scraps
of radiator and/or air-conditioner condenser.

Check after Dismantlement

Check if there is break, damage or the loss of joint in the water tank of radiator. In the
same way check if there is leakage and/or seal aging in the joint of tank and radiator core.
Check if radiator core has corrosion, wind or losing cooling fan. Check if radiator core is
wound and if cooling tube is damaged.
 Benjoy Maintenance Manual –Engine Volume EM-87

Radiator Cap
Component Composition Drawing

Radiator cap Spring

High pressure
valve Deflection Vacuum valve
valve spring

Pressure: Pressure:

Pressure: Kpa (kg/cm2, psi)

Radiator Pressure Cap

Overview
All cooling system radiators are installed with
pressure cap. Pressure releasing point (unit: pound)
is carved on the top of pressure cap.
Cooling system works under the pressure which is a
little higher than atmospheric pressure, which
makes coolant boiling point higher and increases
the cooling ability of radiator. The cap includes a
compression release valve 1 with a spring. There is
a rubber sealing gasket 2 for the sealing of radiator
filler. This is to keep the vacuum in cooling period
and to prevent system from leaking under pressure. 1
2
 Benjoy Maintenance Manual –Engine Volume EM-88

Operation principles
Air vent valve at the center of pressure cap keeps closed when exerting pressure to
cooling system. As coolant cools down, coolant volume compresses which generates
vacuum in cooling system. This results that vacuum valve opens and the coolant in
recycle/overflow container is sucked back to radiator through the connecting hose. If
vacuum valve is clogged at off position or twisted with overflow hose, radiator hose shall
be shrunken after it cools down.
Diagnosis and Test
Sealing parts from radiator cap to filler
Test pressure release of the sealing parts (or sealing) on pressure cap through
dismounting the overflow hose on the spraying nipple of radiator filler. Connect the hose of
pressure testing tools to the spraying nipple. It may be necessary to cut hose from the
adapter of its filler. Pump air to the radiator.
Caution:
Sign of “do not open at high temperature” on the radiator pressure cap is a safe
pre-warning sign. At high temperature, cooling system generates pressure. To
avoid burning or body injury, do not dismount the radiator cap when system is at
high temperature and/or under pressure.
Except for the following purposes, never dismount the radiator cap at any time:
1. Check and adjust the freezing point of anti-icing liquid.
2. Use new anti-icing liquid to refill system.
3. Conduct maintenance.
4. Check if there is vacuum leakage.
Caution:
If car has just traveled, wait for at least 15 minutes before dismounting radiator cap.
Use a cloth to press the hose on radiator and check if the system is under pressure.
Put the cloth on the cap but not press it. Rotate the cap anti-clockwise to the first
stop. Make liquid flow from coolant recycle/overflow hose to recycle/overflow
container. Press the hose on radiator to determine
when pressure is released. When coolant and steam
are not pushed to the container and the pressure in
system decreases, completely dismount radiator
cap.
Radiator Cap
Dismount pressure cap (1) from radiator. Make sure
sealing surface is clean. Use water to wet rubber gasket
and connect pressure cap to pressure tester (2).
Operate the hand pump of pressure tester and make the pressure of tester increase to
138 kPa. If pressure cap (1) can not keep pressure at least 131 kPa, replace pressure cap.
Pressure cap may be good when testing with pressure tester. After installing it onto
radiator, pressure or vacuum may not be kept. If so, check if sealing gasket of radiator
filler and cap top is damaged. It is also required to check if there is dirt or deformation
which affects correct sealing of the cap.
 Benjoy Maintenance Manual –Engine Volume EM-89

Attention:
Pressure tester of radiator is very sensitive to small air leakage. This leakage does
not affect cooling system. The pressure cap which never has coolant leakage must
not be replaced only because it has slow leakage when checking with this tester.
Fill water to the tester. Put it upside down. Re-check pressure cap to determine if it
needs replacement.
Clean
Only use neutral soap and water to clean radiator cap. Usage of any type of solution may
cause damage to radiator cap sealing.

Check
Set cap level with eyes and let right side up so air vent valve at the bottom of cap opens. If
rubber sealing gasket expands and affects air vent valve opening, replace cap.
Level cap with eyes and let top part down. If there is light between air vent valve and
rubber sealing gasket, replace cap. Do not use spring as cap of air vent valve. Radiator
cap shall be the type designed for coolant recycle/overflow system, with fully sealing
diaphragm spring and rubber sealing gasket. This sealing gasket is used to seal the top
surface of radiator filler. Use correct cap to make coolant return to radiator.

1. Check if radiator cap has damage, crack or

aging. Aging

Aging

2. Connect radiator cap to tester.

3. Increase the pressure until the pointer stops

swinging.

4. If readings can not keep stable for about 10

minutes, replace radiator cap.

 Benjoy Maintenance Manual –Engine Volume EM-90

Radiator Fan Motor Assembly

Component Composition Drawing

Check:
Fan Motor of Radiator and Fan Motor of Condenser

1. Connect motor terminal to power supply and check the rotation status of fan motor.

2. Check if there is abnormal noise when motor

operates.

Radiator Fan Motor Relay

1. Dismount radiator fan motor relay (high
terminal and low terminal) from its box in
engine cab.

2. Check conductive property between

terminals.
 Benjoy Maintenance Manual –Engine Volume EM-91

Radiator Fan
1. Check if fan blade has damage or crack.
2. Check if the bolt hole on fan central shaft hub
has crack or damage.

Installation
Installation sequence is in reverse to that of
dismantlement.
Illustration:
1. Never let fan contact fan cover in
installation.
2. After installation, make sure there is no
abnormal noise or tremble when fan
rotates.

EM110
Dismantlement and Installation

Dismantlement Steps:
1. Cut off grounding wire of battery.

EM111

2. Cut off connector of fan motor and wire

harness of fan cover.
 Benjoy Maintenance Manual –Engine Volume EM-92

3. Dismount the four assembly bolts on fan cover.

EM112

4. Dismount fan motor cover.

5. Dismantle fan mounting clip and separate fan
motor and fan.
6. Dismount the three screws and fan motor.

EM113

Installation:
Install in the reverse order of dismantlement steps.
 Benjoy Maintenance Manual –Engine Volume EM-93

Thermostat
Component Composition Drawing

Radiator outlet pipe

Radiator intake device

Washer Thermostat

Check: Thermograph
Thermostat
1. Heat thermostat as shown in the figure.
2. Check if valve works normally.
3. Test temperature when valve opens.
Opening valve temperature: 80~84°C
Fully open temperature: 95°C
Water

Installation:
1. Check if thermostat flange is correctly fixed
in the sleeve of thermostat cover.
2. Install entrance device and install the
entrance device bolt of engine coolant.
Tightening torque: 10~15Nm

3. Refill with coolant.

 Benjoy Maintenance Manual –Engine Volume EM-94

Dismantlement and Installation

Dismantlement Steps:

1. Discharge the coolant until the level is lower than EM114

thermostat.

EM115

2. Dismount entrance device and washer.

 Benjoy Maintenance Manual –Engine Volume EM-95

Analysis of Overheat Reasons

Troubleshooting Table
Trouble Items to Be Checked

Water pump has Driver belt wears out or

trouble looses

Thermostat is
Bad clogged at “off” －
radiation position
Cooling fan is Dirt or paper scraps blocks
damaged Mechanical damage
Cooling tube of Too much foreign matters
radiator is blocked (rust, dirt, sand etc.)
Spare Cooling fan does not
part work
trouble Fan rotation
of Insufficient
resistance is too Fan assembly －
cooling air flow
strong
system
Fan blade is
damaged
Damaged
－ － －
fan cover
Wrong
coolant － － －
mixing ratio
Poor quality
of engine － Engine coolant sticks －
coolant
Thimble looses
Coolant hose
Hose breaks
Sealing property is not
Water pump
good
Loose
Radiator cap Sealing property is not
Engine coolant leaks good
Insufficient
O-ring is damaged,
engine
aging or installed wrong
coolant
Radiator Water tank of radiator
breaks
Radiator core breaks
Fluid reservoir Fluid reservoir breaks
Cylinder cover ages
Tail gas leaks to cooling
Fluid reservoir leaks Cylinder cover lining
system
ages
Spare Rotating speed of
part engine without load is
trouble too high
Abnormal travel
except Long time low speed
cooling travel
system Superhigh speed travel
Engine is over loaded
Driving system has trouble
Wheel and tire of wrong
specifications are installed
－
Brake is blocked
Ignition timing is not
correct
Air flow is Blocked air vent valve
－ －
not fluent of bumper
Install car cover
Blocked radiator grid Mud or paper scraps
blocks
Radiator is blocked －
Condenser is blocked Air flow is not fluent
 Benjoy Maintenance Manual –Engine Volume EM-96

Fog lamp is too large

 Benjoy Maintenance Manual –Engine Volume EM-97

Diagnosis Table of Cooling System

Trouble Possible Reasons
Readings of 1 Does DTC show that open thermostat is blocked?
water 2 Does water temperature sensor connect?
thermometer is 3 Does water thermometer work normally?
low. 4 Coolant level is low in cold temperature and warm air effect is poor.
5 Internal air door of warm air heater or controller works abnormally.
Readings of 1 Normally drag trail, climb on precipitous slope, car travels in slow traffic,
water or engine is idling in high temperature and with air-conditioner on. High
thermometer is sea level will intensify this kind of status.
high or warning 2 Is the readings of water thermometer correct?
light of coolant 3 Is water temperature warning light unnecessarily on?
is on. There 4 Is the level in coolant recycle and overflow tank and radiator low?
may be loss or 5 Pressure cap of radiator is not screwed down. If it looses, boiling point of
leakage of coolant will decrease. Please refer to the following step 6 at the same
coolant in time.
cooling system. 6 Radiator cap is not sealed well.
7 Radiator level is low but level of the recycle and overflow tank of coolant
is not low. It means radiator does not absorb coolant from recycle and
overflow tank when engine cools down.
8 The density of coolant is not correct.
9 Coolant does not flow through system.
10 Cooling fans of radiator or air-conditioning condenser is too dirty or
blocked.
11 Radiator core is corroded or blocked.
12 Fuel system or ignition system has trouble.
13 Brake is slow.
14 The paper board or anti-worm plate is used so air volume is
decreased.
15 Thermostat is partly or completely closed.
16 Cooling fan does not work normally.
17 Cylinder gasket leaks.
18 Warm air heater core leaks.
Readings of 1 When operating in cold weather and heater unit is at high temperature,
water readings of water thermometer may decrease a little.
temperature is 2 The water thermometer or water thermometer sensor installed in engine
not stable loses effect or is short circuit. Or the wire of this circuit corrodes or looses.
(fluctuate, 3 Readings of water thermometer still increases when stopping car after
circulate or car travels with heavy load (engine still runs).
irregular). 4 When restarting the heated engine, the readings of water thermometer
is high.
5 The level in radiator is low. (Cooling system may accumulate air so
thermostat turns on late).
6 Cylinder gasket leaks so that fuel enters cooling system and thermostat
turns on late.
 Benjoy Maintenance Manual –Engine Volume EM-98

7 Water pump impeller does not connect well with the shaft.
8 The accessory driver belt looses. (water pump slides)
9 The inlet end of water pump leaks, resulting in the air is accumulated in
the cooling system and the start of thermostat is delayed.

Trouble Possible Reason

Pressure cap of radiator sprays Pressure release valve on the radiator cap loses effect.
steam and/or coolant enters
overflow tank.
Readings of water thermometer
may exceed normal value but
not very high, the level of
coolant in recycle/overflow tank
may be high.
Coolant drops on ground, 1 Coolant leaks from radiator, cooling system hose,
steam does not spray from water pump or engine etc.
radiator cap. Readings of water 2 Engine is too hot.
thermometer is high or hot, 3 Freezing point of coolant is not correct. Mix may be
overflow or early ignition (not too thick or too thin.
caused by ignition system).
Reading of water thermometer
may be high or low.
When engine operates, one or When engine cools down, vacuum generated by
more hoses are shrunken. cooling system does not get supplemented through
coolant recycle/overflow system.
Cooling fan has noises. 1 Fan blades loose.
2 Blade strikes around parts.
3 Air in radiator or air condenser is blocked.
Heat effect is poor, thermostat 1 Is there any DTC device?
loses effect at on position. 2 Coolant level is low.
3 Heat hose/joint is blocked.
4 Heat hoses twist.
5 Water pump does not pump water through air heat
core. After engine is warm enough, the two heat hoses
of heater should touch hot. If only one is hot, water
pump may work abnormally or heater core may be
blocked. Accessory driver belt may slide so water
pump does not work well.
In damp weather, Engine is In damp weather, (snow, ice or rain) when thermostat
warm and keeps operating but turns on, water around radiator may vapor. Thermostat
water thermometer at grid part turns on so hot water enters radiator. After water enters
of front car is in normal range. hot radiator, it will become steam. This usually happens
in cold days when no fan or air flow blows steam away.
Coolant color. Coolant color is not the necessary sign of corrosion
and anti-icing effect of coolant.
Do not determine coolant status through coolant color.
The level of coolant Coolant volume changes with engine temperature so
recycle/overflow tank changes. the level of overflow tank may change. If tank level is
Water temperature is normal. between FULL sign and ADD sign at normal operation
Benjoy Maintenance Manual –Engine Volume EM-99

temperature, the level will return to this range after

operating in high temperature.
 Benjoy Maintenance Manual –Engine Volume EM-100

Air Intake System

Fuel injector

Gasket

Pressure
maintaining
case
Absolute
pressure of
intake manifold
and intake
Throttle temperature
position sensor
sensor

Idling conductThrottle valve Intake

device casing manifold
Torque: Nm
0.3—

Intake Manifold
Diagnosis and Test
Leakage of Intake Manifold

The distinguish feature of intake manifold air leakage is the vacuum is lower than that of
normal intake manifold. And one or more cylinder may not work.

Caution:
Be very careful when engine operates.
Never stand in a line with fan.
Do not put hand near driving pulley fan.
Do not wear loose clothes.

1. Start engine.
2. Use sprayer to spray little water (with sprayer) in suspicious area.
3. If the rotating speed of engine changes, suspicious area may be found.
4. Repair it as required.
 Benjoy Maintenance Manual –Engine Volume EM-101

Standard Check Procedure- Vacuum Nosepiece Repair of Intake Manifold

Compound intake manifold vacuum nosepiece is repairable. However, if intake manifold
collector is damaged or has rift, replacement of manifold is required. To repair broken or
damaged vacuum nosepiece of compound intake manifold, execute the following
procedures:
Required Spare Parts Required Tools
Brass pipe joint-3/89 external diameter Pipe used tap-1/49-18NPT (American
xl/49 pipe thread (speed control port) standard tap pipe thread)
Pipe used tap-1/29 external diameter xl/49 Drill-7/169
pipe thread (brake booster port) File/ sand paper

Note: When executing this procedure, avoid

the material leftover of intake manifold
entering the collector.
1. File or rub the nosepiece face with the sand
Drill
paper until getting an even surface (vertical to
the axial line of pipe joint (port)).
2. Use a 7/16”drill to drill out a base bore of pipe
joint end (2).
3. Use a 1/4”-18NPT pipe tap (1) to strike
internal thread. Be careful to strike in the
same axle with original pipe joint.
4. Apply the Mopar® thread sealant to the repaired thread of pipe joint.
5. Install repair pipe joint. The tightening torque of repair pipe joint must not be too large.

EM11

Dismantlement and Installation

Dismantlement Steps:
1. Dismantle air filter, intake hose, vacuum pipe
and air throttle body.

EM11
2. Dismantle accelerator pedal control wire.
 Benjoy Maintenance Manual –Engine Volume EM-102

EM11
3. Dismantle nozzle wire and dismount the
packing bolt of intake manifold upper water
pipe.

4. Unscrew two oil rail packing bolts, take down EM11

wire support, and pull out the oil rail and
nozzle unit.
Attention:
When dismantling and installing, be careful
that nozzle washer may drop and replace
nozzle washer after dismantling.

5. Rotate and pull out nozzle from the oil rail.

Attention:
Use a new sealing rubber ring of nozzle when installing.

EM12
6. Unscrew the fixed bolt which connects intake
manifold assembly to cylinder body and take
off intake manifold assembly and gasket.

Check after Dismantlement:

1. Check if nozzle has carbon deposit, ceramic and burn stain. If any, clean or replace
nozzle.
2. Check if intake manifold has broken or leaking places.
3. Check if intake manifold gasket has damage, replace it if any.
4. Dismount nozzle wire and the packing bolt of intake manifold water pipe.

Installation:
1. Screw down the fixed bolt connecting intake manifold assembly to cylinder body.
 Benjoy Maintenance Manual –Engine Volume EM-103

2. Install the oil rail and nozzle.

3. Screw down the oil rail packing bolt.
 Benjoy Maintenance Manual –Engine Volume EM-104

4. Tighten the drawing wire of accelerator pedal.

5. Screw down nozzle wire and pack bolt of intake
EM12
manifold water pipe.

6. Install air filter, intake hose, vacuum hose, and

air throttle body.

EM12

Check
Upper Part of Intake Manifold
Check if intake manifold has:
 Damage and rift.
 Damage or crook on gasket surface.
If intake manifold has any damage or crook, replace it.
If vacuum pipeline is damaged, it is required to conduct repair procedure.

Check— Lower Part of Intake Manifold

Check if intake manifold has:
 Damage and rift.
 Damage or crook on gasket surface.
 Damage on nozzle terminal.
If intake manifold has these problems, replace it.
 Benjoy Maintenance Manual –Engine Volume EM-105

Exhaust System
Component Composition Drawing

Hot protective Block nut: 25-30

cover
25-30

Exhaust manifold

Exhaust manifold
gasket

25-35

Torque: Nm
 Benjoy Maintenance Manual –Engine Volume EM-106

Dismantlement and Installation

Dismantlement Steps

1. Unscrew the four fixed bolts of exhaust EM12

manifold cover, take off exhaust manifold
cover.

EM12
2. Unscrew the fixed bolts of front exhaust pipe
to front catalyst, take off front exhaust pipe.

EM12

3. Cut off wire plug of front and rear oxygen

sensor.

EM12

4. Unscrew the fixed bolts from exhaust manifold

to cylinder body; take off exhaust manifold and
gasket.
Benjoy Maintenance Manual –Engine Volume EM-107
 Benjoy Maintenance Manual –Engine Volume EM-108

Installation:
1. Screw down the fixed bolts from exhaust
EM12
manifold to cylinder body.

2. Install wire plug of front and rear oxygen

EM12
sensor.

EM12

3. Screw the fixed bolt from front exhaust pipe

to front catalyst.

EM13

4. Screw down the four fixed bolts of exhaust

manifold cover.
 Benjoy Maintenance Manual –Engine Volume EM-109

Engine Common Trouble Diagnosis

Trouble Possible Reasons
1 Oil level in crankshaft tank is high or low
2 Oil is thin or diluted 3 Oil is thick
4 Oil pressure is low 5 Tappet has dirt
6 Rocker arm wears 7 Tappet wears
Valve has noise
8 Valve guide wears
9 Radius palpitation of valve seat’
s working surface is too
large
10 There is no tappet central point
1 Oil supply is not enough 2 Oil pressure is low
3 Oil is thin or diluted 4 Oil is thick
Connecting rod has noise 5 Bearing clearance is too large
6 Connecting rod journal deforms
7 Connecting rod is not straight
1 Oil supply is not enough
2 Oil pressure is low
3 Oil is thin or diluted
4 Oil is thick
Main bearing has noise 5 Bearing clearance is too large
6 Axial clearance is too large
7 Crankshaft journal disorders or wears out
8 Fly wheel or hydrodynamic torque converter changed
torque looses
1 Oil level is low
2 Oil pressure sensor has trouble
3 Oil pressure is low
4 Oil filter is blocked
5 Oil pump spare parts wear out
Oil pressure decreases
6 Oil is thin or diluted
7 Oil intake tube of oil pump looses
8 Oil intake tube of oil pump looses
9 Oil pump has crook or rift
10 Bearing clearance is too large
1 Gasket is not aligned right or aging
2 Fastener looses, metal spare parts break or have air bore
Oil is thin
3 Cup blank cover or thread plug does not align right or is
damaged
Oil is consumed or ignition 1 PCV (positive crankcase ventilation) system has trouble
plug has oil stain 2 Piston ring wears out, is scraped or breaks
3 Carbon deposits in oil ring groove
4 Pistons coordinate too tight in ring groove
5 Valve guide wears out
Benjoy Maintenance Manual –Engine Volume EM-110

6 Valve rod oil seal wears out or is damaged

 Engine Volume GI-1

Gasoline Engine (2.4 L4)

General
HFC4GA1-1 gasoline engine series refers to the 2.4L multipoint electric injection
four-cylinder gasoline engine of international advanced technology level, which is
independently developed by the Anhui Jianghuai Automobile Co., Ltd. on the basis of the
assimilation of similar products at home and abroad. It may be used as the matched
power for both off road cars and intermediate cars, also as the update power for the
similar imported cars. It is featured by the compact structure and abundant power as well
as the higher performance-price ratio.

Engine Identification Code

The engine identification code is printed on the
right front side of the upper part of cylinder
body.

Illustration for Engine Identification Code

The composition of engine model is as follows:
First Middle Position
Position Rear Postion
position Product Serial No.
Distortion
differentiation
Corporation Cylinder Technical
Item Type Displacement Dellimiter Structure
code number platform
code characteristic
symbol

Digit 1 2 3 4 5 6 7

HFC 4 G A 1 — 1

1 2 3 4 5 6 7
1. Enterprise Code
HFC— Anhui Jianghuai Automobile Co., Ltd.

2. Number of Cylinders
4— 4 Cylinders
 Engine Volume GI-2

3. Type Code of Engine Fuel

4. G— Gasoline Engine Technical Platform
A— class A technical platform B— class B technical platform
C— class C technical platform D— class D technical platform
5. Engine Displacement
1— Gasoline engine 2.4 L 3— Gasoline engine 2.0 L
6. Delimiter
Use “— ”as the delimiter to separate the main technical structure characteristics and
the distortion part.
7. Symbol of Structure Characterisitc
Symb Gasoline Engine
ol
1 Basic type (natural intake)
Engine Ex-factory No.
Engine Ex-factory No. is composed of eight codes
Ex-factory No. for example:
☆ 5 3 0 0 0 3 6 9 ☆

Year Engine Ex-factory No.

Year
Year Code Year Code Year Code Year Code
2001 1 2009 9 2017 H 2025 S
2002 2 2010 A 2018 J 2026 T
2003 3 2011 B 2019 K 2027 V
2004 4 2012 C 2020 L 2028 W
2005 5 2013 D 2021 M 2029 X
2006 6 2014 E 2022 N 2030 Y
2007 7 2015 F 2023 P 2031 1
2008 8 2016 G 2024 R 2032 2

Engine
Engine Type Code

CKD 1
Gasoline engine
Homemad 3
e
Ex-factory No.
Ex-factory No. is composed of six digits as sequence code.
 Engine Volume GI-3

Specifications Parameters
Item Specifications Parameters Limiting Value
General
Type Transversal, dual-top cam
4

Cylinder diameter 86.5 mm

Hodometer 100 mm
Displacement 2351 cc
Compression ratio 10:1
Ignition sequence 1-3-4-2
Valve Timing
Intake Valure
Open (BTDC) 18º
Close (ABDC) 54º
Exhaust Valve
Open (BBDC) 56º
Close (ATDC) 8º
CylinderHead
Cylinder head flatness Maximum 0.03 mm 0.2 mm
Manifold mounting 0.15 mm 0.3 mm
surface flatness
Enlarged Dimension for Valve Seat Recovery
Intake
0.3 mm O.S. 35.3-35.325 mm
0.6 mm O.S. 35.6-35.625 mm
Exhaust
0.3 mm O.S. 33.3-33.326 mm
0.6 mm O.S. 33.6-33.625 mm
Enlarged Dimension for Valve Conduit Hole Recovery (Intake and Exhaust)
0.05 mm O.S. 12.05-12.068 mm
0.05 mm O.S. 12.25-12.268 mm
0.05 mm O.S. 12.50-12.518 mm
 Engine Volume GI-4

Item Specifications Parameters Limiting Value

Camshaft
Cam height
Intake 35.493mm 34.993mm
Exhaust 35.317mm 34.817mm
External diameter of 26 mm
journal
Bearing gap 0.040-0.076 mm
End gap 0.1-0.2 mm
Valve
Valve Length
Intake 109.5 mm
Exhaust 109.7 mm
External Diameter of Valve Rod
Intake 6.565-6.580 mm
Exhaust 6.530-6.550 mm
Bevel angle 45º-45º5’
Head Thickness of Valve (Edge)
Intake 0.1mm 0.7 mm
Exhaust 1.5 mm 1.0 mm
Gap between Valve Rod and Valve Conduit
Intake 0.020-0.047 mm 0.1mm
Exhaust 0.050-0.085 mm 0.15mm
Valve Conduit
Length
Intake 45.5 mm
Exhaust 50.5 mm
Valve Seat
Contact width of seat 0.9-1.3 mm
Seat bevel angle 44º-44º5’
Maintenance 0.2mm
dimension 0.6 mm

Valve Spring
Free length 45.82 mm 44.82 mm
Load bearing 25.3kg/40mm
Deflection Less than 1.5ºat assembly height 4º
Cylinder body
 Engine Volume GI-5

Cylinder diameter 86.5＋0.03 mm

Non-roundness and less than 0.01 mm
taper of cylinder
diameter
Top surface flatness of less than 0.05 mm 0.1 mm
engine block
Piston
External dimension 86.47-86.5 mm
 Engine Volume GI-6

Item Specifications Parameters Limiting Value

Gap of piston and cylinder 0.02-0.04 mm
Ring Slot Width
No.1 1.22-1.24 mm
No.2 1.51-1.53 mm
Oil ring 2.81-2.83 mm
Maintenance dimension 0.5 mm
Piston Ring
Side Gap
No.1 0.03-0.07 mm
No.2 0.02-0.06 mm 0.1mm
Oil ring 0.06-0.15 mm
End Gap
No.1 0.25-0.35 mm 0.8 mm
No.2 0.40-0.55 mm 0.8 mm
Side wiper blade of oil 0.10-0.40 mm 1.0 mm
ring
Connecting Rod
Camber 0.05 mm
Skewness 0.1 mm
Side gap between big 0.10-0.25 mm 0.3mm
head of connecting rod
and crankshaft
Tension of piston pin 1250±500 kg
External diameter of 48-48.015 mm
connecting rod journal
Oil gap of connecting rod 0.015-0.048 mm 0.1 mm
bearing
Oil Gap of Crankshaft Main Bearing
No.1,2,4,5 journal 0.018-0.036 mm 0.1 mm
No.3 journal 0.024-0.042 mm
Crankshaft
External diameter of 56.982-57.000mm
journal
Non-roundness of shaft less than 0.015 mm
journal
Taper of shaft journal less than 0.005 mm
Axial gap 0.05-0.25 mm 0.25mm
 Engine Volume GI-7

Item Specifications Parameters Limiting Value

Driven gear 0.06-0.12 mm 0.25 mm
Safety Spring
Free length 46.6 mm
In case of loading [61N] 40.1 mm

Balancing Shaft
Front shaft journal diameter 18.467-18.480mm
Rear shaft journal diameter 40.951-40.967mm
Gap
Front 0.020-0.061 mm
Rear 0.050-0.091 mm
Left Balancing Shaft
Front shaft journal diameter 18.467-18.480mm
Rear shaft journal diameter 40.951-40.967mm
Gap
Front 0.020-0.054 mm
Rear 0.042-0.083 mm
Cooling method With the forced circulation of fan
Cooling system capacity 7.0L
Thermostat
Type Wax dual thermostat
Normal opening temperature 82℃
Opening temperature range 80℃-84℃
Full-opening temperature 95℃
Heat Dispersion Temperature
Opening pressure of main valve 107.9±14.7 kpa
Close pressure of main vavle 83.4 kPa
Opening pressure of vacuum valve -8.86kPa
Air Filter
Type Dry type
Filter core Paper filter core
Exhaust Pipe
Muffler Resistance muffler
Suspension system Rubber suspension device
Coolant Temperature Sensor
Type Thermosensitive resistance type
Resistance
20℃ 2.45±0.14 KΏ
80℃ 0.3222 KΏ
 Engine Volume GI-8

Tightening Torque
Item N·m
Engine support separator bolt 90～110
Engine support nut 60～80
Engine support bolt 60～80
Bolt and nut from engine support to cross beam 55～65
Bolt from front roll stop support to cross beam 40～55
Bolt and nut of front roll stop separator 50～65
Bolt from rear roll stop support to cross beam 50～65
Bolt and nut of rear roll stop separator 50～65
Driving shaft support bolt 60～80
Mounting separator bolt of drving shaft 90～110
Air conditioner compressor and support 23～27
Oil pump and support of power steering gear 35～45
Front exhaust pipe and exhaust manifold 30～40
Rocker arm cover bolt 8～10
Center cover bolt 4～5
Camshaft sprocket wheel bolt 80～100
Camshaft bearing cap bolt 19～21
Crankshaft position sensor 10～13
Throttle valve casing seat 15～22
Mounting bolt of air filter 8～10
Damper pulley and crankshaft sprocket wheel 20～30
Cylinder cover bolt using new component 63+loonsen+20±2+90º+90º
Cylinder cover bolt not using new component 20±2+90º+90º
Intake manifold support 18～25
Tension pulley support bolt 23～27
Automatic tensioner bolt 20～27
Tensioner pulley bolt 43～55
Idle gear bolt 30～42
Clamping bolt of front exhaust pipe 20～30
Oil pan (upper and lower) 10～12
Oil pan oil drain plug 35～45
Engine oil screen 15～22
Lubricating oil pump sprocket wheel nut 50～60
Engine oil pressure switch 8～12
Engine oil filter support bolt 20～27
Lubricating oil pump bolt 15～18
Oil seal cover bolt 10～12
 Engine Volume GI-9

Plug cover 20～27

Front cover bolt 20～27
Driven gear bolt 34～40
Engine cooling pump pulley bolt 8～10
Upper cover of timing belt 8～10
Lower cover of timing belt 8～10
Safety plug 40～50
Flywheel 130～140
Right rear cover of timing belt 10～12
Left rear cover of timing belt (upper) 10～12
Connecting rod cover bolt 20+90º
Crankshaft bearing cap bolt 25+90º
M18 25～30
M10 35～55
Generator support bolt 20～25
M9×90 8～12
M8×40 20～-25
Bolt from engine cooling pump to cylinder body 20～27
Engine coolant temperature sensor 20～40
Engine coolant inlet seal bolt 10～15
Mounting bolt of air filter 8～10
Mounting bolt (nut) of syntonizer 8～10
Throttle valve casing to intake manifold 15～22
Mounting bolt of intake manifold (M8) 15～20
Mounting nut of intake manifold 30～42
Bolt from pull rod support to pull rod 35～55
Ignition coil bolt 8～12
Power transistor bolt 10～12
Bolt from front exhaust manifold to cylinder body 20～30
Nut from center exhaust pipe to catalyst 30～40
Bolt from center exhaust pipe to main muffler 30～40
Bolt from center exhaust pipe to support 10～15
Bolt from suspension device to engine block 10～15
Bolt from suspension device to main muffler 10～15
Exhaust manifold nut (8) 25～30
Exhaust manifold nut (10) 35～55
Oxygen sensor 40～50
Air cleaner support bolt 10～13
Connecting bolt of exhaust manifold cover and 12～15
 Engine Volume GI-10

exhaust pipe
Oxygen sensor to exhaust manifold 40～50
Front exhaust pipe support bolt 20～30
Main muffler lifting lug support bolt 10～20
Engine oil height meter 12～15
Stud 30～40
Tensioner arm assembly 17～26
Balancing shaft bolt 34～40
Connecting bolt of starter to cylinder body 27～35
Radiator fan motor bolt 8～10
Oil pipe to cylinder body 10～13
 Engine Volume GI-11

Common Troubles and Causes

Trouble Causes Repair
Damage of cylinder head Replace piston
gasket
Abrasion or damage of piston Replace piston ring
Low pressure of ring
cylinder Abrasion of piston or cylinder Repair or replace piston ring or
cylinder body
Abrasion or damage of valve Repair or replace valve and seat
seat ring
Insufficient height of engine oil Check engine oil
Failure of engine oil pressure Replace engine oil pressure switch
switch
Blockage of engine oil filter Replace enigine oil filter
Abrasion of engine oil pump gear Replace engine oil pump gear or
Fall of engine oil
or cover cover
pressure
Engine oil diluted Replace engine oil and find out the
causes
Failure of engine oil safety valve Repair
(open)
Too large bearing gap Replace bearing
High pressure of Failure of engine oil safety valve Repair
engine oil (close)
Looseness of engine roll stop Retighten
baffle (front and rear)
Looseness of mounting support Retighten
of drving shaft
Looseness of engine mounting Retighten
support
Serious vibration Looseness of center Retighten
of engine components
Damage of mounting partion Replace
plate of drving shaft
Damage of mounting protecting Replace
plate of engine
Damage of engine roll stop baffle Replace

Engine oil diluted (low oil Adjust

Noise in valve pressure)
Abrasion or damage of valve rod Replace
 Engine Volume GI-12

or valve conduit
Noise in Insufficient suppluy of engine oil Check the height of engine oil
connecting rod Thin or diluted engine oil Adjust and find out the cause
and main Too large bearing gap Replace
bearing
Belt tension fails to meet the Adjust the tension of belt
Noise in timing
specification (tensioner of
belt
generator and timing belt)
Coolant leakage Add it to the specified level
Damage of radiator core joint Replace
Hose corrupted or cracked Replace
Low level of
Trouble of radiator cover valve or Replace
coolant
spring
Trouble of thermostat Replace
Trouble of engine water pump Replace

Blockage of Foreign matter in coolant Replace

radiator
Trouble of thermostat Replace
Trouble of radiator cover Replace
Blockage in cooling system Replace
Looseness or drop of driving belt Adjust or replace
Too high
Trouble of engine water pump Replace
temperature of
Trouble of temperature sensor Repair or replace
coolant
conductor
Trouble of fan Repair or replace
Trouble of sensor Replace
Insufficient coolant Add coolant
Too low Thermostat Replace
temperature of Trouble of temperature sensor Repair or replace
coolant circuit
Looseness of hose and pipeline Screw down again
Leakage in
joint
engine oil
Blockage or damage of hose and Replace
cooling system
pipeline
Trouble of Damage of fuse Replace or repair
electrical cooling
fan
Air leakage in Looseness of joint Screw down again
exhaust pipe Damage of pipeline or muffler Repair or replace
 Engine Volume GI-13

Muffler partion plate separated Replace

Damage of rubber suspension Replace

Abnormal noise device
Pipeline or muffler contacting Rectify
with vehicle body
Damage of pipeline or muffler Repair or replace
 Engine Volume GI-14

Special Tools
Ser
Outline
ial Name Code Purpose
drawing
No.

For dismounting
Valve
engine valve and
spring JACF1
1 related parts when
compresso 01
there is no need to
r
take off

T-type
For mounting and Ignition plug
ignition
JACF1 dismounting the
2 plug
02 ignition plug during
sleeve
the replacement
spanner

Play the guiding role

Front oil
when mounting the Guider
seal guider JACF1
3 front oil seal of
of 03
crankshaft
crankshaft

Erector of Front
Oil seal
front oil JACF1 For mounting front cover
4
seal of 04 oil seal of crankshaft
crankshaft

Pressure rod

Forward
mark
Forwar
d mark
Replacer For dismounting and
JACF1
5 of pistion mounting engine Guide block
05
pin piston pin Base
 Engine Volume GI-15

Crankcase
JACF1 For dismounting and
6 oil pan
06 mounting oil pan
stripper

Engine oil For dismounting and

JACF1
7 filter mounting engine oil
07
spanner filter

Timing
For supporting and
toothed JACF1
8 fixing the balancing
belt wheel 08
shaft sprocket wheel
stopper

Handle
Applied with relevant
JACF1
9 Handle erector to install the
09
bearing

Handle

Erector of
Erector of rear oil seal
of crankshaft
rear oil JACF1 For mounting rear oil
10
seal of 10 seal of crankshaft
crankshaft

For dismounting and

Cylinder
JACF1 mountingcylinder
11 head bolt
11 head bolt
spanner
 Engine Volume GI-16

Special
For dismounting and sleeve
Special for
JACF1 mounging the front dual-gea
12 sleeve for
12 cover screw of
dual-gear
engine

Erector for
JACF1 For mounting valve
13 valve oil
13 oil seal
seal

For fixing the

Stopper of JACF1 flywheel to make
14
flywheel 14 the dismantlment
easy

For dismounting the

Valve
JACF1 engine valve and
15 spring
15 related parts in
compresor
disassembly

Withdrawal
tool of JACF1 For dismounting the
16
valve 16 valve conduit
conduit

Erecting
tool for For mounting the oil
JACF1
17 balancing seal at the balancing
17
shaft oil shaft of engine
seal
 Engine Volume GI-17

Oxygen For dismounting and

JACF1
18 sensor mounting the oxygen
18
spanner sensor

Erecting
For mounting the oil
tool for JACF1
19 seal of engine’s
pulley oil 19
timing pulley
seal

Special Illustration:
Overhaul identification notes for 2.4L engine and 2.0L engine:
When the postfix of chart number is GC, GD, GD010 and GD060, it means the
special pieces of 2.0L car’
s engine.
When the postfix of chart number is GB01, it means the special pieces of 2.4L car’
s
engine.
Except the special pieces of 2.4L transverse engine of car, others are all using the
GBOO (equipped with SRV Rein) transverse engine.
Except the special pieces of 2.0L transverse engine of car, others are all using the
2.4L transverse engine of car.

Different Markings of Part Number

Part Number of 2.0L Part Number of 2.４L
Part Name
Engine Engine
Cylinder head gasket 1002210GD010 1002210GB
Engine block 1002101GD010 1002101GB
First gas ring 1004015GC 1004015GA
Second gas ring 1004014GC 1004014GA
Steel strip combination
1004200GC 1004200GA
oil-retaining ring
Piston 1004011GD 1004011GA
Crankshaft 1005013GD 1005013GA
ECM 1026301GD060 1026301GB01
Right balancing shaft 1022011GD 1022011GA
Left balancing shaft 1022013GD 1022013GA
 Engine Volume EE-1

General
Specification Parameters
Ignition
2.0 L4
Model
Primary coil resistance 0.5±0.05Ω
Secondary coil resistance 5,200±400Ω

Ignition Plug
2.0 L4
Ignition plug gap 0.9~1.1 mm

Starter
2.0 L4
Model Decelerating drive
Voltage 12V
Power 1.2kw
End voltage 11V
Current strength 90A or less
Rotating speed 2.800rpm
Number of gear teeth ８
Gear gap 0.5-2.0mm

Generator
2.0 L4
Model Storage battery voltage induction
Rated power 13.5V/95A
Model of voltage adjuster Built-in electronic type
Set voltage of adjuster 14.4±0.3V
Temperature compensation -10±3Mv/℃

Storage Battery
All Engines
Model MF 68 AH, MF 90 AH
5HR 55AH or more
Cold start [-17.8℃] 540AH or more
Converse capacity 122 db
Specific gravity [25℃] 1.280±0.01
 Engine Volume EE-2

Illustration:
The cold starting current refers to the current which the storage battery supplies for 30s
and keeps the terminal voltage equal to or over 7.2V. The rated value of converse
capability is the time when the storage battery supplies the current of 25A and keeps the
minimum end voltage of 10.5V at 26.7℃.

Tightening Torque
Items N·m
Generator terminal (B+) 5~7
Starter terminal (B+) 10~12
Storage battery terminal 4~6
Ignition plug 20~30
 Engine Volume EE-3

Countermeasure
Ignition System
Trouble Causes Repair
Trouble of ignition fastening Replace the igniton fastening
switch switch.
Engine fails to or is Trouble of ignition coil Check the ignition coil.
hard to start (start Trouble of power transistor Check the power transistor.
crankshaft normal). Trouble of ignition plug Replace the ignition plug.
Breakage or damage of ignition Check the high voltage wire.
high voltage wire
Trouble of ignition plug Replace the ignition plug.
Trouble of ignition plug Check the ignition plug.
Poor idle speed or Trouble of high voltage wire Check the high voltage wire.
shutdown. Trouble of ignition coil Check the ignition coil.
Engine accelerates Trouble of ignition plug Replace the ignition plug.
slowly or fails to Trouble of the high voltage wire Check the high voltage wire.
accelerate.
Charging System
Trouble Causes Repair
The lamp of charging alarm Breakage of fuse Check or replace the fuse.
display doesn’
t light up when Burning out of lamp Replace the lamp.
the ignition switch is turned Loose joint of high Screw down the loose joint.
on and the engine is not voltage wire
running. Trouble of electronic Replace the voltage adjuster.
voltage adjuster
During the operation of Looseness or abrasion Adjust the tension or replace
engine, storage battery of belt the driving belt.
requires to be recharged Looseness, corrosion Repair or replace the
frequently and the lamp of or abrasion of the conductor.
charging alarm display conductor of storage
doesn’
t go out. battery
Breakage of fuse Replace the fuse.
Fusion of fuse Replace the blown fuse.
Trouble of electronic Test the generator.
voltage adjuster or
generator
Trouble of circuit Repair the circuit.
Engine accelerates slowly or Looseness or abrasion Adjust the tension or replace
fails to accelerate. Excessive of driving belt the driving belt.
charging. Looseness of circuit Screw down the loose joint or
 Engine Volume EE-4

joint or breakage of repair the circuit.

circuit
Breakage of fuse Replace the fuse.
Poor grounding Repair.
Trouble of electronic Test the generator, repair or
voltage adjuster or replace it if there is trouble.
generator
Storage battery is old Replace the storage battery.
Trouble of electronic Replace the voltage adjuster.
voltage adjuster
Trouble of voltage Repair the circuit.
inductive wire
Starting System
Trouble Causes Repair
Engine is unable to rotate. Low electric quantity Charge or replace the storage
of storage battery battery.
Looseness, corrosion Repair or replace the conductor.
or abrasion of
conductor of storage
battery
Breakage of fuse Replace the fuse.
Trouble of starter Repair the starter.
Trouble of ignition Replace the igntion switch.
switch
Trouble of ignition Replace the ignition fastening
fastening switch switch.
Low electric quantity Replace the ignition fastening
Slow rotation of engine of storage battery switch.
Looseness, corrosion Repair or replace the conductor.
or abrasion of
conductor of storage
battery
Trouble of starter Repair the starter.
Starter keeps running. Trouble of starter Repair the starter.
Trouble of ignition Replace the ignition switch.
switch
Breakage of driving Repair the starter.
Starter is running, but gear or damage of
engine is not running. starter
Breakage of ring gear Replace the flywheel ring gear or
 Engine Volume EE-5

tooth torque converter.

 Engine Volume EE-6

Ignition System (DOHC)

Overview
Ignition timing is controled by the engine control module (ECM), and the timing data
about the running conditions of engine are programmed and stored in ECM. The
running conditions (e.g. speed, load and warm engine status) of engine are tested by
various sensors. Based on these inductive signals and the data stored in ECM, the
signal regarding cutting the primary current is delivered to power transistor. Accordingly,
ignition coil is activated and the timing is controlled at the optimum point.

Crankshaft Position Sensor

Camshaft Position Sensor

 Engine Volume EE-7

Ignition Coil
1. Measurement for Primary Coil Resistance
The resistance of two shown pins are 0.5±0.05Ω

2. Measurement for Secondary Coil Resistance

Measure the resistance among high voltage terminals of ignition coil
Standard value: 5,200±400Ω
 Engine Volume EE-8

Dismantlement and Reassembly

1. Disconnect the negative terminal of storage battery.

EE001

2. Dismantle the airbag module.

Attention:
Loosen the wire harness of horn while EE002
loosening the wire harness of airbag. The
SRS is designed to supply sufficient power
for popping out the airbag within the 30s
after the storage battery is disconnected,
so conducting repair for SRS system
immediately after disconnecting the
conductor of storage battery may lead to
the serious bodily injury.

EE003

3. Screw off locknut and gasket.

4. Dismantle the steering wheel with

special tools.
Attention:
EE004
Dismantle the steering wheel without
hammer.

5. Dismantle upper and lower protective

sleeves of steering column.
Engine Volume EE-9
 Engine Volume EE-10

6. Disconnect the joint and dismantle the

EE005
multifunctional switch.

7. Dismantle the installation bolt and EE006

separate the ignition switch from the
steering column.

Check:
1. Separate the joint which is under the steering column.
2. Check the continuity among the terminals of switch.
3. If the continuity fails to meet the specifications, replace the switch.
Terminal Lighting of the
Ignition Switch Alarm Switch of Lock
Position Key Door and the Key
1 2 3 4 5 6 1 2 3 4 RO RE
Pull out ○ ○ L L
Lock
L F
Accessory ○ ○ F F
Plug into
Open ○ ○ ○ ○ F F
Start ○ ○ ○ F F

Attention:
○— ○: continuity among terminals
RO: rotating locking bar
RE: return locking bar
L: locking
F: free
 Engine Volume EE-11

Test for Ignition Plug

1. Dismantle the ignition plug and the
conductor which connects the
ignition plug.

2. With the outer electrode of ignition

plug grounded, start the engine.

3. Check and confirm the discharging Improper insulation Improper insulation

phenomenon between electrodes.

Attention:
When the ignition plug is about to
be replaced, it is necessary to use Proper
the linear positive parts with Improper insulation
resistance.

Test for Conductor of Ignition Plug

1. When the engine is at idle speed, disconnect one conductor of ignition plug at
one time and check the running performance of engine.
Attention:
Wear rubber gloves during the operation.
2. If the performance of engine is not changed, check the resistance of ignition
plug and itself.
3. Check the crack of cover and case.
4 Measure the resistance.
 Engine Volume EE-12

Charging System
Overview
Charging system includes storage battery, generator with built-in adjuster and the
lamp and circuit of charging indicator. There are six built-in diodes (3-positive and
3-negative) and each one commutes AC to DC. So the end “B”of generator has AC.
In addition, the charging voltage of the generator and itself are adjusted by the
testing system for storage battery voltage. The main parts of generator include rotor,
stator, rectifier, brush, bearing and V-type belt pulley. Brush seat includes one built-in
electronic voltage adjuster.

Stator
Rotor

Front bearing

Rear bearing

Check
Measurement for Voltage Drop of Generator’
s Output Circuit
The test, through the drop of voltage, is
intended to determine whether the circuit
among the terminal “B”of generator and
Generator
the positive end (+) of storage battery is
normal.

Preparation: Ammeter

1. Turn the ignition switch to the position “OFF”.

Attention:
For checking the abnormal conditions
Voltmeter Storage battery
of joint, the method of checking two
terminals and one joint at one time shall
not be adopted during the test.
Engine Volume EE-13
 Engine Volume EE-14

2. Connect the digital ammeter between the generator “B”and the positive (+) pole
of storage battery. Connect the positive (+) conductor of voltmeter to terminal “B”
and the negative (-) conductor to the negative (-) terminal of storage battery.
Test Conditions
1. Start the engine, and
2. Open the headlamp, fan and motor etc. The reading of voltmeter under such
conditions.
Results
1. Voltmeter can show the standard value.
Standard Value: 0.2V as maximum
2. If the value of voltmeter is more than the expected value (maximum 0.2V above),
the circui may be out of order. Under the circumstances:
Check the circuit connecting the positive (+) pole of storage battery with the end
“B”of generator. Check whether there is loose joint and harness discolored due
to the heat. Repair them before the test.
3. After the test, set the idle speed of engine and close the headlamp, fan, motor
and ignition switch.
Test for Output Current
This test is intended to determine whether the output current of generator is normal.
Preparation
1. Check the following items before testing, or rectify them if necessary.
(1) Check whether the storage battery mounted on the vehicle works normally. The
storage battery used to test the output current shall be discharged partially,
otherwise the storage battery fully charged may lead to the wrong results due to
the insufficient load.
(2) Check the tension of generator’
s driving belt.
2. Turn off the ignition switch.
3. Disconnect the grounding wire of storage battery.
4. Disconnect the output conductor of generator from the end “B”.
5. Link up the DC ammeter (0-100A) between the end “B”and the disconnected
output conductor to make sure that the
negative (-) wire of ammeter has been Voltmeter Ammeter

connected to the disconnected output

Check the
conductor. generator

Attention:
Screw down each joint because of the heavy
current and don’t depend on the clamp.
6. Link up the voltmeter (0-20V) between the
terminal “B”and the grounding wire. Connect
the positive (+) wire with the end “B” of
generator, and earth the negative (-) wire.
 Engine Volume EE-15

7. Link up the tachometer of engine, and connect the grounding wire of storage
battery.
8. Open the engine cover.

Test
1. Check whether the reading of voltmeter is the same as that of the voltage of
storage battery. The cases of the reading of voltmeter being 0V may be the
breakage of the generator terminal “B”and the the circuit in negative (-) pole of
storage battery, the fusion of fuse or the poor grounding.
2. Start the engine and turn on the headlamp.
3. Set the headlamp at the high beam, turn the switches of heater and fan to
stages “High”, quickly increase the rotating speed of engine to 2,500rpm and
measure the maximum output current through the ammeter.
Attention:
Charging current will drop quickly after the start of engine. So, it is required to
conduct the operations foresaid quickly to read the right maximum current
value.
Results:
1. The reading of ammeter shall be over the limit value. If the reading is below the
limit value but the output conductor of engine is normal, dismantle the generator
from the vehicle and carry out the test.
Limit (95A engine): 63A
Attention:
The rated output current is marked on the nameplate of generator body.
Output current changes with the electrical load and the temperature change of
generator body. So, it may be impossible to get the rated output current. Under
the circumstances, it is necessary to keep the headlamp on in order to make
the storage battery discharge or increase the electrical load by the light of
other vehicles. If the temperature of generator or the atmospheric temperature
is too high, it may be impossible to reach the rated output current. Under the
circumstances, it is necessary to lower the temperature before the next test.
2. After the test for output current, lower the rotating speed of engine to idle speed
and turn off the ignition switch.
3. Disconnect the grounding wire of storage battery.
4. Dismantle the ammeter, the voltmeter and the engine tachometer.
5. Connect the output conductor of generator to the terminal “B”of generator.
6. Connect the grounding wire of storage battery.
Test for Adjusting Voltage
The test is intended to check whether the
electronic voltage adjuster regulates the voltage Ammeter

correctly.
Preparation
1. Before the test, check the following items and
Voltmeter
 Engine Volume EE-16

rectify it if necessary:
☆ Check whether the storage battery mounted on the vehicle is charged fully.
☆ Check the tension of driving belt of generator.
2. Turn the ignition switch to “OFF”.
3. Disconnect the grounding wire of storage battery.
4. Connect a digital voltmeter between the terminal “S (L)”of generator and the
grounding wire. Connect the positive (+) conductor of voltmeter to the terminal
“S (L)”of generator. Connect negative (-) conductor to the grounding wire or the
negative (-) pole of storage battery.
5. Disconnect the output wire of generator from the terminal “B”of generator.
6. Connect a DC ammeter (0-100A) betwwen the terminal “B” and the
disconnected output wire. Connect the negative (-) conductor of ammeter to the
disconnected output wire.
7. Mount the tachometer of engine and connect the grounding wire of storage
battery.
Test
1. Turn on the ignition switch, and see whether the shown value on voltmeter is the
following value.
Voltage: Storage Battery Voltage
The reason of reading being 0V may be that the circuit among the terminal “S (L)”of
generator and storage battery and the positive (+) pole of storage battery is
disconnected or the fuse melts down.
2. Start the engine and turn off all the lamps and accessories.
3. Run the engine at approximately 2,500rpm. When the output current of
generator drops to 10A or less, read the voltage.
Results:
1. If the voltage readings are in accordance with the values in the following
adjusting voltage table, the voltage adjuster shall be considered normal. If the
readings are not within the standard value range, there is trouble in voltage
adjustment or generator.
Table of Adjusting Voltage
Ambient Temperature Adjusting Voltage (V)
℃ of Voltage Adjuster
-20 14.2-15.4
20 13.9-14.9
60 13.4-14.6
80 13.1-14.5
2. After the test, lower the speed of engine to the idle speed and turn off the
ignition switch.
3. Disconnect the grounding wire of storage battery.
4. Dismantle the voltmeter, the ammeter and the tachometer of engine.
5. Connect the output wire of generator to the terminal “B”of generator.
6. Connect the grounding wire of storage battery.
 Engine Volume EE-17

Voltage Drop Test for Generator Output Wire

The test is intended to determine whether the circuit (including fuse) from the
terminal “B”of generator to the positive (+) pole of storage battery is normal.
1. Before the test, check the following items:
☆ Installation of generator and the joint of circuit.
☆ Tension of the belt of generator.
☆ Fuse.
☆ During the operation of generator, whether there is abnormal noise of generator.
2. Turn the ignition switch to position “OFF”.
3. Disconnect the negative pole conductor of storage battery.
4. Disconnect the output wire of generator from the terminal “B”of generator.
Connect a DC ammeter (0-100A) between the terminal “B” and the
disconnected output wire. (Connect the positive (+) conductor of ammeter to
terminal “B”, and connect the negative (-) conductor of ammeter to the
disconnected output wire.)
Attention:
It is recommended to use the induction ammeter, which can be used to
measure without disconnecting the output wire of generator. Using this
ammeter can reduce the voltage drop due to the looseness of the joint of
terminal “B”.
5. Connect a digital voltmeter between the Ammeter
terminal “B”of generator and the positive (+)
pole of storage battery. (Connect the positive
(+) conductor of voltmeter to the terminal “B”. Generator
Voltage (digital)
Connect the negative (-) conductor of
voltmeter to the positive (+) pole of storage
Storage battery
battery.)
6. Reconnect the negative (-) pole wire of
storage battery.
7. Connect a tachometer or speed measuring device.
8. Start the engine.
9. When the engine is running at about 2,500rpm, adjust the load of generator by
turning on and off the headlamp and other lamps to make the reading of
ammeter exceed 30A slightly.
Limit Value: 0.3V as maximum
Attention:
When the output current of generator is strong and the shown value on
ammeter fails to drop to 30A, set the value to 40A. Read the value shown on
the voltmeter. Under the circumstances, the maximum value shall be changed
to 0.4V.
10.If the value on voltmeter is still above the limit value, there may be trouble in the output
conductor of generator. Check the circuit (including the fuse) between the terminal “B”
of generator and the positive (+) pole of storage battery. If the terminal joint is not
 Engine Volume EE-18

screwed down or the harness is discolored due to the overheating, it shall be repaired
or retested.
11. After the test, make the engine operate at idle speed.
12. Close all the lamps and turn the ignition switch to position “OFF”.
13. Disconnect the tachometer or testing tools.
14. Disconnect the negative (-) pole wire of storage battery.
15. Disconnect ammeter and voltmeter.
16. Connect the output wire of generator to the terminal “B”of generator.
17. Connect the negative (-) pole wire of storage battery.
 Engine Volume EE-19

Generator

Adjusting bolt

20-25 (200-250, 15-18.6)

Generator

Bolt of support rack

Torque: Nm (kg-com, Ib-ft)

Front cover Rear bearing

Retainer Rotor assembly
Screw (4EA)
Belt pulley Front bearing

Hexagon nut

Cover - Terminal B
Rectifier

Isolation ring Bolt (4EA）

Flange

Cover

Adjuster assembly
Rear cover
Stator assembly
 Engine Volume EE-20

Dismantlement and Reassembly

Dismantlement Steps:
1. Dismantle four through bolts. EE007

2. Insert a right-angled screwdriver between

the front support rack and the core of stator, EE008
and prize it down.
Illustration:
a. Don't insert the starter deep, because
the core of stator may be damaged.

b.Because of the fitting ring at the loop of rear bearing, it may be difficult to
take off the rear cover. For easily taking off the rear cover, heat the bearing
cover with a 200W electric iron. Don’t use the spray gun, because it may lead
to the damage of diode assembly.
EE009
3. Make the edge of belt pulley upward and
fix the rotor with soft vice.
Attention:
Don’t make vice cause damage to rotor.

EE010
4. Dismantle the nut of belt pulley, the spring
gasket, the belt pulley and the isolation
ring.
5. Dismantle two sealing elements and the
front support rack.
6. Dismantle the stator assembly from the
vice jaw.
7. Dismantle the screw of brush seat, and the
screw and the nut of rectifier from terminal
 Engine Volume EE-21

“B”.
 Engine Volume EE-22

8. Dismantle the stator assembly from the EE011

rear support rack.
9. Dismantle the oil baffle from the brush
seat.
10. If the stator has been dismantled, weld out
three conductors of stator from the main
diode of rectifier.
Attention:
a. When welding on or welding out, make
sure that the heat of electric iron won’t
pass to the diode for a long time.
b. Don’t exert excessive strength on the EE012
conductor of diode.
11. When separating the rectifier on the brush
seat, weld out two plates welded on the
rectifier.
Check
Rotor
1. Check the continuity of rotor and confirm
the continuity among slip rings. If
resistance is too small, there is short circuit.
EE013
If it is not continuous, there may be broken
circuit and the rotor assembly shall be
replaced.
Resistance Value: Approximately 3.1Ω

2. Check the grounding of rotor coil, and

check whether the slip ring and the core of EE014
rotor are continuous. If they are continuous,
replace the rotor assembly.

Stator
1. Conduct the continuity test for stator coil,
and check whether the conductors of coil
conductor are continuous. Replace the
 Engine Volume EE-23

stator assembly, in case of uncontinuity.

 Engine Volume EE-24

2. Check the grounding conditions of coil,

and check whether the coil and the core of EE015

stator are continuous. Replace the stator

assembly, in case of continuity.

Rectifier
Positive Rectifier Test EE016
Check the continuity of positive rectifier and the
connecting terminal of conductor of stator coil
with ohmmeter and make sure that the
ohmmeter is continuous in only one direction. If
the ohmmeter is continuous in two directions,
the diode is holed. Replace the rectifier
assembly.

Negative Rectifier Test

Check the continuity of negative rectifier and
the connecting terminal of conductor of stator
coil. The ohmmeter shall be continuous in only
one direction.
If the ohmmeter is continuous in two directions,
the diode is holed, the rectifier assembly shall
be replaced.
Test for Three Groups of Diodes
By connecting the ohm wire to two pins of each
diode, check the continuity of three diodes, and
each diode shall be continuous at one direction.
If the diode is continuous at two directions, the
diode may have gotten defective, and the heat
distribution plate assembly shall be replaced. EE017
Replacement for Brush
1. Measure brush’
s extended length shown
at the figure. If the measured value is
below the following limit value, replace the
brush.
 Engine Volume EE-25

Limit Value: 2mm or less

 Engine Volume EE-26

2. After welding out the conductor of brush, it

is allowable to take off the brush. EE018

3. When mounting a new brush, insert it into the brush seat, and then weld up the
conductor.

Reassembly
Reassembly is in the reverse order of dismantlement.

Pay attention to the following items:

Before mounting the rotor into the rear support rack, insert a steel wire through the
small hole on the rear support rack to support the brush. After mounting the rotor,
take out the steel wire.
 Engine Volume EE-27

Storage Battery
Visual Check
Observe the observing hole of storage battery to determine whether
the storage battery is damaged.
1. Check for Current
2. Check Table
Liability
Items Trouble Causes Repair
User Manufacturer
*Damage of storage *Carelessness
battery terminal * Excessive tightness
Replace ○
of storage battery
conductor
Visual
Crack of cover *Carelessness Replace ○
Check
*Leakage of electrolyte
Crack of cover *Carelessness Replace
○
Cover leakage *Poor sealing of Replace ○
cover
*The level of electrolyte *Short circuit in Replace
betweent the poles of simple lattice Replace
simple lattice is above *Evaporation due to Replace ○
Check for
10mm excessively-high ○
Level of
*Insufficient electrolyte temperature ○
Electrolyte
*Excessive
discharging resulting
in loss of electrolyte
1. Storage battery 1. Overcharging Replace and
voltage >13.2V 2. Normal check the ○
2. 12.5V< storage electrical
battery voltage system
<12.9V
3. 12.0V< storage 1. Undercharging Load test for
battery voltage storage
<12.4V 2．Interior trouble battery (refer
○
(pure discharging) to the
4. 11.0V< storage following load
Voltage ○
battery voltage test)
Check
<12.0V
(Excessive
discharging)
5. Storage battery 1. Trouble in charging Replace
voltage: 11.0V or less conditions
2. Long-term ○
discharging for ○
storage battery ○
3. Interior circuit
disconnected
3. Load Test
 宾悦维修手册发动机分册 EE-28

a. Under the half current of cold starting power, discharge the storage battery
for 15s. The voltage of storage battery shall be shown as the following table.
 宾悦维修手册发动机分册 EE-29

Adjustable Voltmeter
Ambient Temperature Adjusting Voltage
Above 20℃ 9.6V
~18℃ 9.5V
~10℃ 9.4V
~4℃ 9.3V
~-1℃ 9.1V
~-7℃ 8.9V
~-12℃ 8.7V

b. When voltage is not within the specified range, carry out the load test again
and recharge the storage battery.
c. The storage battery shall be applicable, if the output of storage battery
exceeds 12.5V after the storage batter has been recharged and deposited
for 2 hours, and the voltage exceeds the standard value after the load test.

Visual Check for Storage Battery

1. Make sure that ignition switch and all accessories are in the position “OFF”.
2. Disconnect storage battery conductor (Firstly disconnect the negative wire).
3. Dismantle the storage battery from the vehicle.

Attention:
In case of cracking or leakage of cover of storage battery, do not have your
skin injured by the electrolyte. When dismantling the storage battery, wear
thick rubber gloves.

1. Check whether the storage battery rack is damaged due to the leakage of
electrolyte. If there is acidic corrosion, it is necessary to clean the
circumference by clean hot water and dry soda water. Scrub the
circumference by the steel wire and the wet surface which carries soda water.
2. Clean the top of storage battery with the same solvent as is used in Step (4).
3. Check the cover and the box of storage battery for crack. If the crack is found,
replace the storage battery.
 宾悦维修手册发动机分册 EE-30

4. Clean the pole of storage battery with the proper tool.

5. Clean the internal surface of terminal clamp with the proper cleaning tools for
storage battery. Replace the damaged or abraded conductor and the
damaged terminal clamp.
6. Install the storage battery onto the vehicle.

7. Connect the conductor terminal with the pole pillar of storage battery to
ensure that the head of terminal is level with the top of pole.

8. Screw down the terminal nut.

9. Apply the mineral oil to all joints after they have been screwed down.

Attention:
When the storage battery is charged, it is necessary to keep the storage
battery circumference away from fire, because the burnable gas may be
generated under the cover of each simple lattic battery. Smoking is
forbidden around the storage battery being charged or charged recently.
Don’t break off the pole circuit at the end of storage battery being charged,
because spark will appear once the circuit is disconnected.
 宾悦维修手册发动机分册 EE-31

Starting System
Composing Parts
Electromagnetic coil

Split ring

Screw

Ball Filling gasket A

Sun gear
Planet gear

Screw of planet gear seat

Hoop tooth ring

Overdrive clutch

Stopping ring

Front support rack

Rear support rack

Brush seat

Armature
Centering rack
assembly

Overview
The starting system includes the storage battery, the starter, the electromagnetic
switch, the ignition switch, the connecting circuit and the storage battery’
s
conductor. With the ignition key turned to the starting position, the current passes
by and excites the electromagnetic coil. Accordingly, the electromagnetic plunger
and the gear lever of clutch are driven (activated) and the clutch pinion mesh with
the ring so as to start the motor. In order to avoid the damage due to the
excessive rotation of pivot of starter, the clutch pinion runs at overspeed.
 宾悦维修手册发动机分册 EE-32

Check
Check for Starter Relay
Dismantle the relay of starter and check the continuity between terminals.
If the continuity is not in specified range, replace the relay.

Terminal No.
85 86 87 30 Relay
Condition
Without excitation ○ ○
With excitation ○ ○ ○ ○

Check for Ignition Switch

Dismantle the switch of ignition lock, and check continuity between terminals. If
the continuity is not within the specified range, replace the switch.

Terminal No.
1 2
Condition
On ○ ○
Off
 宾悦维修手册发动机分册 EE-33

Dismantlement and Reassembly

Starter

Torque: Nm (kg.cm, Ib.ft)

Dismantlement Steps: EE019

1. Disconnect the grounding wire of
storage battery.

2. Dismantle the car speed meter and

shaft conductor.
3. Disconnect the joint and terminal of
starter.
4. Dismantle starter assembly.

Reassembly:
The steps for reassembly is just contrary to those for dismantlement.

Switch
Operation Check: EE020
Adjusting Process for Pinion in Repair Service
1. Disconnect the conductor of
excitation coil from the terminal M of
electromagnetic coil.
Starter Conductor of
2. Connect a 12V storage battery
excitation coil
between the terminal S and M.
 宾悦维修手册发动机分册 EE-34

3. Take out the pinion.

 宾悦维修手册发动机分册 EE-35

Attention:
To prevent the overheating of coil, the test shall be completed quickly (less
than 10s).
4. Check the gap of pinion stopper with plug gauge (pinion gap).
Pinion Gap: 0.5-2.0mm
EE021

Retaining device

Pinion gap

Pinion
5. If the gap of pinion exceeds the
specified value, adjust the gap by
increasing or taking off the
EE022
electromagnetic coil or the gasket
between the front gaskets.

Attraction Test for Electromagnetic

Switch
1. Disconnect the conductor of
EE023
excitation coil from the terminal M of
electromagnetic switch.
2. Connect the 12V storage battery
between the terminal M and S. 12V storage battery

Attention: Starter

To prevent the overheating of coil, the

test shall be completed quickly (less
than 10s).

3. If the pinion moves out, the sucking

coil is normal; if the pinion fails to
move out, replace the
electromagnetic switch.

Retentivity Test for Electromagnetic EE024

Switch:
1. Disconnect the conductor of

Lead wire of
Starter excitation coil
 宾悦维修手册发动机分册 EE-36

excitation coil from the terminal M of

electromagnetic switch.
2. Connect a 12V storage battery
between terminal S and switch body.
 宾悦维修手册发动机分册 EE-37

Attention:
To prevent the overheating of coil, the
test shall be completed quickly (less
than 10s).
3. If the pinion moves out, everything is normal. If the pinion moves forward and
backward repeatedly, keep the circuit open. If the circuit is open, replace the
electromagnetic switch.
Test for Nonloaded Running
Put the starter into the vice with soft clamp, and connect the fully charged 12V
storage battery to starter as follows:
1. Connect and test the ammeter (100A scale) and the cascade carbon plate
rheostat as shown in the figure. EE025 Cascade carbon plate rheostat

Ammeter

Starter
Voltmete 12V
r storage
battery

2. Connect a voltmeter (12V scale) in parallel on the starter.

3. Rotate the carbon plate to the position “OFF”.
4. Connect the conductor of storage battery from the wiring terminal of negative
(-) pole to the body of starter.
5. Adjust the carbon plate till the reading of storage battery voltage is 11V.
6. Make sure that the maximum current is within the specified range and the
starter operates evenly and free.
Current: 90A as maximum
Speed: 3,000rpm as minimum
Return Test for Electromagnetic Switch
1. Disconnect the conductor of EE026
excitation coil from the terminal M of
electromagnetic switch.
2. Connect the 12V storage battery
between the terminal M and the motor Conductor of
Starter excitation coil
body.
Attention:
To prevent the overheating of coil, the
test shall be completed quickly (within
the 10s).
3. Pull out and then release the pinion. If
the pinoin returns to the original
 宾悦维修手册发动机分册 EE-38

position quickly, everything is normal.

Otherwise, replace the
electromagnetic switch.
 宾悦维修手册发动机分册 EE-39

Check EE027
Check for Steering Device
1. Put the armature on a V-shape seat pad, and
check the radial jump with calibration meter.
Radial Jump of Armature
Standard Value: 0.05 mm
Limit Value: 0.1 mm

2. Check the outer diameter of steering device.

Standard Value: 29.4mm EE028

Limit Value: 28.4mm

3. Check the undercut depth of sector teeth.

Standard Value: 0.5mm
Limit Value: 0.2mm
EE029
Sector teeth Undercut

Mica

Brush Seat EE030

Check the continuity between the brush seat plate
and brush seat. Normally it is not continuous.
 宾悦维修手册发动机分册 EE-40

Overdrive Clutch EE031

1. Support the cover of clutch and rotate pinion.
The driving pinion shall rotate in one direction
Loosen
smoothly rather than in the reverse direction.
If the function of clutch appears abnormal,
replace the overdrive clutch assembly. Tighten

2. Check whether the pinion suffers from

EE032
abrasion or rolled edge. If the fact is positive,
replace the overdrive clutch assembly. If the
pinion is damaged, also check the ring gear
for abrasion or rolled edge.

Bushings of Front and Rear Support Racks

Check whether the bushing is abraded or the edge is rolled. If the fact is positive,
replace the front or the rear support rack assembly.

Reassembly for Upper Ring and Split Ring

EE033
Pull out the stopping ring and split ring of
overdrive clutch with the proper pulling tools.

Limit line
Clean the Parts of Starter
1. Don't immerse parts in the cleaning agent.
Cleaning centering rack and the excitation
coil assembly or armature will break the
insulation. Only by cloth can these be wiped.
2. Don't immerse the driving parts in the cleaning agent, because the overdrive
clutch has already been prelubricated at the factory and the solvent will wash
out the lubricant.
3. The driving elements can be cleaned by the brush dipped with the cleaning
agent, then wipe up by cloth.

Replacement for Carbon Brush and Spring

 宾悦维修手册发动机分册 EE-41

1. Replace the carbon brush, if it is abraded or dipped by oil.

2. When replacing the carbon brush of excitation coil, crush the abraded carbon
brush to pieces by pliers without causing
damage to the conductor of carbon brush. EE034
New brush
3. Polish the conductor end of carbon brush by Lead wire of brush
Welding point
sand paper to ensure the good braze welding. (ensure no
residual soldering
4. Insert the conductor into the hole of new on the surface of
brush)
carbon brush and weld the wire. Make sure
that the residual soldering of conductor is
away from the surface of carbon brush.
5. When replacing the grounding carbon brush,
slip out the carbon brush from the carbon brush
bed by prizing the locating spring.

Dismantlement Steps: EE035

Dismantlement for Split Ring and Stopping

Ring
1. Use the sleeve spanner to press the stopping
ring to the side of split ring.

EE036

2. After dismantling the split ring (by split ring

clamp), take off the stopping ring and the
overdrive clutch.

Illustration:
Check parts foresaid. If any abrasion is found, it is recommended to replace
them with new ones.
 Engine Volume EMS-1

Precautions
Precautions for “Airbag” and “Seat Belt Pretensioner” of Safety Restraint
System (SRS)
The SRS, such as airbag and seat belt pretensioner, should be used together with the
safety belt, so as to reduce the dangerous and serious possibilities of getting injured in
case of collision. As to the safety maintenance of the system, please see the section
about the SRS for reference.

Caution:
● To avoid the danger of injury and fatal accident caused by the failure of SRA system,
all the maintenance should be carried out by the authorized JAC exclusive agency
maintenance center.
● Improper maintenance, including improperly dismantling and mounting SRS system,
may cause wrong action of the system, which will bring the injury and fatal accident.
As to the dismantlement methods of spiral cables and airbag modules, please see the
section about the SRS for reference.
● Except the operations specified in this manual, don’
t use the electrical testers to test
any electric circuit of SRS system. The wire harness of SRS circuit can be identified
through the yellow or wire harness joints.

Vehicular OBD system

There is an OBD system in ECM. The MIL will be lit up to warn the driver about the trouble
of degradation in emission system.
Attention:
● Before repairing and checking, do turn the ignition switch to “OFF”, and cut off the
cable of the negative electrode of the storage battery. Either the open circuit or the
short circuit of such circuits of relevant switch, sensor and solenoid valve may cause
the MIL is lit up.
● After work, do connect and lock the joints firmly. Loose (unlocked) joints may open the
circuit and make MIL on. (Make sure there is no water, grease lubricant and pollution,
and the ports are not curled, etc.)
● After work, do arrange and fasten the wire harness properly. If the support interferes
the wire harness and others, short-circuit may be caused, making the MIL on.
● Before delivering the vehicle to the buyer, do clear the useless malfunction information
(having been repaired) of ECM.
 Engine Volume EMS-2

Precautions:
EMS001
● Do use the storage battery of 12 V.
● Don’
t cut off the circuit of storage battery as
the engine is operating.
● Before connecting or cutting off ECM joints,
turn ignition switch to “OFF”and cut off the
grounding cable. Or else, ECM will be
damaged, because ECM still has voltage of
12 V even when the ignition witch is “OFF”.
● Before dismantling the components, turn
EMS002
ignition switch to “OFF” and cut off the
grounding cable.
● Please do not disassemble the ECM.
● If the cable of a storage battery is cut off, the
memory will regain its ECM value. ECM will
begin the self-control according to the initial
value. The operation of engine will have slight
change when the battery is cut off. But it
doesn’
t mean a trouble exists. Don’
t change
any component when the slight change EMS003

happens.
● If the storage battery is cut off, all the
information about the trouble will be lost within
24 hours.
● When dismantling the ECM wire harness joint,
squeeze the red clip to push out the retainer
pin, as shown in the Fig. Don’
t pull the clip
forcefully to avoid the damage.
EMS004

● Press the locating snap-in and pull upwards

ECM dismantling plastic handle, as shown in
the Fig.
 Engine Volume EMS-3

● Pull ECM wire harness plug vertically upwards to take it out. Do not damage (curl or
split) the contact pin port. Make sure the ECM
contact pin port is not bent or split when EMS005
connecting the contact pin joint.
● Connect the ECM wire harness joints firmly.
Poor connection may lead electric coil and
condenser to produce extrahigh (fluctuation)
voltage, which will damage the integrated
circuit chip.
● Keep the engine control wire harness at least
10cm away from the adjacent wire harness, to
avoid the trouble the engine may get from the
noise outside and degraded function of the
chip.
● Keep the parts and wire harness of engine
control system free of damp.
EMS006
● Even the slight leakage in the intake system
may cause serious trouble.
● Don’
t shake or shock the camshaft position
sensor (phrase) or crankshaft position sensor
(position).
● After checking the trouble every time,
remember to clear the trouble code, and make
sure EPC is off when the engine is working
normally.
EMS007
● Don't make the test pen lapped butt when
using voltmeter to test ECM signals, or else,
short circuit may be caused and ECM power
transistor may be damaged.
● Don’
t use the ECM grounding port when
testing input/output voltage, or else ECM
transistor may be damaged. Other grounding
circuitries except ECM grounding port are
available.
● Do not operate the fuel injection pump when there is no fuel in the fuel pipeline.
● Do not tread the accelerator pedal when the engine is getting started.
● Do not make unnecessary acceleration immediately after the engine is started up.
● Do not make unnecessary acceleration till the engine is power off.
● Always dismantle different hoses with different tools.
 Engine Volume EMS-4

Preparations
Special Maintenance Tools
Tool Name:
Ignition Timing Light
Function:
To check the engine ignition timing, etc.

Tool Name:
Digital Multimeter
Function:
To test the characteristic parameters of
electric injection system, such as the
voltage, current and resistance, etc.

Tool Name:
Vacuum Meter
Function:
To inspect the pressure in the intake
manifold.

Tool Name:
Cylinder Pressure Meter
Function:
To examine the pressure in each cylinder.

Tool Name:
Fuel Pressure Meter
Function:
To examine the pressure in the fuel
system, and judge the performance of fuel
injection pump and fuel pressure regulator
 Engine Volume EMS-5

in the system.

Tool Name:
Fuel Injector Cleaning Analyzer
Function:
To analyze the cleaning of the fuel injector.

Tool Name:
Diagnostic Tester
Function:
To analyze the engine control system.
 Engine Volume EMS-6

Fuel Evaporation and Emission System

System Illustration
Intake manifold

Air filter

EVAP carbon
canister purge
control solenoid
valve

Fuel steam
EVAP carbon
canister Air

Oil tank

The fuel evaporation system is used to decrease the exhaust of hydrocarbon from the fuel
system to air. The usage of activated carbon in EVAP carbon canister can achieve such
purpose.
When the engine is not in operation or when fuel is being added into the fuel tank, the fuel
steam evaporating from the sealed tank is conducted to and stored in the EVAP carbon
canister that has activated carbon in it.
When the engine is running, the fuel steam in EVAP carbon canister is conducted into the
intake manifold through the cleaning pipe. The carbon canister solenoid valve is controlled
by ECM. When the engine is working, the steam flow, under the control of the carbon
canister solenoid valve, increases in step with the air flow.
When the engine is idling or lowering down, EVAP carbon canister solenoid valve will shut
the cleaning pipeline of fuel steam.

Element Inspection
EVAP Carbon Canister
Check EVAP carbon canister in the following ways:
1. Block orifice C, and blow into orifice B to check EMS008 A B C
if the air flows from orifice A fluently.
2. Block B, blow into orifice C to check the air
flows from orifice A fluently.
Attention:
Do not inspire any steam into mouth, which is
poisonous and bad to human body.
 Engine Volume EMS-7

Dismantlement and Installation

Dismantlement of Vacuum Hose EMS009
Unscrew the clamping band from carbon canister
to oil tank and to carbon canister solenoid valve.
Pull out the vacuum hose.

Dismantlement of Carbon Canister

Pull the carbon canister upwards to dismount it
from the cage on the engine hatch firewall.

EMS010
 Benjoy Maintenance Manual ---- Engine Volume EMS-8

EVAP Carbon Canister Solenoid Valve

Illustration
The system controls the flow speed of the fuel steam from EVAP carbon canister. The
by-pass pipeline in EVAP carbon canister purge control solenoid valve, through its
opening degree, controls the flow speed. Following the signals sent by ECM, EVAP
carbon canister purge control solenoid valve repeats the operation of on/off. The opening
of the valve changes in order to control the engine best. The best values stored in ECM
are determined by different engine status. When the engine is working, the flow speed of
the fuel steam from EVAP carbon canister regulates itself with the change of air flow.
Elements
EVAP carbon canister purge control solenoid valve EMS011
controls the flow speed of fuel steam from EVAP
carbon canister according to duty ratio. EVAP
carbon canister purge control solenoid valve is
driven by the ON/OFF signals of duty ratio from
ECM. The wider the ON pulse is, the more fuel
steam flows through the valve.

Circuit Diagram

Main relay

Pins:
No.1 (A) is controlled by solenoid valve coil (connected to ECU63#).
No.2 (B) connects to the power supply of main relay.
 Benjoy Maintenance Manual ---- Engine Volume EMS-9

Dismantlement of Carbon Canister Solenoid Valve

1. Dismount the wire harness joint from the
carbon canister solenoid valve. EMS012
Attention: Make sure the ignition switch is off
when dismantling the joint.

EMS013
2. Pull out the vacuum hoses at both ends of the
carbon canister solenoid valve.

3. Push upwards and take out the carbon EMS014

canister solenoid valve from its cage.
 Benjoy Maintenance Manual ---- Engine Volume EMS-10

Positive Crankcase Ventilation System

System Illustration

Air filter Intake hose Throttle valve casing Purification can

PCV valve
Ventilating hose

Fuel injector

Intake manifold

From rocker arm cover To intake manifold

Plunger
Spring

Leaked air

Fresh air

Positive crankcase ventilation valve (PCV valve) conducts the blow-by from crankcase
into the intake manifold. When the engine air throttle is open partly, the intake manifold
takes in the blow-by from crankcase through PCV valve. Normally, the ventilating capacity
of PCV valve is enough for taking in the blow-by from crankcase and some ventilation air.
The ventilation air is taken into the crankcase through the intake pipe. In this process, the
air passes through the hose connecting intake pipe and rocker arm chamber cover. When
the air throttle is open completely, the vacuum degree of intake manifold is not enough to
open PCV valve and take in the blow-by from crankcase. The air will flow through the
connection pipe in opposite direction.
For the vehicle involved with the serious blow-by
in crankcase, the PCV valve can’
t meet its EMS015
requirement. That is because, in any case, there
is always part of air passing through the hose to
the intake manifold.

Dismantlement of PCV Valve and

Vacuum Hose
1. Use the clamping band pliers to dismount the
 Benjoy Maintenance Manual ---- Engine Volume EMS-11

clamping bands at both ends of the PCV valve vacuum hose. Pull out the vacuum
hose.
2. Use an open-end spanner to screw off the
PCV valve from the valve chamber cover. EMS016

3. Check the through ability of PCV valve.

① Dismount the positive crankcase ventilation EMS017
valve.
② Insert a thin stick from the thread side into the
positive crankcase ventilation valve to inspect
the movement of the plug.
③ If the plug can’
t move, it indicates the positive
crankcase ventilation valve is blocked. Please
clean or replace it.

EMS018
PCV valve
 Benjoy Maintenance Manual ---- Engine Volume EMS-12

OBD (On-board Diagnosis) System

Illustration
When the system is working and the engine is in operation, ECM controls the actions of all
system parts and real-timely monitors the parts directly connecting with it. When there is
something wrong with the action of one or some parts, the system will make alarm
automatically, with each trouble corresponding to a respective code. Once there is a
trouble in the system, the system will output the code (i.e. trouble code) through the
diagnosis interface, and turn on the “engine malfunction indicator light”to warn the drivers
about maintenance in time. The trouble code indicates the possible trouble position.
When there is trouble, the system can apply temporary emergency scheme to control the
working of the engine, so that the driver can drive the vehicle to a maintenance station for
maintenance rather than anchoring on the way.

Malfunction Indicator Light (MIL) Illustration

MIL is an indicator connected to OBD system, and if any part related to emission or OBD
system gets in trouble, it will remind the driver (as shown in the Fig).

Performance Principles of MIL

When the trouble of the system or spare parts causes the vehicle emission to exceed the
specified limit, MIL should get activated within required time. Depending on whether and
how much the trouble affects the emission, the MIL should be activated as the following
principles:
Trouble Code for Emission Affected:
Catergory A: Every time the trouble occurs, MIL is lit up and the trouble code is recorded.
Catergory B: In every two successive strokes the trouble occurs, MIL is lit up and the
trouble code is recorded.
Catergory C: In every three successive strokes the trouble occurs, MIL is lit up and the
trouble code is recorded.
Trouble Code for Emission Not Affected:
Catergory C: The trouble code is recorded, but MIL isn’
t lit up.
Catergory D: The trouble code is recorded, but no light is lit up.
MIL Going-off:
In every three successive strokes, if the detection system in control of the activiation of
MIL doesn’
t detect any trouble or other troubles that can activate MIL indepently any more,
MIL will become off.
Clearing-away of Trouble Code:
If the same trouble doesn’
t occur again in over 40 engine warm-up cycles, OBD system
will clear away the trouble codes as well as the information about driving distance and
current data.
Note: A stroke refers to a driving cycle in which all OBD tests can be completed, based on
 Benjoy Maintenance Manual ---- Engine Volume EMS-13

the test procedure of the State III emission standard in Fig. 3.

 Benjoy Maintenance Manual ---- Engine Volume EMS-14

Trouble Diagnosis
Introduction to Trouble Diagnosis
ECM controls the main systems of fuel injection, ignition timing and idle, etc. ECM
receives input signals from the sensor and
immediately drives the actuator. It is very important Sensor

that input and output signals must be accurate and

Actuator
stable. Besides, it should also be made sure that
there is no vacuum leakage, ignition plug
ineffectiveness or other troubles of the engine.

It is more difficult to diagnose an intermittent trouble

than a continuous trouble. Most intermittent troubles
are caused by poor connection or troubles of the
circuit. In such cases, all possible circuits should be Information

inspected carefully to avoid the unnecessary Reason

replacement of any normal spare parts.

The problem sources may not be visually found. It is

necessary to test the circuit by connecting it with the
diagnostic tester and voltage meter. Before carrying
out the inspection, take some time to communicate
with the customer who is not satisfied with the
vehicle’
s traveling performance. Customer is a good
information provider for such problems, especially
the intermittent problems. Their symptom and
condition can be known better through the talk.
Before the diagnosis, inspect common troubles
firstly to exclude the problems of electric control
engine in terms of traveling performance.
 Benjoy Maintenance Manual ---- Engine Volume EMS-15

Basic Diagram of Control System

See the attached sheet
 Electric Management System of Delphi Vehicle Engine, China
Electric Management System of Multipoint Fuel Injection and Direct Ignition

Idle air valve Control valve of

carbon canister

Intake Carbon canister

Engine Control Tactics

Engine trouble temperature

indicator light sensor

ECM engine Throttle valve Fuel injection

control unit casing relay

Throttle position Fuel filter

Trouble sensor
diagnosis and
communication
joint Ignition coil and
control module
Relay of air
conditioner
clutch Intake manifold
absolute pressure
sensor
Fuel rail Fuel pressure
Air Coolant temperature
conditioning assembly adjustor
sensor
demand switch
Fuel injection Fuel injection
nozzle pump
Oxygen sensor
Ignition switch
Crankshaft Three-way
ECM
position sensor catalyst converter
Benjoy Maintenance Manual ---- Engine Volume
EMS-16
 Benjoy Maintenance Manual ---- Engine Volume EMS-17

1. Control Logic of Ignition Switch

To the battery

The first time to turn on the switch

The main relay and fuel injection pump keep connected for 15 seconds

Turn off the switch

System is reset immediately

System is preset

System is shut down

Turn on the switch

The main relay and fuel injection pump keep connected for 15 seconds

Turn off the switch Start and operate the engine

System is preset Turn off the switch

System is shut down System is initialized and preset

System is shut down

2. Control Logic of Fuel Supply System

Logic of Oil Pump
After the ignition switch is turned on, the oil pump will perform for 1.5 seconds. If no
effective 58X signal is detected, the pump will stop working. If ECM detects 2 effective
58X signals after the engine getting to work, the pump will get to work.
If the rotating speed signal is missing for 0.8 seconds or the anti-theft system demands
the oil pump to be turned off, the pump will stop working.
Starting of Pre-injection
There is only once pre-injection in normal starting process. The conditions of pre-injection
are as follows:
- The engine begins to work (at least 2 effective 58X signals are detected).
- The pump relay is closed.
 Benjoy Maintenance Manual ---- Engine Volume EMS-18

- The pump working time exceeds the delay time of pressure storage.
- No pre-injection before.
- If all the conditions are satisfied, pre-injection will be carried on in all cylinders.
Calculations of Fuel Injection
Air fuel ratio (A/F)
Manifold pressure Closed loop
amendment
Inflation Enrichment in
temperature acceleration

Enrichment in
Air flow deceleration
Calculation of fuel
injection amount
Inflation Fuel cut-off in
effectiveness deceleration

Self-learning Exhaust gas cycle

amendment
Nozzle constant Voltage
amendment

Fuel injection pulse

width

– Air fuel ratio (A/F)

Starting A/F, normal A/F, cleaning fuel flood A/F, engine working A/F, cold engine A/F,
warm engine A/F, power enrich A/F, catalyst overheating A/F, engine overheating
protection A/F
– Intake manifold absolute pressure
The intake manifold absolute pressure is sensed through MAP sensor on the intake
manifold.
– Inflation temperature
The inflation temperature refers to the temperature of the air into the cylinder, which is
calculated through the thermometers for water and intake temperatures.
– Inflation effectiveness
The inflation effectiveness is the ratio between the actual air flow into the cylinder and
the air flow calculated according to the ideal state equation.
– Self-learning
The self-learning is for amending the slow changes caused due to the increase of
working time and the production divergence of the engine and complete vehicle.
– Closed loop feedback amendment
The closed loop feedback amendment, depending on the feedback signals from
oxygen sensor, is used to control the actual A/F to approach the theory A/F.
– Fuel enrichment in acceleration
When the system detects the violent increase of TPS, MAP and IAC, in order to
 Benjoy Maintenance Manual ---- Engine Volume EMS-19

prevent the fuel from being diluted momentarily, the enrichment will be carried out to
raise the power.
– Fuel dilution in deceleration
When the system detects the violent decrease of TPS, MAP and IAC, in order to
prevent the fuel from being enriched momentarily, dilution will be carried out to
improve the emission and traveling performance.
– Fuel cut-off in deceleration
When the system detects that the engine and the complete vehicle is getting into
deceleration working condition, it will cut off the oil supply to decrease the emission
and lower the oil consumption.
– Protective fuel cut-off
The system will stop fuel injection in case of any of the following conditions:
● If the engine rotating speed is over 6,000rpm, the fuel supply will be cut off, and
when the speed is below 5,900 rpm, the fuel supply will be recovered.
● If the system detects troubles in the ignition system, the fuel supply will be cut off.
● If the system voltage is over 18V and the rotating speed is over 1,100rpm, the
fuel supply will be cut off, and when the voltage is below 18V, the fuel supply will
be recovered.
– Basic injection nozzle constant
Basic injection nozzle constant reflects the relationship between the engine emission
and the flow at injection nozzle.
– Power supply voltage amendment
When the power supply voltage is changing, the voltage amendment can ensure the
fuel flow to be correct.
Ignition Control Logic
Ignition Coil Magnetizing Control
The magnetizing time of ignition coil determines the ignition energy of ignition plug. If the
time is too long, the coil or coil driver may be damaged, if too short, the misfire may be
caused.
Starting Mode
In starting mode, the system adopts a fixed ignition angle, to ensure the firing of the mixed
air in the cylinder and to provide the torque. After the engine is ignited, with the rotating
speed rising, and can operate by itself, the starting mode will exit.
Calculation of ignition advance angle
 Benjoy Maintenance Manual ---- Engine Volume EMS-20

Main ignition
angle
Water temperature Deceleration oil cut-off
amendment amendment

Air temperature Power enrichment

amendment amendment
Calculation of ignition
advance angle
Elevation Air conditioning
amendment amendment

Idle amendment Amendment in

acceleration

Ignition advance
angle
 Benjoy Maintenance Manual ---- Engine Volume EMS-21

– Ignition advance angle

After the water temperature gets normal, the main ignition angle as the air throttle
opens usually is the minimum ignition angle or the critical point of knock under the
best torque. When the throttle closes, the ignition angle should be less than the
minimum ignition angle to get the idle stablity.
Under the precondition that the cold traveling performance is not influeced, in order to
make it possible for the catalyst to fire, in the process of heating the catalyst, the
basic ignitioni angle can be a specific angle other than the minimum ignition angle or
the critical point of knock; also, under the precondition that the traveling performance
is not influeced, it should be delayed as late as possible.
– Amendment of ignition advance angle
Water temperature amendment, air intake temperature amendment, additional
amendment of elevation, idle amendment, diving amendment, power enrichment
amendment, amendment of fuel cut-off in deceleration, air-coditioner control
amendment, exhaust gas recycle amendment.
– Amendment in acceleration
Ignition advance angle amendment is used to decrease the instability of the engine
rotating speed caused by the wrest shock of driving system, and to eliminate the
possible knock in acceleration processes, so that the acceleration can be carried on
smoothly.
– Power enrichment amendment
Near the external characteristic point, to get better power and torque, A/F will be
enriched to the most diluted A/F of the best torque, so that the ignition can be
amended and the minimum ignition angle can be got.
– Amendment of fuel cut-off in deceleration
When the fuel cut-off in deceleration exits, you can amend the ignition angle to
ensure air throttle with a smooth transition from closing to exiting.
– Air-conditioner amendment
Turn off the air conditioner as the engine is idling. You can amend the ignition
advance angle to ensure the engine with a smooth rotating speed transition.
Logic of Idle Control
The idle air flow control enables the braking system to maintain the target speed when the
throttle valve is closed completely, which can ensure a smooth transition when air going in
and out the throttle valve, to prevent from stalling. As idling, when the engine load is
changing, such control can maintain a steady ratating speed.
 Benjoy Maintenance Manual ---- Engine Volume EMS-22

Basic target speed idle

Voltage compensation Fan compensation

Speed compensation Headlight compensation

Calculation of target idle

Decelaration
Deceleration amendment Air conditioner compensation

Target idle
 Benjoy Maintenance Manual ---- Engine Volume EMS-23

Basic Target Idle

Under different temperatures of coolant, the settings of basic target idle speeds are as
follows:
Target Target Target Target
Coolant idle Coolant idle Coolant idle Coolant idle
temperature℃ speed temperature℃ speed temperature℃ speed temperature℃ speed
RPM RPM RPM RPM
<-28 1,300 8 1,200 56 950 104 825
-28 1,300 20 1,200 68 850 116 925
-16 1,300 32 1,200 80 750 >116 925
-4 1,200 44 1,075 92 750

– System voltage compensation

If the system voltage is below 12V, the system will raise the target idle speed
automatically to increase the electricity generated. The rotating speed is raised by
12.5 rpm per second, and to 150rmp as the maximum speed.
– Speed compensation and deceleration adjustment
To improve the driving performance as fuel cut-off and braking, the target idle speed
at driving is 50rmp higher than that at braking. When decelerating or braking,
decelerate gradually to the braking target idle speed.
– Air conditioner compensation
Turn on the air conditioner when idling. To compensate the compressor power, the
idle speed should be raised by 150rpm.

Knock Control Logic

Knock control has the function of eliminating the possible knock when the engine is
burning, and improving engine power performance and fuel economy. MT20 system can
carry out independent knock control to each cylinder of the engine.
Working Conditions of Knock Control
Knock control system will start its working under the following conditions:
● There is a knock sensor installed on the vehicle, and the knock control function is
applied.
● The engine starts and runs for over 2 seconds.
● The rotating speed is over 800rpm.
● MAP is over 40Kpa.
Knock Control Mode
After the knock or when the knock is possible, delay the ignition angle quickly and properly.
The basic ignition advance angles of system are classified into normal ignition advance
angle and safety ignition advance angle, between which the regulation of knock control is
carried out. The main modes of control schemes are as follows:
– Steady knock control
When the engine is working normally, through knock sensor, ECM collects and
analyzes the sound during the engine’
s burning, and detects the knock after filtering.
 Benjoy Maintenance Manual ---- Engine Volume EMS-24

If the knock is so serious to exceed the allowed limit, the system will delay the ignition
advance angle in the cylinder where the knock occurs, and eliminate the knock in the
following burning cycles, and then the ignition advance angle will recover to the
normal.
– -Transient knock control
The knock is easily to occur during fast accelerating and great changing of engine’
s
rotating speed. After the system forecasts a possible knock, it will delay the ignition
advance angle to prevent overrun knock.
– -Quickly delay to the ignition angle
After the system detects the knock, according to the different rotating speeds of the
engine, it will quickly delay the ignition advance angle by 3-5°, and recover to the
normal within the following 2-3 seconds.
– -Adaptive adjustment to the ignition angle
Because of the production errors and the long-time wearing, there are diversities
among engines. If the system and the engine are initially used or ECM is charged
newly, there will be the possibility of knock when the engine is working. The system
will record it and, after a period of operating mode, the system will be able to
automatically conduct the adaptive adjustment to the ignition advance angle to avoid
the knock.
Air conditioning control logic
ECM monitors A/C request input and A/C evaporator temperature sensor input, and
controls the clutch of air-conditioned compressor through air-conditioner relay. The
system can automatically identify the air conditioning system as soon as it gets into work.
Air conditioning working conditions
Air conditioning system will start to work if the following conditions are satisfied:
● Air conditioner is installed in the vehicle.
● The engine is working for over 5 seconds.
● Air conditioner is turned on.
● The temperature of intake air temperature is over 3.75℃.
● The temperature of coolant water is over 3.75℃.
● The rotating speed of engine is over 600rpm.
● All the air conditioning cut-off modes are not effective.
Air conditioning cut-off mode
In some cases, in order to ensure the power or protect the engine or the air conditioning
system, ECM must cut off the air-conditioned compressor or forbid air conditioning’
s
starting. In order to prevent the compressor clutch from getting on and off too frequently,
once the air conditioning cut-off mode is activated, ECM will delay to ensure a certain time
before the clutch is pulled on again. The modes are listed mainly as follows:
– Air conditioning cut-off mode when engine is heavy-loaded: to ensure power
After the ignition switch is turned on, the oil pump will be working for 1.5 seconds, and
stop working if no effective 58X signals are detected. If the engine is started, and
ECM tests 2 effective 58X signals, the oil pump will begin to work.
● No trouble with TPS or peed sensor.
 Benjoy Maintenance Manual ---- Engine Volume EMS-25

● The engine rotating speed is below 3,600rpm (not in heavy-load cut off mode), or
below 4,000rmp (in heavy-load cut off mode).
● Vehicle speed is below 10kph (not in heavy-load cut off mode), or below 15kph (in
heavy-load cut off mode).
● The opening of the throttle is over 70% (not in heavy-load cut off mode), or over
60% (in heavy-load cut off mode).
– The air conditioning cut-off mode when the throttle is fully open: to ensure
power
● The engine rotating speed is below 5,000rpm.
● No trouble with TPS.
● TPS is over 90%, and had been below this figure since WOT air conditioning is cut
off last time.
– The air conditioning cut-off mode when the rotating speed is too high: to
protect the air conditioning system
● When A/C is off, the engine rotating speed is below 6,000rpm.
● When A/C is on, the engine rotating speed is over 6,200rpm.
– The air conditioning cut-off mode when the temperature of engine cooling
water is too high: to protect the engine
● When A/C is off, the compressor is allowed to be started only if the temperature of
coolant water is below 108℃.
● When A/C is on, the compressor will be cut off if the temperature of coolant water
is over 112℃.
Control Logic of Carbon Canister Solenoid Valve
Carbon canister solenoid valve controls when and how long the pipe between the
activated carbon canister and the intake pipe is open, so as to control how much and
when the fuel steam flows into the cylinder, and in this way, the steam emission of the
vehicles can be best reduced, and the engine performance can be least effected.
Working Conditions of Carbon Canister Solenoid Valve
In order to reduce the influence to normal burning of the engine made by the fuel steam
getting into the cylinder, before the opening of carbon canister solenoid valve, the
following conditions should be satisfied:
● The system voltage is below 17V.
● The operating time of the engine is more than 150 seconds (the water temperature is
below 50.25℃ when the engine is started), or the operating time of engine is more
than 30 seconds (the water temperature is over 50.25℃ when the engine is being
started).
● No trouble with ECM system.
● The engine is in closed loop working mode or is cut off for more than 2 seconds.
● The extent of the air throttle opening is over 1.2% and below 100%.
Working Mode of Carbon Canister Solenoid Valve
The opening of solenoid valve is determined by PWM signals according to the engine
state. In idle state, the maximum opening of carbon canister solenoid valve is 0%. When
idling, the maximum opening of solenoid valve depends on the closed loop air flow, and
 Benjoy Maintenance Manual ---- Engine Volume EMS-26

can reach 100%.

Control Logic of Three-way Catalyst Protection
When the engine is in operation, the system pre-estimates the working temperature of the
three- way catalyst. If the pre-estimated temperature is over the protection temperature,
the timing will begin, and if the working temperature of the three-way catalyst keeps above
the protection temperature, the system will control the fuel supply, and enrich the A/F to
degrade the working temperature of the three-way catalyst. After a while, the system
pre-estimates the temperature has been lowered, and then it will recover the former A/F,
and continue to pre-estimate the working temperature of the catalyst for protection
preparation.
Logic of Mileage Accumulation
The function of mileage accumulation is set specially for the mileage statistics of after-sale
quality assurance. It cannot replace the vehicular odometer. Within the quality assurance
period, the system accumulates the driving mileage and starts the engine protection logic.
If there is no signal from speed sensor, the system will not be able to accumulate the
driving mileage. So if there is trouble with the speed sensor and its related circuit, the
system will limit the driving performance of the engine as that the customers can be
reminded of maintaining it in time.
Mileage Accumulation
The mileage accumulation is based on the pulse signals from the vehicle speed sensor,
with the accumulating capacity to be 0.0-9,999,999.9km and the distinguishable travel is
0.1km. When the recorded mileage reaches 80,000km, the system will stop recording.
After every 5km or every time of power-off, the system will record the accumulated
mileage in EEPROM, and recover the statistic when the power is on again. When ECM is
fully cut off from the power, the accumulated mileage also can be recorded. If the system
doesn’
t detect any trouble with the speed sensor and its circuits (P05000-00), every time
the system receives the 2551/10 pulse signals from the speed sensor, it will record the
accumulation by 0.1 km to the former record.
Oil Cut-off Protection for New Engine
Before the other cut-off protections are started, the system will start its protection function
for new engine if the following conditions are satisfied:
● 20km<accumulated mileage<3,000km;
● Temperature of coolant<19.5℃;
● Temperature of coolant>30.75℃;
● Engine rotating speed is over 2,500rpm.
Protection during the Warranty Period
During the warranty period, to protect the mileage accumulation from being lost because
of the trouble of speed sensor and wiring, the system will apply the following control
procedures:
To record and indicate the speed sensor trouble;
To record the working time of the engine when the speed sensor gets trouble;
To carry on protection measures when there is trouble with the speed sensor.
Protection Mode for Ineffectiveness of Speed Sensor
 Benjoy Maintenance Manual ---- Engine Volume EMS-27

The protection mode for ineffectiveness of speed sensor will be started if the following
states occur simultaneously:
● The total mileage accumulation is over or below 70,000km;
● 10 seconds after the speed sensor gets trouble;
● The protection mode is controlled as follows: When the engine rotating speed is over
2,500rpm, the system will stop oil supply.
 Benjoy Maintenance Manual ---- Engine Volume EMS-28

DTC Index
DTC List
Trouble Trouble Trouble Illustration
Trouble Illustration
Code Code
The signals from the intake manifold The circuit of carbon canister solenoid
P0105-1 absolute pressure sensor are too P0443-1 valve gets short cut to the positive
strong. electrode of power supply.
The signals from the intake manifold The circuit of carbon canister solenoid
P0105-2 absolute pressure sensor are too P0443-2 valve gets open or short cut to the earth.
weak.
The drive circuit of water tank
The signals from the intake low-speed fan relay gets short cut to the
P0110-1 P0480-1
temperature sensor are too weak. positive electrode of power supply.
The drive circuit of water tank
The signals from the intake low-speed fan relay gets short cut to the
P0110-2 P0480-2
temperature sensor are too strong. earth.
The drive circuit of water tank
The signals from the coolant high-speed fan relay gets short cut to
P0115-1 P0481-1
temperature sensor are too weak. the positive electrode of power supply.
The drive circuit of water tank
The signals from the coolant high-speed fan relay gets short cut to
P0115-2 P0481-2
temperature sensor are too strong. the earth.
The drive circuit of air conditioner
The signals from throttle position cooling fan relay gets short cut to the
P0120-1 P0482-1
sensor are too strong. positive electrode of power supply.
The drive circuit of air conditioner
The signals from throttle position cooling fan relay gets open or short cut
P0120-2 P0482-2
sensor are too weak. to the earth.
P0130-4 No oxygen sensor signal. P0500-0 No vehicle speed sensor signal.
The oxygen sensor heating circuit Idle control makes errors.
P0135-1 gets short cut to the positive P0505-0
electrode of power supply.
The oxygen sensor heating circuit The system voltage is too high.
P0135-2 P0560-1
gets open or short cut to the earth.
The oxygen sensor keeps indicating The knock control system fails.
P0170-1 the enrichment of A/F for too long P0607-0
time.
The circuit of trouble indicator light gets
The oxygen sensor keeps indicating
P0170-2 P0650-1 short cut to the positive electrode of
the dilution of A/F for too long time.
power supply.
The circuit of trouble indicator light gets
P0201-0 Fuel injector A (Tank 1) in trouble. P0650-2
open or short cut to the earth.
The circuit of main relay gets short cut
P0202-0 Fuel injector B (Tank 3) in trouble. P1230-1 to the positive electrode of power
supply.
The circuit of main relay gets open or
P0203-0 Fuel injector C (Tank 4) in trouble. P1230-2
short cut to the earth.
The circuit of air conditioner relay gets
P0204-0 Fuel injector D (Tank 2) in trouble. P1530-1 short cut to the positive electrode of
power supply.
The relay of fuel injection pump gets The circuit of air conditioner relay gets
P0230-1 short cut to the positive electrode of P1530-2 open or short cut to the earth.
power supply.
The relay of fuel injection pump gets EEPROM makes errors.
P0230-2 P1604-0
open or short cut to the earth.
The knock sensor is connected Something wrong with anti-theft
P0325-0 P1610-0
poorly. controller.
No signal from 58X crankshaft Something wrong with communication
P0335-0 P1610-8
position sensor. between ECM and anti-theft controller.
Wrong signals from 58X crankshaft The temperature of front air conditioning
P0335-8 P2000-1
position sensor. evaporator is too high.
The signals from the camkshaft are The temperature of front air conditioning
P0342-0 P2000-2
too weak. evaporator is too low.
 Benjoy Maintenance Manual ---- Engine Volume EMS-29

The signals from the camkshaft are The temperature of rear air conditioning
P0343-2 P2001-1
too strong. evaporator is too high.
 Benjoy Maintenance Manual ---- Engine Volume EMS-30

Diagnosis System Interface Special for Chosen car series

JAC Car

Special for JAC car

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Trouble Diagnosis System Special

for JAC Car

Developed by Launch Tech. Co., Ltd.

Please log on in time

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Version Information
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Choose diagnosis software version

V10.01 Complete System Special for JAC Car

This program can diagnosis all the

electric systems of JAC cars produced
in and before 2007.

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 Benjoy Maintenance Manual ---- Engine Volume EMS-31

DTC P0105 Intake Manifold Absolute Pressure Sensor

Illustration
The pressure diaphragm inside the intake manifold absolute pressure sensor is connected
with a magnet core inside the coil. If the intake pressure in the intake pipe changes, the
diaphragm will drive the core to move, meanwhile, the output voltage of the sensor will
change and ECU can calculate the engine intake flow according to the output voltage of
the sensor. Then the engine controls the fuel injection based on these signals and
referring to other signals.

Intake manifold absolute pressure/ Intake

temperature sensor

Pins:
No.1 (A) Signals from intake pressure sensor
(connected with ECU 42#);
No.2 (B) Standard 5V power supply (connected
with ECU 4#); Intake pressure/
No.3 (C) Signals from intake temperature Temperature sensor
sensor (connected with ECU 27#);
No.4 (D) Sensor grounding wire (connected
with ECU 21#).

Diagnosis Steps
Trouble P0105-1 The signals from the intake manifold absolute pressure sensor are too
Code strong.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● When the engine stops: 90kPa.
scheme ● When the engine is idling: =45kPa.
● When the engine is working: the manifold pressure changes with the
opening of air throttle.
● If the cylinder judgement is based on the pressure, there is 50% possibility
that the injection order will mismatch by 360°.
Wiring terminal: MT20U Pressure/temperat Normal testing signal
ure sensor
5V reference voltage: 04 B 5V
Manifold pressure 42 A 0.5~4.5V
signal:
Sensor signal position: 21 D 0V
Judgement Conditions Possible Causes Countermeasures for
Reference
The engine is running 1） The wire harness pressure signal gets 1) Repair the wire
No TPS trouble short cut to 5V reference voltage or the harness.
MAP>98.117kpa positive electrode of power supply. 2) Replace the
TPS<19.141% 2) The sensor is damaged. sensor.
Lasting time of the 3) There is something wrong with the 3) Replace ECM.
 Benjoy Maintenance Manual ---- Engine Volume EMS-32

trouble>2.5 seconds pressure signal input interface of ECM.

Trouble P0105-2 The signals from the intake manifold absolute pressure
Code sensor are too weak.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● When the engine stops: 90kPa.
scheme: ● When the engine is idling: =45kPa.
● When the engine is working: the manifold pressure changes
with the opening of air throttle.
● If the cylinder judgement is based on the pressure, there is
50% possibility that the injection order will mismatch by 360°.
Wiring MT20U Pressure/ Normal testing
terminal: temperatur signal
e sensor
5V reference 04 B 5V
voltage:
Manifold 42 A 0.5~4.5V
pressure
signal:
Sensor signal 21 D 0V
position:
Judgement Conditions Possible Causes Countermeasures
for Reference
No TPS troubles 1) The connectors are not connected 1) Reconnection.
MAP<14.017kpa well. 2) Repair the wire
PRM<1,050rpm 2) The pressure signal circuit of the harness.
TPS>18.75% wire harness is open. 3) Repair the wire
Lasting time of the 3) The pressure signal circuit of the harness.
trouble>2.5 seconds wire harness gets short cut to the 4) Repair the wire
earth. harness.
4) The 5V reference voltage circuit is 5) Repair the wire
broken. harness.
5) The circuit of sensor signal 6) Repair the wire
position is broken. harness.
6) The 5V reference voltage and the 7) Replace the
reference grounding wire of sensor.
harness are reverted (which may 8) Replace ECM.
cause damage to the sensor).
7) The sensor is damaged.
8) There is something wrong with the
MAP signal interface of ECM.
 Benjoy Maintenance Manual ---- Engine Volume EMS-33

Dismantlement and Installation of Intake Pressure Sensor

1. Pull out the wire harness joint of intake pressure sensor.
Attention:
Make sure the ignition switch is off when EMS019

dismantling the plug of intake pressure sensor.

2. Dismount the fixing rack bolts of intake

EMS020
pressure sensor.

Attention: EMS021
Pay attention to the position of the sealing ring,
and not to damage or lose it when dismantling it.

Installation
Smear some oil on the sealing ring part of the intake pressure sensor, in order to install
the intake pressure sensor more properly and easily.
 Benjoy Maintenance Manual ---- Engine Volume EMS-34

1. Install the intake pressure sensor onto the

EMS022
intake manifold, and screw down the fixed
bolt with the required torque.

2. Plug the wire harness joint of the intake

pressure sensor into the plug seat of the EMS023
intake pressure sensor. Make sure it has
been plugged well, without loosing or
releasing.
Attention:
After installation, start the engine, read the trouble
code and data flow with a diagnostic tester, to see
if the value of intake pressure sensor is in the
specified scope.
 Benjoy Maintenance Manual ---- Engine Volume EMS-35

DTC PO110 Intake Temperature Sensor

Illustration
The intake temperature sensor subassembly is an electric resistance of negative
temperature coefficient (NTC). The resistance value descends as the arising of the intake
temperature. The engine ECU monitors the chang of intake temperature through a
contrast circuit inside.

Intake manifold absolute pressure/ Intake

temperature sensor

Pins:
No.1 (A) Signals from intake pressure sensor
(connected with ECU 42#); Intake pressure/
No.2 (B) Standard 5V power supply (connected with Temperature sensor
ECU 4#);
No.3 (C) Signals from intake temperature sensor
(connected with ECU 27#);
No.4 (D) Sensor grounding wire (connected with
ECU 21#).
 Benjoy Maintenance Manual ---- Engine Volume EMS-36

Diagnosis Steps
Trouble P0110-1 The signals from the intake temperature sensor are too weak.
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● Intake temperature is below coolant temperature, but not over 44.25℃.
scheme:
Wiring terminal: MT20U Pressure/ Normal testing signal
temperature
sensor
Intake 27 C 0.5~4.5V
temperature
signal:
Sensor signal 21 D 0V
positioin:
Judgement Conditions Possible Causes Countermeasures for
Reference
Working time of the 1) The connectors are not connected very 1) Reconnection.
engine>120 seconds well. 2) Repair the wire
MAT<-38.25℃ 2) The temperature signal circuit is harness.
Lasting time of the trouble>2 open. 3) Repair the wire
seconds 3) The sensor signal position is open. harness.
4) The sensor signal circuit gets short 4) Repair the wire
cut to the positive electrode of power harness.
supply. 5) Replace the
5) The sensor is damaged. sensor.
6) There is something wrong with this 6) Replace ECM.
signal input interface of ECM.

Trouble P0110-2 The signals from the intake temperature sensor are too strong.
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● Intake temperature is equal to coolant temperature, but not over 44.25℃.
scheme:
Wiring terminal: MT20U Intake Pressure/ Normal testing signal
temperatu temperature
re sensor sensor
Intake 27 B C 0.5~4.5V
temperature
signal:
Signal sensor 21 A D 0V
position:
Judgement Conditions Possible Causes Countermeasures for
Reference
Working time of the 1) The temperature signal circuit gets 1) Repair the wire
engine>60 seconds short cut to the earth. harness.
MAT>148.5℃ 2) The sensor is damaged. 2) Replace the
Lasting time of the trouble>2 3) There is something wrong with this sensor.
seconds signal input interface of ECM. 3) Replace ECM.

Dismantlement and Installation of Intake Pressure Sensor

 Benjoy Maintenance Manual ---- Engine Volume EMS-37

Please refer to the “Dismantlement and Installation of Intake Pressure Sensor”section for
the dismantlement and installation of intake temperature sensor.

DTC P0115 Water Temperature Sensor

Illustration
The water temperature sensor is used to supply information about coolant temperature.
The water temperature signals sent to the engine can help it control the ignition timing and
injection pulse width as the engine’
s starting, idling and normal working. The water
temperature signals are sent to the instrument for display on it. The water temperature
signals are the most important signals as the engine’
s cold starting. The fuel injection flow
during the cold starting is based on the signlas sent by the water temperature sensor.
The sensor is a sensitive electric resistance of negative temperature coefficient. Its
resistance value descends as the arising of the coolant temperature, and ascends as the
dropping of the coolant temperature, not in linear relationship, however. According to the
signals sent by the sensor, ECU monitors the chang of water temperature through a
contrast circuit inside.

To instrument

Pins:
There are three pins in this sensor, which can
be replaced with each other.
No.1 (A) Sensor grounding wire (connected
with ECU 5#).
No.2 (B) Water temperature sensor signal Water temperature
(connected with ECU 43#). sensor

No.3 (C) To water temperature meter of the Circuit Diagram of Coolant

Temperature Sensor
console.

Natural Parameter (Standard Value):

Temperature (℃) Electric resistance (Ω)
－10 16,120
0 9,399
 Benjoy Maintenance Manual ---- Engine Volume EMS-38

60 671
90 241
 Benjoy Maintenance Manual ---- Engine Volume EMS-39

Diagnosis Steps
Trouble
P0115-2 The signals from the coolant temperature sensor are too strong.
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● The intake temperature is adopted as starting, and the temperature rises
scheme: to 79.5℃ along with the time and then be fixed.
Coolant temperature
Wiring terminal: MT20U Normal testing signal
sensor
Signals from
coolant 43 B 0.5~4.5V
temperature:
Sensor signal
05 A 0V
position:
Countermeasures for
Judgement Conditions Possible Causes
Reference
Working time of the 1) The temperature signal circuit gets 1) Repair the wire
engine>2 seconds short cut to the earth. harness.
CTS>135℃ 2) The sensor is damaged. 2) Replace the
Lasting time of the trouble>2 3) There is something wrong with this sensor.
seconds signal input interface of ECM. 3) Replace ECM.

Trouble
P0115-1 The signals from the coolant temperature sensor are too weak.
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● Adopt intake temperature as starting, and develop it to 79.5℃ before fixing
scheme: the temperature.
Coolant temperature
Wiring terminal: MT20U Normal testing signal
sensor
Coolant
43 B 0.5~4.5V
temperature:
Sensor signal
05 A 0V
position:
Countermeasures for
Judgement Conditions Possible Causes
Reference
1) The connectors are not connected very 1) Reconnection.
well. 2) Repair the wire
2) The temperature signal circuit is open. harness.
Working time of the
3) The sensor signal grounding is open. 3) Repair the wire
engine>10 seconds
4) The temperature signal circuit gets harness.
CTS<-38.25℃
short cut to the positive electrode of power 4) Repair the wire
Lasting time of the trouble>2
supply. harness.
seconds
5) The sensor is damaged. 5) Replace the
6) There is something wrong with this sensor.
signal input interface of ECM. 6) Replace ECM.
 Benjoy Maintenance Manual ---- Engine Volume EMS-40

Dismantlement and Installation of Water Temperature Sensor

1. Pull out the wire harness joint of water

temperature sensor. EMS024

Attention:
Make sure the ignition switch is off when
dismantling the plug of water temperature sensor.

EMS025

2. Put a suction towel under the water

temperature sensor, and dismount the water
temperature sensor, then block the mounting
hole of the water temperature sensor with a
piece of glabrous cotton.

EMS026

Installation
Wipe the threaded position of the water
temperature sensor, and smear waterproof
sealant on the threaded position of the water
temperature sensor.

EMS027
Install the water temperature sensor to the water
pipe of the engine, and dry up the coolant water
leaking around, plug the wire harness joint of the
water temperature sensor, start the engine, and
read the trouble code and data flow, to see if the
engine is working normally.
Benjoy Maintenance Manual ---- Engine Volume EMS-41
 Benjoy Maintenance Manual ---- Engine Volume EMS-42

DTC P0120 Throttle Postion Sensor

Illustration
MT20U TPS (throttle position sensor) is used to supply information about rotatory angle of
the air throttle and its speed, as well as the idling position. Accoding to the information,
ECU can get the engine load information, work codition (e.g. starting, idling, reverse
dragging, partly-loaded and fully-loaded), acceleration and deceleration. The sensor is a
three-way type, and ECU inspects the opening of the throttle by monitoring the change of
voltage.
The TPS is of sliding resistor type structure (i.e. variable linear resistor). The ECU
monitors the voltage of signal output terminal and gets the opening signal of the throttle
through contrasting circuits in the computer. ECU doesn’
t accept voltage signals directly
inside, but detects the input signal ratio, so as to prevent problems about signal fluctuation
caused by voltage fluctuation.

Pins:
No.1 (A) Standard power supply of 5V (connected with
ECU 20#);
No.2 (B) Sensor grounding wire (connected with ECU 5#);
No.3 (C) Sensor signals (connected with ECU 24#).

Throttle position sensor

Circuit Diagram of
Throttle Position Sensor
 Benjoy Maintenance Manual ---- Engine Volume EMS-43

Diagnosis Steps
Trouble P0120-1 The signals from throttle position sensor are too strong.
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● The opening of TPS is set as 0% as idling, and when the rotating speed
scheme: changes, it changes along with the changs of the rotating speed.
● The function of automatical zero calibration is paused.
● The fuction of fuel flood clearing is paused.

Wiring terminal: MT20U Throttle position sensor Normal testing signal

5V reference 20 A 5V
voltage:
Throttle position 24 C 0.5~4.5V
signal:
Sensor signal 05 B 0V
positioin:
Judgement Conditions Possible Causes Countermeasures for
Reference
The engine is running, 1) The sensor signal circuit gets short cut to 1) Repair the wire
with its rotating the positive electrode of power supply or the harness.
speed<3,000rpm, however; reference voltage circuit. 2) Replace the
No MAP trouble, and MAP 2) The sensor is damaged. sensor.
is 70kPa; 3) There is something wrong with the input 3) Replace ECM.
Lasting time of the signal interface of ECM.
trouble>2.5 seconds

Trouble P0120-2 The signals from throttle position sensor are too weak.
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● Set the opening of TPS as 0% as idling, and when the rotating speed
scheme: changes, change the opening along with the changs of the rotating speed.
● The function of automatical zero calibration is paused.
● The fuction of fuel flood clearing is paused.

Wiring terminal: MT20U Throttle position sensor Normal testing signal

5V reference 20 A 5V
voltage:
Throttle position 24 C 0.5~4.5V
signal:
Sensor signal 05 B 0V
positioin:
Judgement Conditions Possible Causes Countermeasures for
Reference
Lasting time of the 1) The connectors are not connected very 1) Re-joint.
trouble>2 seconds well. 2) Repair the wire
2) The sensor signal circuit is open. harness.
3) The sensor signal circuit gets short cut to 3) Repair the wire
the earth. harness.
4) The sensor is damaged. 4) Replace the
5) There is something wrong with the input sensor.
signal interface of ECM. 5) Replace ECM.
Benjoy Maintenance Manual ---- Engine Volume EMS-44
 Benjoy Maintenance Manual ---- Engine Volume EMS-45

Dismantlement and Installation of

Throttle Position Sensor EMS028
1. Pull out the plug of throttle position sensor.
Attention:
Make sure the ignition switch is off when
dismounting the plug of throttle position sensor.

EMS029
EMS029

2. Dismantle the support bolts of throttle position

sensor, and then the throttle position sensor.

Installation
Install the throttle position sensor in the reverse order of dismantlement.

Attention:
Plug the wire harness joint, start the engine, and read the trouble code and data flow, to
see if the engine is working normally.
 Benjoy Maintenance Manual ---- Engine Volume EMS-46

DTC P0130 P0135 P0170 Front Oxygen Sensor

Illustration
The oxygen sensor is used to supply information about whether there is excessive oxygen
after the fuel injected into the engine cylinder is completely burned in the air intake. The
ECU controls the endless loops for quantifying fuel according to such information, so the
three kinds of toxic compositions, i.e. HC, CO and NOx can be converted and cleaned in
the triple effect catalytic converter.
The sensor sub-assembly of oxygen sensor is a ceramic tube with holes, which is
surrounded by the exhaust outside and is open for free air inside. The sensor calculates
the injection pulse width indirectly according to differnce between the oxygen densities
inside and outside the tube, and supply the information to ECU, which can control fuel
injection again. Meanwhile, it detects the data output by rear oxygen sensor, and contrasts
the data of front and rear oxygen sensor in the ECU, to check whether the triple effect
catalytic converter is woking well.
The working voltage of oxygen sensor is limited in the fluctuation of 0.1-0.9V, and should
change 5-8 times every 10 seconds. The change frequency below this figure indicates the
sensor is aged and needs replacement. Such sensor is un-repairable.

Main relay

Oxygen sensor

Pins:
No.1 (A) Oxygen sensor signal low-level (connected
with ECU 6#); Oxygen sensor
No.2 (B) Oxygen sensor signal high-level
(connected with ECU 62#);
No.3 (C) Connected to the power supply of main Circuit Diagram of Front Oxygen

relay; Sensor

No.4 (D) Sensor heating wire control (connected

with ECU 61#).
Benjoy Maintenance Manual ---- Engine Volume EMS-47
 Benjoy Maintenance Manual ---- Engine Volume EMS-48

Rear Oxygen Sensor (RO2S)

The structures and detections are
the same between front and rear
oxygen sensors, but the purposes
of the two are different.

Purpose:
The purpose of front oxygen sensor
is to examin the oxygen content of
the exhaust gas, so as to judge
whether the fuel injection is
exessive or not. The sensor
transforms the oxygen content in Main relay

exhaust after burning into electric

signal, and transfers it to ECU. ECU
controls the injection pulse width
based on the signal information,
and adjusts A/F, so as to indirectly
control the tail gas emission of the
engine.
The purpose of rear oxygen sensor
is to examine the oxygen content in
exhaust from triple effect catalytic
converter. The sensor transforms
such signals into dot signals and
transfers them to ECU. After
Rear oxygen sensor
comparing the signals from rear and
front sensors, ECU judges whether
the triple effect catalytic converter is Circuit Diagram of Rear Oxygen
working well. Sensor
The trouble diagnosis,
troubleshooting, signal diagnosis,
etc. are the same as front oxygen
sensor.
Pins:
No.1 (A) Oxygen sensor signal low-level (connected with ECU 6#);
No.2 (B) Oxygen sensor signal high-level (connected with ECU 38#);
No.3 (C) Connected to the power supply of main relay;
No.4 (D) Sensor heating wire control (connected with ECU 64#).
Benjoy Maintenance Manual ---- Engine Volume EMS-49
 Benjoy Maintenance Manual ---- Engine Volume EMS-50

Diagnosis Steps
Trouble P0130-4 No oxygen sensor signals.
Code:
Preparation of ●The trouble light keeps on till no trouble.
emergency control ● A/F cannot be controled with loop closed.
scheme:
Wiring terminal: MT20U Heated Normal testing signal
oxygen
sensor
System main power \ C 12V
supply:
Heating driver: 61 D 0V
Strong oxygen 62 B 0~1,000mV
sensor signal: fluctuation
Weak oxygen 06 A 0V
sensor signal:
Judgement Conditions Possible Causes Countermeasures for
Reference
360.24mV<oxygen sensor 1) The connectors are not 1) Reconnection.
signal<538.19 mV connected very well. 2) Repair the wire
Working time of the engine>40 seconds 2) The sensor signal circuit gets harness.
No TPS or MAP troubles open. 3) Replace the
Coolant tempetature>72℃ 3) The sensor becomes inactive sensor.
Fall into closed loop fuel control state gets virus or over heated. 4) Replace ECM.
TPS>10.156% 4) There is something wrong with
Lasting time of the trouble>15 seconds this signal input interface of ECM.
Diagnosis Steps
Trouble P0135-1 Oxygen sensor heating circuit gets short cut to the positive electrode
Code: of power supply.
Preparation of ●The trouble light keeps on till no trouble and the ignition swith is turned off.
emergency control ● The working time of the system as loop closed is delayed.
scheme:
Wiring terminal: MT20U Heated Normal testing signal
oxygen
sensor
System main power \ C 12V
supply:
Heating driver: 61 D 0V
Strong oxygen 62 B 0~1,000mV
sensor signal: fluctuation
Weak oxygen 06 A 0V
sensor signal:
Judgement Conditions Possible Causes Countermeasures for
Reference
Lasting time of the trouble>1 1) The heating driver circuit gets short cut 1) Repair the wire
second to the positive electrode of power supply. harness.
2) The sensor is damaged. 2) Replace the
3) There is something wrong with this sensor.
signal input interface of ECM. 3) Replace ECM.
Trouble P0135-2 Oxygen sensor heating circuit gets open or short cut to the earth.
Code:
Preparation of ● The trouble light keeps on till no trouble. Turn off the ignition swith.
emergency control ● The working time of the system as loop closed is delayed.
scheme:
Wiring terminal: MT20U Heated Normal testing signal
oxygen
sensor
System main power \ C 12V
supply:
Heating driver: 61 D 0V
Strong oxygen 62 B 0~1,000mV
sensor signal: fluctuation
 Benjoy Maintenance Manual ---- Engine Volume EMS-51

Weak oxygen 06 A 0V
sensor signal:
Judgement Possible Causes Countermeasures for
Conditions Reference
No trouble with the 1) The connectors are not connected very well. 1) Reconnection.
main relay. 2) The wire harness of this heating driver circuit is 2) Repair the wire
Lasting time>1 open. harness.
second. 3) The wire harness of this heating driver circuit gets 3) Repair the wire
short cut to the earth. harness.
4) The sensor is damaged. 4) Replace the
5) There is something wrong with this signal input sensor.
interface of ECM. 5) Replace ECM.
Diagnosis Steps
Trouble P0170-1 Oxygen sensor keeps indicating the enrichment of A/F for too long.
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● A/F cannot be controled with loop closed.
scheme:
Wiring terminal: MT20U Heated Normal testing signal
oxygen
sensor
System main power \ C 12V
supply
Heating driver: 61 D 0V
Strong oxygen 62 B 0~1,000mV
sensor signal: fluctuation
Weak oxygen 06 A 0V
sensor signal:
Judgement Conditions Possible Causes Countermeasures for
Reference
Signal of oxygen 1) The sensor signal circuit is open to 5V
sensor>998.26 mV or 12V. 1) Repair the wire
Working time of the 2) The sensor is damaged. harness.
engine>40 seconds 3) There is something wrong with this 2) Replace the
No TPS or MAP troubles signal input interface of ECM. sensor.
Fall into closed loop fuel 3) Replace ECM.
control state
TPS>10.156%
Lasting time of the
trouble>15 seconds
Trouble P0170-2 Oxygen sensor keeps indicating the dilution of A/F for too long.
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● A/F cannot be controled with loop closed.
scheme:
Wiring terminal: MT20U Heated oxygen Normal testing signal
sensor
System main power \ C 12V
supply:
Heating driver: 61 D 0V
Strong oxygen 62 B 0~1,000mV
sensor signal: fluctuation
Weak oxygen 06 A 0V
sensor signal:
Judgement Conditions Possible Causes Countermeasures for
Reference
Signal of oxygen sensor<52.083 1) The sensor signal circuit gets short 1) Repair the wire
mV cut to the earth. harness.
Working time of the engine>40 2) The strong and weak signal circuits 2) Repair the wire
seconds are inversed. harness.
No TPS or MAP troubles 3) The sensor is damaged. 3) Replace the
Coolant temperature>72℃ 4) There is something wrong with this sensor.
Fall into closed loop fuel control signal input interface of ECM. 4) Replace ECM.
state
TPS>10.156%
 Benjoy Maintenance Manual ---- Engine Volume EMS-52

Lasting time of the trouble>15

seconds
 Benjoy Maintenance Manual ---- Engine Volume EMS-53

Dismantlement and Installation of Oxygen Sensor

EMS03
1. Pull out the plug of oxygen sensor.
Attention:
Make sure the ignition switch is off when pulling
out the plug of oxygen sensor.

EMS03

2. Dismantle the front sensor with a wrench.

EMS03

3. Dismantle the rear sensor with a wrench.

Note:
EMS03
Block the installation hole with a piece of glabrous
cotton to prevent the stuff or oil from getting into
the exhaust manifold.
 Benjoy Maintenance Manual ---- Engine Volume EMS-54

Check visually the appearance of the oxygen

sensor. EMS03
Brown red: Satanism
Grey-white: Normal
Black: Carbon deposit

Installation

Install the oxygen sensor in the reverse order of

dismantlement.

Attention:
Plug the wire harness joint, start the engine, and read the trouble codes and data flow, to
see if the engine is working normally.
 Benjoy Maintenance Manual ---- Engine Volume EMS-55

DTC P0201 P0202 P0203 P0204 Fuel Injector

Illustration
The MT20U applies the sequence fuel injection technique. The signals of sequence
injection are supplied by intake pressure sensor. If the intake pressure sensor gets
damaged, the grouped injection method will be applied according to ignition sequence.
Based on the instruction of ECU, the fuel injector injects fuel in required time, and in this
way, supplies fuel to the engine and atomizes it.
ECU sends electric pulse to injector coil, which can form magnetic force. When the
magnetic force strengthens so much that it can overcome the composite force of return
spring pressure, needle valve gravity and friction, the needle valve begins to rise and the
injection process begins. When the injection pulse is ended, the pressure of return spring
makes the needle valve close again.

Main relay

Picture of Solenoid Injector

Pins:
No. 1 Cylinder 1 injector control limit (connected with ECU 55#)
No. 2 Cylinder 2 injector control limit (connected with ECU 70#)
No. 3 Cylinder 3 injector control limit (connected with ECU 56#)
No. 4 Cylinder 4 injector control limit (connected with ECU 71#)
Diagnosis Steps
P0201-0 Injector A (Cylinder 1) circuit gets trouble.
Trouble Code: P0202-0 Injector B (Cylinder 3) circuit gets trouble.
P0203-0 Injector C (Cylinder 4) circuit gets trouble.
P0204-0 Injector D (Cylinder 2) circuit gets trouble.
Preparation of emergency control ● The trouble light keeps on till no trouble.
scheme: ● None.
Fuel injection
Wiring terminal: MT20U Normal testing signal
nozzle
System main power
\ A 12V
supply:
0-12V appropriate
Injector A (Cylinder 1): 55 B
square wave
0-12V appropriate
Injector B (Cylinder 3): 56 B
square wave
0-12V appropriate
Injector C (Cylinder 4): 71 B
square wave
 Benjoy Maintenance Manual ---- Engine Volume EMS-56

0-12V appropriate
Injector D (Cylinder 2): 70 B
square wave
Countermeasures for
Judgement Conditions Possible Causes
Reference
1） The corresponding injector ciruit gets 1） Repair the wire
short cut to the positive electrode of harness.
The ignition swith is turned power supply or the earth. 1) Repair the wire
on. 1) The corresponding injector ciruit is open. harness.
The fuel injection pump 2) The connectors are not connected very 2) Reconnection.
works well. well. 3) Replace the
Ignition voltage>10V. 3) The injector circuit is damaged. damaged injection
4) There is something wrong with this signal nozzle.
interface of ECM. 4) Replace ECM.

Dismantlement and Installation of Injector

1. Pull out the fuel injection pump relay of the
EMS03
engine, turn on the ignition switch, start the
engine, keep it running till it flames out, then
turn off the ignition switch, and pull out the
wire harness of the injector.

2. Place a piece of oil suction cotton right under EMS03

the connector between oil pipe and fuel rail,
loose the fuel clamping band, and pull out the
oil-in pipe from the fuel rail.

3. Dismantle the two fixed bolts for fixing the

EMS03
fuel rail, pull upwards to get out the fuel rail
and injector assembly.

EMS03
4. Get down the snap-in of the injector on the
fuel rail, and get off the injector.
 Benjoy Maintenance Manual ---- Engine Volume EMS-57

Installation
EMS03
1. Dismantle the sealing ring of injector, and
desert it. Replace it with a new sealing ring.
Smear some engine oil onto the sealing ring.

2. Install the injector onto the fuel rail, and EMS04

mount the snap-in.

EMS04

3. Install the fuel rail assembly carefully to the

right position, install the fixed bolt of fuel rail,
connect the oil pipe with fuel rail, and fasten
the clamping band.

Attention:
Plug the injector plug, start the engine, read the trouble codes and data flow, to see if the
engine is working normally.
Benjoy Maintenance Manual ---- Engine Volume EMS-58
 Benjoy Maintenance Manual ---- Engine Volume EMS-59

DTC P0230 Oil Pump Relay and Oil Pump

Illustration
It delivers the fuel in tank to the oil supply master pipe of the engine through a certain oil
pressure and fuel flow, and keeps the oil pressure stable (through oil pressure controller).
Its componets and and principles are that the electric oil pump is consisted of a DC motor, a
vane pump, and an end cap (integrated with the check valve, pressure relief valve and
anti-electromagnetic interference sub-assembly) and installed on the same shaft with the
motor, and sealed in the same enclosure. The maximum pressure at the outlet of electric oil
pump is determined by pressure relief valve, which is between 450-650kPa. But the
maximum pressure of the whole fuel system is determined by oil pressure controller, and
usually is 350kPa for MT20U electronic injection system.
If the oil tank lack oil for a long time, and the oil pump can not get well lubricated, the pump
may be sintered or burned. The temperature of fuel makes great influence on the
performance of the fuel injection pump, so when it is working under high temperature for too
long, if the fuel temperature overruns a certain value, the oil pressure in the fuel injection
pump will violently lower. So if the warm engine can not be started, please check whether it
is because the working performance of the fuel injection pump in high temperature is poor.

Main power
supply

Oil pump as indicated by the arrow

Power relay

Oil pump control

Pins:
The oil pump has two pins to be related to the oil pump relay. Beside the two pins, there
are “+”and “-”marked on the oil pump housing, representing the positive and negative
electrodes.
Pin ECU 47# controls the fuel injection pump relay.
Benjoy Maintenance Manual ---- Engine Volume EMS-60
 Benjoy Maintenance Manual ---- Engine Volume EMS-61

Diagnosis Steps
Trouble P0230-1 Relay of fuel injection pump gets short cut to the positive electrode of
Code: power supply.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● None.
scheme:
Wiring terminal: MT20U Oil pump relay Normal testing signal
System main power \ Refer to instructions 12V
supply: of electric appliance
system
Relay driver: 47 Refer to instructions 0V (working), 12 (stopped)
of electric appliance
system
Judgement Conditions Possible Causes Countermeasures for
Reference
Lasting time >1.5625 1) The circuit of relay driver gets short 1) Repair the wire
seconds cut to the positive electrode of system harness.
power supply. 2) Replace the relay.
2) The relay is damaged. 3) Replace ECM.
3) There is something wrong with this
signal input interface of ECM.
Trouble P0230-2 Fuel injection pump gets open or short cut to the earth.
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● None.
scheme:
Wiring terminal: MT20U Fuel injection pump Normal testing signal
System main power \ Refer to instructions 12V
supply: of electric appliance
system
Relay driver: 47 Refer to instructions 0V (working), 12 (stopped)
of electric appliance
system
Judgement Conditions Possible Causes Countermeasures for
Reference
Lasting time >1.5625 1) The connectors are not connected 1) Reconnection
seconds very well. 2) Repair the wire
2) The circuit connecting system main harness.
power supply is broken. 3) Repair the wire
3) The circuit of relay driver gets short harness.
cut to the negtive electrode of system 4) Repair the wire
power supply. harness.
4) The circuit of relay driver is open. 5) Repair the relay.
5) The relay is damaged. 6) Replace ECM.
6) There is something wrong with this
signal input interface of ECM.
 Benjoy Maintenance Manual ---- Engine Volume EMS-62

Dismantlement and Installation of Oil Pump:

1. Dismount the backrest of the rear seat.
EMS04

2. Telescope the special tools (twisting wrench +

fixed tray for locknut) on the outside of the EMS04

locknut, and use the twisting wrench to unscrew

and get down the locknut.

EMS04

EMS04

EMS04
 Benjoy Maintenance Manual ---- Engine Volume EMS-63

3. Take out the fuel injection pump. Notice that when it reaches the position of oil float,
please incline the fuel injection pump to avoid damaging the oil float.

EMS04

4. Get down the Y-shaped sealing ring at the

mouth of sensor.

EMS04

Installation:
The installation sequence is just in reverse to that
for dismantlement.
 Benjoy Maintenance Manual ---- Engine Volume EMS-64

DTC P0325 P0607 Knock Sensor

Illustration
The knock sensor is used to supply knock information of the engine to ECU for its knock
control. It is a sensor of vibration acceleration, which is installed on the cylinder body
usually between cylinder 2 and cylinder 3, and it is helpful for the knock balance. Through
the vibration frequency signals from knock sensor filtrated inside ECU, ECU judges
whether the engine has any knock. If knock signals are detected, ECU will decrease
gradually till no knock, and recover gradually to the knock limit. Circulations are repeated
in this way.

Pins:
No.1 (A) Knock sensor signal 1 (ECU 5#)
No.2 (B) Knock sensor signal 2 (ECU 69#)
Diagnosis Steps
Trouble P0325-0 The knock sensor is connected poorly.
Code:
Preparation of ● The trouble light keeps on till the ignition switch is off.
emergency control ● Apply the scheme of safety ignition advance angle.
scheme:
Wiring terminal: MT20U Knock sensor Normal testing signal
Knock signal: 69 0~1V
Sensor signal 05 0V
position:
Judgement Conditions Possible Causes Countermeasures for
Reference
Rotating speed of the engine 1) The connectors are not connected 1) Reconnection
>2,000rpm very well. 2) Repair the wire
MAP>50kPa 2) The circuit of knock signal is open. harness.
Lasting time >5 seconds 3) The sensor signal position gets short 3) Repair the wire
cut. harness.
4) The circuit of knock signal gets short 4) Repair the wire
cut to other circuits. harness.
5) The sensor is damaged. 5) Replace the sensor.
6) There is something wrong with this 6) Replace ECM.
signal input interface of ECM.
Trouble P0607-0 The knock control system becomes inactive.
Code:
Preparation of ● The trouble light keeps on till the ignition switch is off.
emergency control ● The ignition advance angle will be delayed (apply control of safety ignition
scheme: advance).
Wiring terminal: 69# MT20U ECM Normal testing signal
ECM: Troubles inside ESM \
Judgement Conditions Possible Causes Countermeasures for
 Benjoy Maintenance Manual ---- Engine Volume EMS-65

Reference
1) ECM is damaged. 1) Replace ECM.
DTC P0335 Crankshaft Position Sensor
Illustration
Crankshaft position sensor is used to supply signals of engine rotating speed, rotatory
angle and dead center to ECU, for the systems of ignition, fuel injection and timing.
MT20U electronic injection system applies rotating speed sensor of magnetic coil type,
and send signals of alternating current and alternating voltage. ECU receives those
signals and transfers them into the digital signals that engine ECU can recognize, and
uses them for the system control. Flywheel ring gear is installed together with signal gear,
which is of 58X gear type and is used to supply information about rotating speed,
alternator angle and dead center to ECU. The point where there are continous notches is
dead center.

Pins:
No.1 (A) Sensor signal wire high-level
(connected with ECU l2#);
No.2 (B) Sensor signal wire low-level
(connected with ECU 28#);
No.3 (C) Sensor grounded (connected with
ECU 73#).
Diagnosis Steps
Trouble
P0335-8 Wrong signals from 58X crankshaft position sensor.
Code:
Preparation of emergency ● The trouble light keeps on till no trouble.
control scheme: ● None.
Wiring terminal: MT20U Crankshaft position sensor Normal testing signal
Strong crankshaft >400mV sine wave
12 A
signal: ( with sensor B)
Weak crankshaft >400mV sine wave
28 B
signal: ( with sensor A)
System grounding
73 C 0V
wire:
Countermeasures for
Judgement Conditions Possible Causes
Reference
The engine works. 1) Signal circuit is shielded poorly. 1) Apply shielding
 Benjoy Maintenance Manual ---- Engine Volume EMS-66

Number of gears into ECM in 2) There are mental foreign bodies in 58x wires.
5 cintinuous circulations is not gear ring. 2) Clean 58x gear
58. ring.

Trouble P0335-
No signals from 58X crankshaft position sensor
Code: 0
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● None.
scheme: ● The engine cannot be started.
Crankshaft position Normal testing
Wiring terminal: MT20U
sensor signal
>400mV sine
High crankshaft
12 A wave
signal:
(with sensor B)
>400mV sine
Low crankshaft
28 B wave
signal:
(with sensor A)
System
73 C 0V
grounding wire:
Countermeasures
Judgement Conditions Possible Causes
for Reference
1) The connectors are not 1) Reconnection
Start the engine.
connected very well. 2) Repair the wire
No signals of engine
2) The high and low signals are harness.
rotating speed.
connected reversely. 3) Repair the wire
MAP is reduced by
3) The signal circuit is open. harness.
2.9509kPa.
4) The signal circuit gets short cut to 4) Repair the wire
System voltage is
other circuits. harness.
reduced by 0.8V.
5) The sensor is damaged. 5) Replace the
Vehicle velocity<4km/h
6) There is something wrong with sensor.
Lasting > 2 seconds
this signal input interface of ECM. 6) Replace ECM.

Dismantlement and Installation:

See the mechanical section about Dismantlement of Crankshaft Position Sensor of
Timing System for reference.
 Benjoy Maintenance Manual ---- Engine Volume EMS-67

DTC P0351 P0352 Ignition Coil

Illustration
The ignition coil transforms the low-tension electricity of primary winding into
high-tension electricity of secondary winding, and produces sparks through ignition plug,
to ignite the mixture gas of fuel and air in the cylinder.
MT20U adopts grouping ignition techinique. Basing on the theory that the mutual
induction of magnetic coil can produce high energy, it controls the electric time and, when
power off, it makes use of the high-tension electricity in secondary coil, to penetrate the
spark gap and produce bursting sparks that can ignite the mixture gas. Because during
the emission process of the engine, the air ionization is serious and the electric
resistance is low, only low voltage is enough to penetrate the spark gap. So the system
adopts grouping ignition techinique, which can save engergy and, in this way, reduce the
cost.
ECU has no function of carrying out trouble diagnosis to ignition coil, so if the ignitioin coil
catches trouble, there will be no trouble code. Only through checking the electric
resistance of ignition coil can the working state of ignition coil be diagnosized. Normally,
the ignition coil produces much heat at its working, but ignition coils with too high
temperature may cause its electric resistance to increase, which will lead to troubles like
unstable working and automatical flameout. But ECU can monitor the control wire of
ignition coil, and when a ignition coil catches trouble, it will shut off the fuel injecter of the
related cylinder.

Main relay

Pins:
No.1 (c) Coil primary winding (connected with ECU 32#);
No.2 (A) Coil primary winding (connected with ECU 52#);
No.3 (B) Coil power supply (connected with system main relay).
Diagnosis Steps
Trouble The ignition coil cylinder 1-4 driver circuit is short circuited to the
P0351-1
Code: anode of power supply.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● Stop the fuel injection to cylinder 1-4.
scheme: ● Raise the target ilde speed to 1,200rpm.
Pressure/temperatur
Wiring terminal: MT20U Normal testing signal
e sensor
System main power
\ B 12V
supply:
0-12V appropriate square
Cylinder 1-4 driver: 32 C
wave signal
 Benjoy Maintenance Manual ---- Engine Volume EMS-68

Induction peak value>300V

0-12V appropriate square
Cylinder 2-3 driver: 52 A wave signal
Induction peak value>300V
Countermeasure for
Judgment Conditions Possible Causes
Reference
1) The cylinder 1-4 driver circuit is short
1) Repair the wire harness.
Lasting time is 1.25 circuited to the anode of power supply.
2) Replace the ignition coil.
seconds. 2) The ignition coil is damaged.
3) Replace ECM.
3) ECM fails.

Trouble The ignition coil cylinder 1-4 driver circuit is open or short circuited to
P0351-2
Code: the grounding wire.
Preparation of
● The trouble light keeps on till no trouble.
emergency control
● Stop the oil injection to cylinder 1-4.
scheme
Wiring terminal: MT20U Ignition coil Normal testing signal
System main power
\ B 12V
supply:
0-12V appropriate square
wave signal
Cylinder 1-4 driver: 32 C
Induction peak
value>300V
0-12V appropriate square
wave signal
Cylinder 2-3 driver: 52 A
Induction peak
value>300V
Countermeasure for
Judgment Conditions: Possible Causes
Reference
1) The joints are not connected very well.
2) The cylinder 1-4 driver circuit is short 1) Re-joint.
circuited to the negative electrode of 2) Repair the wire harness.
Lasting time is 1.25
system power supply. 3) Repair the wire harness.
seconds.
3) The cylinder 1-4 driver circuit is open. 4) Replace the ignition coil.
4) The igniation coil is damaged. 5) Replace ECM.
5) ECM fails.

Diagnosis Steps
Trouble The cylinder 2-3 driver circuit is short circuited to the anode of power
P0352-1
Code: supply.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● Stop the oil injection to cylinder 2-3.
scheme: ● Raise the target ilde speed to 1,200rpm.
Wiring terminal: MT20U Ignition coil Normal testing signal
System main power
\ B 12V
supply:
0-12V appropriate square
Cylinder 1-4 driver 32 C wave signal
Induction peak value>300V
0-12V appropriate square
Cylinder 2-3 driver 52 A wave signal
Induction peak value>300V
Countermeasure for
Judgment Conditions Possible Causes
Reference
1) The cylinder 2-3 driver circuit is short
1) Repair the wire harness.
Lasting time is 1.25 circuited to the anode of power supply.
2) Replace the ignition coil.
seconds. 2) The ignition coil is damaged.
3) Replace ECM.
3) ECM fails.
Trouble The cylinder 2-3 driver circuit is short circuited to the anode of power
P0352-2
Code: supply.
 Benjoy Maintenance Manual ---- Engine Volume EMS-69

Preparation of
● The trouble light keeps on till no trouble.
emergency control
● Stop the oil injection to cylinder 2-3.
scheme:
Wiring terminal: MT20U Ignition coil Normal testing signal
System main power
\ B 12V
supply:
0-12V appropriate square wave
Cylinder 1-4 driver: 32 C signal
Induction peak value>300V
0-12V appropriate square wave
Cylinder 2-3 driver: 52 A signal
Induction peak value>300V

Judgment Possible Causes Countermeasure for Reference

Conditions
Lasting time is 1) The joints are not connected very well. 1) Re-joint.
1.25 seconds. 2) The cylinder 2-3 driver circuit is short 2) Repair the wire harness.
circuited to the negative electrode of 3) Repair the wire harness.
system power supply. 4) Replace the ignitioin coil.
3) The cylinder 2-3 driver circuit is open. 5) Replace ECM.
4) The ignition coil is damaged.
5) ECM fails.

Dismantlement and Reassembly of EMS04

Ignition Coil
1. Dismount the four fixed bolts in the retainers
of the engine cover on the ignition coil.

EMS04
2. Pull off the wire harness joint of ignition coil.
Meanwhile, make sure the ignition switch is
turned off when pulling off the wire harness
joint.

3. Pull the high-tension cable off the ignition coil EMS05

and ignition plug.
Benjoy Maintenance Manual ---- Engine Volume EMS-70
 Benjoy Maintenance Manual ---- Engine Volume EMS-71

4. Dismount the two fixed bolts of the ignition

EMS05
coil, and pull upwards and get out the ignition
coil.

Reassembly
Reassemble it in reverse order of the dismantlement.

Attention:
After the ignition coil installment is finished, start the engine, and read the trouble codes
and data flow, to see whether the engine is working normally.
 Benjoy Maintenance Manual ---- Engine Volume EMS-72

DTC P0443 Carbon Canister Solenoid Valve

Illustration
It controls the cleaning flow from the carbon canister to main intake tube. The adsorptive
capacity of carbon canister is limited, so if the steam fuel absorbed on carbon canister
cannot be consumed, the oil may be volatilized outside, polluting the air and adding
dangerous factors.
Inside the carbon canister is a solenoid valve group, which controls the opening of the
solenoid valve through the dignified control pulse square wave sent by ECU. Its opening
changes with differences of engine work condition. When the engine is heavy-loaded and
idling, the carbon canister doesn’t join in performance in order to ensure the output power of
the engine.

Picture of carbon canister solenoid valve Main relay

Pins:
No.1 (A) Carbon canister control (connected with
ECU63#);
No.2 (B) Connected with main relay power.

Carbon canister
solenoid valve

Diagnosis Steps
Trouble The circuit of carbon canister solenoid valve is
P0443－1
Code: short circuited to the anode of power supply.

Preparation of emergency The trouble light keeps on till no trouble.

control scheme: Turn off the carbon canister solenoid valve.

Carbon
canister Normal testing
Wiring terminal: MT20U
solenoid signal
valve
System main power
\ B 12V
supply
63 A 0~12V Square
 Benjoy Maintenance Manual ---- Engine Volume EMS-73

wave
Countermeasu
Judgment Conditions Possible Causes re for
Reference
1) Repair the
1) The circuit of solenoid valve
wire harness.
driver is short circuited to the anode
2) Replace the
Lasting time>2 seconds of power supply.
solenoid valve.
2) The olenoid valve is damaged.
3) Replace
3) ECM fails.
ECU.

Trouble P0443- The circuit of carbon canister solenoid valve is short

Code: 1 circuited to the anode of power supply.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● Turn off the carbon canister solenoid valve.
scheme:
Wiring terminal: MT20U Carbon canister Normal testing
solenoid valve signal
System main \ B 12V
power supply:
Solenoid valve 63 A 0-12V square wave
driver:
Judgment Possible Causes Countermeasure for
Conditions Reference
Lasting 1) The joints are not connected very 1) Re-joint.
time>5seconds well. 2) Repair the wire
2) The circuit of solenoid valve driver is harness.
short circuited to the negtive electrode 3) Repair the wire
of power supply. harness.
3) The circuit of solenoid valve driver is 4) Repair the wire
open. harness.
4) The connecting circuit to the system 5 ） Replace the
main power supply is open. ignition coil.
5) The solenoid valve is damaged. 6) Replace ECM.
6) ECM fails.

Dismantlement and Reassembly of Carbon Canister Solenoid

Valve
Refer to the fuel evaporation emission system.
Benjoy Maintenance Manual ---- Engine Volume EMS-74
 Benjoy Maintenance Manual ---- Engine Volume EMS-75

DTC P0480 P0481 Cooling Fan

Illustration
MT20U controls the speed of the fan. The control system controls the high speed and low
speed of the fan according to the signals about water teperature and air conditioner, and
controls the delaying of fan system if necessary.
Working conditions for the fan:
The low-speed gear is turned on when the water temperature reaches 98℃ and turned off when
94℃.
The low-speed gear is turned on when the water temperature reaches 98℃ and turned off when
94℃.
Turn on the air conditioner.
If the water temperature is over 101℃ after power-off, the fan will keep on working for 1
minute.
If the water emperature is over 94℃ after power-off, the fan will keep on working for 0.5
minute.
If the water emperature is below 85℃ after power-off, the fan will stop working.

Main
power

High-speed fan
relay

Double-speed
Low-speed fan relay
fan

Diagnosis Steps
Trouble P0480-1 The circuit of relay of water tank low-speed fan is short
Code: circuited to the anode of power supply.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● None.
scheme: ●The fan doesn’ t work, and is started with high speed when the water
temperature reaches 98℃.
Wiring terminal: MT20U Relay of low-speed fan Normal testing signal
Battery: \ Refer to illustrations of 12V
electric appliance
system
Relay driver: 67 Refer to illustrations of Working=0V
electric appliance Un-working=12V
system
Judgment Conditions Possible Causes Troubleshooting plans
Lating time>3 1) The circuit of relay driver is short circuited to 1) Repair the wire
 Benjoy Maintenance Manual ---- Engine Volume EMS-76

seconds the anode of power supply. harness.

2) The relay is damaged. 2) Replace the relay;
3) ECM fails. 3) Replace ECM.
 Benjoy Maintenance Manual ---- Engine Volume EMS-77

Trouble P0480-2 The circuit of relay of water tank low-speed fan is short
Code: circuited to the anode of power supply.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● None.
scheme: ●The fan doesn’ t work (circuit being open), and and is started with high
speed when the water temperature reaches 98℃.
● The fan always works (circuit being short circuited to the ground).
Wiring terminal: MT20U Low-speed fan relay Normal testing signal
Battery: \ Refer to illustrations of 12V
electric appliance system
Relay driver: 67 Refer to illustrations of Working=0V
electric appliance system Un-working=12V
Judgment Possible Causes Countermeasure for
Conditions Reference
Lasting time>3 1) The joints are not connected very well. 1) Re-joint.
seconds 2) The circuit of relay driver is short circuited to the 2) Repair the wire
negative electrode of power supply. harness.
3) The circuit of relay driver is open. 3) Repair the wire
4) The circuit connected to the battery is open. harness.
5) The relay is damaged. 4) Repair the wire
6) ECM fails. harness.
5) Replace the relay.
6) Replace ECM.
Diagnosis Steps
Trouble P0481-1 The circuit of relay of water tank high-speed fan is short
Code: circuited to the anode of power supply.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● None.
scheme:
Wiring terminal: MT20U High-speed relay Normal testing signal
Battery: \ Refer to illustrations of 12V
electric appliance
system
Relay driver: 50 Refer to illustrations of Working=0V
electric appliance Un-working=12V
system
Judgment Conditions Possible Causes Countermeasure for
Reference
Lasting time>3 1) The circuit of relay driver is short circuited to 1) Repair the wire
seconds the anode of power supply. harness.
2) The relay has breakge. 2) Replace the relay.
3) ECM fails. 3) Replace ECM.
Trouble P0481-2 The circuit of relay of water tank high-speed fan is short
Code: circuited to the anode of power supply.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● None.
scheme: ● The fan always works(circuit being short circuited to the ground).
Wiring terminal: MT20U High-speed relay Normal testing signal
Battery: \ Refer to illustrations of 12V
electric appliance
system
Relay driver: 50 Refer to illustrations of Working=0V
electric appliance Un-working=12V
system
Judgment Conditions Possible Causes Countermeasure for
Reference
Lasting time>3 seconds 1) The joints are not connected very well. 1) Re-joint.
 Benjoy Maintenance Manual ---- Engine Volume EMS-78

2) The circuit of relay driver is short circuited to 2) Repair the wire

the negative electrode of power supply. harness.
3) The circuit of relay driver is open. 3) Repair the wire
4) The circuit connected to the battery is open. harness.
5) The relay is damaged. 4) Repair the wire
6) ECM fails. harness.
5) Replace the relay.
6) Replace ECM.
Dismantlement and Reassembly of Cooling Fan
Refer to the Cooling System in Engine Mechanical Section.

DTC P0500 Vehicle Speed Sensor

Circuit Diagram

Diagnosis Steps
Trouble P0500-0 No signals from speed sensor
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● None.
scheme: ● Driving limit may be applied.
Preparation of MT20U Speed sensor Normal testing signal
emergency control
scheme:
Sensor signal position: 03 / 0-12V square wave
Judgment Conditions Possible Causes Countermeasure for
Reference
The engine works. 1) The joints are not connected very 1) Re-joint.
Vehicle speed<2kph well. 2) Replace the flexible
MAP<25.82Kpa 2) The circuit from gear-box to meter shaft or signal wire.
1200rpm<rotation speedof signal is broken down. 3) Replace the wire
the engine<5000rpm 3) The wire from meter to ECM is harness.
The throttle valve is closed broken down. 4) Replace the speed
The trouble lasts for 5 4) The speed sensor is damaged. sensor.
seconds. 5) The meter fails. 5) Adjust or replace the
6) ECM fails. meter.
6) Replace ECM.
 Benjoy Maintenance Manual ---- Engine Volume EMS-79

Dismantlement and Reassembly of Speed sensor:

1. Pull out the joint of speed sensor.
EMS05
2. Dismantle the fixing bolts in speed sensor, and
pull out the speed sensor.
 Benjoy Maintenance Manual ---- Engine Volume EMS-80

DTC P0505 Ilde Stepping Motor

Illustration
It is used to control the area of air flow in the side passage inside the throttle valve, so as to
control the intake flow of the engine. Referring to the signals sent by the sensors, ECU can
control the rotation speed of the engine in target limit, and the target rotation speed is
determined by the coolant temperature. The essence of stepping motor is a micro motor.
For the motor coils are charged with currents in different directions, the motor will rotates in
different directions, and the motor axis rotates with the rotation of lead screw, to controls the
opening of the valve indirectly. MT20U controls the nornal and reverse rotation of the motor
through the dignified square wave signals, to control the process of stepping motor.
0

Stitch:
No. 1(B) Idle stepping motor control (connected
with ECU 33#)
No. 2(A) Idle stepping motor control (connected with ECU 34#)
No. 3(D) Idle stepping motor control (connected with ECU 54#)
No. 4(D) Idle stepping motor control (connected with ECU 53#)
Diagnosis Steps
Trouble P0505-0 Idle Control Error
Code:
Preparation of emergency ● The trouble light keeps on till no trouble.
control scheme: ● Pause the ilde adjustment.

Wiring terminal: MT20U Idle control valve Normal testing signal

Idle valve A- High: 54 D 0-12V squrare wave
(with idle valve C)
Idle valve A- Low: 53 C 0-12V squrare wave
(with idle valve D)
Idle valve B- High: 33 B 0-12V squrare wave
(with idle valve A)
Idle valve B- High: 34 A 0-12V squrare wave
(with idle valve B)
Judgment Conditions Possible Causes Countermeasure for
Reference
The engine ildes. 1) The joints are not connected very 1) Re-joint.
The water temperature well. 2) Repair the wire harness.
reaches normal value. 2) Some circuit of the idle valve is 3) Repair the wire harness.
No TPS or VSS troubles. open. 4) Clear the leak trouble.
Deviation to the target 3) The corresponding between idle 5) Replace the idle control
rotation speed >180rpm valve connector and ECM connector is valve.
Lasting time >15 wrong. 6) Replace ECM.
seconds 4) The intake manifold leaks.
5) The idle control valve is damaged.
 Benjoy Maintenance Manual ---- Engine Volume EMS-81

6) ECM fails.
 Benjoy Maintenance Manual ---- Engine Volume EMS-82

Dismantlement and Reassembly of Idle Motor

1. Pull out the wire harness joint of the idle motor.
Make sure the ignition switch is off when EMS05
dismounting the joint.

2. Dismantle the fixing bolts of the idle motor,

and dismount the idle motor and its seal ring.

EMS05

Reassembly:
Replace the seal ring of the idle motor, and install
EMS05
the idle motor in the reverse order of
dismantlement.

Attention:
After installation, plug the wire harness joint, start
the engine, and read the trouble codes and data
flow, to see whether the engine is working normally.
 Benjoy Maintenance Manual ---- Engine Volume EMS-83

DTC P0560 Excessive High System Voltage

Diagnosis Steps
Trouble P0560-1 Excessive High System Voltage
Code:
Preparation of emergency ● The trouble light keeps on till no trouble.
control scheme: ● The system stops fuel injecting.
Wiring terminal: MT20U Ignition switch Normal testing signal
Ignition switch: 01 Refer to illustrations of 12V
electric appliance system
Judgment Conditions Possible Causes Countermeasure for
Reference
Connect the ignition switch 1) The adjuster for electric generator is 1) Replace the broken
System voltage >17.2V damaged. voltage adjuster.
Lasting time >5 seconds 2) Wrongly use high voltage battery. 2) Use right battery.
DTC P0650 Trouble Indicator Light
Illustration

Trouble
indicator light

Diagnosis Steps
Trouble P0650-1 The circuit of trouble indicator light is short circuited to the anode of
Code: power supply.
Preparation of ● The light cannot be turned on.
emergency control
scheme:
Wiring terminal: MT20U System trouble indicator Normal testing signal
light
Ignition switch: \ Refer to illustrations of 12V
electric appliance system
Indicator light 31 Refer to illustrations of Off =12V
driver: electric appliance system On=0V
Judgment Conditions Possible Causes Countermeasure for
Reference
Lating time>2 seconds 1) The circuit of wire hareness J1-31 is short 1) Repair the wire
circuited to the anode of system power harness.
supply.
Trouble P0650-2 The circuit of trouble indicator light is open or short circuited to the
Code: ground.
Preparation of ● The light cannot be turned on (circuit being open).
emergency control ● The light is always on (circuit being short circuited to the ground).
scheme
Wiring terminal: MT20U System trouble indicator Normal testing signal
 Benjoy Maintenance Manual ---- Engine Volume EMS-84

light
Ignition switch: \ Refer to illustrations of 12V
electric appliance system
Indicator light 31 Refer to illustrations of Off=12V
driver: electric appliance system On=0V
Judgment Conditions Possible Causes Countermeasure for
Reference
Lating time>2 seconds 1) The trouble light is installed poorly. 1) Re-install the light.
2) The circuit to ignition switch fails. 2) Repair the wire
3) The driver circuit is short circuited to the harness.
negative electrode of power supply. 3) Repair the wire
4) The trouble light is damaged. harness.
4) Replace the light.

DTC P1230 Main Relay

Diagnosis Steps
Trouble P1230-1 The circuit of main relay is short circuited to the anode of power
Code: supply.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● The main relay cannot be started.
scheme:
Wiring terminal: MT20U Main power supply Normal testing signal
relay
Ignition switch: \ Refer to illustrations of 12V
electric appliance
system
Relay driver: 58 Refer to illustrations of Working=0V
electric appliance Un-working=12V
system
Judgment Conditions Possible Causes Countermeasure for
Reference
Lating time >1 second 1) The circuit of relay is short circuited to 1) Repair the wire
the anode of power supply. harness.
Trouble P1230-2 The circuit of main relay is open or short circuited to the ground.
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● The main relay cannot be started (circuit being open).
scheme: ● The main relay can be started normally (circuit being short circuited to
the ground).
Wiring terminal: MT20U Main power supply Normal testing signal
relay
Ignition switch: \ Refer to illustrations of 12V
electric appliance
system
Relay driver: 58 Refer to illustrations of Working=0V
electric appliance Un-working=12V
system
Judgment Conditions Possible Causes Countermeasure for
Reference
Lating time>1 second 1) The relay is installed poorly. 1) Re-install the relay.
2) The circuit the igintion switch is open. 2) Repair the wire
Benjoy Maintenance Manual ---- Engine Volume EMS-85

3) The circuit of relay is open. harness.

4) The circuit of relay is short circuited to 3) Repair the wire
the negtive electrode of power supply. harness.
5) The relay is damaged. 4) Repair the wire
harness.
5) Replace the relay.
 Benjoy Maintenance Manual ---- Engine Volume EMS-86

DTC P1530 P2000 Control of Air-conditioning Compressor

Illustration

Power
supply

Requirement
signal of air
conditioner

Clutch of air-conditioning
compressor

Diagnosis Steps
Trouble P1530-1 The circuit of air-conditioning compressor relay is short circuited
Code: to the anode of power supply.
Preparation of emergency ● The trouble light keeps on till no trouble.
control scheme: ● The air conditioner doesn’ t work.
Wiring terminal: MT20U Conpressor relay Normal testing signal
Battery: \ Refer to illustrations of 12V
electric appliance
system
Relay driver: 46 Refer to illustrations of Working=0V
electric appliance Un-working=12V
system
Judgment Conditions Possible Causes Countermeasure for
Reference
Detect the air 1) The circuit of repairment wire harness is short 1) Repair the wire
conditioner system circuited to the possitive electrode of power harness.
Lasting time>3 supply. 2) Replace the relay.
seconds 2) The relay is damaged. 3) Replace ECM.
3) ECM fails.
Trouble P1530-2 The circuit of air-conditioning compressor relay is open or short
Code: circuited to the ground.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● The air conditioner doesn’ t work (circuit being open).
scheme: ● The air conditioner works normally (circuit being short circuited to the
ground).
Wiring terminal: MT20U Conpressor relay Normal testing signal
Battery: \ Refer to illustrations of 12V
electric appliance
system
Relay driver: 46 Refer to illustrations of Working=0V
electric appliance Un-working=12V
system
Judgment Conditions Possible Causes Countermeasure for
Reference
Detect the air 1) The joints are not connected very well. 1) Re-joint.
conditioner system 2) The circuit to battery is open. 2) Repair the wire
 Benjoy Maintenance Manual ---- Engine Volume EMS-87

Lasting time>3 3) The circuit of repairment wire harness is short harness.

seconds circuited to the negative electrode of power 3) Repair the wire
supply. harness.
4) The circuit of repairment wire harness is open. 4) Repair the wire
5) The relay is damaged. harness.
6) ECM fails. 5) Replace the relay.
6) Replace ECM.
DTC P1530 P2000 Control of Air-conditioning Compressor
Illustration

Power
supply

Requirement
signal of air
conditioner

Clutch of air-conditioning
compressor

Diagnosis Steps
Trouble P1530-1 The circuit of air-conditioning compressor relay is short circuited
Code: to the anode of power supply.
Preparation of emergency ● The trouble light keeps on till no trouble.
control scheme ● The air conditioner doesn’ t work.
Wiring terminal: MT20U Conpressor relay Normal testing signal
Battery: \ Refer to illustrations of 12V
electric appliance
system
Relay driver 46 Refer to illustrations of Working=0V
electric appliance Un-working=12V
system
Judgment Conditions Possible Causes Countermeasure for
Reference
Detect the air 1) The circuit of repairment wire harness is short 1) Repair the wire
conditioner system circuited to the possitive electrode of power harness.
Lasting time > 3 supply. 2) Replace the relay.
seconds 2) The relay is damaged. 3) Replace ECM.
3) ECM fails.
Trouble P1530-2 The circuit of air-conditioning compressor relay is open or short
Code: circuited to the ground.
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● The air conditioner doesn’ t work (circuit being open).
scheme ● The air conditioner works normally (circuit being short circuited to the
ground).
Wiring terminal: MT20U Conpressor relay Normal testing signal
Battery: \ Refer to illustrations of 12V
electric appliance
system
 Benjoy Maintenance Manual ---- Engine Volume EMS-88

Relay driver: 46 Refer to illustrations of Working=0V

electric appliance Un-working=12V
system
Judgment Conditions Possible Causes Countermeasure for
Reference
Detect the air 1) The joints are not connected very well. 1) Re-joint.
conditioner system 2) The circuit to battery is open. 2) Repair the wire
Lasting time > 3 3) The circuit of repairment wire harness is short harness.
seconds circuited to the negative electrode of power 3) Repair the wire
supply. harness.
4) The circuit of repairment wire harness is open. 4) Repair the wire
5) The relay is damaged. harness.
6) ECM fails. 5) Replace the relay.
6) Replace ECM.

Diagnosis Steps
Trouble P2000-1 Air-conditioning Evaporator with Excessive High Temperature
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● None.
scheme:
Wiring terminal: MT20U Sensor of front air Normal testing signal
conditioning evaporator
Temperature signal: 26 Refer to illustrations of 0.5~4.5V
electric appliance
system
Sensor signal 05 Refer to illustrations of 0V
position: electric appliance
system
Judgment Conditions Possible Causes Countermeasure for
Reference
Temperature indicated 1) The circuit of temperature signal is short 1) Repair the wire
>144℃ circuited to the negative electrode of harness.
Lasting time>3 seconds power supply. 2) Replace the sensor.
2) The sensor is damaged. 3) Replace ECM.
3) ECM fails.
Trouble P2000-2 Air-conditioning Evaporator with Excessive Low Temperature
Code:
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● None.
scheme:
Wiring terminal: MT20U Sensor of front air Normal testing signal
conditioning evaporator
Temperature signal: 26 Refer to illustrations of 0.5~4.5V
electric appliance
system
Sensor signal 05 Refer to illustrations of 0V
position: electric appliance
system
 Benjoy Maintenance Manual ---- Engine Volume EMS-89

Judgment Conditions Possible Causes Countermeasure for

Reference
Temperature indicated 1) The joints are not connected very well. 1) Re-joint.
>-36℃ 2) The circuit of temperature signal is short 2) Repair the wire
Lasting time> 3 seconds circuited to the possitive electrode of harness.
power supply. 3) Repair the wire
3) The circuit of temperature signal is harness.
open. 4) Replace the sensor.
4) The sensor is damaged. 5) Replace ECM.
5) ECM fails.
 Benjoy Maintenance Manual ---- Engine Volume EMS-90

DTC P1604 ECM

Illustration
ECU is an engine electric control center of actuator driver circuit, which is centered with a
micro processor and only has the input joint of sensor signal. It receives and deals with
the engine state signals from sensors, and sends control signals to actuators, to keep the
engine work as required in the best condition for the insurance of good power capacity
and fuel economic consumption and well emission of fuel. It is consisted of shielded
housing and printing circuit board, on which assembled with many electric control units for
the control of electric injection.
Normal operation voltage: 9~16V
Over-voltage protection: +24V/-12V<60 seconds

Functions:
Multipoint ordering fuel injection system
Grouped ignition system
Idle control
Endless loop control of automatic knock
Sensor power supply: 5V/l00mA
Endless loop control, with automatic adaption
Double oxygen sensor
Emission carbon canister control
Air conditioner ECU control
Engine trouble indicater light
Signal output of of engine rotation speed
Trouble self-diagnosis, with function of scintillation code
Accept signals of engine load
Definition of ECU Wiring
Stitch Joint point Type Stitch Joint point Type
Control fire wire of ignition
1 Input 2 Unused
switch (power supply)
3 Sensor of vehicle speed signal Input 4 5V standard power supply Output
Grounding wire of 5V Signal from front oxgen sensor
5 Grounding 6 Input
standard power supply (low level)
7 Unused 8 Unused
9 Unused 10 Unused
Signal from rotation speed
11 Diagnosis communication Output 12 Input
sensor (high level)
13 Unused 14 Unused
15 Unused 16 Unused
Power supply of storage Power supply of storage
17 Input 18 Input
battery (+12v) battery (+12v)
19 Unused 20 5V standard power supply Output
Grounding wire of 5V
21 Grounding 22 Unused
standard power supply
Signal from throttle position
23 Unused 24 Input
sensor
 Benjoy Maintenance Manual ---- Engine Volume EMS-91

Temperature sensor of air

25 Unused 26 Input
conditioning evaporator
Temperature sensor of intake Signal form rotation speed
27 Input 28 Input
manifold sensor (low level)
29 Unused 30 Diagnosis requiment Input
Touble indicator light of the
31 Input 32 Ignition coil(1, 4) Input
engine
33 Idle stepping motor driver coil Output 34 Idle stepping motor driver coil Output
A
35 Unused 36 Unused
37 Unused 38 Signal from rear oxgen sensor Input
(low level)
39 Requirement signal of air Input 40 Unused
conditioner
41 Unused 42 Signal from intake pressure Input
sensor
43 Signal from coolant Input 44 Unused
temperature sensor
45 Signal of engine rotation speed Output 46 Relay control Output
47 Control of fuel injection pump Output 48 Unused
49 Unused 50 Control of high-speed fan Input
51 Unused 52 Ignition coils 2 and 3 Input
53 Idle stepping motor driver coil c Output 54 Idle stepping motor driver coil Output
D
55 Fuel injector 1# Input 56 Fuel injector 2# Input
57 Unused 58 Unused
59 Unused 60 Unused
61 Control of front oxgen sensor Input 62 Signal from front oxgen sensor Input
heating (high level)
63 Control of carbon canister Input 64 Control of rear oxgen sensor Input
valve heating
65 Unused 66 Unused
67 Control of low-speed fan Input 68 Unused
69 Signal of knock sensor Input 70 Fuel injecter 3# Input
71 Fuel injecter 4# Input 72 Unused
73 Grounding power Grounding None

Diagnosis Steps
Trouble P1604- EEPROM Error
Code: 0
Preparation of ● The trouble light keeps on till no trouble.
emergency control ● Anti-theft vehicle style; the engine can not be started.
scheme: ● The function of mileage accumulation is inactive.
Wiring terminal: MT20U ECM Normal testing
signal
ECM: Troubles inside ECM \
Judgment Conditions Possible Causes Countermeasure for
Reference
Something wrong 1) ECM fails. 1) Replace ECM.
Benjoy Maintenance Manual ---- Engine Volume EMS-92
 Benjoy Maintenance Manual ---- Engine Volume EMS-93

Dismantlement and Reassembly of ECM

1. Turn off the ignition switch, and dismount the
pile head at the negative electrode of power EMS05
supply.

2. Pull out the bayonet catch of the wire harness EMS05

joint of the engine computer, pull
dismantlement handle knob of ECM upwards
to separate the wire harness joint from ECM,
and turn upwards to take out ECM wire
harness.

EMS05

3. Dismount the four fixed bolts from ECM to fire

wall, and dismantle the engine computer.

Reassembly
Reassemble the ECM in the reverse order of dismantlement and plug the wire harness
joint.

Attention:
Start the engine, and read the trouble codes and data flow, to see whether the engine is
working normally.
 Benjoy Maintenance Manual ---- Engine Volume EMS-94

Maintenance Procedures for Common Troubles

The engine cannot rotate or rotate slowly when being started
No. Operation steps Testing Subsequent step
result
Inspect the sopts between the two connectors of Yes Next.
1 storage battery with a universal meter to see whether
Repair or replace
there is voltage between 10-12.5V. No
the storage battery.
Turn the ignition switch to “ON”. Inspect, with a Yes Next.
universal meter, the connector connecting the anode
Repair or replace
2 of power supply and ignition switch, to see whether
the connector or
there is storage battery voltage between 10-12.5V. No
replace the
conducting wire.
Keep the ignition switch at starting gear. Inspect, with Yes Next.
a universal meter, the connector connecting the
3 Repair or replace
starter pull-in coil on ignition switch, to see whether No. the ignition switch.
there is storage battery voltage over 8V.
Repair or replace
Inspect, with a universal meter, the engine to see Yes
4 the engine.
whther it is broken or short circuited.
No Next.

Check the engine to see whether it is siezed as a Yes Shoot the trouble.
5
result of poor greasing. Next Next.
In winter, check whether the starter is over resisted as Replace the proper
Yes
a result of poor greasing and improper gearbox oil fuel.
6
(the more the viscosity is, the bigger the engine Check others.
No
resistence becomes).

The engine can rotate but cannot be started successfully.

Yes Repair or replace the
Check whether the oil return pipe is blocked or oil return pipe.
17
bent. No Replace the fuel
pressure generator.
Connect the adapter between ECU and the wire
harness and inspect Pins of No.1, 17 and 18, to Yes Next.
see whether there are voltages and whether the
18
positive power wire connected with the ECU Pins Repair or replace the
above and the grounding wire connected with No wire harness.
No.73 are in normal state.
Check whether the parts of intake system is Yes Repair them.
19
leaking. No Next.
Check whether the sensors of intake mainfold Yes Repair or replace it.
20 abosolute pressure and temperature are blocked.
No Next.

Inspect whether the coolant temperature sensor Yes Next.

21
is working well. No Repair or replace it.
Check whether it is mechanical reasons, such as Troubleshoot the
22 Yes
the gap between piston and cylinder being too mechanical problems.
 Benjoy Maintenance Manual ---- Engine Volume EMS-95

large or the cylinder leaks, which cause the

No Replace ECU.
engine unable to be started.
 Benjoy Maintenance Manual ---- Engine Volume EMS-96

It’
s difficult to start the warm vehicle

No. Operation steps Testing Subsequent step

result
Turn the ignition switch to “ON”and then inspect with Troubleshoot the
Yes
1 trouble diagnostic tester whether there are any displayed problems.
records about trouble information. No Next.
Connect the valve of fuel oil meter. Make short circuit
Yes Next.
with pins of No.30 and 87 on the oil pump relay, and
2
fuel injection pump relay to get the pump work, then
No 9
check whether the fuel pressure is 350kPa.
Cut off the connection pipeline, turn off the ignition Yes Next.
switch, and examine whether the pressure of fuel
3 Repair the leaking
system still keeps between 250-300kPa 1 hour later No
(whether the system has internal drainage). fuel system.
Put through the connection pipeline, and intercept the Replace the fuel
oil return pipe with oil return interceptor, and close the Yes
pressure adjuster.
4 valve of oil pressure meter. Turn off the ignition
switch, and examine whether the pressure of fuel
No Next.
system still keeps between 250-300kPa 1 hour later.
Check whether the fuel injector and fuel pipeline have Replace the fuel
oil breakage. Yes injector or fuel
5 pipeline.
No Next.
Pull out the joint of water temperature sensor and try Check the coolant
starting the engine, to see whether it can be started Yes temperature or
6 successfully. circuit.
No Next.
Connect the adapter between ECU and the wire
harness and inspect pins of No.1, 17 and 18 to see Yes Next.
whether there are voltages and whether the positive
7
power wire connected with the above ECU pins and Repair or replace the
the grounding wire connected with No.73 are in No
wire harness.
normal state.
Replace the fuel and hot start the engine again, to see Yes End.
8 whether it can be started successfully.
No Replace ECU.
Check whether the fuel pipeline is blocked or bent, Yes Next.
9 and wheher the pressure regulating valve works well.
No Repair or replace it.
Check the two ends of the fuel injection pump Yes Next.
connector with a universal meter to see whether there Repair or replace the
10 are storage battery voltages. fuel injection pump
No
and the conducting
wire.
Check whether the resistance volume of fuel injection Yes Next.
11 pump is correct with a universal meter. Replace the fuel
No
injection pump.
Check whether the fuel injection pump is seized. Replace the fuel
Yes
12 injection pump.
No Replace ECU.
 Benjoy Maintenance Manual ---- Engine Volume EMS-97

The rotation speed is normal, but the starting is difficult all through
No. Operation steps Testing Subsequent step
result
Turn the ignition switch to “ON”and inspect, with Troubleshoot the displayed
Yes
1 trouble diagnostic tester, whether there are any problems.
records about trouble information. No Next.
Check whether the air filter is fluent. Yes Next.
2
No Replace it.
After successful starting, inspect whether the Yes Next.
3 pressure of intake manifold is between 35-55kPa Shoot the leaking trouble of
No
when idling. intake system.
Tread the air throttle to see whether it is easy to Replace and then check the air
4 Yes
start. throttle and idle passege.
Connect the valve of fuel oil meter. Make short Yes Next.
circuit with pins of No.30 and 87 on the oil pump
5 relay, and fuel injection pump relay to get the
pump work, then check whether the fuel pressure No 9
is 350kPa.
Get the storage battery to supply 12V voltage Yes 8
6 directly to fuel injector with the special joint, to see
whether the fuel injector works well. No Next.
Re-check whether the fuel injector works well after Yes Next.
7 its getting cleaned.
No Replace the fuel injector.
Check whether the fuel goes bad or contains Yes Replace the fuel.
8 water. No 14
Inspect whether the fuel pressure is below 350 Yes Next.
9 kPa. No 13
Close the valve of fuel oil meter, and re-connect Yes Next.
the ignition switch to make the fuel injection pump
10
work again, to see whether oil pressure can be No 12
established.
Open the valve of fuel oil meter, and clamp the oil Replace the fuel pressure
Yes
return pipe with oil return interceptor to prevent adjuster.
11
from oil return, to see whether oil pressure can be Repair the fuel injector or fuel
No
established. pipeline.
Check whether the induction manifold is blocked Repair or replace the induction
Yes
or leaking. manifold.
12
Replace the fuel injection
No
pump.
Check whether the oil return pipe is blocked or Repair or replace the oil return
Yes
bent. pipe.
13
Replace the fuel pressure
No
adjuster.
Pull out the joint of idle actuator on wire harness Yes Next.
before the engine coolant temperature reaches
14 Repair or replace the idle
35℃, to see whether its rotation speed No
decelerates (the engine in trouble mode). actuator.
Turn the ignition switch to “ON”. Inspect whether Yes Next.
voltages of the following pins are normal, i.e.
15 Check the wire harness and
whether No.1, 17 and 18 is storage battery voltage No
of 12V or so, or whether No.73 is 0. joints.
Make the engine work ilding, and inspect whether Yes Next.
16 the ignition advance angle is normal when the
No Check others.
coolant temperature is normal.
Check whether the cylinder pressure of the engine Yes Next.
17 is normal.
No Troubleshoot the problems.
Check whether the sensors of intake mainfold Yes Repair or replace it.
18 abosolute pressure and temperature are blocked. No Next.
 Benjoy Maintenance Manual ---- Engine Volume EMS-98

Inspect whether the coolant temperature sensor is Yes Replace ECU

19
working well. No Repair or replace it.

It’
s diffuclt to start the cold vehicle

No. Operation steps Testing Subsequent step

result
Turn the ignition switch to “ON” and inspect, with Troubleshoot the
Yes
1 trouble diagnostic tester, whether there are any displayed problems.
records about trouble information. No Next.
Inspect whether the coolant temperature sensor is
working well with a universal meter. Or take the place Yes Next.
of the starter of coolant temperature sensor with 1.5K
2
ohm series between pins of No.42 and No.05 of ECU.
If the engine can be started, the abnormity of coolant No Replace the sensor.
temperature sensor can be indicated.
Connect the ignition switch, connect adapter between
Yes Next.
ECU and the wire harness and inspect whether
3 voltages of the following pins are normal, i.e. whether
Repair the wire
No.1, 17 and 18 is storage battery voltage of 12V or No
harness and joints.
so, or whether No.73 is of 0.
Check whether the air filter is fluent. Yes Next.
4
No Replace it.
After successful starting, inspect whether the Yes Next.
pressure of intake manifold is between 35-55kPa
5 Troubleshoot the
when idling.
No leakage of intake
system.
Tread the air throttle to see whether it is easy to start. Check the air throttle
Yes
6 and idle passege.
No Next.
Pull out the joint of idle actuator on wire harness Yes Next.
before the engine coolant temperature reaches 35℃,
7 Repair or replace the
to see whether its rotation speed decelerates (the No
engine in trouble mode). idle actuator.
Connect the valve of fuel oil meter (the joint is
different for different vehicle styles). Connect directly Yes Next.
the stitch of No.86 of fuel injection pump relay to the
8
ground. Turn on the ignition switch to make the fuel
injection pump relay and fuel injection pump work, to No 12
see whether the oil pressure is 350kPa or so.
Get the storage battery to supply 12V voltage directly Yes 11
9 to fuel injector with the special joint, to see whether
the fuel injector works well. No Next.
Re-check whether the fuel injector works well after the Yes Next.
10 its getting cleaned.
Replace the fuel
No
injector.
Check whether the fuel goes bad or contains water. Yes Replace the fuel.
11
No 17
Inspect whether the fuel pressure is below 350 kPa. Yes Next.
12
No 16
13 Close the valve of fuel oil meter, and re-connect the Yes Next.
 Benjoy Maintenance Manual ---- Engine Volume EMS-99

ignition switch to make the fuel injection pump work

again, to see whether oil pressure can be established. No 15

Replace the oil

Open the valve of fuel oil meter, and clamp the oil Yes
pressure adjuster.
return pipe with oil return interceptor to prevent from
14 Repair and replace
oil return, to see whether oil pressure can be
No fuel injector or oil
established.
pipe.
Check whether the induction manifold is blocked or Repair or replace the
Yes
leaking. induction manifold.
15
Replace the fuel
No
injection pump.
Check whether the oil return pipe is blocked or bent. Repair or replace the
Yes
oil return pipe.
16
Replace the fuel
No
pressure adjuster.

Yes Next.
Check whether the cylinder pressure of the engine is
17
normal.
No Trouble shoot.

Yes Repair it.

Check whether the intake system of the engine is
18
leaking or blocked.
No Next.

Yes Repair or replace it.

Check whether the sensors of intake mainfold
19
abosolute pressure and temperature are blocked.
No Replace ECU.
 Benjoy Maintenance Manual ---- Engine Volume EMS-100

The idle speed is not stable at any time

No. Operation steps Testing Subsequent

result step
Turn the ignition switch to “ON” and Troubleshoot the
inspect, with trouble diagnostic tester, Yes displayed
1
whether there are any records about problems.
trouble information. No Next.
Replace or repari
Check whether the idle stepping motor Yes
2 the idle actuator.
actuator is stuck.
No Next.
Connect the ignition switch, inspect Check the wire
whether the water temperature sensor, Yes harness and
3
idle stepping motor and ECU are joints.
connected well. No Next.
Make the engine work ilding, cut off the Yes 8
fire cyliner by cylinder, to see whether the Next.
4
engine rotation speed declines and No
fluctuates.
Yes Next.
Check whether the working states of all Check the fuel
5
fuel injectors in all cylinders work well. No injector and wire
harness.
Check whether the resistance volumes of Yes Next.
6 high-tension wires in all cylinders are Replace them.
No
normal.
Check whether the ignition coil is Yes Replace them.
7
damaged. No Next.
Yes Next.
8 Check whether the ignition plug is normal. Replace the
No
ignition plug.
Connect the valve of fuel oil meter. Make Yes Next.
short circuit with pins of No.30 and 87 on 13
9 the fuel injection pump relay, and get the
No
pump to work, then check whether the fuel
pressure is 350kPa.
Use a special joint to get the storage Yes 12
battery to supply 12V voltage directly to Next.
10
fuel injector, to see whether the fuel No
injector works well.
Yes Next.
Re-check whether the fuel injector works
11 Replace the fuel
well after its getting cleaned. No
injector.
 Benjoy Maintenance Manual ---- Engine Volume EMS-101

Check whether the fuel goes bad or Yes Replace the fuel.
12
contains water. No 18
Inspect whether the fuel pressure is below Yes Next.
13
350 kPa. No 17
Close the valve of fuel oil meter, and Yes Next.
re-connect the ignition switch to make the 16
14
fuel injection pump work again, to see No
whether oil pressure can be established.
Replace the oil
Open the valve of fuel oil meter, and
Yes pressure
clamp the oil return pipe with oil return
adjuster.
15 interceptor to prevent from oil return, to
Repair or replace
see whether oil pressure can be
No the fuel injector
established.
or oil pipe.
Repair or replace
Yes the induction
Check whether the induction manifold is
16 manifold.
blocked or leaking.
Replace the oil
No
pump.
Repair or replace
Yes the oil return
Check whether the oil return pipe is pipe.
17
blocked or bent. Replace the oil
No pressure
adjuster.
Check whether the sensors of intake Yes Clean them up.
18 mainfold abosolute pressure and Next.
No
temperature are blocked.
Make the engine work ilding and check Yes Next.
whether the oxygen sensor works well
after the coolant temperature reaches the
Chech the
19 valume equal to the temperature
No oxygen sensor
activated in closed loop control, to see
and wire harness.
whether the oxygen sensor works
normally (fluctuating between0-1V).
Check whether the intake system of the Clear up the
Yes
20 engine is leaking. leakage.
No Next.
Check whether the cylinder pressure of Yes Next.
21
the engine is normal. No Trouble shoot.
Make the engine work ilding, and inspect Yes Replace ECU.
whether the ignition advance angle is
22
normal when the coolant temperature is No Check others.
normal.
 Benjoy Maintenance Manual ---- Engine Volume EMS-102

The idle speed is not stable when warming up the engine

No. Operation steps Testing Subsequent

result step
Turn the ignition switch to “ON” and Troubleshoot the
inspect, with trouble diagnostic tester, Yes displayed
1
whether there are any records about problems.
trouble information. No Next.
Yes Next.
2 Check whether the air filter is fluent.
No Replace it.
Make the engine work ilding, inspect Yes Next.
whether the pressure of intake manifold is Eliminate the
3
between 35-55kPa when idling in No leakage trouble
worm-operation. of intake system.
Turn off the engine, connect the ignition
Yes Next.
switch, and connect adapter between
ECU and the wire harness and inspect
4 whether voltages of intake temperature
sensor, water temperature sensor and No Inspect them.
No.4 and 20 pins of ECU (used as 4.5-5V
sensor power supply) are normal.
Pull out the joint of idle actuator at the end Yes Next.
of worm-operation, to see whether the
5 Replace the idle
engine rotation speed changes (the No
actuator.
engine being in trouble mode).
Inspect whether the coolant temperature Yes Next.
6
sensor is working well. No Replace it.
Make the engine work ilding, and inspect Yes Replace ECU.
whether the ignition advance angle is
7
normal when the coolant temperature is No Check others.
normal.
Benjoy Maintenance Manual ---- Engine Volume EMS-103
 Benjoy Maintenance Manual ---- Engine Volume EMS-104

The idle speed is not stable after warming up the engine

No. Operation steps Testing Subsequent

result step
Turn the ignition switch to “ON”and inspect, Troubleshoot the
with trouble diagnostic tester, whether there Yes displayed
1
are any records about trouble information. problems.
No Next.
Turn the ignition switch to “ON", connect
adapter between ECU and the wire harness, Yes Next.
and inspect whether voltages output from
intake manifold abosolute pressure sensor, Repair or replace
2
intake temperature sensor output, coolant the wire harness
temperature sensor, oxygen sensor output No
and its relevant
stitch and the voltage output from ECU to idle parts.
actuator are normal.
Turn off the engine, and check whether the air Yes Next.
3
filter is fluent. No Replace them.
Inspect whether the pressure of intake Yes Next.
manifold is between 35-55kPa when idling. Eliminate the
4
No leakage trouble
of intake system.
Connect the valve of fuel oil meter (the joint is Yes Next.
different for different vehicle styles). Make
short circuit with pins of No.30 and 87 on the
5
fuel injection pump relay, and get the pump No 9
work, then check whether the fuel pressure is
350kPa or so.
Use the special joint and get the storage Yes 8
battery to supply 12V voltage directly to fuel
6
injector, to see whether the fuel injector works No Next.
well.
Re-check whether the fuel injector works well Yes Next.
7 after its getting cleaned. Replace the fuel
No
injector.
Check whether the fuel goes bad or contains Yes Replace the fuel.
8
water. No 14
Inspect whether the fuel pressure is below Yes Next.
9
350 kPa. No 13
Close the valve of fuel oil meter, and Yes Next.
re-connect the ignition switch to make the fuel
10
injection pump work again, to see whether oil No 12
pressure can be established.
 Benjoy Maintenance Manual ---- Engine Volume EMS-105

Open the valve of fuel oil meter, and clamp the Replace the oil
oil return pipe with oil return interceptor to Yes pressure
prevent from oil return, to see whether oil adjustor.
11
pressure can be established. Repair or replace
No the fuel injector
or oil pipe.
Check whether the induction manifold is Repair or replace
blocked or leaking. Yes the induction
12 manifold.
Replace the fuel
No
injection pump.
Check whether the oil return pipe is blocked or Repair or replace
bent. Yes the oil return
pipe.
13
Replace the oil
No pressure
adjustor.
Make the engine work ilding, and inspect Yes Next.
whether the ignition advance angle is normal Adjust the
14
when the coolant temperature is normal. No ignition advance
angle.
Pull out the coolant temperature sensor, to Replace the
inspect whether the engine works well. coolant
Yes
15 temperature
sensor.
No Next.
Check whether the cylinder pressure of the Yes Next.
16
engine is normal. No Trouble shoot.
Check whether the resistance volumes of Yes Next.
17
high-tension wires in all cylinders are normal. No Replace them.
Inspect whether the ignition coil and Yes Replace them.
18
high-tension wires have breakage or cracks. No Next.
Check whether the ignition plug works well. Yes Replace ECU.
19 Replace the
No
ignition plug.
 Benjoy Maintenance Manual ---- Engine Volume EMS-106

The idle speed is not stable or flameout happens when using loading
appliance (air conditioner, etc.)
No. Operation steps Testing Subsequent
result step
Turn the ignition switch to “ON”and inspect, Troubleshoot the
with trouble diagnostic tester, whether there Yes displayed
1
are any records about trouble information. problems.
No Next.
Turn on the air conditioner, connect adapter Yes Next.
between ECU and the wire harness, and Inspect the air
2
inspect whether there are signals from ECU No conditionor
air conditioner switch and pressure signal. circuit.
Check whether the electric magnetic clutch Yes Next.
and air condition pump of the presser and
3 Repair or replace
compressor in air conditioner system works No
them.
well.
Turn the ignition switch to “ON”. Inspect Yes Next.
4 whether voltages of the pins of No.33, 34, 53 Check the control
No
and 54 (output to idle actuator) are normal. circuit.
Dismount the stepping motor, and check Replace the
Yes
5 whether the stepping motor is stuck or stepping motor.
operating inflexible. No Next.
Start the engine, turn on the air conditioner, Yes Replace ECU.
and check with trouble diagnostic tester to see
6 whether the idle actuator works well at that Replace the idle
No
time according to the step number of step actuator.
motor.
Benjoy Maintenance Manual ---- Engine Volume EMS-107
 Benjoy Maintenance Manual ---- Engine Volume EMS-108

Periodic stability occurs (ECU needs re-study by itself after power off)
No. Operation steps Testing Subsequent
result step
Turn the ignition switch to “ON”and inspect, with Troubleshoot
trouble diagnostic tester, whether there are any Yes the displayed
1
records about trouble information. problems.
No Next.
Check whether the air filter is fluent. Yes Next.
2
No Replace it.
Make the engine work ilding, and inspect whether Yes Next.
3 the intake pressure is between 35-55 kPa. Check intake
No
and leakage.
Make the engine work ilding, cut off the fire cyliner Yes 7
4 by cylinder, to see whether the engine rotation
No Next.
speed declines and fluctuates.
Turn the ignition switch to “ON”, connect adapter Yes Next.
between ECU and the wire harness, and inspect
whether voltages output from intake manifold
abosolute pressure sensor, intake temperature Repair or
5
sensor output, coolant temperature sensor, oxygen No replace the wire
sensor output, electric position, ignition switch and harness.
the voltages of ECU pins of No.33, 34, 53 and 54
(output to idle actuator) are normal.
Make the engine work ilding, and inspect whether Yes Next.
6 the ignition advance angle is normal when the
No Check others.
coolant temperature is normal.
Check whether sensor holes of the sensors of Yes Clear them up.
7 intake mainfold abosolute pressure and
No Next.
temperature are blocked.
Check whether the fuel goes bad or contains Replace the
Yes
8 water. fuel.
No Next.
Get the storage battery to supply 12V voltage Yes Next.
directly to fuel injector with the special joint, to see Inspect the fuel
9 whether the fuel injector works well. injector and the
No
related wire
harness.
Check whether the resistance volumes of Yes Next.
10
high-tension wires in all cylinders are normal. No Replace them.
Inspect whether the ignition coil and high-tension Yes Replace them.
11
wires have breakage or cracks. No Next.
Check whether the ignition plug is normal. Yes Replace ECU.
12
No Replace the
 Benjoy Maintenance Manual ---- Engine Volume EMS-109

ignition plug.

The idle speed is too high (ECU needs re-study by itself after power off)

1 Turn the ignition switch to “ON”and Troubleshoot the

Yes
inspect, with trouble diagnostic tester, displayed problems.
whether there are any records about Next.
No
trouble information.
2 Check whether the guy cable Repair or replace
Yes
connecting the accelerator pedal is them.
stuck or over tightened. No Next.
3 Check whether the carbon canister Repair or replace
solenoid valve, fuel pressure adjuster, Yes them.
forced ventilating vacuum of
Next.
crankshaft, vacuum hose of brake
system are installed firmly or No
damaged.
4 Make the engine work ilding, shift to Next.
Yes
neutral gear, tread brake pedal, to see
whether the idle rotation speed is too 6
No
high.
5 Clamp the vacuum hose, to see Repair or replace the
Yes
whether the idle speed turns to be vacuum booster.
normal. Next.
No

6 Clamp the forced ventilating vacuum Yes Replace PCV valve.

of crankshaft, to see whether the idle
No Next.
speed turns to be normal.
7 Clamp the control valve hose of Replace the control
carbon canister, to see whether the Yes valve of carbon
idle speed turns to be normal. canister.
No Next.

8 Check whether the idle actuator is Yes Repair or replace it.

stuck or operating inflexible. No Next.
9 Check whether there are leakages in Yes Repair or replace it.
other places of the intake manifold. No Next.
10 Check whether the seal ring of fuel Yes Next.
injector is in good condition. No Replace the seal ring.

11 Check whether the sensors of intake Replace ECU.

Yes
mainfold abosolute pressure and
temperature are in good condition. No Replace the sensors.
 Benjoy Maintenance Manual ---- Engine Volume EMS-110

Rotation speed cannot be elevated or flameout happens in acceleration

1 Turn the ignition switch to “ON” and inspect, with trouble Troubleshoot the
Yes
diagnostic tester, whether there are any records about trouble displayed problems.
information. No Next.
2 Check whether the air filter is fluent. Yes Next.
No Replace it.
3 Make the engine work ilding, and inspect whether its rotation Yes Next.
speed is normal when idling.
Inspect and repair it
No by referring to that
of idle trouble.
4 Make the engine work ilding, inspect whether the intake Yes Next.
pressure is between 35-55kPa when idling.
No Inspect and repair it.
5 Make the engine work ilding, and inspect whether the ignition Next.
Yes
advance angle is normal when the coolant temperature is
normal. Adjust the ignition
No
advance angle.
6 Connect the valve of fuel oil meter. Make short circuit with pins Yes Next.
of No.0 and 87 on the oil pump relay, and get the pump work,
10
then inspect whether the fuel pressure is 350kPa or so. No

7 Get the storage battery to supply 12V voltage directly to fuel Yes 9
injector with the special joint, to see whether the fuel injector
No Next.
works well.
8 Re-check whether the fuel injector works well after its getting Yes Next.
cleaned. Replace the fuel
No
injector.
9 Check whether the fuel goes bad or contains water. Yes Replace the fuel.
No 15
10 Inspect whether the fuel pressure is below 350 kPa. Yes Next.
No 14
11 Close the valve of fuel oil meter, and re-connect the ignition Yes Next.
switch to make the fuel injection pump work again, to see 13
No
whether oil pressure can be established.
12 Open the valve of fuel oil meter, and clamp the oil return pipe Replace the fuel
Yes
with oil return interceptor to prevent from oil return, to see pressure adjuster.
whether oil pressure can be established. Repair or replace
No the fuel injector or
oil pipe.
13 Check whether the induction manifold is blocked or leaking. Repair or replace
Yes the induction
manifold.
Replace the oil
No
pump.
14 Check whether the oil return pipe is blocked or bent. Repair or replace
Yes
the oil return pipe.
Replace the fuel
No
pressure adjustor.
 Benjoy Maintenance Manual ---- Engine Volume EMS-111

15 Turn on ignition switch to “ON”. Connect adapter between ECU Yes Next.
and the wire harness and inspect whether voltages of the Repair or replace
output signal terminal of ECU throttle position sensor and pins the wire harness.
of No.4 and 20 (used for sensor power supply of 4.5 and 5V) No
are normal.
16 Check whether the ignition coil, high-tension wire and ignition Yes Replace ECU.
plug are normal. Repair the relevant
No
parts.

Reaction is slow in acceleration

1 Turn the ignition switch to “ON” and inspect, with trouble Troubleshoot the
diagnostic tester, whether there are any records about trouble Yes displayed problems.
information.
No Next.
2 Turn off the engine, and check whether the air filter is fluent. Yes Next.
No Replace it.

3 Make the engine work ilding and inspect whether the idle speed Yes Next.
is normal.
Inspect it by refering to
No
trouble items of idle.
4 Make the engine work ilding and inspect whether the pressure Yes Next.
of intake manifold is between 35-55kPa when idling.
No Inspect and repair it.
5 Turn on ignition switch to “ON”. Connect adapter between ECU Next.
Yes
and the wire harness and inspect whether voltages of the
output signal terminal of ECU throttle position sensor and pins Repair or replace the
of No.4 and 20 (used for sensor power supply of 4.5 and 5V) No wire harness.
are normal.
6 Make the engine work ilding, and inspect whether the ignition Yes Next.
advance angle is normal when the coolant temperature is Check others.
normal. No
7 Connect the valve of fuel oil meter. Make short circuit with pins Next.
Yes
of No.30 and 87 on the fuel injection pump relay, and get the
pump work, then check whether the fuel pressure is 350kPa. No 11
8 Re-check whether the fuel injector works well after the its Yes 10
getting cleaned.
No Next.
9 Re-check whether the fuel injector works well after the being Yes Next.
cleaned.
Replace the fuel
No
injector.
10 Check whether the fuel goes bad or contains water. Yes Replace the fuel.
No 16
11 Inspect whether the fuel pressure is below 350 kPa. Yes Next.
No 16
12 Close the valve of fuel oil meter, and re-connect the ignition Next.
Yes
switch to make the fuel injection pump work again, to see
whether oil pressure can be established. No 14
13 Open the valve of fuel oil meter, and clamp the oil return pipe Replace the pressure
Yes
with oil return interceptor to prevent from oil return, to see adjustor.
whether oil pressure can be established. Repair or replace the
No
fuel injector or oil pipe.
14 Check whether the induction manifold is blocked or leaking. Repair or replace the
Yes
induction manifold.
Replace the fuel
No
injection pump.
 Benjoy Maintenance Manual ---- Engine Volume EMS-112

15 Check whether the oil return pipe is blocked or bent. Repair or replace the oil
Yes
return pipe.
Replace the pressure
No
adjuster.
16 Check whether the emission system or three-way catalyst is Replace or clean it.
Yes
blocked.
Replace ECU.
No
 Benjoy Maintenance Manual ---- Engine Volume EMS-113

Performance is poor and weak in acceleration

Check whether there are troubles like slidding of Yes Repair them.
clutch, low pressure of tire, brake drgging, dimension
1
error of tires and positioning error of four wheels, and No Next.
so on.
Check whether the air throttle can be completely Yes Next.
2 open. Repair or replace the air
No
throttle.
Turn the ignition switch to “ON”and inspect, with Troubleshoot the displayed
Yes
3 trouble diagnostic tester, whether there are any problems.
records about trouble information. No Next.
Make the engine work ilding, and inspect whether Yes Next.
4 the ignition advance angle is normal when the
coolant temperature is normal. No Check others.

Turn the ignition switch to “ON”, connect adapter Yes Next.

between ECU and the wire harness, and inspect
whether voltages output from pins of intake manifold
abosolute pressure sensor, throttle position sensor,
5 intake temperature sensor output, coolant Repair or replace the wire
No
temperature sensor, pins of the ECU oxygen harness.
grounding wire and signal output terminal and pins of
No.4 and 20 for sensor power supply of 4.5-5V are
normal.
Make the engine work ilding, and inspect whether Yes Next.
6
the intake pressure is between 35-55 kPa. No Inspect it.
Connect the valve of fuel oil meter. Make short circuit Yes Next.
with pins of No.30 and 87 on the fuel injection pump
7
relay, and get the pump work, then check whether No 11
the fuel pressure is 350kPa or so.
Get the storage battery to supply 12V voltage directly Yes 10
8 to fuel injector with the special joint, to see whether
No Next.
the fuel injector works well.
Re-check whether the fuel injector works well after its Yes Next.
9
getting cleaned. No Replace the fuel injector.
Check whether the fuel goes bad or contains water. Yes Replace the fuel.
10
No 16
Inspect whether the fuel pressure is below 350 kPa. Yes Next.
11
No 15
Close the valve of fuel oil meter, and re-connect the Yes Next.
ignition switch to make the fuel injection pump work
12
again, to see whether oil pressure can be No 14
established.
Open the valve of fuel oil meter, and clamp the oil Replace the pressure
Yes
return pipe with oil return interceptor to prevent from adjustor.
13
oil return, to see whether oil pressure can be Repair or replace the fuel
No
established. injector or oil pipe.
Check whether the induction manifold is blocked or Repair or replace the
Yes
leaking. induction manifold.
14
Replace the fuel injection
No
pump.
Check whether the oil return pipe is blocked or bent. Repair or replace the oil
Yes
return pipe.
15
Replace the pressure
No
adjustor.
16 Check whether the sensors of intake mainfold Yes Next.
 Benjoy Maintenance Manual ---- Engine Volume EMS-114

abosolute pressure and temperature are in good

No Replace the sensors.
condition.
 Chassis Volume

Preface

This Benjoy Maintenance Manual is prepared to help the technical service

personnel exactly understand and acquaint himself with JAC cars, thus
enabling them to fast and reasonably maintain JAC cars. This Maintenance
Manual consists of four volumes respectively for the engine, chassis, vehicle
body & electric appliance, and circuit overhaul.
The chassis volume explicates the chassis system and the technical standard
for its components’ assembly, disassembly, testing, commissioning and
diagnosis.
For replacement of fittings, only the original ones recommended by JAC can
be used. In maintenance, always observe strictly the tightening torque given in
the maintenance manual. If the efficiency of locking device is damaged during
the dismantlement, the replacement with a new one is required.
No part of this Manual may be reproduced or used in any form or by any
means without prior written license; otherwise any infraction will be prosecuted
for.

Compiler
July, 2007
 Chassis Volume

Contents
Manual of Gearbox

Overview ....................................MT-1 Reversing Middle Gear .............MT-43

Tightening Torque .................... MT-1 Speedometer Gear ....................MT-44

Precautions ............................... MT-5 Selector Rod ..............................MT-45

Preparations ............................ MT-6 Controller Casing ......................MT-47

Countermeasure for Noise, Vibration Clutch Casing ............................MT-50

and Unsmoothness ................. MT-9 Gearbox Casing......................... MT-53

Oil of Gearbox Oil ..................... MT-10 Differential .................................MT-55

Gearbox Assembly ................... MT-11 Selector Rod Assembly............MT-58

Input Shaft .................................MT-27 Common Troubles and

Output Shaft .............................. MT-34 Countermeasure........................MT-60

Clutch

Overview ....................................CL-1 Adjustment of Clutch Pedal.....CL-4

Overhaul Specifications...........CL-1 Clutch Assembly.......................CL-5

Tightening Torque .................... CL-1 Hydraulic System of Clutch .....CL-9

Precautions ............................... CL-2 Clutch Pipeline ..........................CL-12

Preparations．................... .......CL-2 Common Troubles Diagnosis..CL-14

Clutch Pedal.................... ..........CL-3

Front Axle

Overview ....................................FAX-1 Front Wheel Hub and Steering Knuckle

Overhaul Specifications...........FAX-1 ....................................................FAX-4

Precautions..................... ..........FAX-2 Front Drive Shaft.......................FAX-12

Preparations..............................FAX-3 Common Troubles Diagnosis..FAX-24

Rear Axle
 Chassis Volume

Overview ....................................RAX-1 Rear Wheel Hub...................RAX-3

Overhaul Specifications...........RAX-1 Steering Knuckle.......................RAX-6

Precautions ............................... RAX-2 Common Troubles and

Preparations..............................RAX-2 Countermeasure........................RAX-9

Front Suspension

Overview........ ............................ FSU-1 Arm and Front Suspension Arm...

Overhaul Specifications...........FSU-1 ....................................................FSU-13

Precautions...................... .........FSU-3 Stabilizer Rod......................... ...FSU-17

Preparations..............................FSU-3 Auxiliary Frame .........................FSU-21

Front Suspension Assembly ...FSU-3 Common Troubles and

Front Suspension Upper Suspension Countermeasure........................FSU-26

Arm............................................. FSU-6

Front Damper...................... ......FSU-9

Front Suspension Rear Suspension

Rear Suspension

Overview....................................RSU-1 Horizontal Push-and-pull Rod RSU-14

Overhaul Specifications...........RSU-1 Front and Rear Transverse Slide Bars

Precautions..................... ..........RSU-3 of Rear Suspension ..................RSU-16

Preparations..............................RSU-3 Rear Antisway Bar ....................RSU-20

Rear Suspension Assembly .....RSU-4 Rear Underframe.......................RSU-23

Rear Damper..................... ........RSU-6 Common Troubles and

Rear Suspension Arm ..............RSU-11 Countermeasure.. .....................RSU-26

Wheel and Tyre

Overview....................................WT-1 Preparations.................... ..........WT-3

Overhaul Specifications...........WT-1 NVH Countermeasure...............WT-4

Air Pressure of Wheel........... ...WT-2 Wheel....................... ..................WT-5

Precautions..................... ..........WT-3 Tyre Assembly...........................WT-7

 Chassis Volume

Transposition of Tyre......... ......WT-9 Common Troubles and

Four-wheel Alignment ..............WT-10 Countermeasure........................WT-13

Spare Tyre.......................... .......WT-12

Brake System

Overview....................................BR-1 Main Cylinder of Brake..... ........BR-16

Overhaul Specifications...........BR-1 Vacuum Booster.................. .....BR-18

Precautions..................... ..........BR-1 Vacuum Pipeline.................. .....BR-20

Preparations..............................BR-2 Front Disc Brake........... ............BR-21

Brake Pedal..................... ..........BR-4 Rear Disc Brake.................. ......BR-30

Brake Fluid....................... .........BR-8 Common Troubles and

Braking Pipeline and Hose ....BR-12 Countermeasure. ......................BR-39

Catalogue of Parking Brake

Overview....................................PB-1 Preparations........................ ......PB-2

Overhaul Specifications........... PB-1 Parking Braking System .........PB-3

Precautions...................... .........PB-2 Parking Braking Control .........PB-5

Anti-lock Braking System

Overview....................................ABS-1 Common Troubles and Analysis of ABS

Precautions..................... ..........ABS-1 ...................................................ABS-12

Preparations..............................ABS-2 Basic Check for ABS ................ABS-88

System Description........... .......ABS-3 Wheel Speed Sensor ...............ABS-89

Anti-lock Braking Mode...... .....ABS-6 ABS Assembly...........................ABS-92

Trouble Diagnosis … … … … .....ABS-8 Deflation for ABS. .....................ABS-95

 Chassis Volume

Catalogue of Power Steering

Overview....................................PS-1 Power Steering Gear.................PS-15
Overhaul Specifications...........PS-1 Power Steering Pump ...............PS-28
Precautions..................... ..........PS-2 Hydraulic Pipeline .....................PS-33
Preparations..............................PS-3 Pressure Testing of Power Steering
Power Steering Fluid..... ...........PS-4 System........................................PS-36
Steering Wheel..........................PS-6 Diagnosis Info and Countermeasure
Steering Column.............. .........PS-10 Procedure...................................PS-37
 Chassis Volume MT-1

Overview
The installation of gearbox on the vehicle functions to provide neutral gear, forward gear,
forward gear range and reverse gears. With a transmission ratio as low as possible, the
gearbox can promote the rotating torque inputted by engine, and accordingly speed up the
vehicle till the expected speed. With the max. transmission ratio, the gearbox shall make
sure the engine has the min. rev. when the vehicle travels at cruise speed, to save fuel
and lower noise. At the mean time, some middle transmission ratios shall be assigned to
ensure the engine won’
t accelerate or decelerate when the vehicle shifts gear. The vehicle
shall start both from forward and reverse directions as required so that the gearbox has
the same reverse transmission as that of the first gear transmission.

Tightening Torque

Item Torque N•m (kgf)

Installation bolt for lower cover 6.9 (0.7)
Bolt for interlocking plate 30 (3.1)
Installation bolt for clutch casing to gearbox casing 44 (4.5)
Installation bolt for clutch release bearing retainer 9.8 (1.0)
Installation bolt for controller casing 18 (1.9)
Installation bolt for gearbox cable bracket 18 (1.9)
Installation bolt for speedometer gear 3.9 (0.4)
Installation bolt for stopper support 22 (2.3)
Installation bolt for selector rod 18 (1.9)
Installation nut for selector rod 11 (1.2)
Installation bolt for differential drive gear 132 (13.5)
Reversing light switch 32 (3.3)
Installation bolt for front bearing seat 18 (1.9)
Lifting spring component 32 (3.3)
Installation bolt for reversing middle gear shaft 48 (4.9)
Installation bolt for roll restrictor bracket 69 (7.0)

Attention:
The refueling bolt (with a tightening torque of 29~34N•m) and bleeding bolt (with a
tightening torque of 43~50N•m) of the gearbox shall be tightened. If not, tighten
them.
 Chassis Volume MT-2

Adjusting Snap Ring and Gasket

Name of Parts Thickness mm ID Mark
Snap ring (used for adjusting the axial 2.24 none
clearance of the front bearing of the 2.31 blue
input shaft) 2.38 brown
2.31 Black (2)
2.35 none
2.39 blue
Snap ring 2.43 brown
(used for adjusting the axial clearance 2.47 green
of the rear bearing of the input shaft)
2.51 white
(used for adjusting the axial clearance of
the front bearing of the input shaft) 2.55 yellow
2.59 black
2.63 orange
2.67 blue
2.71 brown
2.82 －
2.86 －
2.90 －
Thrust plate
2.94 －
(used for adjusting the axial clearance
2.98 －
of the fifth gear of the input shaft)
3.02 －
3.06 －
3.10 －
Snap ring 1.43 Green (2)
(used for adjusting the axial clearance of 1.51 White (2)
the front bearing of the output shaft) 1.59 Yellow (2)
2.81 green
2.85 white
2.89 yellow
Snap ring
2.93 black
(used for adjusting the axial clearance
of the third gear of the output shaft)
2.97 orange
3.01 red
3.05 peach
3.09 blue
 Chassis Volume MT-3

Name of Parts Thickness mm ID Mark

0.80 80
0.83 83
0.86 86
0.89 89
0.92 92

Gasket 0.95 95
(used for adjusting the pretightening of 0.98 98
the differential casing) 1.01 01
1.04 04
1.07 07
1.10 J
1.13 D
1.16 K

Gasket 1.19 L
(used for adjusting the pretightening of 1.22 G
the differential casing) 1.25 M
0.75~0.82 -

Gasket 0.83~0.92 -
(used for adjusting the gearbox 0.93~1.00 -
clearance of the differential casing) 1.01~1.08 -
1.09~1.16 -
 Chassis Volume MT-4

Main Technical Parameters and Preparatory Materials:

(1) Main Technical Parameters
Speed Ratio Ⅰ
Torque 230N•m
Type Manual
Drive Mode Front wheel 2-wheel drive
Transmission Gear 5
Transmission Ratio See the Specification Table
Speedometer Gear Transmission Ratio See the Specification Table
Clutch Control Hydraulic
Weight (kg) 45（without oil）
Specification for Gearbox Lubricating Oil JAC 80W-90 (GL-5)
Fill the necessary volume from the side plug hole.
Filling Method for Gearbox Lubricating Oil
Lubricating oil level: lower plane of the plug hole.
Filling Volume of Gearbox Lubricating Oil 2.2L
 Chassis Volume MT-5

Precautions
Precautions in Dismantlement
1. Use the special tool when explaining on usage of special maintenance tools.
Attention shall be paid to the safe operation, and operation in no accordance with the
descriptions is not allowed.
2. Take care not to damage the combined or sliding surfaces.
3. Prepare spare parts kit and rack for storing spare parts Dismantled. The orderly
storage shall be carried out, when necessary, the mark shall be made to avoid
confusion, misplacement, knocking or scuffing.
4. The basic principles for releasing bolts and nuts: firstly release the outermost,
secondly the diagonal, and the like. Supposing the release sequence is specified,
operate in the specified sequence.
5. Try to use the appropriate dismantlement tools for dismantlement and reassembly so
as to avoid damaging the gear.
6. Prepare sufficient auxiliary materials for random usage in the overhaul.
7. Try to reference the contents of the Maintenance Manual in working process.
Precautions in Check, Maintenance and Replacement
1. Prior to the maintenance or replacement, make a thorough examination of spare
parts. The damaged must be replaced.
2. Take care to overhaul the parts of aluminum alloy, to avoid damaging the surface to
be processed.
3. The bolts and other tightening parts with standard tightening torque requirements
must be tightened by special tool as required.
4. After overhaul, the disposable articles must be replaced with new ones.
5. Try to reference the contents of the Maintenance Manual in working process.
Precautions in Assemblage and Installation
1. Tighten nuts and bolts by torque spanner.
2. Replace with new lining, oil seal or O-ring.
3. Thoroughly rinse, clean and then dry spare parts.
4. Don’ t damage the sliding or combined surface. Thoroughly clear away chopped cloth
or dust. Coat the gearbox oil before assembly.
Precautions in Liquid Sealing
1. The special methods are unnecessary for dismantlement of parts assembly with
sealant.
2. In some occasions, it’s necessary to gently knock parts with mallet or similar tool so
as to damage the sealant on bind area or gently knock the even, smooth and thin
sealant scraper into the bonding surface. Pay attention not to damage the bonding
surface.
Essentials on Coating
Precautions in Usage of FIPG Assembled Parts
1. The sealant shall be uniformly coated on the specified diameter. The surrounding of
the hole to be assembled shall be encircled to prevent sealant from into the hole to be
assembled. The sealant not hardened shall be removed away.
2. The parts shall be mounted at specified positions in the wet sealant state (within 15
minutes).
3. Take care not to stick the sealant on unnecessary positions in the installation process.
After the installation of parts, the sealant shall be waited for hardening (needing 1
hour), when the coated position shan’ t be oiled or wetted or the engine is started.
4. The coating steps of FIPG sealant varies with shapes of parts. Please refer to the
coating methods described in the document.
Form-in-Place Gasket (FIPG) Sealant
To obtain sufficient sealability, special attention shall be paid to coating amount, position
and surface status in the usage of the sealant. Insufficient coating will produce leakage or
blockage, while the excessive coating will result in overflow of gasket to block the water or
oil circuit or make the circuit become narrow. Therefore, appropriate amount of sealant
shall be coated to avoid leakage out of the binding surface.
 Chassis Volume MT-6

Preparations
1. Special Tools
Name Purpose
No. Tool Drawing

Used for assembly

and dismantlement
Bearing
JAC-T1B001 of (input shaft)
puller
bearing, bearing and
sleeve

Used for assembly

Bearing and dismantlement of
JAC-T1B002
puller (output shaft) bearing,
bearing and sleeve

Used for
Spring pin
JAC-T1B003 dismantlement of gear
remover
shifting fork spring pin

Used for
dismantlement of
Bearing
JAC-T1B004 bearing retainer and
remover
tapered roller bearing
at clutch casing

Together with Installer Erector cover

and installation
Installer adaptor, used for
JAC-T1B005
cover assembly of bearings
on input and output
shafts of gear
Together with (Erector adaptor 100)
installation adaptor
and tool cover, used
Installer JAC-T1B006
for assembly of
bearings on input and
output shafts of gear
Together with
(Erector adaptor 200)
installation adaptor
and tool cover, used
Installer JAC-T1B007
for assembly of
bearings on input and
output shafts of gear

Together with Roller bearing

Installation Installer, used for

JAC-T1B008
adaptor roller bearing on input
shaft of gear
 Chassis Volume MT-7

Together with
Installer, used for
Installation
JAC-T1B009 assembly of rear
adaptor
bearing on input and
output shafts of gear
Together with
Installer, used for
assembly of inner
retainer, spherical
Installation bearing, reversing
JAC-T1B010
adaptor gear and its bearing
sleeve of input shaft
roller bearing and
output shaft roller
bearing on gear
Together with
四档齿轮
4-speed gear
Installer, used for
assembly of
Installation fourth-speed gear,
JAC-T1B011
adaptor fifth-speed gear
sleeve and fifth
gear-reversing
synchronizer hub
Together with
Installer, used for
assembly of 1-speed gear sleeve

Installation second-speed gear,

JAC-T1B012
adaptor third-speed gear and
first-speed gear
sleeve on output shaft
of gear
Together with
Installer, used for
assembly of inner
Installation
JAC-T1B013 retainer and bearing
adaptor
(F5M42-Z-F6N6) of
differential tapered
roller
Together with
Installer, used for 5-speed gear sleeve

assembly of input
Installation
JAC-T1B014 fourth-speed gear
adaptor
sleeve and fifth-speed
gear on input shaft of
gear
Together with
Installer, used for
assembly of 1-2-speed
Installation first-speed gear synchronizer hub
JAC-T1B015
adaptor sleeve and first and
second-speed
synchronizer hub on
output shaft of gear
 Chassis Volume MT-8

Handle

Used for assembly of

Handle JAC-T1B016 bearing together with
associate Installer

Together with
installation handle,
Installation
JAC-T1B017 used for assembly of
adaptor Transmission casing
seal ring at lower
cover of gear
Together with
installation handle,
Installation used for assembly of
JAC-T1B018 Roller bearing
adaptor outer retainer of upper retainer

tapered roller bearing

on clutch casing

Installation Oil seal at position of

tool of Mounting tool of
JAC-T1B019 installing differential differential oil seal
differential
oil seal on gear casing

Together with
Handle
installation handle,
Installation used for assembly of Retainer
JAC-T1B020
adaptor tapered bearing outer
retainer on clutch
casing

Installation Oil seal at position of

tool of Mounting tool of
JAC-T1B021 installing differential differential oil seal
differential
oil seal on gear casing

Two seat
pads
JAC-T1B022
under
gearbox

2. Lubricating Grease
Item Specified Lubricating Grease
In conformity with Class API hypoid
Oil seal lip on drive shaft
gearbox oil SAE 75W/85W of over GL-4
Oil seal lip on input shaft
JAC genuine brand lubricating grease part
Supporting seat pad for selection
No. 0101011
lever
 Chassis Volume MT-9

Countermeasure for Noise, Vibration and Unsmoothness

Trouble Possible Cause Judgment and Countermeasure

 Excessive abrasion of  Check whether the control system pushes
round arc groove of the gearshift rocker boom of the gearbox
shifting fork shaft, and into position, or dismantle the gear, shift
elastic deformation of gear with hand pushing the shifting fork,
lock ball spring. and then check it for mesh.
 Excessive abrasion of  In case that it is meshed incompletely,
shifting fork work check the shifting fork for deformation or
Skip back to neutral
surface. excessive abrasion.
gear in traveling
 Excessive abrasion of  In case that the gearbox sleeve is
gear or gear sleeve completely meshed, check the gearbox
binding surface. sleeve and the back taper part of coupling
 Axial looseness of gear. gear for abrasion.
 In case of excessive clearance in shifting,
check the retaining spring in the fork shaft
groove for abrasion or failure.
Difficult gear shift with
serious impact sound or
 Serious abrasion of
difficult shift of one gear  Replace the synchronizer ring.
synchronizer ring
under the state of no
clutch trouble
The gearbox with  Some gear teeth  Check the positions with troubles, and
noise broken. then shoot them.
①Regular impact  Excessive big gear  Dismantle and clean them, and the
sound; ②Uniform clearance or gear damaged gear or bearing shall be
noise damaged. replaced.
 Abrasion of bearing.  Change oil or fill new oil.
 Insufficient lubricating
oil.
 Excess oil or excessive  Dismantle the refueling screw plug, and
high oil level. then check the oil level.
 Excessive abrasion or  Replace oil seal.
damage of oil seal.  Dismantle parts of binding surfaces, check
 Uniform coating of the knock positions, repair them and then
Oil leakage sealant or sealing paper uniformly coat them with glue.
gasket damaged.  Replace air plug.
 Failure of air plug.
 The knocked positions
on binding surface not
repaired timely.
 Too dirty lubricating
oil.  Replace lubricating oil.
 Insufficient lubrication  Check the lubricating oil level, and then
Abnormal damage of or lubricating oil in no fill new oil or change it.
bearing conformity with  Replace the bearing.
requirements or with
poor quality.
 Unqualified bearing.
 Chassis Volume MT-10

Change of Gearbox Oil

Attention: The JAC 80W-90 (GL-5) lubricating
oil is used in the gearbox.
1. Check gearbox oil Gearbox oil

Observe whether the gearbox oil is at the

lower plane of the plug hole from the side
plug hole. If it is lower than the lower plane, fill
lubricating oil.

2. Fill gearbox oil

① Park the vehicle on a horizontal place,
dismantle the drain bolt and then drain
gearbox oil out.
Oil orifice bolt

② Replace the gasket with a new one, and then

mount the drain bolt.
Oil drain bolt

③ Fill lubricating oil of appropriate volume into

the gearbox from side pouring orifice till the
lower plane of the pouring orifice. The filling
amount is about 2.2L.

④ Confirm that the oil level is under the pouring

orifice.

⑤ Start the vehicle till the gearbox oil has the

normal temperature, and then check the
gearbox for leakage.
 Chassis Volume MT-11

Gearbox Assembly

Profile Drawing of Gearbox

1. Middle gear of reversing gear 2. Fourth-speed gear

3. Third and Fourth-speed synchronizer 4. Third-speed gear

5. Gearbox casing 6. Clutch casing

7. Release bearing retainer 8. Input shaft

9. Output shaft 10. Differential

11. First-speed gear 12. First and Second-speed synchronizer

13. Second-speed gear 14. Fifth-speed gear

15.Fifth-speed－reversing synchronizer 16. Reversing gear

 Chassis Volume MT-12

Transmission ratio of gearbox

Model F5M42 -R5A4C (2.0L) -V4B2B (2.4L)

1ST

2ND
Transmi
ssion 3RD
ratio of
gearbox
4TH

5TH

Final deceleration ratio 4.312 4.312

Speedometer gears
28/36 27/26
number

Engine equipped 4GA3 4GA1

 Chassis Volume MT-13

Gearbox Assembly Diagram

Dismantlement and Reassembly

Lubricating all inner parts with gear

oil in assembly

TFM0925

1. Roll restrictor bracket 2. Bracket for gearshift cable

3. Selection lever 4. Gear of speedometer

5. Reversing light switch 6. Sealing gasket

7. Lifting spring component 8. Sealing gasket

 Chassis Volume MT-14

Lubricating all inner parts with gear

oil in assembly

TFM0597

9. Interlocking plate bolt 10. Sealing gasket

11. Controller casing 12. Neutral position return spring

13. Lower cover 14. Middle gear shaft bolt of reverse gear

15. Sealing gasket 16. Middle gear of reverse gear

17. Seal cover 18. Gearbox casing

19. Outer retainer 20. Washer

21. Magnetic plug seat

 Chassis Volume MT-15

Lubricating all inner parts with gear oil

in assembly

TFM0598

23. Spring pin 24. First－second-speed gear shifting slide rail subassembly

25. First－second-speed gear shifting fork 26. Spring pin

27. Spring pin 28. Third－fourth-speed gear shifting slide rail subassembly

29. Third－fourth-speed gear shifting fork 30. Fifth-speed－reverse gear shifting slide

rail subassembly

31. Fifth-speed－reverse gear shifting fork 32. Front bearing seat

33. Input shaft 34. Output shaft

35. Differential component 36. Clutch casing

 Chassis Volume MT-16

Dismantlement Steps:
1. Dismantle the roll restrictor bracket.
Screw off the two fastening bolt as shown in MT001
the drawing.
Attention:
One at each side

2. Dismantle the gearshift cable bracket.

Screw off the two fastening bolts as shown in MT002
the figure, and then take out the gearshift
cable bracket.

Tightening Torque: 22 N•m

3. Dismantle the selection lever.

Screw off the two fastening bolts for fastening MT003
the selection Lever.

Tightening Torque: 18 N•m

4. Dismantle the speedometer sensor.

Screw off the fastening bolt of the MT004
speedometer sensor as shown in the figure
and take out the speedometer sensor.
Tightening Torque: 3.9 N•m
 Chassis Volume MT-17

5. Dismantle the reversing light switch.

Attention: MT005
Mount the sealing gasket.

Tightening Torque: 32 N•m

6. Dismantle the lifting spring component.

Attention:
Mount the sealing gasket.
7. Dismantle the interlocking plate bolt. MT006
Attention:
Mount the sealing gasket.
Tightening Torque: 30 N•m

8. Dismantle the controller casing.

Screw off the fastening bolt as shown in the MT007
figure.
Tightening Torque: 18 N•m

9. Dismantle the neutral position return spring.

Tightening Torque: 32 N•m

10. Dismantle the lower cover.

MT008
Screw off the lower fastening bolt.
Tightening Torque: 6.9 N•m

11. Dismantle the reversing middle gear shaft bolt.

Attention:
Mount the sealing gasket.
Tightening Torque: 48 N•m
 Chassis Volume MT-18

12. Dismantle the sealing cover.

Expand the spring snap ring, and dismantle Seal cover
MT009
the snap ring from the groove of the roller
bearing.

Remarks:
Once the spring snap ring is expanded, the
spring snap ring will go out due to its gravity
of the output shaft.

MT010

Spring snap ring

13. Screw off the fastening bolts in gearbox and

clutch casing, and then take out the gearbox MT011
casing.

Attention:
The mere part screws are indicated here, and
all fastening bolts shall be screwed off.
Tightening Torque: 44 N•m

14. Dismantle the outer retainer.

Dismantle it with special tool as shown in the
figure. MT012

Outer
retainer
 Chassis Volume MT-19

15. Dismantle the magnetic plug seat.

MT013 5-4-speed gear
16. Dismantle the first-speed － second-speed shifting fork

gear shifting slide rail/first-speed － 2-speed

gear shifting fork. 3-4-speed gear
shifting fork

Attention:
Mount the spring pin

17. Dismantle the third and fourth-speed gear

shifting slide rail/third and fourth-speed gear MT014 3-4-speed gear
shifting fork
shifting fork/fifth-speed and reverse gear
shifting slide rail/fifth-speed and reverse gear
shifting fork. as shown in the following:
① ① Move the third and fourth-speed gear 5-4-speed gear
shifting fork
shifting fork and fifth-speed and reverse gear
shifting fork toward the direction shown in the
figure.

② Slide the third and fourth-speed gear shifting MT015 5-4-speed gear
shifting fork
fork and fifth-speed and reverse gear shifting
fork toward the direction shown in the figure,
3-4-speed gear
and then dismantle it together with the gear shifting fork

shifting fork.

MT016 Input shaft

18. Dismantle the front bearing seat.
Output shaft
19. Dismantle the input shaft.
 Chassis Volume MT-20

20. Dismantle the output shaft.

MT017 Input shaft

Output shaft

21. Dismantle the differential component. MT018

22. Dismantle the clutch casing.

MT019

Check after Dismantlement

1. Reversing light switch.
Check the circuit between terminals for
open circuit.
State of Switch Circuit
When Pressed Open
When Released Connected
 Chassis Volume MT-21

2. Measure the clearance between the output

shaft and its bearing.
3. In case that the clearance exceeds the
specified max. value, check the contact
surface of the first-speed gear and bearing,
and first and second-speed synchronizer
assembly, and replace the damaged or
worn parts.

4. Measure the clearance between the

second-speed and Third-speed gears.

5. In case that the clearance exceeds the

specified max. value, check the contact
surface of the second and third-speed gear
and gears, and first and second-speed
synchronizer assembly, replace the
damaged or worn parts.

Washer

Adjustment before Assemblage

Choose the washer thickness to adjust the
pretightening of the differential.

1. Place the soldering tin sheet (with a length

of 10mm and a diameter of 1.6mm) in the
position of the gearbox casing shown in the
figure, and then mount the outer retainer of
bearing and differential.
2. Mount the clutch casing, and then screw
down the bolt till the specified torque.
3. In case that the soldering tin isn’ t flattened,
replace it with a rough soldering tin sheet.
Repeat the Step (1) and (2).
4. Measure the flattened soldering tin sheet for
its thickness (T) with micrometer calipers,
and then choose the thickness of the
washer mounted on the basis of the
following equation.
Washer Thickness:
（T+0.05mm）~（T+0.11mm）
 Chassis Volume MT-22

Reassembly MT020
1. Mount the differential component.

Differential assembly

Clutch casing

2. Mount the output shaft. MT021 Input shaft

Output shaft

3. Mount the input shaft. MT022 Input shaft

Output shaft

4. Mount the front bearing seat.

5. Mount the fifth-speed and reverse gear MT023
3-4-speed gear
shifting fork/fifth-speed and reverse gear shifting fork

shifting slide rail/third and fourth-speed gear

shifting fork/ gear shifting slide rail.
① Move the third and fourth-speed 5-4-speed gear
shifting fork
synchronizer sleeve and fifth-speed and
reverse synchronizer toward the direction
shown in the figure.
 Chassis Volume MT-23

② Mount the third and fourth-speed gear MT024 3-4-speed gear shifting slide
rail
shifting slide rail and its shifting fork, and
3-4-speed gear shifting fork
the fifth-speed and reverse gear shifting
slide rail and its shifting fork. 5-speed to reversing gear
shifting slide rail

5-4-speed gear
shifting fork

③ Mount the gear shifting forks inside the MT025 5-speed to

reversing gear
sleeve, meanwhile, move the gear shifting shifting
五档-倒档 slide rail
换档导轨
slide rail toward the direction shown in the 3-4-speed gear
shifting slide rail
figure.

MT026 5-4-speed gear

6. Mount the first-speed－second-speed gear shifting fork

shifting slide rail/gear shifting fork.

3-4-speed gear
shifting fork

7. Mount the magnetic plug seat.

8. Mount the outer retainer. MT027
 Chassis Volume MT-24

9. Mount the gearbox casing.

① Extrude sealant of 1.5mm diameter at the MT028
position of the gearbox casing shown in the
figure.
Sealant specified:
JAC genuine brand sealant part No. MD997740
or Equivalents.
Attention:
The sealant line extruded shall keep uniform,
continuous, without break or excessive
coating.

② Mount the gearbox casing, and then expand

the spring snap ring. MT029
③ Screw down the bolt of the gearbox casing
till the specified torque.
Remarks:
Turn over the gearbox to make the output
shaft automatically embedded into the Spring snap ring

groove due to its gravity.

10. Mount the seal cover. Seal cover

Press the seal cover into the bottom as MT030
shown in the figure.

11. Mount the reverse gear middle gear shaft

bolt.
Attention:
Mount the sealing gasket.

12. Mount the lower cover.

① Extrude sealant of 1.5mm diameter at the
position of the gearbox casing shown in the
figure.

Sealant specified:
JAC genuine brand sealant part No. MD997740
Attention:
The sealant line extruded shall keep uniform,
continuous, without break or excessive
coating. MT031
13. Mount the neutral position return spring.
 Chassis Volume MT-25

14. Mount the controller casing.

MT032
① Extrude sealant of 1.5mm diameter at the
position of the gearbox casing shown in the
figure.

Sealant specified:
JAC genuine brand sealant part No. MD997740
Attention:
The sealant line extruded shall keep uniform,
continuous, without break or excessive
coating.

MT033

15. Mount the interlocking plate bolt。

MT034
Attention:
Mount the sealing gasket.
Tightening Torque: 30 N•m

16. Mount the lifting spring component.

Attention:
Mount the sealing gasket.
Tightening Torque: 32 N•m
17. Mount the reversing light switch.
Attention:
Mount the sealing gasket.
Tightening Torque: 32 N•m
 Chassis Volume MT-26

18. Mount the speed sensor.

O-seal ring
Coat the gearbox oil on the O-seal ring on
the speed sensor gear, which shall conform
to the Class API hypoid gear lubricating oil
SAE 75W/85W of over GL-4.

19. Choose the selector rod. Control shaft

Coat the slide surface of the control shaft of MT037

the selector rod supporting cushion block
Cushion block of
with lubricating grease. selector rod

Specified lubricating grease:

JAC genuine brand sealant part No. 0101011

20. Mount the gear shifting cable bracket. MT038

Tightening Torque: 18 N•m

21. Mount the roll restrictor bracket.

Attention: MT039
One at each side
Tightening Torque: 22 N•m
 Chassis Volume MT-27

Input Shaft
Dismantlement and Reassembly

Lubricating all inner parts with gear oil in

the assembly

1. Snap ring 2. Roller bearing

3. Thrust plate restrictor 4. Thrust plate

5. Fifty-speed gear 6. Fourth-speed gear

7. Needle bearing 8. Fourth-speed gear sleeve

9. Synchronizer ring 10. Synchronizer spring

11. Synchronizer sleeve 12. Third and fourth-speed Synchronizer hub

13. Synchronizer ring 14. Synchronizer spring

15. Third-speed gear 16. Needle bearing

17. Snap ring 18. Front bearing

19. Oil seal 20. Input shaft

 Chassis Volume MT-28

Dismantlement Steps:
MT040
1. Dismantle the snap ring. Special tool

2. Dismantle the roller bearing.

3. Dismantle the thrust plate restrictor/thrust MT041

Special tool
plate.
4. Dismantle the fifty-speed gear.

5. Dismantle the fourth-speed gear sleeve.

MT042
Mount a special tool on the third-speed gear
Special tool
to dismantle the fourth-speed gear sleeve.

6. Dismantle the needle bearing/fourth-speed MT043

gear sleeve. Special tool

7. Dismantle the synchronizer sleeve/synchronizer spring/synchronizer ring.

8. Take down the third and fourth-speed synchronizer hub.
9. Dismantle the synchronizer sleeve/synchronizer spring/synchronizer ring.
10. Dismantle the third-speed gear/needle bearing.
11. Dismantle the snap ring /front bearing.
 Chassis Volume MT-29

12. Dismantle the oil seal.

Check after Dismantlement

1. Input shaft
① Check the outer diameter surface at the
installation part of the needle bearing for
damage, abnormal abrasion or seizure.
② Check the spline for damage or abrasion.

2. Needle bearing
Check the input shaft and gear for correct
assembly, smooth rotation, looseness or
noise.
3. Synchronizer ring
① Check the gearbox surface of the clutch
gear for damage.
② Check the conical surface for damage or
abrasion, the screw for crushing.

③ Place the annular gear of the synchronizer

under the pressing state, and then check
the clearance “A”. If “A”is less than the limit
value, replace it.
Limit value: 0.5mm

Synchronizer ring Gear

4. Synchronizer sleeve and hub

① Mount the synchronizer sleeve and hub
together, and then check them for
smoothness and seizure.

② Check the front and rear ends inside the

sleeve for damage.
Attention:
In case of replacement of synchronizer
sleeve or hub, the complete set of them shall
be replaced.
 Chassis Volume MT-30

5. Synchronizer spring
Check the spring for looseness, deformation
or damage.
6. Speed gear
① Check the tooth flank of the inclined gear
and clutch gear for damage or abrasion.
② Check the conical surface of the
synchronizer for roughening, damage or
abrasion.
③ Check the inner diameter of gear and front
and rear ends for damage or abrasion.

Reassembly MT044
1. Mount the oil seal. Oil seal

Press the oil seal in till the dimension shown

in the figure.

2. Mount the roller bearing. MT045 Special tool

Mount it with special tool.

Special tool

Special tool
Special tool

3. Mount the spring snap ring.

MT046
Choose the thickness of spring snap ring to
make the axial clearance of the input shaft
front bearing in conformity with the
standard.

Standard value: -0.01~0.12mm Spring snap ring

 Chassis Volume MT-31

4. Mount the third-speed gear/needle bearing.

5. Mount the synchronizer spring. MT047
Mount the synchronizer spring at the position
shown in the figure.

Synchronizer spring

6. Mount the third and fourth-speed MT048

synchronizer hub.
Mount the third and fourth-speed
synchronizer hub at the position shown in
Rear of gearbox
the figure.
Attention:
During the reassembly of the synchronizer
ID mark
hub, confirm the synchronizer ring is not
blocked.

MT049 Special tool

Special tool
Special tool
Special tool

7. Mount the synchronizer sleeve.

MT050
① Fit the synchronizer at the position shown in Rear of gearbox

the figure.

ID mark
 Chassis Volume MT-32

② When mounting the synchronizer sleeve, Synchronizer sleeve

confirm that the two deep tooth grooves of MT051
the synchronizer hub in appropriate
conformity with the two high tooth bars of
the sleeve.

Synchronizer wheel
hub

8. Mount the fourth-speed gear sleeve.

MT052 Special tool

Special tool

Special tool Special tool

9. Mount the fifty-speed gear. MT053

Special tool

Special tool

Special tool Special tool

专用工具

10. Mount the thrust plate restrictor. Limiter of thrust

MT054 plate
Before mounting the thrust plate, confirm
that the thrust plate for inclination.

Thrust plate
 Chassis Volume MT-33

11. Adjust the thrust plate’

s thickness to make
MT055
the axial clearance of the input shaft
fifty-speed gear in conformity with the
standard.
Standard value:
-0.01~0.09mm

Thrust plate

11. Mount the roller bearing.

MT056 Special tool

Special tool
Special tool

12. Mount the spring snap ring.

MT057
Choose the thickness of the spring snap
ring to make the axial clearance of the rear
bearing of the input shaft in conformity with
the standard.
Mount the spring snap ring:
Spring snap
Standard value: 0.01~0.12mm ring
 Chassis Volume MT-34

Output Shaft
Dismantlement and Reassembly

Lubricating all inner parts with

gear oil in the assembly

1. Spring snap ring 2. Roller bearing

3. Reversing gear sleeve 4. Needle bearing
5. Reversing gear 6. Synchronizer ring
7. Synchronizer spring 8. Synchronizer sleeve
9. Fifth-speed and reverse synchronizer hub 10. Synchronizer ring
11. Synchronizer spring 12. Fifty-speed gear
13. Needle bearing 14. Fifth-speed gear sleeve
15. Fourth-speed gear 16. Spring snap ring
17. Third-speed gear 18. Second-speed gear
19. Needle bearing 20. Second-speed gear sleeve
21. Inner synchronizer ring (including 22 and 23） 22. Synchronizer friction cone
23. Outer synchronizer ring 24. Synchronizer spring
25. Synchronizer sleeve 26. First and second-speed synchronizer
hub
27. Synchronizer ring group 28. Synchronizer spring
29. First-speed gear 30. Needle bearing
31. First-speed gear sleeve 32. Spring snap ring
33. Inner retainer of roller bearing 34. Output shaft
 Chassis Volume MT-35

Dismantlement Steps: MT058 Ball bearing

1. Dismantle the spring snap ring. Special tool

2. Dismantle the roller bearing.

3. Dismantle the reversing gear bearing sleeve

with special tool, fit the special tool on the MT059
Sleeve
reversing gear, and then dismantle the Special tool

reversing gear bearing sleeve.

4. Take down the needle bearing/reversing MT060 Sleeve

Special tool
gear/synchronizer ring/synchronizer ring.
5. Dismantle the reversing gear bearing sleeve.
Fit the special tool on the reversing gear,
and then dismantle the reversing gear
bearing sleeve.

6. Dismantle the fifth-speed and reverse MT061 Synchronizer wheel

synchronizer hub. Special tool hub

Fit the special tool on the second-speed

gear, and then dismantle the third-speed
gear.

7. Take down the synchronizer ring and

spring.
 Chassis Volume MT-36

8. Dismantle the fifty-speed gear/needle MT062

bearing/fifth-speed gear sleeve. 3-speed gear

9. Take out the fourth-speed gear.

Special tool
10. Dismantle the third-speed gear. Fit the
special tool on the second-speed gear, and
then dismantle the third-speed gear.

11. Take down the second-speed gear and MT063

needle bearing.
12. Dismantle the second-speed gear sleeve.
Sleeve
Fit the special tool on the third-speed gear, Special tool

and then dismantle the fourth-speed gear

sleeve.

13. Dismantle the inner synchronizer ring/synchronizer spring.

14. Dismantle the synchronizer sleeve.
15. Dismantle the first and second-speed synchronizer hub.
16. Take down the synchronizer ring/synchronizer spring.
17. Dismantle the first-speed gear roller bearing/needle bearing/first-speed gear sleeve.
18. Dismantle the spring snap ring, and then take out the inner retainer of the roller
bearing.
Check after dismantlement
1. Output shaft
Check the spline part for damage or
abrasion.

2. Needle bearing
① Mount the bearing sleeve and gear together to check them for smoothness,
looseness or with noise.
② Mount the synchronizer ring.
③ Check the gearbox of speeds for damage or abrasion.
 Chassis Volume MT-37

3. Speed gear
① Check the teeth of the clutch gear for
damage or abrasion.
② Check the conical surface for damage or
abrasion, the screw for crushing.

③ Press the annular gear of the synchronizer

down, and then measure the clearance “A”.
If the “A”is less than the limit value, replace
it.

Limit value: 0.5mm

Synchronizer ring Gear shifting fork

4.Outer synchronizer ring/inner synchronizer

ring/synchronizer conical ring
① Check the tooth and conical flanks of the
clutch gear for cruise or damage.

② Mount the outer and inner rings, and then

measure the clearance “A”in the state of Gear

pressing them toward the gear. If the “A”is

less than the limit value, replace it.
Outer ring

Limit value: 0.5mm

Attention: Conical ring

If the replacement of the outer, inner or

conical ring is necessary, the complete set of
Inner ring
them shall be replaced.
 Chassis Volume MT-38

5. Synchronizer sleeve and hub

① Mount the synchronizer sleeve and hub
together, and then check them for smooth
sliding.

② Check the front the front and rear ends

inside the sleeve for damage.
Attention:
If the replacement of the synchronizer sleeve
or hub is necessary, the complete set of
synchronizer sleeve and hub shall be
replaced.

6. Synchronizer spring
Check the spring for looseness, deformation
or abrasion.
7. Transmission gear
① Check the tooth flank of the inclined gear
and the clutch gear for damage or abrasion.
② Check the conical ring surface of the
synchronizer for roughing, damage or
abrasion.
③ Check the front and rear ends inside the
gearbox for damage or abrasion.

MT064 Special tool

Reassembly Special tool Special tool

1. Mount the inner retainer of the roller bearing

(with special tool shown in the figure). Inner retainer

MT065
2. Mount the spring snap ring. Special tool

Choose and then mount the spring snap

ring to make the axial clearance of the Special tool
output shaft front bearing in conformity with
Sleeve
the standard value. Special tool
Standard value: -0.01~0.12mm
3. Mount the first-speed gear sleeve.
 Chassis Volume MT-39

4. Mount the first-speed gear. MT066

5. Mount the synchronizer spring.
Mount the synchronizer spring at the position
shown in the figure.

Synchronizer spring

6. Mount the first and second-speed

MT067
synchronizer hub.
The reassembly of the synchronizer hub is
shown in the figure.
Rear of gearbox
Attention:
Before mounting the synchronizer hub,
confirm the synchronizer ring for seizure.
ID mark

MT068 Special tool

Special tool

Synchronizer
wheel hub Special tool

7. Mount the synchronizer sleeve.

① Mount the synchronizer sleeve at the
MT069
position shown in the figure. ID groove

Rear of gearbox

Synchronizer sleeve
MT070
② Before mounting the synchronizer sleeve,
confirm that two deep teeth grooves of the
synchronizer hub are aligned to the two high
teeth bars of the sleeve.

Synchronizer hub
 Chassis Volume MT-40

8. Mount the synchronizer spring.

MT071

Synchronizer spring

9. Mount the second-speed gear sleeve. MT072

Special tool

Special tool

Thrust plate of Special tool

sleeve

10. Mount the second-speed gear.

11. Mount the third-speed gear.

MT073 Special tool

Special tool

3-speed gear

Special tool

12. Mount the spring snap ring.

Choose and then mount the spring snap MT074
ring to make the axial clearance of the
third-speed gear on the output shaft in
conformity with the standard value.
Standard value: -0.01~0.09mm

Spring snap ring

 Chassis Volume MT-41

13. Mount the fourth-speed gear. MT075 Special tool

Special tool

Special tool
4-speed gear

14. Mount the fifty-speed gear sleeve. MT076 Special tool

Special tool

Special tool
Sleeve

15. Mount the fifty-speed gear.

16. Mount the fifth-speed and reverse MT077
Synchronizer hub.
Mount the fifth-speed and reverse
synchronizer hub at the position shown in
the figure. Rear of gearbox

Attention:
Before mounting the fifth-speed and reverse ID mark
synchronizer hub, confirm that the
synchronizer ring isn’t seized.

MT078 Special tool

. Special tool

Synchronizer
hub Special tool
 Chassis Volume MT-42

17. Mount the reversing gear/needle

bearing/reversing gear bearing sleeve. MT079
Special tool

Reversing gear

Sleeve

18. Mount the spherical bearing.

MT080 Special tool

Special tool
Ball bearing

19. Mount the spring snap ring.

Choose and then mount the spring snap MT081
ring to make the axial clearance of the rear
bearing on the output shaft in conformity
with the standard value.
Standard value: -0.01~0.09mm

Spring snap ring

 Chassis Volume MT-43

Reversing Middle Gear

Dismantlement and Reassembly

Lubricating all inner parts

with gear oil in the assembly

1. Spring snap ring 2. Thrust washer

3. Reversing middle gear 4. Needle bearing
5. Reversing middle gear shaft

Dismantlement Steps

1. Dismantle the spring snap ring.

2. Take out the thrust washer.
3. Take out the reversing middle gear.
4. Dismantle the Needle bearing.

Check after Dismantlement

Needle bearing
1. Mount the shaft and gear together, and then check them for smoothness, loose
sliding or with noise.

2. Check the bearing retainer for deformation.

Reassembly
The reassembly is in reverse order compared to the dismantlement.
 Chassis Volume MT-44

Speedometer Gear
Dismantlement and Reassembly

Lubricating all inner parts

with gear oil in the
assembly

1. E-clamp 2. Speedometer gear

3. O-seal ring 4. Speed sensor

Dismantlement Steps
1. Dismantle the E-clamp.
2. Dismantle the speedometer gear.
3. Dismantle the O-seal ring.

Check after Dismantlement

1. Check the teeth of the speedometer gear for being broken, if any, replace it.
2. Check the O-seal ring for aging, the elasticity for deformation.

Reassembly
The reassembly is in reverse order compared with the dismantlement.
Attention:
Before the reassembly, the O-seal ring shall be coated with lubricating oil.
 Chassis Volume MT-45

Selector Rod
Dismantlement and Reassembly

1. Dustproof cover 2. Nut

3. Spring washer 4. Washer
5. Liner of selector rod 6. Slide block of selector rod
7. Selector rod 8. Liner of selector rod
9. Dustproof cover 10. Shaft of selector rod

Dismantlement Steps
1. Dismantle the dustproof cover.

2. Screw off the fastening nut.

Attention:
Spring washer and washer

3. Take down the selector rod.

Attention:
Liner sleeve of selector rod and dustproof cover

4. Dismantle the shaft of selector rod.

 Chassis Volume MT-46

Dustproof
Check after Dismantlement
1. Check the sealing gasket for damage, and
the dustproof Cover for damage, if any,
replace them.
2. Check whether the slide block can freely
slide.

Reassembly
The reassembly is in reverse order compared to the dismantlement.

Attention:
The dustproof cover shall be mounted at the position shown in the figure.
Before the reassembly, the O-seal ring shall be coated with lubricating grease of
certain amount.
 Chassis Volume MT-47

Controller Casing
Dismantlement and Reassembly

1. Bolt 2. Spring mattress

3. Pin 4. Return spring
5. Limit plate 6. Restrictor support
7. Interlocking plate 8. Lockpin
9. Control claw 10. Stopper sleeve casing
11. Neutral position return spring 12. Neutral position return spring seat
13. Controller casing 14. Needle bearing
15. Oil seal 16. Control shaft cover
17. Control shaft component 18. Ventilating tube
Dismantlement Steps
1. Dismantle the two fastening bolts, when attention shall be paid to the spring mattress.
2. Dismantle the pin, return spring and limit plate.
3. Take down the restrictor bracket.
4. Dismantle the lockpin.
MT082
Strike the lockpin out as shown in the figure.
Storage pin

Control handle

5. Dismantle the control claw.

6. Take out the stopper body.
7. Dismantle the neutral position return spring/neutral position return spring seat.
8. Dismantle the control shaft casing.
9. Dismantle the needle bearing/oil seal/control shaft cover.
10. Dismantle the control shaft component.
11. Dismantle the ventilating tube.
 Chassis Volume MT-48

Check after Dismantlement

1. Check the return spring for its strength and elasticity, if it is excessive loose, replace
it.
2. Check the needle bearing.
① Mount the control shaft and controller casing together, and then check them for
smoothness, sliding or with noise.
② Check the shaft cage for deformation.
MT083

Reassembly
1. Mount the air port.
① Coat the surface inserted with sealant.
Specified Sealant:
3M SUPER WEATHERSTRIP No.8001 or
equivalents

MT084
② Confirm that the projection faces the arrow
direction.

2.Mount the control shaft component/needle MT085

Control hood
bearing/oil seal/control shaft cover. casing

① Mount the needle bearing

Needle
Press the needle bearing in the dimension bearing
shown in the figure.
Face with model
At this moment, the side with model countermark
countermark shall be controlled at one side
of the controller casing.

② Mount the oil seal MT086

Coat the lip of oil seal with gearbox oil.
Gearbox oil:
In conformity with the Class API hypoid
gearbox oil SAE 75W/85W of over GL-4.
 Chassis Volume MT-49

3. Mount the neutral position spring seat and

spring. MT087
Lock pin

4. Mount the limiter body and control claw.

5. Mount the lockpin.

Strike the lockpin in toward the direction Control handle
shown in the figure.

6. Mount the limiter bracket, limit plate and MT088 Localizer

Control shaft
return spring.

7. Mount the pin.

Mounting
The reassembly method is shown in the direction

figure. Gap

Spring pin

Spring pin
MT089

8. Mount the fastening bolt.

 Chassis Volume MT-50

Clutch Casing
Dismantlement and Reassembly

1. Release bearing seat of clutch 2. Oil seal

3. Oil seal 4. Outer retainer
5. Roll bearing 6. Outer retainer
7. Liner 8. Clutch casing

Dismantlement Steps MT090

1. Dismantle the release bearing of the clutch.
2. Take down the oil seal.
3. Dismantle the outer retainer.
Dismantle it with special tool shown in the
figure.

MT091

Dismantle it with special tool shown in the

figure.

Retainer
 Chassis Volume MT-51

4. Dismantle the roller bearing.

5. Take out the liner.

Check after Dismantlement

1. Oil seal
Check the oil seal for damage.
2. Roller bearing
Check the roller bearing for looseness.
3. Check the clutch casing for deformation.

Reassembly
1. Mount the liner. MT092
Press the liner into the position shown in the Cut end
Exhaust groove
figure to make the liner cut end inconsistent
with the air groove.

Position shown in the figure

2. Mount the outer retainer.

① Mount the outer retainer to make the model MT093
countermark side at the position shown in
the figure. Model countermark
side

② Mount the outer retainer.

MT094
 Chassis Volume MT-52

3. Mount the oil seal. MT095

Coat the gearbox oil at the lip of the oil seal.
Specified Oil:
Class API hypoid gearbox oil SAE 75/85W of
over GL-4.

4. Mount the release bearing of the clutch. MT096

 Chassis Volume MT-53

Gearbox Casing
Dismantlement and Reassembly

1. Oil seal 2. Needle bearing

3. Lubricating oil conduit 4. Snap ring
5. Liner 6. Gearbox casing

Dismantlement Steps
1. Dismantle the oil seal.

2. Take down the needle bearing.

3. Dismantle the lubricating oil conduit.

4. Dismantle the liner.

Check after Dismantlement

1. Check the oil seal for trouble.

2. Check the needle bearing for looseness or abrasion.

 Chassis Volume MT-54

Reassembly
1. Mount the liner. MT097
Cut end

Press the liner into the position shown in the

figure to make the liner cut end inconsistent
with the air groove.

Exhaust groove

MT098

2. Mount the lubricating oil conduit.

Model
3. Mount the needle bearing. MT099 countermark

Press the needle bearing in till being aligned

with the casing surface, and then confirm
that the model countermark surface is at the
position shown in the figure.

MT100
4. Mount the oil seal.
Coat the gearbox oil on the lip of the oil
seal.
Specified Oil:
Class API hypoid gearbox oil SAE 75/85W of
over GL-4.
 Chassis Volume MT-55

Differential

Dismantlement and Reassembly

Lubricating all inner parts

with gear oil in the assembly

1. Drive gear of differential 2. Tapered roller bearing

3. Lockpin 4. Pinion spoke
5. Pinion 6. Washer
7. Side gear 8. Spacer ring
9. Differential casing

Dismantlement Steps
1. Dismantle the drive gear of the differential. MT101
2. Dismantle the tapered roller bearing.

3. Take out the lockpin, and then dismantle the pinion spoke, pinion and side gear.
 Chassis Volume MT-56

Washer and Spacer Ring

Check after Dismantlement

1. Check the gearbox for abrasion.
2. Check the tapered roller bearing for looseness and with stain, if any, replace it.

Reassembly
1. Mount the washer/half axle gear/washer/planet gear/planet gear shaft.
① Mount the washer at the rear of the half axle gear, and then mount the half axle gear
into the differential casing.

Remarks: before mounting new half axle, choose a washer of medium thickness
(0.93−1.00mm).

② Mount the washer at the rear of the planet MT103

gear to make it joggle with the half axle gear
at 7 points simultaneously, rotate it to make
it mounted into the specified position.

③ Insert the planet gear shaft. Measure the

rotating moment of half axle gear. MT104
Specified Value: 0 N•m MAX
 Chassis Volume MT-57

2. Mount the lockdown pin at the position MT105

Differential
shown in the figure. body Lock pin

Pinion shaft

3. Mount the ball bearing.

Mount it with special tool shown in the MT106
figure.
Ball bearing

4. Mount the main decelerating driven gear.

① Coat the sealant on whole screw part of the MT107
bolt.
Specified sealant: LT243

② Screw down to the specified moment in the

order shown in the figure.
MT108
 Chassis Volume MT-58

Selector Rod Assembly

Dismantlement and Reassembly
Parts Composition Drawing

Handle

Reversing
lever

Casing body

Support

Unit for moment: N•m

Dismantlement Steps
1. Dismantle the auxiliary console platform assembly (refer to the auxiliary console
platform of the inner decoration).
2. Dismantle the split pin and clamp (at one side of selector rod).
3. Dismantle the gearbox shifting mechanism assembly.
4. Dismantle the bolt.
5. Dismantle the split pin and clamp (at one side of gearbox).
6. Dismantle the gearbox shifting and selector guys.

MT109
 Chassis Volume MT-59

Check:
Check the selector guy for normal operation or damage.
Check the gearbox shifting guy for normal operation or damage.
Check the protective cover for damage.
Check every liner for abrasion, peel off, adherence, unsmooth rotation or damage.
Check the elasticity of return spring for lower or damage.

Reassembly:

1. Coat the multi-purpose lubricating grease on the sliding surface of the liner.
2. The reassembly is in reverse order compared to the dismantlement.
 Chassis Volume MT-60

Common Troubles and Countermeasure

The common troubles of the mechanical transmission involve oil leakage, abnormal
noise, trip stop and confused gears.

Oil leakage:
1. Trouble: the periphery of the gearbox and casing side covers, screw plugs of filler and
discharge ports, first shaft oil return screw, second shaft oil seal (or return oil screw)
or bearing covers with obvious oil leakage.
2. Cause:
① The binding plane deforms.
② The sealing gasket is excessive thin, hardened or damaged at the binding plane.
③ The fastening screws at the gearbox, casing side and bearing covers are loosened or
their fastening sequences are in unconformity with the requirements.
④ The oil seal and axle neck are mounted on different shaft, oil seal is mounted
reversely, abraded or hardened, or the axle neck and shaft are mounted on different
shaft.
⑤ The oil return screw and axle neck are mounted on different shaft, the oil return screw
groove deposits seriously or has burr to block the oil return.
⑥ The axle neck of the oil seal is abraded into groove.
⑦ The screw plug at the oil inlet or outlet is loosened or the screw is damaged.
⑧ The casing with casting defect or crack.

Abnormal noise:
1. Trouble: loudly joggle noise of the transmission gear or running noise of bearing;
abnormal noise of the gearbox such as dry grinding and impact.
2. Cause:
① The roller bearing lacks oil (such as the front guide bearing of the first shaft), the ball
bearing deforms due to abrasion, the rolling passage has mottling, delamination or
scars, the inner and outer rolling passages rotate on the shaft or in the casing, or the
bearing clearance is excessive.
② The poor gear processing accuracy or inappropriate heat treatment results in gear
deflection or gear shape changed.
③ Excessive teeth or spline matching clearance.
④ No finishing on the tooth flank maintained for burr and swell is made.
⑤ The teeth flank peels off, delaminates, defects or abrades excessively or the gears
aren’
t replaced in pairs in the maintenance course.
⑥ The first, second and middle shafts deforms due to bend.
⑦ After the maintenance of the bearing hole on the casing, the central distance of the
 Chassis Volume MT-61

two holes changes or the two axial lines are unparallel.

⑧ The gearbox shift fork after maintained has the camber unaligned or it after abraded
is too thick in single pile welding, resulting in the associate gear location unaligned.
⑨ The fastening nut of the second shaft loosened or the axial orientation of other shafts
unaligned; some gear teeth broken.
⑩ The sunken groove or steel ball of the self-locking device is seriously abraded or the
self-locking spring is worn out or broken, resulting in the gearbox shift offside; the
insufficient or deteriorated gearbox oil, gearbox oil in unconformity with requirements
or gearbox oil with foreign substances.

Trip stop:
1. Trouble: the vehicle accelerates or climbs over slope with heavy load, the gearbox
shift lever will automatically jump return to the neutral position sometimes.
2. Cause:
① A pair of clutch gears joggled are abraded into cone shape at the joggled position.
② Owing to change of the central position of the clutch casing rear hole or verticality of
the relative crankshaft axial line of the binding plane of the clutch and gearbox casing,
or excessive looseness of the bearings of first and second shafts, the first and second
shafts and crankshaft are on the same axial line.
③ The insufficient joggle or the self-locking steel ball doesn’
t go into the sunken groove
after gear shift.
④ The axial or radial clearance of shafts is excessive.
⑤ For the gearbox with multiple joggled gears, the joggled gear on the second shaft has
excessive axial or radial clearance.
⑥ The sunken groove or steel ball of the self-locking device is seriously abraded or the
self-locking spring is worn out or broken.

Confused gear:
1. Trouble: in the state of the clutch separated completely, the gearbox cannot be
shifted, or the gearbox is confused.
2. Cause:
① The interlocking device is damaged.
② The lower end of the gearbox shift lever is insufficient in length, the lower work
surface or the guide groove of the guide block on the gearbox shift fork shaft is
abraded excessively.
③ The locating pin of the ball head of the gearbox shift lever is loosened or broken, or
the ball head and hole is abraded excessively.
 Chassis Volume CL-1

Overview
The clutch connects engine and transmission. Its separation allows the driver to choose
appropriate gear. When firstly driving the vehicle of manual transmission, the release of
clutch pedal for first several times will result in extinction or abrupt tremble forward, but
after that, you shall make the clutch act gently, slowly close the clutch, and then make the
engine rev. rise up, at this moment the vehicle can start from the parking location. The
main spare parts of the clutch assembly include pressure disc assembly, flywheel and
clutch driven disc. The former two are the driving part of the clutch (input components).
The clutch driven disc connects with the input shaft of the transmission by spline so as to
transmit power to the transmission. When the clutch is closed, the clutch driven disc is
clamped between the flywheel and pressure disc tightly to make the rotating moment of
engine to the transmission. When the clutch is open, the pressure disc moves to depart
from the clutch driven disc flywheel, at this moment, the pressure on the driven disc is
relieved, and the power transmitted by way of the clutch breaks.

Basic Specifications
Item Specification
Work mode of clutch Hydraulic
Type of clutch disc Dry-type single film spring
Type of clutch cover Film spring

Overhaul Specifications
Item Specification (Limit Value)

Immersion depth of rivet into clutch surface 0.3

Height difference at film spring end 0.5
Clearance between inner circle of disengage 0.15
cylinder and outer circle of piston

Tightening Torque
Item Specification N•m
Clutch disengage cylinder and its oil inlet 18~30N•m
tube assembly connected with steel tube of
clutch
Hydraulic oil tube bracket of clutch 18
Disengage cylinder adaptor of clutch 22
Disengage cylinder deflation screw plug of 11
clutch
Disengage cylinder reassembly bolt of clutch 18

Ball screw 35
 Chassis Volume CL-2

Precautions:
1. The recommended clutch fluid is the brake fluid “DOT 4”.
2. No repetitive use of the clutch fluid discharged is allowed.
3. Take care not to splash clutch fluid on the lacquer finish.
4. Apply new clutch fluid to wash all spare parts of main cylinder and concentric driven
cylinder.
5. No use of mineral oil including gasoline and coal oil is allowed, otherwise the rubber
parts in the hydraulic system will be eroded.
6. Dismantle the mat when checking the clearance between clutch pedal and floor.
7. The sliding parts of clutch sheet stained with oil dirt will damage the seal ring,
accordingly resulting in leakage of clutch fluid.
8. No separation of main and driven cylinders is allowed.

Warning:
When maintaining the clutch components, no treatment with sand paper or brush or
compressor is allowed against dust, but the cleaning with cloth dipped with water shall be
carried out. The friction sheet of clutch contains asbestine fiber, supposing that the dust is
produced in maintenance, the asbestine fiber in dust will be suspended in air, which will
result in serious injury on human bodies after air with asbestine fiber is inhaled.

Preparations:
Special Maintenance Tool

Tool Name Purpose

Reassembly of clutch
Guide sleeve of clutch disc
disc
 Chassis Volume CL-3

Clutch Pedal
Dismantlement and Reassembly

Dismantlement Steps:
1. Screw off the fastening nut of clutch handspike and brake pedal.
2. Dismantle the fastening screw cap of clutch support and general brake pump.
3. Take out the clutch pedal assembly parts.

Reassembly:
The reassembly is in reverse order compared with the dismantlement.

Dismantlement of Clutch Pedal:

Dismantlement Steps:
1. Screw off the fastening bolt of clutch pedal and support.
2. Dismantle the clutch pedal, return spring and liner, etc.

Reassembly:
The reassembly is in reverse order compared with the dismantlement.
Attention:
The spring liner shall be coated with lubricating grease in the reassembly process.
 Chassis Volume CL-4

Inspection of Clutch Pedal

Inspection Baffle height Handspike Locknut
1. Check the pedal shaft liner for abrasion.
2. Check the pedal shaft for bend.
3. Check the pedal boom for bend or twist.
4. Check the clutch pipeline and reservoir
hose for crack or blockage.
5. Check the spring for aging. Locknut
Adjusting
6. Check the pedal pad for damage or abrasion. bolt

1.3kgm
The damaged or deformed ones discovered
in the check shall be replaced.
Adjustment of Clutch Pedal
1. Remove the pedal pad below the clutch pedal.
Pedal play
2. Measure the height of clutch pedal.
Standard value of clutch pedal height (A):
162 — 167mm
3. If the height of the clutch pedal exceeds
the standard value, unscrew the
lockdown nut, and then adjust the clutch
pedal height till the standard value by
way of adjusting the length of handspike.
Finally, adjust the length of limit bolt to
make the bolt and limit support on the
pedal contact exactly.
Attention: at this moment, don’t press the handspike of the main cylinder inward.
The limit bolt only functions auxiliary
limiting.
4. Confirm the free stroke of the clutch
pedal, and the distance between the Free stroke of clutch pedal Clearance between pedal and
footrest when the clutch pedal
clutch pedal and footrest within the range at the bottom

of standard value when the clutch is

separated.
Free stroke of clutch pedal
Standard value (C): 6 ~ 13mm
Standard value of distance between the
clutch pedal and footrest when the clutch is
separated (D): over 85mm.
5. If the free stroke of the clutch pedal and
the clearance are out of the range of the
standard value, please deflate the
hydraulic system or check the main
cylinder or clutch body.
6. Lay back the pedal pad.
 Chassis Volume CL-5

Clutch Assembly
Components Drawing

Transmission assembly

Clutch cover Clutch disc

Side Cover of Clutch and Clutch Disc

Dismantlement and Reassembly
Dismantlement Steps:
1. Fit the special tool. Special tool

2. Loosen the bolt for a circle once clockwise till the spring has no tension.

3. Dismantle the side cover of clutch and clutch disc.

 Chassis Volume CL-6

Reassembly
Reassembly of Clutch Disc
1. Lock the clutch disc with special tool.

Reassembly of Side Cover of Clutch Special tool

1. Fit the special tool.
2. Gradually screw down the bolt clockwise.
Tightening Torque: 18.6-25.5N•m

Special tool

Flywheel
Dismantlement and Reassembly
Dismantlement Steps:
Special tool
1. Fasten the flywheel with special tool.

2. Dismantle the bolt clockwise slowly and

steadily.
3. Take down the flywheel.

Reassembly Special tool

1. Mount the flywheel on the crankshaft.
2. Please clean the screw thread and bolt
hole before reuse of bolt, and then coat
the bolt with locking glue.

Attention:
The locking glue is unnecessary in the usage of new bolt.
3. Screw down the lockdown bolt of flywheel
manually.
4. Fit the special tool on the flywheel. Special tool
5. Gradually screw down the lockdown bolt
of the flywheel clockwise.
Tightening Torque: 108-115N•m
 Chassis Volume CL-7

Attention:
The lubricating grease of appropriate amount shall be coated on every part to prevent the
clutch from slide and shake.

Check of Clutch Assembly

1. Clean the clutch casing by way of vacuum dust remover or cloth, but not compressed
air. Check the rear bearing oil seal of the engine and front oil seal of the gearbox for
oil leakage. If oil leakage exists, repair it.
2. The friction surface of the pressure disc shall uniformly contact with surface of clutch
disc. In case that some position is excessively abraded, it indicates that the pressure
disc is mounted inappropriately.
3. Check the friction surface of flywheel for color change, partial damage, little crack or
abrasion.

Check of Clutch
Sinkage of rivet
1. Don’
t touch the clutch disc with dirty hand or
sleeve. In case that the friction liner is
contaminated by oil or lubricating grease, replace
the clutch disc. Measure the rivet depth. If it is less
than 3mm, replace it.
Limit Value: 0.3mm
2. Check the wheel hub spline and torsion spring in
the clutch disc for excessive abrasion.
3. Wash the friction surface of the pressure
disc with detergent.
4. Check the three anchor pins on the flywheel for being mounted into position.
5. Mount the clutch sheet and input shaft, and then check the slide and clearance under
its rotation. Supposing that no smooth slide or excessive clearance exists, recheck
them after washing and assembly. If the clearance is excessive, replace the clutch
sheet or input shaft.

Release Bearing of Clutch

Attention:
Since the release bearing is filled with
lubricating grease, the detergent or similar
liquid cannot be used for wash it.
1. Check the bearing for seizure, damage,
with noise, or abnormal rotation.
Meanwhile, check the film spring contact
surface for abrasion.
2. If the contact surface of the shifting fork is
abraded abnormally, replace the bearing.
 Chassis Volume CL-8

Reassembly of Release Bearing

Coat the position of the release bearing of

Lubricating
clutch shown in the figure with lubricating

grease
grease.

Specified Lubricating Grease

JAC pure brand lubricating grease

Detachable Shifting Fork

Supposing the contact surface with the release bearing is abraded, replace the
detachable shifting fork.

Dismantlement Steps:
1. Dismantle the shifting fork in the direction
shown in the figure.

Release
yoke

2. Reassembly Coating with

Note: lubricating
grease
Coat the position shown in the figure with
Filling
lubricating grease. lubricating
grease

Filling
lubricating
grease
 Chassis Volume CL-9

Hydraulic System of Clutch

Main Cylinder of Clutch

Dismantlement Steps:
1. Drain out the brake fluid.
2. Dismantle the brake oil tube.
3. Dismantle the anchor pins for main cylinder handspike and clutch pedal.
4. Screw off the fastening bolts for clutch support and main cylinder.
5. Take down the main cylinder of the clutch.

Reassembly
The reassembly is in reverse order compared with the dismantlement.
Attention:
Exhaust the clutch after the completion of reassembly.
Dismantlement of main cylinder of clutch:
Don’
t dismantle the main cylinder of the clutch, if necessary, the whole replacement can
be carried out.
 Chassis Volume CL-10

Release Cylinder of Clutch

Dismantlement and Reassembly
Dismantlement Steps:
1. Drain out brake fluid.
2. Dismantle the oil tube.
3. Dismantle the two fastening bolts of the release cylinder.
4. Take out the release cylinder of clutch.

Check after Dismantlement:

Check the oil tube adaptor for leakage and the dustproof cover for damage.

Reassembly
The reassembly is in reverse order compared with the dismantlement.
Attention:
Exhaust the system of air after the reassembly of the release cylinder of clutch.
 Chassis Volume CL-11

Dismantlement of Release Cylinder of Clutch

1. Cylinder body 2. Deflation bolt

3. Handspike 4. Dustproof cover
5. Piston 6. Piston ring
7. Bolt

Dismantlement Steps:
1. Take out the dustproof cover.
Attention:
Take care not to damage the dustproof cover. The damaged dustproof cover shall
be replaced with a new one.
2. Dismantle the piston from the release cylinder by way of compressed air.
Attention:
 The coverage with towel shall be taken to prevent the piston from ejection out.
 Slowly pump in compressed air to prevent brake fluid from splash.

Check after Dismantlement

Check the cylinder body for rust or damage, if any, a whole replacement shall be
conducted.
Reassembly
Re-mount them in the same order as the dismantlement steps. After the inner face of the
release cylinder and all surfaces of piston and piston ring are coated with brake fluid,
insert the piston and piston ring into the release cylinder.
 Chassis Volume CL-12

Clutch Pipeline

1 2

1. Oil tube 2. Booster valve 3. Oil tube adaptor

Check:
1. Check the clutch pipeline for blockage or bend. Check the clutch hose for bend,
damage, crack or oil leakage.
2. Check the hose adaptor and pipeline for oil leakage.

Note:
For the vehicles of Benjoy series, in the hydraulic pipeline of standard configuration 2.0L
and 2.4L clutches, the 2.4L clutch shall be added with a supercharger.

System Exhaust
The system shall be exhausted of air when dismantling the clutch pipe, hose or
main/release cylinder, or the clutch pedal loose.
 Chassis Volume CL-13

Attention:
Apply the oil specified. No mixing of oil of different brands is allowed.

Specified Oil:
1. Unscrew the deflation bolt of the
disengage cylinder of clutch. Deflation bolt

2. Slowly pump the clutch cylinder till air is exhausted completely.

3. Place the clutch pedal downward till the deflation screw plug is re-fastened.
4. Fill the oil specified into the main cylinder of the clutch.
Attention:
The quick and repetitive control of the
clutch pedal within the B-C range will
damage the location of the disengage
cylinder of clutch.
In the operation of exhaust, tread down the
clutch pedal till the floor after the pedal
returns to the “A”position.
 Chassis Volume CL-14

Common Troubles Diagnosis

Trouble Possible Cause Countermeasure
Slide of the clutch Insufficient free stroke of the Adjustment
pedal
No response of the vehicle to the Blockage of the hydraulic Maintenance or
speed of engine during the system replacement of
acceleration parts
Excessive abrasion of the Replacement
friction liner of the clutch disc
Insufficient speed The clutch friction liner too Replacement
hard or oily on the surface
Slope climbing with insufficient The pressure disc or Replacement
driving power flywheel damaged
The pressure spring Replacement
weakened or broken
The clutch pedal with Adjustment
excessive free stroke
The hydraulic oil of leakage, Maintenance or
mixed with air or the pipeline replacement of
Different gear shift (with noise when blocked parts
shifting gear)
The clutch disc spring Replacement
abraded or eroded
abnormally
The clutch vibrating (twisted Replacement
or deformed) excessively
During the inoperation The clutch pedal with Adjustment
of the clutch insufficient clearance
The clutch disc friction disc Replacement
abraded excessively
The clutch noisy after The release bearing Replacement
being released abraded abnormally or
damaged
Noise from The clutch noisy during The slide surface of the Maintenance
clutch the release bearing sleeve with
insufficient lubricating
grease
The clutch assembly or Maintenance
bearing mounted
inappropriately
The clutch noisy when The guide bearing damaged Replacement
the vehicle rocks
abruptly

Difficult pedal force The clutch pedal with Maintenance

insufficient lubrication
The clutch disc spline with Maintenance
 Chassis Volume CL-15

insufficient lubrication
The clutch releasing lever Maintenance
shaft with insufficient
lubrication
The front bearing holder with Maintenance
insufficient lubrication
The clutch pedal with Adjustment of
excessive free stroke pedal free stroke
Failure of disengage cylinder Maintenance of
of clutch release cylinder
The clutch disc displaced, Check the clutch
Difficult or no gear shift with excessive radial skip or disc
liner broken
The input shaft spline or Maintenance
clutch disc dirty when necessary
Failure of the clutch Replacement of
pressure disc clutch cover
The clutch pedal with Adjustment of
insufficient free stroke pedal free stroke
Blockage of the hydraulic Maintenance or
system replacement of
parts
Slide of the clutch The clutch disc liner oily or Check the clutch
worn through disc
Failure of pressure disc Replacement of
clutch cover
The detachable shifting fork Check the shifting
adhered together fork
The clutch disc liner oily or Check the clutch
worn through disc
Failure of pressure disc Replacement of
clutch cover

The clutch shaking The clutch film spring Replacement of

severely/rattling bended clutch cover
The torsion spring abraded Replacement of
or broken clutch disc
The engine fixing device Replacement
loosened when necessary

The clutch with noise The clutch pedal liner Replacement of

damaged clutch pedal liner
The inner parts of the casing Replacement
loosened when necessary
The release bearing Replacement of
abraded or dirty release bearing
 Chassis Volume CL-16

The detachable shifting fork Maintenance

or connecting rod adhered when necessary
together
 Chassis Volume FAX-1

Overview
Components Diagram

Steering knuckle

Combined bearing

Front
wheel hub

Drive
shaft

Front axle is composed of steering knuckle, front wheel hub, combined bearing and drive

shaft. The combined bearing matches with the front wheel hub pressure and fixed

together with the steering knuckle. Furthermore, combined bearing applies the biserial

annular thrust ball bearing.

Overhaul Specifications

Threshold
Item Standard Value
Value

Wheel load axial clearance ＿ -0.005

Wheel bearing starting torque Nm 200~260 N•m ＿
 Chassis Volume FAX-2

Precautions
Please follow the following precautions when disassembling and
maintaining the drive shaft.
① Don’
t try to dismantle the universal joint of the wheel side, when it cannot be

dismantled.

② Keep the working area clean.

③ Clean the external surface of the parts before the disassembly and maintenance.

④ The place for disassembly and maintenance must be cleaned. Take care not to

contaminate components and prevent foreign substances from coming into them in

the working process.

⑤ The components after disassembly must be reassembled in the right order. Take care

to complete this process. If pausing during the work, the components should be

covered with a clean cover.

⑥ Only the cloth made of paper, but not the cloth made of fabric can be used, because

the fiber flock will adhere to the components.

⑦ The dismantled components except rubber components should be cleaned with

kerosene and then dried with compressed air or wiped with cloth made of paper.

⑧ Assemble the dismantled suspension components, and then check the wheel location

and make adjustment when necessary.

Precautions for check, maintenance and replacement

① Before maintenance and replacement, a thorough check of the spare parts should be

carried out.

② For the disposable spare parts should not be used repeatedly.

③ After check and maintenance, the fastenings must reach the specified moment.
 Chassis Volume FAX-3

Preparations
Special maintenance tools
Name No. Tool Usage

Fixing the wheel

End fork JAC-T1D001
hub
clamp

Disengagement of
drawing
Steering the control arm ball die
joint

transmitting JAC-T1D003 ball joint of wheel cord

rod system front end with the

nut
die steering knuckle
 Chassis Volume FAX-4

Front Wheel Hub and Steering Knuckle

Check and maintenance on the motor
Make sure if the fixation status (loosening or clearance) of every element and the element
status (abrasion or breakage) are normal.

Checks for wheel bearing

1. Move the wheel hub and bearing assembly along the axial direction by hands, and
make sure the wheel bearing are not loosened.
2. Rotate the wheel hub to make sure there is no abnormal noise or other unusual
status. If there is an unusual status, please replace the wheel hub and bearing
assembly.

Front Wheel Hub

Dismantling and Reassembly

1. Front wheel brake disk 2.Front wheel hub shaft

3. Front wheel hub bearing 4. Dustproof cover of front brake

5. Left front steering knuckle 6. Front wheel hub bolt

7. Rear front steering knuckle 8. Front wheel hub shaft and bearing subassembly
 Chassis Volume FAX-5

Disassembly Steps: FAX001

1. Lift up and support the vehicle, and dismantle

the front wheel tyre with tools.

Attention:

Before lifting up the motor, unscrew the

fastening bolt of tyre firstly.

Tightening Torque: 86~116 N•m

FAX002
2. Dismantle the wheel speed sensor from the

steering knuckle.

Attention:

Please don’t pull forcibly the wire harness of

wheel speed sensor.

When mounting, pay attention to the clearance

between the wheel speed sensor and the

wheel hub. FAX003

3. Disconnect the wire harness joint of the

thickness sensor of the friction wafer.
Attention:
Please don’t pull forcibly the wire harness of
thickness sensor.

FAX004
4. Dismantle the fastening bolt of brake tongs FAX004
with tools, and then hoist the brake tongs to
a place that will not influence the work.
Attention:
Take care not to let the brake disk fall to the
ground.
Don’t step on the brake pedal after
disassembling the brake tongs.
Tightening Torque: 90~110 N•m
 Chassis Volume FAX-6

5. Dismantle the cotter pin, and then loosen

the wheel hub locknut with tools. FAX005
Attention:
The used cotter pin can not be used
repeatedly.
Tightening Torque: 200~260 N•m

6. Use rubber hammer or wood block to knock

out the drive shaft lightly. FAX006
Attention: wood

① The placing angle for universal joint of the

drive shaft should not be too large, and take
care not to stretch the slip joint too much.
② The casing (universal joint subassembly)
shaft and some other spare parts must be well
supported when lowering the drive shaft.
Note:
If the wheel hub bearing assembly and the
drive shaft can not be separated from each
other after finishing the above operations, the
puller can be used (or appropriate tools).
7. Screw off the brake disk stop bolt, and then
FAX007
dismantle the brake disk.
Tightening Torque: 20~25 N•m

FAX008
8. Screw off four fastening bolts of the wheel

hub from the steering knuckle.

Tightening Torque: 200~260 N•m

 Chassis Volume FAX-7

9. Take off the front wheel hub bearing FAX009

assembly from the steering knuckle.

Check after disassembly

Check if the elements have the damage of distortion, crack or some others. If so, please
replace them.
Reassembly
Reassembly is in reverse order compared to the disassembly.
 Chassis Volume FAX-8

Steering Knuckle
Dismantling and Reassembly

1. Dustproof cover 5. Lower front load bearing arm ball and spigot head
2. Cotter pin 6. Connecting bolt for vibration reduction fork and
lower front load bearing arm
3. Steering tie rod end joint 7. Steering knuckle
4. Lower front guiding arm ball and spigot head

Dismantlement Steps: FAX010

1. Lift up the motor, and then dismantle the
front wheel tyre with tools.
Attention:
Before lifting up the motor, unscrew the
fastening bolt of tyre firstly.
Tightening Torque: 86~116 N•m

2. Dismantle the fastening bolts of wheel

speed sensor, and then pull the sensor FAX011
probe away from the steering knuckle.
Attention:
Please don’t pull forcibly the wire harness of
wheel speed sensor.
When installing, pay attention to the clearance
between the wheel speed sensor and the wheel
hub.
 Chassis Volume FAX-9

3. Disconnect the wire hardness of friction wafer FAX012

thickness sensor.
Attention:
Please don’t pull forcibly the wire harness of
thickness sensor.

4. Screw off the fastening bolt of brake tongs, FAX013

and hoist the brake tongs at a place where
the work won’ t be affected.
Attention:
Take care not to let the brake disk fall on the
ground.
Don’t step on the brake pedal after
disassembling the brake tongs.
Tightening Torque: 90~110 N•m
FAX014
5. Dismantle the limit screw of front brake disk,
and then take out the front brake disk.
Tightening Torque: 20~25 N•m

FAX015
6. Unscrew the locknut of the wheel hub, use
rubber hammer or wood block to knock wood

out the drive shaft lightly from the wheel

hub.

FAX016

7. Dismantle the nuts from tie rod end threaded

stud of steering gear.
 Chassis Volume FAX-10

FAX017
8. Use the puller to separate the tie rod

threaded stud from the steering knuckle

9. Unscrew the button head nut of the upper

swing，and then use the puller (2) to separate

the upper ball joint threaded stud from the

steering knuckle

FAX018

Tightening Torque: 28~36 N•m

10. Unscrew the nut of the front lower swing arm， FAX019

and then use the puller (1) to separate the bolt

of the front lower swing arm from the steering

knuckle.

11. Unscrew the nut of the rear lower swing arm，

FAX020
and then use the puller (1) to separate the

threaded stud of the rear lower swing arm

from the steering knuckle.

12. Dismantle the steering knuckle and the wheel

hub assembly from the vehicle.

 Chassis Volume FAX-11

13. Unscrew the fastening bolts of the wheel hub,

FAX021
and then take out the steering knuckle.

Check after disassembly

Check if the elements have the damage of distortion, crack or some others. If so, please
replace them.

Check of ball joint

Check if the dustproof cover of steering tie rod outer sleeve ball joint have the damage of
crack, shaft clearance and distortion.
 Chassis Volume FAX-12

Front Drive Shaft

Check and maintenance on vehicle
1. Check if there is loosening or other damage to the set parts of drive shaft and
universal joint.
2. Check if there is crack or other damage to the dustproof cover.
Attention:
If there is noise or vibration of the drive shaft,
please replace the drive shaft assembly
wholly.
Replacement of drive shaft dustproof cover FAX010
1. Lift up the motor, and then dismantle the front

wheel tyre with tools.

Attention:
Before lifting up the motor, unscrew the
fastening bolt of tyre firstly.
Tightening Torque: 86~116 N•m

2. Dismantle the wheel speed sensor from the FAX023

steering knuckle.

Attention:
Please don’t pull forcibly the wire harness of
wheel speed sensor.
When installing, pay attention to the clearance

between the wheel speed sensor and the

wheel hub.
FAX024
3. Loosen the fastening bolt of brake hose.

4. Screw off the collar nut that connecting the

upper front swing arm ball joint and the

FAX025
steering knuckle, and then loosen the

spherical hinge.

Tightening Torque: 28~36 N•m

 Chassis Volume FAX-13

5. Unscrew the nut, and then dismantle the ball FAX026

joint that connecting the steering tie rod and
the steering knuckle.

6. Dismantle the set nut and bolt, and then FAX027

separate the steering knuckle from the
support component.
Tightening Torque: 100~120 N•m

7. Dismantle the cotter pin, and then loosen the

wheel hub locknut with tools.
Attention: FAX028
The used cotter pin can not be used
repeatedly.

Tightening Torque: 200~260 N•m

8. Use hammer (or other appropriate tools)

and wood block to knock one end of the FAX029
drive shaft lightly to an appropriate wood

position, and then dismantle the wheel

hub locknut.
Attention:
① The placing angle for universal joint of the
drive shaft should not be too large, and take
care not to stretch the slip joint too much.
② The casing (universal joint subassembly),
shaft and some other spare parts must be
supported when lowering the drive shaft.
Note:
If the wheel hub and the drive shaft can not be separated from each other after
finishing the above operations, the puller can be used (or appropriate tools).
 Chassis Volume FAX-14

9. Dismantle the drive shaft from the wheel hub FAX030

and the bearing assembly.

10. Use the crowbar to pry the connecting parts of

the transmission and the drive shaft, and then
take off the drive shaft from the vehicle.
Check and Reassembly:
1. Dismantle the clamping band of dustproof cover, and then dismantle the dustproof
cover from the universal joint subassembly.
2. Screw the drive shaft puller (or appropriate tools) in the bolt hole of universal joint
subassembly. Use one hand to support the drive shaft, and use the sliding hammer (or
appropriate tools) to pull out the universal joint subassembly from the shaft.

Attention: FAX031
① Align the sliding hammer and the drive
shaft, and then pull it out firmly and
evenly.
② If the universal joint subassembly cannot
be pulled out, the driving, dismantle the
drive shaft from the vehicle first and try
again. Annular collar
3. Dismantle the annular collar from the shaft.
4. Dismantle the dustproof cover from the drive shaft.
5. Use the paper towel to wipe the lubricating
grease on the universal joint subassembly.
FAX032
6. Daubing appropriate amount of lubricating
grease on the cusp hole of the universal joint
subassembly until the lubricating grease
begin to flow out of the circular groove and the
cusp hole. After daubing well, use wiping cloth Universal joint
to wipe the old outgoing lubricating grease. subassembly
7. Use tape to muffle the spline to avoid damage
to the dustproof cover.
Mount the new dustproof cover and the clamping band of it on the shaft.
Attention:
Please don’t use the clamping band of dustproof cover and the dustproof cover
repeatedly.
8. Dismantle the tape muffling around the drive shaft spline.
9. Place the annular collar on the groove of the drive shaft edge. Align the middle shaft
on the edge of drive shaft and the universal joint subassembly. And then use the
annular collar to mount the drive shaft on the universal joint subassembly.
 Chassis Volume FAX-15

Attention:
① Please don’t use the annular collar repeatedly.

② It’s recommended to apply the drive knuckle inserter when mounting the ring
circlip.

10. Mount the universal joint assembly on the

drive shaft with plastic hammer. FAX034
universal joint
subassembly

Attention:
Confirm the universal joint subassembly is
properly joggled when the drive shaft rotates.

11. Daub an amount of lubricating grease on the

inner dustproof cover from its big diameter
side. Prevent the dustproof
cover from deformation
FAX035
12. As shown in the drawing, mount the dustproof
cover firmly on the inslot (indicated with the
mark *).
Attention:
If the lubricating grease adheres to the set
surface (with the mark *) of the drive shaft and
the dustproof cover of the universal joint
subassembly, the dustproof cover may fall off.
Wipe all the lubricating grease on the surface. Prevent the dustproof
FAX036 cover from deformation
13. Side insert the screwdriver with flat blade into
the dustproof ring inside from the big diameter
of the dustproof cover into its inside to
exhaust air inside, and then adjust its installed
Screwdriver with
length against its deformation. flat blade or
similar tool
Attention:
① The dustproof cover with installed length
more than the standard value may result in
its damage.
② Take care not to let the tip of screwdriver
with flat blade touch the dustproof cover FAX037
inside.
14. Use the dustproof cover clamping band shown
in the figure to roll the tool, and then a new
dustproof clamping band to fasten the big and
small ends of the dustproof cover.
Attention:
No repetitive use of the dustproof cover
 Chassis Volume FAX-16

clamping band is allowed.

15. Fasten the universal joint subassembly and drive shaft, and then confirm their proper
locations when rotating the dustproof cover. If the dustproof cover is installed
improperly, please re-mount it with a new dustproof cover clamping band.
16. Confirm that the ring circlip at the drive shaft side of the transmission is joggled
completely.
17. Insert the drive shaft into the wheel hub and bearing assembly, and then temporarily
screw down the locknut of the wheel hub.
18. Mount nuts and bolts for the steering knuckle and pillar.
FAX038
Tightening Torque: 100~120 N•m

19. Mount the steering tie rod on the steering

knuckle. FAX039

20. Before the installation, mount the nut for

connecting the suspension arm ball knuckle FAX040
and steering knuckle.

Tightening Torque: 28~36 N•m

21. Mount the wheel sensor on the steering

knuckle. FAX041
 Chassis Volume FAX-17

Attention:
No pull of speed sensor wire harness with
force is allowed.
Pay attention to the clearance between the
speed sensor and wheel hub during the
installation.

22. Screw down the locknut to the specified torque,

FAX042
and then mount the cotter pin.

Attention:
The cotter pin used cannot be used again.
Tightening Torque: 200~260 N•m

23. Mount the wheel. FAX043

Attention:
When mounting the tyre, do fit the locknut at
the specified torque.

Specified torque: 86~116 N•m

 Chassis Volume FAX-18

Dismantling and Reassembly (left)

1. Cotter pin 2. Nut

3. Spring washer 4. Left drive shaft

Disassembly
1. Lift up the vehicle to dismantle the front tyre. FAX044
Attention:
Firstly loosen the locknut of the tyre before
lifting up the vehicle.
Tightening Torque: 86~116 N•m

2. Dismantle the wheel sensor from the steering FAX045

Knuckle.

Attention:
No pull of speed sensor wire harness with
force is allowed.
Pay attention to the clearance between the
speed sensor and wheel hub during the
installation.
 Chassis Volume FAX-19

3. Loosen the fastening bolt for brake hose.

FAX046

4. Screw off the nut for connecting the front

upper suspension arm ball knuckle and
steering knuckle, and then loosen the FAX047
spherical hinge.
Tightening Torque: 28~36 N•m

5. Unscrew the nut, and then dismantle the

knuckle joint head for connecting the steering
tie rod and steering knuckle.
FAX048

6. Dismantle the locknut and bolt, and then

release the steering knuckle from the column FAX049
component.

Tightening Torque: 100~120 N•m

 Chassis Volume FAX-20

7. Dismantle the cotter pin, and then unscrew

the locknut of the wheel hub with tool. FAX050
Attention:
The cotter pin used cannot be used again.
Tightening Torque: 200~260 N•m

8. Gently strike the release wheel hub and

FAX051
bearing assembly at one end with hammer (or
Wood
other appropriate tool) and wood, and then
dismantle the locknut.

Attention:
① When dismantling the drive shaft, place the
universal joint of the drive shaft at a proper
angle. Take care not to stretch the sliding
joint.
② Do support the casing body (universal joint
subassembly), shaft and other spare parts
when placing the drive axle down.
Note:
Supposing the wheel hub bearing assembly
and drive shaft cannot be separated after the
previous operations, the puller (or appropriate
tool) shall be applied.
9. Pry the connection of the transmission and FAX052
drive shaft with crowbar, and then take out the
drive shaft out of the vehicle.

Attention:
Take care not to damage the transmission
casing when prying the drive shaft with
crowbar.

Check after Disassembly

1. Move the universal joint upward and downward, leftward and rightward to check it for
smooth movement and serious looseness.
2. Check the dustproof cover for crack, damage or leakage of lubricating grease.
3. If discovering the unconformities, dismantle the drive shaft and then replace the spare
parts troubled with new ones.
Reassembly
Attention:
 Chassis Volume FAX-21

Replace the oil seal at the transmission drive axle side with a new one before mounting
the drive shaft.
① The reassembly is in reverse order compared with the disassembly. No repetitive use
of unusable spare parts is allowed.
② Mount the protective device at the side of the transmission drive axle to protect the
spline against damaging the oil seal when inserting the drive shaft. Gently strike the
steering knuckle with hammer to make the drive shaft into it completely and then
fasten it with locknut.
Attention:
Confirm that the ring circlip is joggled completely.
Dismantling and Reassembly (Right)
Component Drawing

1. Right drive shaft 2. Cotter pin

3. Nut 4. Spring washer

Disassembly Steps:
1. Lift up the vehicle, and then dismantle the tyre
out of it with special tool. FAX053
Attention:
Firstly unscrew the fastening bolt before lifting
the Vehicle.
Tightening Torque: 28~36 N•m

2. Dismantle the wheel sensor out of the

steering knuckle. FAX054
Attention:
No pull of speed sensor wire harness with
force is allowed.
Pay attention to the clearance between the
speed sensor and wheel hub during the
installation.
 Chassis Volume FAX-22

3. Unscrew the fastening bolt of the brake hose.

FAX055

4. Screw off the nut for connecting the front FAX056

upper suspension arm ball joint and steering
knuckle, and then loosen the spherical hinge.
Tightening Torque: 28~36 N•m

5． Unscrew the nut, and then dismantle the ball FAX057

joint head for connecting the steering tie rod
and knuckle.

6. Dismantle the locknut and bolt, and then

release the steering knuckle out of the column FAX058
component.

Tightening Torque: 100~120 N•m

 Chassis Volume FAX-23

7. Dismantle the cotter pin, and then unscrew FAX059

the locknut of the wheel hub with tool.

Attention:
The cotter pin used cannot be used again.
Tightening Torque: 200~260 N•m

8. Gently strike the release wheel hub and

bearing assembly at one end with hammer (or FAX060
other appropriate tool) and wood, and then wood

dismantle the locknut of the wheel hub.

Attention:
① When dismantling the drive shaft, place
the universal joint of the drive shaft at a
proper angle. Take care not to stretch the
sliding joint.
② Do support the casing body (universal
joint subassembly), shaft and other spare
parts when placing the drive axle down.
Note: FAX061
Supposing the wheel hub bearing assembly
and drive shaft cannot be separated after the
previous operations, the puller (or appropriate
tool) shall be applied.
9. Pry the connection of the transmission and
drive shaft with crowbar, and then take out the
drive shaft out of the vehicle.

Attention:
Take care not to damage the transmission
casing when prying the drive shaft with
crowbar.

Attention:
① When dismantling the drive shaft, place the universal joint of the drive shaft at a
proper angle. Take care not to stretch the sliding joint.
② Do support the casing body (universal joint subassembly), shaft and other
spare parts when placing the drive axle down.
 Chassis Volume FAX-24

Check after Disassembly

1. Move the universal joint upward and downward, leftward and rightward to check it for
smooth movement and serious looseness.
2. Check the dustproof cover for crack, damage or leakage of lubricating grease.
3. If discovering the unconformities, dismantle the drive shaft and then replace the spare
parts troubled with new ones.
Reassembly
Attention:
Replace the oil seal of the transmission drive shaft with a new one before mounting
the drive shaft.
The reassembly is in reverse order compared with the disassembly.
Note:
No repetitive use of unusable spare parts is allowed.
Common Troubles Diagnosis

Position Trouble Cause

With noise ● Looseness due to improper installation
● Interference from parts
● Tyre
● Wheel
● Steering
Shaking ● Looseness due to improper installation
● Interference from parts
● Tyre
● Wheel
● Steering
Vibrating ● Looseness due to improper installation
● Interference from parts
● Tyre
Front
● Steering
axle
Oscillating ● Looseness due to improper installation
● Interference from parts
● Tyre
● Wheel
● Steering
Violently trembling ● Looseness due to improper installation
● Tyre
● Wheel
● Steering
Bad traveling comfort ● Looseness due to improper installation
and maneuverability ● Interference from parts
● Tyre
● Wheel
 Chassis Volume RAX-1

Overview
Components Diagram

Oil seal Rear steering

knuckle

Rear phonic wheel

Rear wheel <motor with ABS>
hub shaft 请核实，原文是“带 ABS 的汽车”。

Combined
Oil seal
bearing

Rear axle is composed of steering knuckle, rear wheel hub, combined bearing and rear

wheel hub shaft. The combined bearing matches with the axial pressure of rear axle and

is fixed with bolts together the steering knuckle. Furthermore, combined bearing uses

biserial annular thrust ball bearing of the same model to the front axle. Motor with ABS,

whose rotors used to check the speed, is fixed on the rear axle shaft, but the speed

sensor is fixed on the steering knuckle.

Overhaul Specifications

Item Threshold Value

Wheel bearing axial clearance mm 0.05

Wheel bearing rotation-sliding resistance
18
force N
 Chassis Volume RAX-2

Precautions
① Keep the working area clean in the maintenance process.
② Clean the external surface of the parts before dismantlement and maintenance.
③ The place for dismantlement and maintenance must be cleaned. Take care not to
contaminate components and avoid enter of foreign matters at work.
④ The components after dismantlement must be reassembled in the right order. Take
care to complete this process. If pausing during the work, the components should be
covered with a clean cover.
⑤ Only the cloth made of paper, but not the cloth made of fabric can be used, because
the fiber flock will adhere to the components.
⑥ The dismantled components except from rubber components should be cleaned with
kerosene and then dried with compressed air or wiped with cloth made of paper.
⑦ Assemble the dismantled suspension components, and then check the wheel
location and make adjustment when necessary.
Precautions for check, maintenance and replacement
① Before maintenance and replacement, check the spare parts wholly. First use the
same way to check the newly replaced spare parts, if necessary, please replace them.
② For the one-off spare parts should not be used repeatedly.
③ After check and maintenance, the fastenings must reach the specified moment.

Preparations
General maintenance tools

Name Drawing Description

Electri
Dismantle the wheel nut
c tool
 Chassis Volume RAX-3

Rear Wheel Hub

Dismantlement and Reassembly

1. Rear wheel brake disk 2. Rear wheel hub shaft

3. Dustproof cover of left rear brake 4. Left rear steering knuckle
5. Dust guard 6. Rear wheel hub bolt
7. Installation pipe of the damper 8. Rear phonic wheel
9. Special nut 10. Dustproof cover of right rear brake
11. Right rear steering knuckle 12. Rear wheel hub bearing
13. Rear wheel hub shaft and bearing subassembly
Visual check:
Make sure if the fixation status (loosening, clearance) of every element and the element
status (abrasion, breakage) are normal.
Check for the wheel bearing:
1. Move the wheel hub assembly along the axial direction by hands, and make sure the
rear wheel hub shaft and bearing subassembly are not loosened.
2. Rotate the wheel hub to make sure there is no abnormal noise or other unusual
status. If there is an unusual status, please replace the wheel hub assembly.
Dismantlement and Reassembly
RAX001
Dismantlement Steps:
1. Lift up the motor, and then dismantle the rear
wheel tyre with tools.
Attention:
Before lifting up the motor, unscrew the
fastening bolt of tyre firstly.
Tightening Torque: 86~116 N•m
 Chassis Volume RAX-4

2. Dismantle the wheel sensor from the steering RAX002

knuckle.

Attention:

Please don’t pull forcibly the wire harness of

wheel speed sensor.

When installing, pay attention to the

clearance between the wheel speed sensor

and the wheel hub.

RAX003

3. Screw off the fastening bolt between the

steering knuckle and the wheel hub

assembly.

Take out the brake disk and wheel hub

assembly wholly.

Tightening Torque: 56~70 N•m

RAX004
4. Loosen the parking handle, and then unscrew

the fastening bolt of brake tongs, hoist the

brake tongs assembly to a place that will not

influence the work.

Attention:
Take care not to let the brake disk fall unto
the ground.
Don’t step on the brake pedal after
disassembling the brake tongs. RAX005
Tightening Torque: 56~70 N•m

5. Screw off the brake disk stop bolt, and take out

the brake disk.

Tightening Torque: 20~25 N•m

Chassis Volume RAX-5
 Chassis Volume RAX-6

6. Take out the rear wheel hub shaft and

RAX006
bearing components.

Reassembly:

Reassembly is in the reverse order compared with the dismantlement.

 Chassis Volume RAX-7

Steering Knuckle
Dismantlement and Reassembly

1. Longitudinal push-and-pull rod 2. Front transverse slide bar

3. Rear transverse slide bar 4. Rear damper assembly
5. Upper rear suspension arm assembly 6. Steering knuckle
7. Steering knuckle cover

Dismantlement Steps:
1. Lift up the motor; dismantle the rear
RAX007
wheel tyre with tools.

Attention:

Before lifting up the motor, unscrew the

fastening bolt of tyre firstly.

Tightening Torque: 86~116 N•m

 Chassis Volume RAX-8

2. Disconnect the wheel speed sensor RAX008

wire hardness of rear wheel, loosen

the fastening bolt of the sensor, and

then take out the wheel speed sensor.

Attention:
Please don’t pull forcibly the wire harness of
wheel speed sensor.
When installing, pay attention to the clearance

between the wheel speed sensor and the wheel

hub.

RAX009
3.

Loosen the parking brake, and then

unscrew the adjusting screw of the

parking brake, and then take out the

brake guy wire from the rear brake.

4. Screw off the fastening bolt between

RAX010
the steering knuckle and the wheel

hub assembly.

Take out the brake disk and wheel hub

assembly wholly.

Tightening Torque: 56~70 N•m

5. Loosen the fastening bolt of

brake tongs, and hang the brake
RAX011
tongs on a place that will not

influence the work.

Attention:
Take care not to let the brake disk fall
unto the ground.
Don’t step on the brake pedal after
 Chassis Volume RAX-9

disassembling the brake tongs.

Tightening Torque: 56~70 N•m

6. Dismantle the fastening bolt of RAX012

longitudinal push-and-pull rod.

Tightening Torque: 90~110 N•m

7. Dismantle the fastening bolt of front RAX013

transverse slide bar.

Tightening Torque: 135~155 N•m

8. Fastening bolt of the rear transverse

RAX014
slide bar.

Tightening Torque: 98 N•m

9. Bolt of rear damper assembly. RAX015

Tightening Torque: 56~70 N•m

Chassis Volume RAX-10
 Chassis Volume RAX-11

10. Bolt of upper rear suspension arm

RAX016
assembly.

Tightening Torque: 90~110 N•m

11. Take out the steering knuckle. RAX017

Reassembly:
The reassembly Steps are the same as the dismantlement Steps.

Common Troubles and Troubleshooting

Trouble Cause
 Inappropriate reassembly and loosened
 Spare parts interference
With noise  Rear axle and rear suspension
 Tyre
 Brake
 Rear axle and rear suspension
 Tyre
Shaking
 Brake
 Inappropriate installation and loosened
Vibration  Rear axle and rear suspension
 Tyre
Uncomfortable riding  Spare parts interference
and difficult operation  Brake
 Inappropriate installation and loosened
 Chassis Volume FSU-1

Overview
Components Diagram

Upper suspension arm

Underframe Steering knuckle

Lower front Damper
suspension arm

Lower rear
suspension arm

Benjoy front suspension is of separated type and a structure of multiple connecting rods,
with special triple connecting rods, spiral spring, bilateral damper of cylinder type, as well
as transverse stabilizer rod. This kind of suspension is characterized with the suspension
with three transverse arms each side, the shaking upward and downward of wheels in
conformity with the necessary kinematical feature by way of rational configuration of upper
and lower transverse arms, and transmitting force to the vehicle body through the
transverse arm. Based on the mutual locations of transverse arms, the height of the lateral
and longitudinal inclination centers can be determined so as to change the length of the
transverse arm, and also affect the angle movement of the wheel shaking upward and
downward, viz. the change of the camber angle of the wheel. Its major control parts are
the three transverse booms and the damper. The upper suspension arm is of U shape,
with one end articulated with the steering knuckle and other end connected with the
vehicle body by front and rear liners. The lower suspension arm is divided into the front
and rear suspension arms, of which, the front suspension arm is articulated with the
steering knuckle at one end and connected with the auxiliary frame by liner at other end.
The rear suspension arm is of L shape, with one end articulated with the steering knuckle
and other end connected with the auxiliary frame by liner. The lower fork of the damper is
mounted on the front suspension arm, with the upper end connected with the vehicle body.
The auxiliary frame is connected with the vehicle body by liner.
Overhaul Specifications
Left front suspension arm (the end with rubber liner fixed on auxiliary 90~110N•m
frame)
Left front suspension arm (the ball stud head fixed on steering knuckle 60~72N•m
with nut)
Front suspension rear suspension arm ball joint starting torque 1~6N•m
 Chassis Volume FSU-2

The end of left rear suspension arm fastening bolt with rubber liner fixed 79~86N•m
on auxiliary frame
Left rear suspension arm pin head fixed on steering knuckle 60~72N•m
Front suspension front suspension arm ball joint starting torque 1~6N•m
Left upper suspension arm assembled at vehicle body hole location 70~86N•m
Ball head of left upper suspension arm fixed at the steering knuckle 28~36N•m
Left front damper column assembly (at the corresponding hole of left 100~120 N•m.
front suspension arm assembly)
Upper bracket installed at the specified locations in the vehicle body 56~70N•m
Front stabilizer rod assembly fastened at corresponding locations in 56~70N•m
auxiliary frame
Front suspension upper transverse arm ball joint starting torque 1.0~5
Ball studs of front stabilizer rod assembly respectively installed into the 56~70N•m
specified locations in the front damper assembly
Tightening torques of ball stud and stabilizer rod 56~70N•m.
Ball stud turning moment of stabilizer rod assembly 0.5~1.5N•m
Auxiliary frame
Front fastening bolt 88N•m
Middle fastening bolt 88N•m
Rear fastening bolt 108N•m

Item Standard Value

Front suspension upper transverse arm ball joint starting torque Nm 1.0~5
Front suspension front suspension arm ball joint starting torque Nm 1~6
Front suspension rear suspension arm ball joint starting torque Nm 1~6
Front connecting rod ball joint starting torque Nm ≤6

Item Standard Value

Upper transverse arm ball joint starting torque Nm 1.0~5
Front suspension rear suspension arm ball joint starting torque Nm 1~6
Lower bearing arm ball joint starting torque Nm 1~6
Front connecting rod ball joint starting torque Nm ≤6

Front Wheel Parameters Standard Value Remarks

Inner wheel turning angle 37°45’16”±1°30’
Steering angle
Outer wheel turning angle 29°46’16”±1°30’
Camber angle of wheel 0°8’±30’
Castor angle 6°±1°30’
Front wheel Knuckle pin angle 8°38’±1°30’
alignment Sum of front
parameters wire harness at
Front wire harness 0°11’
±9’
left and right
sides
Damper
Item M/T
 Chassis Volume FSU-3

Stroke mm 115
Damping force [for Stretching N 1442±160
0.39m/sec] Compression N 490±55
 Chassis Volume FSU-4

Precautions
1. When installing rubber liner, final tightening must be carried on when tires are
on the ground and the vehicle is under idle condition. Be sure to scour spilt oil
as it will shorten rubber liner’s life time.
2. Idle condition means fuel, engine coolant fluid and lubricant are full, spare tire,
jack, vehicular tools and foot mat are at the appointed position.
3. Do check the wheel alignment after the maintenance of the suspension parts.
4. Locknut can not be used repeatedly. Always use new nut when installing. When
substituting and ahead of tightening locking nut, do not rub oil on the locking
nut.

Preparations
Special Tools for Maintenance

Name No. Tool Purpose

Release of toe Drawing
Ball die
Steering control arm ball joint
Cord
linkage draw JAC-T1D003 joint and
steering Nut

knuckle
Anti-vibration Dismantlement
spring and
disassembling reassembly Spring

tool JAC-T1D004 used in compressor

suspension
spring damper
coil
Chassis Volume FSU-5
 Chassis Volume FSU-6

Front Suspension Assembly

Pre-check of front wheel alignment of front suspension assembly
Check:
1. The tire for proper air pressure and abrasion.
2. The wheel for skip.
3. The wheel bearing and shaft end for gap.
4. The fixing point of axle and suspension for looseness and deformation.
5. Every suspension beam, steering knuckle, stay and transverse connecting rod for
crack, deformation and other damage.
6. The vehicle for height.

Check and adjustment of front wheel alignment

Description
Park the vehicle on the level ground and measure wheel alignment under the idle
condition. Before measuring wheel alignment, you should overhaul front suspension,
turning system, wheel and front wheel bearing to let it achieve normal condition.
1. Front wire harness
Standard Value
Front wire harness angle (each wheel) 0°11’
±9’
If the front wire harness is out of the standard scope, make adjustment by means of:
1. Align the steering wheel at the right middle and then fix it in the middle.
2. Loosen the locknut at the tie rod end.

3. Rotate the tie rod for equivalent amount

clockwise or counterclockwise, and
then adjust the front wire harness angle
at the standard value.

4. Lock down the locknut at the tie rod

end.
Tightening Torque: 45~55N•m
 Chassis Volume FSU-7

5. Check the front wire harness angle on

the turning tester.

2. Camber angle, castor angle and knuckle pin angle

Standard Value:
Camber angle 0°8’ ±30’
(left and right difference within 30)
Castor angle 5°36’ ±1°30’
(left and right difference within 30)
Knuckle pin angle 8°38’ ±1°30’
Caution:
1. The camber angle and castor angle shall be preset at ex-factory, and no
adjustment is necessary.
2. If the camber angle, knuckle pin angle and castor angle are out of the standard
range, please check the suspension beam, steering knuckle, column and
transverse link for abrasion and damage. If any, replace the spare parts
troubled.
3. As for cars using aluminum wheels, connect
camber angle/castor angle/main pin gauge to
drive axle with tools. Tighten special tools
with Tightening Torque (200~260N•m) which
is also used to drive shaft nut.
4. Don’t make the wheel bearing bear load
when screwing down nut.
Chassis Volume FSU-8
 Chassis Volume FSU-9

Front Suspension Upper Suspension Arm

Dismantlement and Reassembly

1. Front upper suspension arm ball joint and steering knuckle adaptor
2. Flange face locknut 3.Upper suspension arm welding
4. Upper suspension arm connecting pin 5.Dustproof cover

Dismantling Steps
1. Lift the car and disassemble the front tire with tools.
Caution: FSU001
Before lifting the car, loosen tire fastening bolt first.

Tightening Torque: 86~116 N•m

 Chassis Volume FSU-10

2. Screw off the nut for connecting the front FSU002

upper suspension arm ball joint steering
knuckle, and then loosen the spherical hinge.
Tightening Torque: 28~36 N•m

3. Screw off the two locknuts for fastening the

upper suspension arm on the frame. FSU003

Tightening Torque: 70~86 N•m

4. Take out the front upper suspension arm FSU004

assembly.

FSU005
Check after Dismantlement
1. Check the upper suspension arm for
deformation, crack or other damage. If any,
please replace it.
2. Check the upper suspension arm ball stud for
its starting torque.
Standard Value: 1.0~5Nm
Chassis Volume FSU-11
 Chassis Volume FSU-12

Reassembly FSU006
Front upper transverse arm column
Pay attention to the following essentials and install pin assembly

in opposite order of disassembly procedures.

Reassembly essentials for assembly of pin

Install pin assembly to angle as described in the

diagram. Front upper transverse
arm

Note:
If front upper suspension arm shaft is installed
according to above-mentioned angles, the Ball stud cover
V-translot 请核
standard dimensions are as follows: 实，Vee slot?

A: 299.9mm
B: 234.0mm

Reassembly essentials for ball joint dustproof

cover
1. Spread universal lubricating grease on the lip Dustproof cover
FSU008
and inner parts of the new dustproof cover.
2. Press dustproof cover with tools until it is Detachable
spring
complete in position. flange
Chassis Volume FSU-13
 Chassis Volume FSU-14

Front Damper
Dismantlement and Reassembly

1. Installation nut for stabilizer connecting rod 2. Lower installation nut of

damper
3. Installation bolt for damping fork 4. Upper installation nut of
damper
5. Damping fork 6. Damper assembly

Dismantlement Steps FSU009

1. Lift the car and take off the front tire with tools.
Caution:
Before lifting the car, release the tires’fastening bolt.
2. Take off the front upper suspension arm
assembly. (Please refer to disassembly of
 Chassis Volume FSU-15

front upper suspension arm assembly)

Tightening Torque: 28~36 N•m
3. Before disassembling, stabilize connecting
rod installation flange lock nut, and then FSU010
disconnect front transverse connecting rod
assembly of stabilizer bar with front damper.

Tightening Torque: 42~54 N•m

4. Take off damper and lower front suspension

arm installation bolt. FSU011

Tightening Torque: 100~120 N•m

5. Take off three lock nuts which are used to fix

damper from the car. FSU012

Tightening Torque: 56~70 N•m

6. Take off damper assembly. FSU013

Reassembly

Installation is in opposite order of the disassembly.

Attention:
 Chassis Volume FSU-16

① Make sure to fasten every spare part taken off from spiral spring damper under
idle condition.
② Check wheel for alignment after reassembly.
 Chassis Volume FSU-17

Disassembly and Assembly

1. Nonmetal insert locknut 2. Damper dog

3. Buffer block 2 4. Upper bracket weld assembly of front spring
5. Front spring seat 6. Sleeve for buffer block
7. Buffer block 1 8.Stopper sleeve
9. Stopper 10. Front spring
11. Front damper dustproof cover 12. Plastic seat pad
13. Front fork fixture block 14. Front fork of left damper
15. Flange face bolt 16. Flange face bolt
17. Flange face locknut 18. Flange face locknut
19. Anchor pin 20. Front stopper installation seat
21. Lower bracket of front spring
Disassembly
1. Compress spiral spring with special tools
described in the diagram.
Caution:
① Install special tools homogeneously to
make them achieve maximum length
within installation range.
② Compress the spiral spring after special
tools are installed completely on spiral
spring.
③ Air tool can not be used to fasten special
 Chassis Volume FSU-18

tools’bolt.
2. When fixing cylinder rod, take off locknut.

3. Take off damper dog, buffer block 2, front spring seat, sleeve for buffer block, buffer
block 1, stopper sleeve, stopper, front spring, front damper dustproof cover and plastic
seat pad in turn from front fork fixture block. Release special tools slowly, and then take
off spiral spring and dustproof cover.

Check after Disassembly

1. Check front fixture block for deformation, crack and breakage. If any, please replace it.
2. Check front fixture block for oil leak. If any, please replace it.
3. Check reassembly baffle pad for crack and rubber spare parts for abrasion. If any,
please replace them.
4. Check spiral spring for crack, abrasion and breakage. If any, please replace it.

Assembly
Assemble in opposite order of disassembly.
Caution:
① Turn the big end of the spiral spring downward to align with the lower spring
seat.
② Compress the spiral spring after special tools are sure to be completely
installed onto spiral spring.
 Chassis Volume FSU-19

Front Suspension Rear Suspension Arm and Front

Suspension Arm

Dismantlement and Reassembly

1. Flange locknut of front suspension, rear suspension arm ball stud and steering knuckle
2. Front suspension rear suspension arm installation bolt
3. Front suspension rear suspension arm 4. Dustproof cover
5. Damper lower installation bolt and nut
6. Flange locknut of front suspension front suspension arm ball stud and steering knuckle
7. Front suspension front suspension arm installation bolt and nut
8. Front suspension front suspension arm
9. Dustproof cover

Dismantlement Steps
1. Lift the car to take off front tires with tools.
Caution: FSU014
Before lifting the car, unscrew the tires’
fastening bolt.
2. Take off cotter pin and drive shaft nut from
front wheel hub, and then release drive shaft.

Tightening Torque: 200~260 N•m

 Chassis Volume FSU-20

3. Screw off the grip nut, and then release the FSU015
connection between front suspension rear
suspension arm ball stud and steering
knuckle.
Tightening Torque: 60~72 N•m

4. Take off two fastening bolt of rear suspension FSU016

arm installation panel support.
.

5. Screw off two fastening bolts of front FSU017

suspension rear suspension arm.
Tightening Torque: 79~86 N•m

6. Take off front suspension rear suspension FSU018

arm.

7. Take off damper lower installation bolt and FSU019

nut.

Tightening Torque: 100~120 N•m

 Chassis Volume FSU-21

8. Screw off the joint nut, and pry out ball hinge,
and then release the connection between FSU020
front suspension front suspension arm ball
stud and steering knuckle.
Tightening Torque: 60~72 N•m

9. Screw off the front suspension arm installation

panel support grip nut and bolt, and then take FSU021
out stiffening pate.

10 Screw off front suspension front suspension FSU022

arm installation bolt and nut.

Tightening Torque: 90~110 N•m

11. Take off front suspension front suspension

arm from frame. FSU023
 Chassis Volume FSU-22

Check after Dismantlement

1. Check front suspension rear suspension arm, front suspension front suspension arm
for deformation, crack or other breakages. If any, please replace them.
 Chassis Volume FSU-23

2. Check ball stud’ s starting torque with tools

FSU024
described in the diagram.
Front suspension rear suspension arm ball
joint starting torque
Standard Value: 1~ 6 N•m

Lower bearing arm ball stud starting torque

Standard Value: 1~6 N•m

Reassembly FSU025
Installation is in opposite order of the disassembly.
Attention Dustproof
When installing new dustproof cover, make cover
sure that the universal lubricating grease is
coated on the lip and inner parts of dustproof
cover, and then use tools to compress
dustproof cover until it is completely inserted
to its position.
 Chassis Volume FSU-24

Stabilizer Rod

Dismantlement and Reassembly

1. Steady connecting rod installation nut

2. Front transverse stabilizer rod connecting rod assembly
3. Front transverse stabilizer rod pressure plate
4. Pressure plate liner of front transverse stabilizer rod
5. Front transverse stabilizer rod

Dismantlement Steps
FSU026
1. Lift the car to take off front tires.
Caution:
Before lifting the car, screw off the tires’fastening bolt.
2. Screw off the installation nut in the lower part of
front transverse connecting rod assembly of
stabilizer, and then disconnect front transverse
bar connecting rod assembly from stabilizer
rod.
Tightening Torque: 56~70 N•m

FSU027

3. Screw off the installation nut in upper part of

front transverse stabilizer rod, and then take
off front transverse connecting rod assembly
of stabilizer rod from damper front fork.
Tightening Torque: 56~70 N•m
Chassis Volume FSU-25
 Chassis Volume FSU-26

4. Lift the car to screw off the fastening bolt of

front suspension arm installation panel FSU028
support, and then take off installation panel
support (at left and right sides).

5. Screw off the fastening bolt of auxiliary frame FSU029

connecting stiffening plate, and then take off
auxiliary frame connecting stiffening plate.

6. Screw off the engine bracket assembly FSU030

fastening bolt, and then take off engine bracket
assembly.

7. Screw off the forepart exhaust pipe grip nut,

FSU031
and then take off forepart exhaust pipe
assembly.
 Chassis Volume FSU-27

FSU032

8. Take off front transverse stabilizer rod FSU033

pressure plate fastening bolt, and then take
out front transverse stabilizer rod.
Tightening Torque: 56~70 N•m

Check after Dismantlement FSU034

1. Check stabilizer rod, front transverse
connecting rod assembly of stabilizer rod,
steady liner and steady clamping band for
deformation, crack and breakage. If any, please
replace them.
2. Check starting torque of front connecting rod
assembly ball joint .
Standard Value: 0.5~1.5 N•m

Check of shaft end gap

1. Move ball point end along with axial direction to check for looseness.

Shaft end gap: 0 mm

2. If the measured value exceeds prescribed limit, please replace the transverse
connecting rod.
 Chassis Volume FSU-28

Reassembly
Installation is in opposite order of the disassembly.
 Chassis Volume FSU-29

Diagnosis and Steps

Check of suspension parts
If there are the following cases, please replace suspension parts.
1. Bending suspension parts.
2. Abrasive suspension parts.
3. Spoiled suspension parts.

Do not heat, quench or line up spare parts. Bend or spoil of suspension spare parts
always indicates accidents or driving against rules. When suspension spare parts are
found to be bent or spoiled, make a complete check about the following parts.
1. Steering knuckle.
2. Ball joint connection.
3. Steering apparatus ball joint accessory.
4. Torque value of connecting fastener from control arm to frame.
5. Check the connection from stay to steering knuckle.
6. Check the connection between front lower control arm ball joint bolt and steering
knuckle.

Check of ball joint and steering knuckle

1. Every time when check front lower control arm ball joint bolt, check the front lower
control arm ball joint bolt for its tightness in the steering knuckle sleeve.
2. Lift the car to the extent that tires are completely off the ground.
3. Hold the tires at top and bottom.
4. Move the tire bottom to and fro to check the move condition of ball joint bolt end face
on the steering knuckle or crown nut.
5. If locknut is loose, it indicates that ball joint bolt may be bent, or steering knuckle
sleeve’ s installation hole is spoiled.
6. Check whether there is any horizontal shift of steering knuckle relative to control arm.
7. If there is any looseness in connection, or ball joint’ s seal is cut off, please replace
them.
8. Substitute abrasive or spoiled spare parts with correct maintenance spare parts.
Chassis Volume FSU-30
 Chassis Volume FSU-31

Auxiliary Frame
Dismantlement and Reassembly

1. Auxiliary frame welding assembly components

2. Auxiliary frame connecting stiffening plate II
4. Front suspension arm installation panel support II
6. Rear suspension arm installation panel support I
8. Auxiliary frame connecting stiffening plate I
9. Front suspension arm installation panel support I
11. Rear suspension arm installation panel support II 12. Bolt
13. Combined bolt 14. Combined bolt
15. Flange face bolt 16. Flange face bolt
17. Flange face bolt 18. Auxiliary frame installation
gasket
19. Flange face bolt 20. Flange face nut
21. Flange face locknut 22. Flange face locknut
23. Flat washer

Dismantlement Steps:
1. Discharge power steering solution (Please FSU035
refer to discharge of power steering solution)
2. Lift the car to take off left and right front tires
with tools.
Caution:
Before lifting the car, screw off the tires’
fastening bolt firstly.
 Chassis Volume FSU-32

3. Take off air cleaner and air hose (air intake).

FSU036

4. Take off carbon canister. (take the charcoal

canister from the upward direction shown in FSU037
the figure.)

5. Screw off oil pipe joint nut, and then release

high and low oil pipes at the steering box.
Caution: FSU038
Pay attention to installation of gasket, and
before releasing oil pipe, discharge power
steering solution. Please refer to discharge of
power steering solution.

6. Take off engine suspension fixed to the frame. FSU039

 Chassis Volume FSU-33

7. Take off fastening bolt connected with power

steering box. FSU040

8. Release tie rod from steering knuckle.

FSU041

9. Lift the car to take off engine deflector.

10. Screw off the forepart exhaust pipe grip nut,
FSU042
and then take off forepart exhaust pipe.

FSU043
 Chassis Volume FSU-34

11. Release engine bracket assembly’

s four FSU044
fastening bolts.

12. Take off left and right front suspension arm FSU045
installation panel support.
Tightening Torque: 88 N•m

13. Take off rear suspension arm fastening bolt, FSU046

and then release front suspension arm from
auxiliary frame.

14. Screw off the stiffening plate grip nut and bolt,
FSU047
and then take out stiffening plate.
 Chassis Volume FSU-35

15. Screw off front suspension front suspension

FSU048
arm installation bolt and nut, and then release
suspension arm from auxiliary frame.

FSU049
16. Take off auxiliary frame’
s two fixed bolts fixed
to the body.
Tightening Torque: 108 N•m

17. Take out auxiliary frame assembly wholly.

18. Take off power steering box and connecting
stiffening plate from auxiliary frame.

Check after Dismantlement

Check auxiliary frame for deformation, crack or other damage. If any, please replace it.

Reassembly:
Reassembly is in opposite order of the disassembly.
Caution:
Please don’t use spare parts which can not be used repeatedly, and all bolts should
be screwed to the prescribed torque. Finally, align the wheels.
 Chassis Volume FSU-36

Common Troubles and Countermeasure

Diagnosis for Noise of Front Suspension

Steps Operation Yes No
Definition: Any noises that are given out from the car’s front part triggered by
ground speed or traveled pavement and are relevant to front suspension.
Important precautions: It is necessary to
compare this car with a same normal car to
decide whether the customers’complained System is
1 Go to step 2
failures are car’
s normal working characteristic normal
or not. Attempt to reproduce noise. Road-test
car generates abnormal noises or not.
1. Change transmission to “parking gear”.
2. Close ignition device.
Go to step
2 3. Knock the front part of the car to reproduce Go to step 3
4
noise.
With noise or not?
1. Knock the front part of the car, and then use
stethoscope to make sure the source of
noise.
3 Go to step 1 —
2. When necessary, maintain or change
questionable parts.
Have carried out repair or not?
1. Lift and support the car properly.
Go to step
4 2. Check all front suspension parts for Go to step 5
6
breakage. Any damaged parts?
Repair any spoiled parts.
5 Go to step 1 —
Have carried out repair or not?
1. Check tires for filling pressure.
2. Check tires for abnormal abrasion. Go to step
6 Go to step 7
Whether the tires display abnormal tread 9
abrasion?
1. Substitute tires.
2. Road test car. Go to step
7 Go to step 8
Whether the noise is given out from the rear 9
part now?
Substitute tires that give out noise.
8 Go to step 1 —
Have carried out repair or not？
Make sure ball joint and steering box pull rod’
s
lubrication. When necessary, lubricate or Go to step
9 Go to step 1
substitute them. 10
Have repaired any parts or not？
10 Make sure all wheel nuts are fastened to the Go to step 1 Go to step
 Chassis Volume FSU-37

prescribed torque, and then fasten according 11

to requirement.
Have fastened all wheel nuts?
Push and pull the mainstay by hands. Go to step Go to step
11
Whether the mainstay becomes loose or not? 12 14
1. Check stay fastener to discern whether the
fastener’s fastening torque value coincides
with standard requirement, and then fasten Go to step Go to step
12
according to requirement. 2. Push and pull 14 1
mainstay by hands.
Whether the mainstay becomes loose or not?
Substitute released or abrasive the mainstay
parts. Please refer to the substitution of stay
13 Go to step 1 —
parts and/or spring of front suspension.
Have carried out repair or not?
Push and pull stabilizer shaft by hands.
Go to step Go to step
14 Whether stabilizer shaft becomes loose or
15 19
not?
2. Push and pull stabilizer shaft by hands.
Go to step Go to step
15 Whether stabilizer shaft becomes loose or
18 1
not?
Check the position of stabilizer shaft‘
s loose
position. Go to step Go to step
16
Whether stabilizer shaft’s connecting parts 17 20
become loose or not？
Substitute stabilizer shaft’
s connecting rod.
17 Go to step 1 —
Have carried out repair or not?
Substitute stabilizer shaft’
s insulator and/or
18 bracket. Go to step 1 —
Have carried out repair or not?
Check control arm for looseness or move. Go to step Go to step
19
Have observed looseness or move or not？ 20 22
1. Check whether control arm fastener’ s
fastening torque value coincides with standard
Go to step Go to step
20 requirement or not.
21 1
2. Check whether the control arm becomes
loose or not.
Substitute any abrasive or loose control arm
liners
21
“Please refer to the substitution of lower Go to step 1 －
control arm sleeve (the front part)”.
Have carried out repair or not?
 Chassis Volume FSU-38

Diagnosis for Common Troubles

Position Trouble Possible Causes and Questionable Spare Parts

 Improper installation and looseness
 Deformation, breakage or warping of stay
 Aging of liner or installation spots
 Interference of spare parts
 Fatigue of spring
Noise  Looseness of suspension
 Front axle and front suspension
 Wheels
 Drive shaft
 Brake
 Turning
 Improper installation and looseness
 Deformation, breakage or warping of the mainstay
 Aging of liner or installation spots
 Interference of spare parts
Shake  Looseness of suspension
 Front axle and front suspension
 Wheels
 Drive shaft
 Brake
 Turning
 Improper installation and looseness
Front  Deformation, breakage or warping of stay
 Aging of liner or installation spots
suspension
Vibration  Interference of spare parts
 Fatigue of spring
 Front axle and front suspension
 Drive shaft
 Turning
 Improper installation and looseness
 Deformation, breakage or warping of stay
 Aging of liner or installation spots
 Interference of spare parts
Tremble  Incorrect alignment of wheels
 Front axle and front suspension
 Brake
 Turning
 Wheels
 Improper installation and looseness
 Deformation, breakage or warping of stay
Uncomfortable  Aging of liner or installation spots
riding or  Interference of spare parts
difficult  Fatigue of spring
operation  Incorrect alignment of wheels
 Fatigue of stabilizer rod
 Front axle and front suspension
 Wheels
 Chassis Volume RSU-1

Overview
Components Diagram

Upright column
assembly of rear damper

Steering
knuckle
Rear The upright
underframe rear
suspension

Right rear
transverse slide
bar

Rear antisway bar

Front antisway bar

Longitudinal push-and-pull
rod

The rear suspension can also be called independent suspension, space four-bar linkage,
coil spring, two-way actions telescopic tamper, and with stabilizer rod. The characteristics
of the suspension: there are four cross arms and a tamper at each side of the suspension,
and the reasonable arrangement of each cross arm could make the run-out of the wheels
meet the kinematics characteristics, and transfer the power by the cross arm to the body.
According to the mutual positions of the cross arms, the height of the roll center and the
trim center, change of the cross arms’height can also influence angular motion of the
run-out of the wheels, that is the change of the camber angles of the wheels. The main
control components are the four cross arms and the damper. The upper suspension arm
is a U-arm, with one end connected to the steering knuckle with liner, and the other end
connected to the body with both the front and rear liners. The lower suspension arm
includes both front and rear arms which are nearly paralleled and a longitudinal
suspension arm, one end of the front and rear arms are connected with the steering
knuckle, and the other end is connected to the underframe with liner. One end of the
longitudinal suspension arm is articulated to the steering knuckle, and the other end is
articulated to the longitudinal beam with liner. The lower part of damper is fixed on
steering knuckle, and the upper part is connected with the body. The underframe is
connected to the body with liner.
 Chassis Volume RSU-2

Overhaul Specifications

Rear-wheel Alignment Parameter Threshold Value

Camber angle -40’±30’
Toe-in 0°9’±9’

Item Specification
Stroke mm 184
Damping force Extension N 1125
[0.39 m/Sec] Compression N 380

Specifications of Torque

Fix longitudinal push-and-pull 135~155N•m

rod on body
Fix longitudinal push-and-pull 90~110N•m
rod on steering knuckle
Fix the left front transverse slide bar to rear 90~110N•m
underframe
Fix to rear steering knuckle 98N•m
Fix the left rear transverse slide bar to the 56~70N•m
rear underframe
Fix the head of ball and spigot on steering 28N•m
knuckle
The lower suspension arm of the starting 1~6N•m
torque of ball and spigot
Set the rear antisway bar & ball and spigot 42~54N•m
in the antisway bar separately.
Pivoting moment of ball and spigot of the 0.5~1.5N•m
stabilizer rod assembly
Install the top of the upright column 56~70 N•m
assembly of damper on the body
Fixed at the previous position of installation 56~70 N•m
pipe of the damper of rear steering knuckle
Fix mounting panel for front suspension 42~54N•m
arm on body
Fix mounting panel for front suspension 90~110N•m
arm on steering knuckle
Fix rear underframe on body 90~110N•m
 Chassis Volume RSU-3

Precautions
1. When mounting the rubber liner, the final screwing must be done in a condition
that the unloaded tyres touch the ground. The engine oil will shorten the service
life of rubber liner. Do clean the overflowed engine oil.
2. Unloaded condition means fuel, engine coolant and lubricant are full, and the
spare tyre, jack, driver tools and pedal pad are all in the appointed place.
3. After maintaining the suspension components, the position of wheel must be
checked.
4. The locknut can not be reused. The new nut should always be mounted. When
replacing the locknut, don’t scrub the engine oil before screwing down it.

Preparations
Special Repair Tools

Name No. Tool Purpose

The front ball Drawing
Ball die
joint of control joint
Cord
arm of the
Steering
JAC-T1D003 wheel Nut
driving rod
separated from
the steering
knuckle
Applied for the
disassembly
and reassembly
Disassembly Spring

of the compressor

tools of JAC-T1D004
suspension
damp spring
damp coil
spring
 Benjoy Maintenance Manual — Chassis Volume RSU-4

Rear Suspension Assembly

Check and Maintenance of Vehicle
Make sure whether the fixing conditions (loose, clearance) and status of every element
are normal.
Check of the ball joint end play.
1. Put the iron column or something like that between the suspension arm and axle.
2. Pry up and down to measure the end play.
Caution:
Be careful not to damage the dustproof cover of ball joint. And please
don’t damage the installing part for overexertion.
Check of Damper
Check whether the mounting part is linking oil, damaged and broken.
Previous Check of Rear Wheels Position
1. Check whether the air pressure of wheel is correct and whether the tyres are
abrasive.
2. Check whether the tyres can run out.
3. Check the wheel end play.
4. Check the ball joint end play of suspension arm.
5. Check the height conditions of vehicle.
6. Check to see if each fixed point of rear underframe and suspension is loosened and
distorted with naked eyes.
7. Check if there is any crackle, distortion and other damages of each bar.
Check of Rear Wheel Position
Stop the vehicle on the level ground before checkup to measure the wheels location.

Check whether the rear suspension, air pressure of wheels and wheel hub bearing are
loosened to make them achieve the normal states, before measuring the wheels position.
Check of Rear Wheel Toe-in.
1. Stop vehicle on the level ground straightly, and then press its front part hard to make it
vibrated up and down, which will let the vehicle stabilized.
2. Draw the baseline of tyre tread (rear) at the same height of the wheel hub center as
the measuring point.
3. Measure the distance of point A (rear).
4. Push the vehicle forward slowly to make the wheels roll 180°(i.e.1/2 circle).

Forward
Wheel
hub
center

Baseline
Measuring point
 Benjoy Maintenance Manual — Chassis Volume RSU-5

Illustration:
Line paralleling with
If pushing the wheels roll over 180° (i.e.1/2
center-line of body
circle), the forth step should be restarted.
Caution:
Do not push the vehicle backward at this
moment.

Total toe-in=A-B

5. Measure the distance of point B.

Cross beam
6. Work out the toe-in value of rear wheels
according to the measured distance.
Standard Value: 0°9’±9’

7. If the wheel toe-in is not in the specified

range, then the adjusting bolt of the front
transverse slide bar should be rotated to the
left and right directions with the same
extent.
To the left: clockwise rotation → toe-out
direction
To the right: clockwise rotation → toe-in
direction
Check of Camber Angle
Make use of proper orientator to measure
camber angles of the left and right wheels.
Standard Value: -50’±30

Note
① The camber angle that has been designed previously before leaving factory cannot be
adjusted.
② If camber angle is not in the range of standard value, please check and replace the
bended and damaged spare parts.
③ Adjust the front part of vehicle about 1.3mm.
 Benjoy Maintenance Manual — Chassis Volume RSU-6

Rear Damper
Dismantlement and Reassembly

1. Flange face locknut 2. Bolt 3. Rear damper

Dismantlement Steps
1. Lift the vehicle and dismantle the tyres of rear RUS001
wheels.
Caution:
Unscrew the fixed bolt for tyres before lifting
vehicle.
Tightening Torque: 86~116 N•m
Benjoy Maintenance Manual — Chassis Volume RSU-7
 Benjoy Maintenance Manual — Chassis Volume RSU-8

2. Dismount the bolt that supports the damper on

RUS002
wheel hub.
Tightening Torque: 56~70 N•m

3. Pull up the buckles of rear seats and lay down

the rear seats.
RUS003
4. Take out of the bayonet catches of coatrack,
then take out the coatrack and cut off the lamp
wire harness. (refer to the interior and exterior
trimmings part)

RUS004
5. Dismount the two fixed nuts of fixed damper.
Tightening Torque: 56~70 N•m

RUS005

6. Remove the coil spring damper assembly

downwards.
 Benjoy Maintenance Manual — Chassis Volume RSU-9

Check after Dismantlement

1. Check whether there is any deformation, crackle or other damages of damper. If there
is, please replace it.
2. Check whether the damper is of leakage, if it leaks, please replaces it.
3. Check if the seal of rigid sealing support has any crackle, distortion or stripping. If
there is, please replace it.
Reassembly
Mount the rear damper in the reverse sequence of dismantlement.

Disassembly and Assemblage

1. Nonmetal insert locknut 2. Damper dog

3. Buffer block II 4. Upper bracket weld assembly of rear spring
5. Rear spring seat 6. Buffer block sleeve
7. Buffer block I 8. Stopper sleeve
9. Stopper 10. Rear spring
11. Dust cover of rear damper 12 Plastic pad
13. Rear damper 14. Flange face locknut
15. Bolt 16. Anchor pin
17. Front stopper installation seat 18. Lower bracket of rear spring

Disassembly Steps
1. Make use of the special tools as the sketch
presents to compress the coil spring.
Note
① Install the special tools equally to get the
extreme length in the range of installation.
② Make sure the special tools have been fixed
to coil spring, which can be pressed then.
 Benjoy Maintenance Manual — Chassis Volume RSU-10

③ The special tools screwing down the bolts cannot be pneumatic tools.
2. Fix the piston rod firmly and dismount the
caulking nut.

3. Remove the damper dog, buffer block II, rear spring seat, buffer block sleeve, buffer
block I, stopper sleeve, stopper, dustproof cover of rear damper and plastic pad from
the damper in turn.
4. Release the special tools slowly, and then take off the coil spring as well as dustproof
cover from the damper.

Check after Dismantlement

1. Check whether the damper is linking oil; please
replace it if it does.
2. Check the damping force of damper, please
replace it if it isn’
t qualified.
3. Check whether the lower spring seat has any
crackle and distortion.
4. Check if the buffer block is damaged.
5. Check whether the spring seat of rear damper has Edge of coil spring Spring seat
any abrasion, crackle or distortion, if any, please
replace the defective spare parts.
Assemblage
Assemblage steps are the reverse sequences of
disassembly.

Caution: Bracket

①When mounting the coil spring, be sure of

aligning the edge and the step part of the
Forward
spring seat of damper.
② The bracket should be mounted to the position
presented in the drawing. Inner tube of
lower liner
 Benjoy Maintenance Manual — Chassis Volume RSU-11

③ As mounting the caulking nut, which should be screwed up temporarily before

dismounting the special tools for spring compression,then screw down the
caulking nut according to the specified torque.
Tightening Torque: 49 N•m
 Benjoy Maintenance Manual — Chassis Volume RSU-12

Rear Suspension Arm

Dismantlement and Reassembly

1. Upper rear suspension arm, connecting bolt & nut of steering knuckle
2. Flange face bolt 3. Upper rear suspension arm assembly
4. Liner retaining plate of the upper rear suspension arm

RUS006

Dismantlement Steps:
1. Lift vehicle and dismount the tyres of rear
wheels.
Caution:
Unscrew the fixed bolt for tyres before lifting vehicle.
Tightening Torque: 86~116 N•m
RUS007
 Benjoy Maintenance Manual — Chassis Volume RSU-13

2. Dismount the upper rear suspension arm

and the connecting bolt and nut of the
RUS007
steering knuckle.
Tightening Torque: 90~110 N•m

3. Dismantle the four fixed bolts which fix the

upper rear suspension arm on the chassis. RUS008
Tightening Torque: 42~54 N•m

4. Take out upper rear suspension arm from

chassis.
RUS009

Check after Dismantlement

Check whether the upper rear suspension arm has any distortion, crackle or other
damages. Please replace it if the above cases exist.
 Benjoy Maintenance Manual — Chassis Volume RSU-14

Reassembly
Pay attention to the following mounting essentials and install in the reverse sequence of
dismantlement.

RUS010 Liner retaining

Mounting Essentials of Liner Retaining Upper suspension
arm
plate of the upper
rear suspension arm
Plate of the Upper Rear Suspension Arm
Upper suspension

Screw down the mounting bolt and nut of connecting arm 请核实？

board of upper rear suspension arm to make the

dimension showed in the drawing reach the standard Fixed bolt of the upper rear suspension
arm
value.
Standard Value: 43.6±1 mm

Upper end of bracket of

RUS011 upper suspension arm

Section center of
suspension arm

RUS012

Caution:
Install the liner retaining plate of the upper rear
suspension arm according to the above standard
value, then the characteristic dimensions are as
follows:
B: 213.5 mm C: 269.2 mm
 Benjoy Maintenance Manual — Chassis Volume RSU-15

Longitudinal Push-and-Pull Rod

Dismantlement and Reassembly

1. Bolt 2. Hexagon flange face bolt

3. Longitudinal push-and-pull rod
 Benjoy Maintenance Manual — Chassis Volume RSU-16

Dismantlement Steps:
1. Lift vehicle and dismantle the tyres of rear RUS013
wheels.
Caution:
Unscrew the fixed bolt for tyres before lifting vehicle.

Tightening Torque: 86~116 N•m

2. Unscrew the nut and then prize up the ball

joint of steering knuckle and longitudinal RUS014
push-and pull rod.
Tightening Torque: 90~110 N•m

RUS015

3. Dismount the fixed bolt before taking off

longitudinal push-and pull rod.
Tightening Torque: 135~155 N•m

Check after Dismantlement:

Check whether the longitudinal push-and pull rod has any distortion, crackle or other
damages. Please change it if the above cases exist.
Reassembly
Reassembly is in accordance with the reverse sequences of dismantlement.
Check and adjust the rear wheel position after installation.
 Benjoy Maintenance Manual — Chassis Volume RSU-17

Front and Rear Transverse Slide Bars of Rear Suspension

Dismantlement and Reassembly

1. Connecting rod of the rear stabilizer bar

2. Connecting bolt of front transverse slide bar and steering knuckle
3. Connecting bolt of the front transverse slide bar and the beam of rear suspension arm
4. Front transverse slide bar
5. Connecting nut of ball stud of the rear transverse slide bar and steering knuckle
6. Connecting bolt of rear transverse slide bar and rear underframe
7. Rear transverse slide bar assembly
RUS016
Dismantlement Steps of Front Transverse
Slide Bar:
1. Lift vehicle and then dismount the tyres of
rear wheel with tools.
Caution:

Unscrew the fixed bolt for tyres before lifting vehicle.

Tightening Torque: 86~116 N•m

RUS017

2. Uncouple the speed sensor wiring wire

harness which is fixed on front transverse
slide bar.
 Benjoy Maintenance Manual — Chassis Volume RSU-18

3. Dismount the nut of connecting rod of the

RUS018
rear stabilizer bar.

4. Dismount the connecting bolt of front

RUS019
transverse slide bar and steering knuckle.
Tightening Torque: 98 N•m

5. Dismount the connecting bolt of front

transverse slide bar and rear underframe. RUS020

Tightening Torque: 90~110 N•m

6. Take off the front transverse slide bar from

rear underframe. RUS021

Check after Dismantlement:

Check whether the front transverse slide bar is bended, cracked and damaged, if the
above cases exist, please replace it.
 Benjoy Maintenance Manual — Chassis Volume RSU-19

Reassembly:
Mount the front transverse slide bar in the reverse sequence of dismantlement and screw
down the bolt as well as the nut to the specified torque.

Dismantlement Steps of Rear

RUS022
Transverse Slide Bar:
1. Lift vehicle and dismount the tyre of rear
wheel with tools.
Caution:
Unscrew the fixed bolt for tyres before lifting
vehicle.
Tightening Torque: 86~116 N•m

2. Dismount the connecting nut of ball stud of

RUS023
rear transverse slide bar and steering
knuckle.
Tightening Torque: 98 N•m

RUS024
3. Dismount the connecting bolt of rear
transverse slide bar and rear underframe.
Tightening Torque: 90~110 N•m

4. Take off rear transverse slide bar from rear RUS025

underframe.
 Benjoy Maintenance Manual — Chassis Volume RSU-20

Check after Dismantlement

Check whether the rear transverse slide bar is bended, distorted and damaged, if the
above cases
exist, please replace it.

Reassembly
Install the rear transverse slide bar in the reverse sequence of dismantlement and screw
down the bolt as well as the nut to the specified torque.
Check and adjust the rear wheels position after installation.
 Benjoy Maintenance Manual — Chassis Volume RSU-21

Rear Antisway Bar

Dismantlement and Reassembly

1. Flange face locknut 2. Connecting rod assembly of the rear stabilizer

bar
3. Outer-ram plate of rear antisway bar 4. Pressure plate liner of rear antisway bar
5. Rear antisway bar

Dismantlement Steps
1. Lift vehicle and then dismount the tyres of RUS026
rear wheels.

Caution:
Unscrew the fixed bolt for tyres before lifting
vehicle.
Tightening Torque: 86~116 N•m
 Benjoy Maintenance Manual — Chassis Volume RSU-22

RUS027
2. Screw off the fixed nut of connecting rod
before dismounting the connecting rod
assembly.

3. Dismount the fixed bolt which fixes rear

antisway bar on underframe.
Caution:
There are four left and right bolts in all
Tightening Torque: 42~54 N•m RUS028
4. Take off the rear transverse slide bar from
underframe.
Check after Dismantlement
1. Check whether the rear antisway bar,
outer-ram plate of rear antisway bar,
connecting rod assembly of the rear
stabilizer bar and pressure plate liner of rear
antisway bar are distorted, cracked and
RUS029
damaged. If the above cases exist, please
replace them.
2. Check the starting torque of ball joint of rear
antisway bar.
Standard Value: 0.5~1.5 Nm

Reassembly
Install the rear antisway bar in the reverse
sequence of dismantlement.
Caution: RUS030
About 0mm
The mark should be put on the left and the
dimension of liner should be in accordance
with the sketch presentation as mounting the
stabilizer rod.
 Benjoy Maintenance Manual — Chassis Volume RSU-23

Diagnostic Message and Procedure

Check of Suspension Components
If the following cases occur, please replace the suspension components.
1. Bended suspension components.
2. Abrasive suspension components.
3. Damaged suspension components.
To heated, quench and align the spare parts will make them bended or damaged,
which often cause accident. When finding out the spare parts of suspension arm
bended or damaged, please check the following components thoroughly.
1. Steering knuckle.
2. Ball joint connection.
3. Ball joint accessories of steering device.

Check of Following Components

1. Check the torque value of connecting fastener of guide arm with rear underframe.
2. Check the connection of damper and steering knuckle.
3. Check the connection between ball stud of front transverse slide bar and steering
knuckle.
 Benjoy Maintenance Manual — Chassis Volume RSU-24

Rear Underframe

Dismantlement and Installation

1. Rear underframe assembly 2. Left front transverse slide bar assembly

3. Left rear transverse slide bar assembly 4. Right front transverse slide bar assembly
5. Right rear transverse slide bar assembly 6. Bolt
7. Hexagon flange bolt 8. Eccentric bolt
9. Eccentric pad 10. Spring washer
11. I-type hexagon nut 12. Flange face nut

Dismantlement Steps:
1. Lift vehicle and dismount the two tyres of
rear wheels.
Caution:
Unscrew the fixed bolt for tyre before lifting the RUS031
vehicle.
Tightening Torque: 86~116 N•m
 Benjoy Maintenance Manual — Chassis Volume RSU-25

2. Dismount the nut of connecting rod of rear

stabilizer bar and uncouple the connecting RUS032
rod from front transverse slide bar.

3. Cut off ABS wiring wire harness joint from

underframe and take out the wiring wire
harness from underframe.
RUS033

4. Dismount the connecting bolt of front

transverse slide bar and rear underframe.
Tightening Torque: 90~110 N•m

RUS034

5. Dismount the connecting bolt of rear

transverse slide bar and rear underframe. RUS035

Tightening Torque: 56~70 N•m

 Benjoy Maintenance Manual — Chassis Volume RSU-26

6. Dismount the fixed bolt which fixes rear

underframe on body. RUS036

Caution:

There are left and right four bolts in all.

Tightening Torque: 90~110 N•m

7. Take out rear underframe.

Caution:
Screwing down the nut temporarily could prevent the damage of thread and the
sudden dropout of ball joint detacher (proper tool).
Check if there is any distortion, crackle or other damages of the element, if there is,
change it.
Reassembly
Mount rear underframe in accordance in the reverse sequence of dismantlement.

Caution:
Please don’t use the spare parts repeatedly which cannot be reused.
 Benjoy Maintenance Manual — Chassis Volume RSU-27

Common Trouble and Countermeasure

Part Cause Possible Cause and Countermeasure
 Improper installation, and loosened
 Distortion, damage and contort of damper
 Aging of bushing or mounting part
 Interference of spare parts
 Spring fatigue
Rear
Noise  Suspension loosened
Suspension
 Rear axle and rear suspension
 Tyre
 Wheel
 Brake
 Steering
 Improper installation and loosened
 Distortion, damage and contort of damper
 Aging of bushing or mounting part
 Interference of spare parts
Jitter  Suspension loosened
 Rear axle and rear suspension
 Tyre
 Wheel
 Brake
 Steering
 Improper installation and loosened
 Distortion, damage and contort of damper
 Aging of bushing or mounting part
 Interference of spare parts
Quake
 Suspension loosened
 Rear axle and rear suspension
 Tyre
 Steering
 Improper installation and loosened
 Distortion, damage and contort of damper
 Aging of bushing or mounting part
 Interference of spare parts
 Incorrect wheel alignment
Flutter
 Rear axle and rear suspension
 Tyre
 wheel
 Brake
 Steering
 Benjoy Maintenance Manual — Chassis Volume RSU-28

Part Cause Possible Cause and Countermeasure

 Improper installation and loosened
 Distortion, damage and contort of damper
 Aging of bushing or mounting part
 Interference of spare parts
Uncomfortable
Rear  Spring fatigue
riding or difficult
suspension  Incorrect wheel alignment
operation
 Stabilizer rod fatigue
 Rear axle and rear suspension
 Tyre
 wheel
 Chassis Volume WT-1

Overview
Tyre is an important component of a car. Proper operation or improper will directly influence
vehicle performance and service life of tyre, so it connects with transportation cost, raw materials
consumption, personnel and property safety. We must operate and handle troubles of tyre properly
in order to maintain vehicle performance and reduce its abrasion. Security, economy amenity and
so on of a car when traveling are separately connected with tyre’s reliability, rolling resistance,
adhesion and buffer performance, so generally there are strict regulations on tyre assemblage.
When replacing the original wheel, the tyre chosen should coincide with the wheel’s specification,
at the same time, characteristics of structure, layer or load index, speed lever and figure type of the
tyre should also be paid attention to. Tyre plays an important role in a car, so its proper
maintenance, transposition and timing four-wheel alignment are necessary in daily maintenance.
Replacement means make timing four-wheel alignment to tyre. Bad condition of car can influence
service life of tyre, for example, brake goggling can result in tyre’s hauling traveling, increase its
abrasion or single tyre’s serious abrasion and so on, so proper operation of tyre is necessary to
maximize its function.
Item Specification
Model Aluminum
Size 16×7J
Tyre
Wheel setover mm 45
Pitch diameter (P. C. D.) mm 108 删除的内容: （
Model Aluminum
删除的内容: ．
Size 16×7J
Tyre [optional]
Wheel setover mm 45 删除的内容: ．
Pitch diameter (P. C. D.) mm 108 删除的内容: ．
删除的内容: ）
Overhaul Specifications 删除的内容: 〔
删除的内容: 〕
Item Threshold Value
Tread depth of tyre mm 7.8 删除的内容: （
Wheel runout (radial runout) mm Aluminum Below 0.7 删除的内容: ．
Wheel runout (transverse runout) mm Aluminum Below 1.0
删除的内容: ．
删除的内容: ．
删除的内容: ）
Tyre Pressure
删除的内容: （

Item Standard Air Pressure 删除的内容: ）

Front wheel 250±10KPa 删除的内容: （

Rear wheel 250±10KPa 删除的内容: ）

 Chassis Volume WT-2

Precautions
删除的内容: d
Precautions Luring Lifting Car
① Close the door, hood and luggage carrier when lifting car. Lift it from its gravity center so
删除的内容:
that one side of the car won’t overload or the front-end/the rear-end overweight.
删除的内容:
② Mat of lifter should be extended to its extreme in order to provide stable platform.
③ Every mat should be underlaid at the low part of the car; intensity of every part should be
enough to bear the car’s weight.
④ Lift the car at 30cm’s height and stop lifting, swing the vehicle at full tilt and check if the car
is stable. If the car is lifted at a short distance from the ground and seems stable, then it is
necessary to examine while continuing lifting the car until get the expectation value.
⑤ Extract safety mortise lock and reverse control direction before lowering the lifter. To ensure
its safety, falling speed should be well controlled.
Precautions in Tyre Operation
① There should be an adaptive process in tyre operation. Restrict speed; restrict load and avoid
performing in bad work conditions to ensure that every part of tyre adapts deformation
gradually. Avoid producing too much heat to damage delamination. 批注 [n1]: 请核实

② New tyre should avoid emergent starter, sharp turn and emergent brake. .
③ When performing at a high speed, do have a rest per hour traveling to lower the temperature
of tyre and reduce its fatigue.
④ If there is abnormal noise during performance, stop the car immediately and check.
⑤ Remove sundries such as carpolites, iron chips and so on which are entrained in the figure of 批注 [n2]: 请核实

tyre in time; check and ensure the pressure of tyre within the range of specification before
traveling; check heat generation condition and have a rest properly during a long time of
traveling.
⑥ Often check the fixed bolt of wheel when traveling. When mounting or replacing new tyres,
fixed bolt of tyre should reach specified torque.
Preparations
General Maintenance Tool
Name Picture Illustration

Electric tool Dismantle nut of wheel

 Chassis Volume WT-3

NVH Countermeasure

Trouble
Uncomfortable
Tyre Riding or
Noise Shake Vibration Tremble
Difficult
Operation
Improper
installation, ● ● ● ●
loosed
Un-round ● ● ● ●
Unbalanced ● ● ● ●
Incorrect tyre
● ● ● ● ●
pressure
Unsymmetrical
● ● ● ●
abrasion of tyre
Deformation or
● ● ● ●
damage
Possible
Disaccord ● ● 删除的内容: C
cause and
Size of tyres
questionable ● ● ● ● 删除的内容: Q
spare parts disaccords
删除的内容: S
Front axle and
● ● ● ● ● 删除的内容: P
front suspension
Rear axle and
● ● ● ● ●
rear suspension
Tyre
Wheel ● ● ● ●
Drive axle ● ● ●
Brake ● ● ●

Turnaround ● ● ● ●

●Application
 Chassis Volume WT-4

Wheel
Caution:
Tyre with Excessive Air Pressure:
1. Overload of tyre can make the tyre too hot because of excessive friction, so the tyre may
leak-off and cause serious accident.
2. It is easy to scuff, puncture or blow out due to abrupt collision (such as meeting with pits)
删除的内容:
because of too much tyre inflation, so it should keep the pressure value recommended.
Tyre with Insufficient Pressure:
1. Insufficient tyre inflation is as dangerous as overload of tyre. The accident arisen may cause
serious personnel injury. It is necessary to check all tyres to make the pressure of tyre keep
the pressure value recommended. Inspect pressure in cold conditions of tyre.
2. Worn tyre may cause accident. Replace the tyre in time if the thread abrades seriously or the
tyre has worn.
Check
1 Inspect the tyre inflation pressure. Adjustment is necessary if the pressure is out of the range
of standard value.
批注 [n3]: 图片中需要翻译否
Standard Trace Routine 请核实
Car’s serviceability is stable and the car drives stably when
the tyre pressure reaches the specified value. Correct
regulations of tyre pressure can be found in the “tyre
pressure tag”provided for this car (generally in the door
case of the driver). Using dial barometer with super
performance to check tyre pressure is recommended. Colde
tyre pressure should be checked once every month. Inspect
tyre pressure frequently is necessary as ambient
temperature changes acutely. The tyre pressure decreases with the decrease of the outdoor
temperature. Replace protective cap of air valve and tighten it by hand after the check of air
pressure. Inflation pressure specified in the tyre pressure tag is cold inflation pressure. Inflation
pressure in cold conditions is measured when the vehicle in running for at least three hours or the
vehicle drives less than 1 mile (1.6 kilometer) after in the fly for at least three hours. Tyre inflation
pressure may heighten 2-6 pound/inch 2 (14-41 KP) during the vehicle’
s performance time. Do not
decrease this normal formation of air pressure.
 Chassis Volume WT-5

删除的内容: g
Incorrect Gas Inflation May Result in:
删除的内容: i
1. Not enough gas inflation of tyre can result in fast 删除的内容: m
abrasion at its shoulder, deflection of wheel, increase of 删除的内容: r
rolling resistance and consumption of fuel oil.

2. Too much tyre inflation can cause quick abrasion in the centre of tread of tyre and make the
tyre lose its buffer capacity.

3. Inspect if the aluminum wheel deforms, have cracks

or have other damage. Dismount the wheel and check
it is run-out if it deforms.
a. Dismount the tyre from the aluminum wheel and mount it to the equilibrator of tyre.
b. Set the dial indicator as shown in the figure.
Note: 删除的内容: ：
带格式的: 字体: 非加粗,
The run-out of wheel (dial indicator value) refers 字体颜色: 黑色
Maintenance data and specification
Check of tyre abrasion
Measure the depth of tread. Transverse run-out Radial
run-out
删除的内容: V
Threshold value: 1.6mm
删除的内容: ：
Remark:
When the depth of tread reduces to 1.6mm or less, it will present the mark of abrasion. It is
necessary to replace the wheel when the abrasion mark presents. The abrasion mark rubber
strip through the tread will be bared at this time, and this reminds you that this tyre can’t be
used any more, or it will skid or float when traveling.
删除的内容: T
Cleansing of tyre
Remove the inoxidizing coating on the surface of tyre before delivery of vehicle. In order to
remove the inoxidizing coating, first wipe it with hot water and soak it for several minutes, and
then brush the coat with badger softener. The coat can also be removed with steam cleansing.
Attention: Do not do the cleansing with petrol, mineral oil, oil-based solvent or steel brush.
 Chassis Volume WT-6

Tyre Assembly
Balance of Wheel
Accepted form (embedded inside and hanging outside)
Dismantlement
1. First dismount the tyre which needs to adjust balance
from the car.
2. Dismount both the inboard and outboard weight from
the wheel. Clear the scree on the wheel. Sundries are
not permitted on the wheel. They should be cleared.
Attention:
Be careful and don’t scuff the wheel when dismantling.
3. Dismount the weight in and out of the car with weight.
Attention:
Be careful and don’t scuff the wheel when dismantling.
Adjustment of Balance of Wheel
Attention:
If the tyre equilibrator has two set modes of bonding weight model and imbedding weight
model, then choose and adjust the imbedding weight model which applied to the running
wheel.
1. Make the centre hole as the guideline; mount the running wheel to the equilibrator. Start the
tyre equilibrator.
2. After the unbalanced value of both inside and outside presenting in the indicator of tyre
equilibrator, make outside unbalanced value multiply 5/3 to determine in-service heft of the
weight. Choose the outboard weight which is closest to calculated numeric value to mount to
specified outboard position or mount to specified relative angle of the wheel.
Attention:
Mounting inboard weight should be later than mounting of the outboard weight.
Before mounting weight, do clear up matching surface of the wheel.
Indicated unbalanced value multiply 5/3 equals to heft of weight to be mounted.
Calculation Example:
23 g ×5/3 = 38.33 g = 40 g weight (closest to calculated numeric value). Pay attention that chosen
heft of the weight should be close to calculated balance weight value.
For Example:
37.4 = 35 g
37.5 = 40 g
 Chassis Volume WT-7

a. Mount the weight in the position shown in the left figure.

删除的内容:
b. The weight should be left in the grooved area in
the inwall of running wheel when mounting it
on the running wheel as shown in the left figure.
The centre of the weight should match the
position (angel) indicated by the wheel
Indicated position (angle) of
equilibrator.
equilibrator of the vehicle
Attention:
① Weight can’t be used repeatedly, change for
new weight every time.
② Mounted weight can’t exceed three blocks.
c. If calculated heft of the weight exceeds 50g
(1.76 oz), then mount two weights in a straight
line (as shown in the left figure).
Attention:
Never put weights on another weight.
Inside Outside

3. Restart the wheel equilibrator.

4. Knock in imbedding weight in the inside of running wheel according to the position (angel)
indicated by the wheel equilibrator.
Attention:
Mounted weights can’t exceed two blocks.
Pre-installation wheel assembly balance test, the test requires the whole heft of the weights
not more than 97g.
5. Start the equilibrator. Make sure residual unbalanced value of both sides are only 10 g (0.35
oz) or lower separately. If residual unbalanced value of any side exceeds 10 g (0.35 oz), then 删除的内容: ，

repeat steps of weight mounting. Balance of wheel (maximal unbalanced volume permitted):
Note: Maximal unbalanced volume permitted.
Dynamic state (wheel rim) 10 g (one side), static state (wheel rim) 20 g (one side)
 Chassis Volume WT-8

Transposition of Tyre
Correction Chart of Preposition off-track 批注 [n4]: 是否需要大写？
删除的内容:
Inspect road test in advance

Inspect driving tyre

● Same size
● Same manufacture
● Same depth of tyre
● Adjust the pressure to
specified value

Inspect if suspension parts

loosen, abrade, damage or are in
bad condition.

Inspect if the brake is blocked.

Road test Good

Preposition off-track of vehicle

Overlap changeover of front tyre and wheel

assembly

Road test

Preposition and off tracking of vehicle Preposition and off tracking of vehicle
in the same direction in the same direction

It might be caused by front-wheel The tyre might be in a bad condition

alignment. Inspect the castor angel,
camber angel of wheel and toe-in Interchange right rear tyre and wheel
assembly with right front tyre and wheel
Wheel-alignment out of the range of assembly
critical field

Road test Good

Road test Good
Preposition and off tracking of Replace the right rear
wheel wheel

Interchange left rear tyre and wheel

assembly with left front tyre and wheel
assembly

Road test Good

Replace the right

rear wheel
 Chassis Volume WT-9

Attention: 删除的内容: ：

The tyre should be transposed every 8,000 kilometers, replaced with new tyre and
transposed at the same time every 50,000 kilometers.
Caution:
In order to ensure the speed performance of vehicle, the speed rank of the replaced tyre should be
equal to or higher than the original one. If the mounted tyre is in low speed rank, performance of
the vehicle might be affected and the speed ability of the vehicle might reduce to the maximal
speed performance of the replaced tyre. Consult the tyre manufacturer on the maximal speed rank
in order to avoid serious or lethal contretemps. Front wheel tyre and rear wheel tyre take on
different load and carry out different functions on turning, drive and brake. They have different
attrition rate and tend to present irregular abrasion print. This can be 批注 [n5]: 遗漏半句

Advantages of replacement of tyre: 删除的内容: R

删除的内容: T

1. Prolong the service life of the tread of tyre.

2. Keep towing lever.

3. Travel stably and quietly.
Method of tyre replacement recommended is shown in the figure.
Other methods can also be used, but they can’t make full use of all tyres.

Four-wheel Alignment
Four-wheel alignment data refers to wheel alignment data in this chapter.
Operation of four-wheel alignment refers to the User’s Guide of four-wheel equipment.
 Chassis Volume WT-10

Installation of Tyre
Mount the wheel
1. If it is handwork, there should be two steps in tightening, first forecasting tighten in turn,
align the wheel, and then symmetrically tighten it according to diagonal order.

Tightening Torque: 86~116N•m 删除的内容: ～

2. If tightening by automatic tightening machine, it is necessary to adjust the tightening torque

to 86~116N•m, tighten it in one time. 删除的内容: ～

Replacement of Tyre
Attention: 删除的内容: ：

It is dangerous to use improper wheel, wheel bolt or wheel nut. This will affect the brake
performance and operation performance of vehicle, let the tyre leak off and make the vehicle
out of control. It may cause accident to injure you or other body, so do use the correct wheel,
wheel bolt or wheel nut. When should replace with the new tyre is judged according to cue
mark of tread abrasion. The cue mark of tread abrasion will appear when the tread abrades
to 1.6mm or less.
It is necessary to replace with new tyre if one of the following conditions occurs:
1. At least three locations appear cue mark of tread
abrasion.
2. Curtain line or curtain cloth comes out in the tyre
rubber.
3. Tread or side piece cracks, the gape is deep
enough to see the curtain line or curtain cloth.
Home position indicator point “C”of tread abrasion (six

point around eqispaced)

4. The tyre bulges, swells or laminates
5. The tyre is punctured; scuffed or has other damage. Damaged size and parts are difficult to
repair.
Attention: 删除的内容: ：

① Using wrong wheel can also cause problems in aspects such as service life of bearing,
cool-off of brake, proofing of car speed meter or odometer, beam-focusing of front light,
height of bumper, ground clearance of vehicle, clearance between tyre and car body,
clearance between tyre and bottom plate.
② If you need replace the wheel, you must use the tyre made by the factory of Jianghuai
Car Co., Ltd.
 Chassis Volume WT-11

Spare Tyre
Note: 删除的内容: ：

Spare tyre used in a car is prepared for some sudden conditions. Its dynamic balance is
factory-adjusted, so when you want to use it, just dismount and use.
Position of Spare Tyre
It is beneath the carpet of luggage carrier.
It can be seen after opening rear luggage carrier and
pulling up the carpet.

Tightening Torque: 22N•m~27N•m 删除的内容: ～

Spare
tyre

Application:
Loosen the bolt of support rack of fixed tyre, and then take it off.
Attention: 删除的内容: ：

Pay attention to the steps when mounting the tyre. Tighten it step by step and reach specified
tightening torque.

Tightening Torque: 86~116N•m 删除的内容: ～

删除的内容:
删除的内容: N.m
 Benjoy Maintenance Manual — Chassis Volume WT-12 删除的内容: “Only for Yo
u”

Common Troubles and Countermeasure:

删除的内容: ．
1. Cause of Partial Common Troubles of Wheel and Countermeasure
删除的内容:
Trouble Possible Cause Countermeasure
Improper adjustment of front wheel Calibration
Too much resistance in the hinge of lower
Difficult Replacement
suspension arm when steering
steering
Wheel planished Adjustment
No power and resistance Repair or replacement
Failure of
Improper adjustment of front wheel Adjustment
steering wheel
Improper adjustment of front wheel Calibration
Shock absorber broken Repair or replacement
Suspension
Out-break or abrasion of antisway bar Replacement
smoothness no
Out-break or abrasion of rotary spring Replacement
good
Abrasion of liner of lower suspension arm Replacement
Improper charging pressure of tyre Calibration
Abnormal Improper adjustment of front wheel Calibration
abrasion of
Abrasion of shock absorber Replacement
tyre
Improper adjustment of front wheel Calibration
Less steering resistance at the hinge of lower
Off-track Repair
suspension arm
Letup or abrasion of liner of lower suspension arm Replacement
Improper adjustment of front wheel Calibration
Car always Too much resistance in the hinge of lower 删除的内容:
Replacement
runs to one suspension arm
side Break or abrasion of rotary spring Replacement
Lower suspension arm bended Replacement
Improper adjustment of front wheel Calibration
Too much resistance in the hinge of lower
Replacement
Front wheel suspension arm
swinging Break or abrasion of antisway bar Replacement
Abrasion of liner of lower suspension arm Replacement
Abrasion of shock absorber abrasion Replacement
 Benjoy Maintenance Manual — Chassis Volume WT-13 删除的内容: “Only for Yo
u”

Trouble Possible Cause Countermeasure

Break or abrasion of rotary spring Replacement

Car body Break or abrasion of rotary spring Replacement

droopy Trouble in shock absorber Replacement

Spare parts loosed Retightening

Break or abrasion of wheel bearing Replacement

Abnormal
Replacement of worn 删除的内容:
voice Malfunction of shock absorber
spare parts

Problems in tyre Replacement

Excessive tyre pressure Adjust pressure

Shock absorber malfunction Replacement

Car controlling
Tighten to specified
no good Nut of wheel loosed
torque

Break or looseness of rotary spring Replacement

Problems in tyre Replacement

Abrasion of liner Replacement

Car body leans There are problems in drive axle and suspension Replacement
to one side arm assembly

Replacement
Break or looseness of rotary spring
 Benjoy Maintenance Manual — Chassis Volume WT-14 删除的内容: “Only for Yo
u”

删除的内容: ．
2. Common Abrasion of Tyre and Countermeasure:

Trouble Possible Cause Countermeasure 带格式的: 字体: 加粗, 字

体颜色: 黑色
Not enough
Abrasion gas charging
block at the or not
shoulder enough
transposition
Adjust gas
Excessive charging pressure
Abrasion gas charged
block in the or not
centre enough
transposition

Adjust gas
Tread crack Insufficient gas charged
charging pressure

Excessive
extroversion
Inspect
Abrasion at of wheel
extroversion of
one side
wheel

Improper
toe-in of
Rim in a
wheel Adjust toe-in of
shape of
front wheel
feather

Wheel
unbalanced
Adjust unbalanced
Bare spot
wheels

Transposition of
Abrasion in Insufficient transposition of tyre or
tyre, check front
a shape of abrasion or inaccurate suspension
suspension
groove alignment
alignment
 Chassis Volume BR-1

Overview
A basic braking system comprises following components:
1. The brake pedal;
2. The master cylinder of brake;
3. The vacuum booster;
4. The brake pipe and the hoses;
5. The disc brakes (front and rear);
6. The stop lamp switch;
7. The brake fluid level sensor.
All brakes are servo-assisted and equipped with vacuum boosters. Whether a JAC
Benjoy employs the Antilock braking system (ABS), the hydraulic braking system is in the
form of front-rear split. In other words, the front and the rear wheel brakes respectively
take a circuit of master cylinder. The JAC Benjoy is provided with the front and the rear
disc brakes, which control the braking of corresponding wheels. In addition, this car has
an ABS, which carries components that are applied to most non-ABS vehicle. For more
details of individual spare parts in a basic braking system, see the relevant sections in
this chapter.

Overhaul Specifications

Item Specification
Master cylinder Internal diameter (mm) 25.4
Effective diameter mm 7″+8″
Vacuum booster
Augmented thrust ratio of vacuum booster 5.6
Pressure limiting valve Depressurizing ratio —
Effective diameter of brake disk (mm) 280
Front brake
Wheel cylinder diameter (mm) 54
Effective diameter of brake disk (mm) 245
Rear brake
Wheel cylinder diameter (mm) 38

Standard Threshold
Item
Value value
Free stroke of brake pedal (mm) 3－8 －
Clearance between brake pedal and footrest (mm) 50 or greater －
Output pressure of pressure limiting valve Input pressure —— －
 Chassis Volume BR-2

(bar) Output
—— －
pressure
Thickness of friction lining of front brake (mm) 14 2
Thickness of front brake disk (mm) 22 20.4
Run-out of front brake disk (mm) 0.03 －
Thickness of friction lining of rear brake (mm) 12 2
Thickness of front brake disk (mm) 10 8.4
Run-out of rear brake disk (mm) 0.03 －

Tightening Torque
Front Brake Disk
2 stop bolts of front brake disk 20~25N•m
Set bolt of front brake tongs 90~110N•m
Tightening torque for perforation bolt 25~30N•m
Tightening brake tongs for male adaptor of brake hose 25~30N•m
The female adaptor end of brake hose and the brake pipe 18~30N•m
Tightening torque for fastening bolt of rear brake tongs 56~70N•m
Braking pipeline joint connected with ABS hydraulic adjuster 18~30N•m

Rear Brake Disk

Brake hose and brake tongs 20~25N•m
Set bolt of rear brake tongs 56~70N•m
The inside screw thread of brake hose and brake pipe 18~30N•m
Note:

The standard value of minimum clearance between the head of sensor and the gear ring shall
be 0.8mm. (Adjust the clearance if it is 0.3~1.3mm in excess of the range.)
 Chassis Volume BR-1

Precautions:

① The recommended brake fluid is “DOT 4”.

② Do not reuse the brake fluid which has been discharged.
③ Do not splash the brake fluid to any painted surface; or else, the painted surface will be
damaged. In case the brake fluid splashes onto the painted surface, immediately sweep
away the fluid by clean water.
④ Use the undefiled brake fluid to clean or rinse all spares parts of the master cylinder and
the brake tongs.
⑤ Do not use mineral oils (e.g. gasoline and kerosene) to clean the spare parts of brake
tongs, otherwise the rubber spare parts in hydraulic system will be marred.
⑥ Use the spanner for oil pipe nut to dismantle or install oil pipes.
⑦ It is required to check the torque, in case of installing the brake oil pipes.
⑧ Before the operation, turn off the ignition switch, and disconnect the electrical joint of ABS
actuator and the electrical unit (control device) or the cathode cable of storage battery.
⑨ Perform a trial braking after any maintenance for braking system of JAC Benjoy has been
completed.

Caution:
The brake disk shall be wiped by the unused cloth and then cleaned by the vacuum cleaner.
During the normal lifetime of brake, the dust and filth congregating on the spare parts of brake
may contain asbestos fibers which are from the brake linings of vehicle or fittings. The severe
physical injury may happen to the operator, if excessive asbestos fibers are inhaled. Be highly
careful when overhauling the spare parts of brake. Failing a special device which collects dust
and dregs, do not grind the brake linings. Do not use the compressed air or the dry brush to
clean the spare parts of brake. The spare parts of brake shall be wetted by the atomized water
and then wiped by the wet cloth.
The wiping cloth and the dust which contain asbestos fibers shall be disposed into the labeled
and leakproof recipient. Comply with the method which is provided by the Occupation Safety
and Health Administration (OSHA) and Environment Protection Administration (EPA), when
handling, treating and disposing the dust which may be mingled with asbestos fibers.

Attention:
1. The applicable brake fluid or its equivalent shall be it which is in the sealed recipient. The
brake fluid must be in accordance with standard of DOT 4. Do not use the
petroleum-based oil fluid, as which may damage the oil seal of braking system. The brake
 Chassis Volume BR-2

fluid may harm painted surfaces. Promptly sweep away the fluid by clean water,
once the brake fluid splashes onto any painted surface.
2. Do not use gasoline, kerosene, alcohol, engine lubricating oil, transmission oil or any oily
fluid that contains minerals to clean the spare parts of braking system, for those oils may
mar the rubber bowl and the oil seal.
3. During the overhaul, keep the lubricating grease and any other foreign body away from the
brake tongs assembly, the brake linings, the brake disk and the outer surface of wheel
hub.
4. The brake tongs of disc brake is made of aluminum. When handling the brake disk or the
brake tongs, be careful to avoid damaging them and bruising or scuffing the brake pad and
lining. The brake fluid must meet the standard of DOT 4.
5. The correct operation is very significant, whenever the operator switches on or off the
battery.
6. Before dismounting the store solution tank cover, wipe it clean and prevent filth or other
foreign bodies from falling into the master cylinder. Notice that: the applicable brake fluid
or its equivalent shall be it that is new and in the sealed recipient; the brake fluid must be
in accordance with standard of DOT 4.
7. Never step on the brake pedal during the deflation or after the loosening of deflation screw.
Or else, the air volume will be increased and the additional deflation will be entailed.
8. When deflating the braking system, do not let the brake fluid in store solution tank of
master cylinder run out lest an empty store solution tank should cause more air enter the
braking system. Frequently check the height of brake fluid level and filling the brake fluid
according to the requirement.
9. So far as the deflation for braking system, the following sequence shall be applied to
pipelines of wheels for the purpose of sufficiently removing the residual air away from the
hydraulic braking system.
Right rear wheel
Left rear wheel
Right front wheel
Left front wheel
10. It is recommended to deflate pressure in the brake system by way of pressure deflation to
ensure that air in the braking system will be exhausted. Alternatively, it is available to
adopt the manual deflation method, but which needs more time to completely exhaust air.
 Chassis Volume BR-3

Preparations
General Tools for Maintenance

Tool Name Illustration

Used for dismounting the

Electric tools spare parts of front and rear
brake tongs and the wheels.

Used for dismantling and

Cuffs for oil pipe nut
mounting brake pipelines.
 Chassis Volume BR-4

Brake Pedal
Dismantlement and Reassembly

1. Bracket assembly of brake pedal 2. Weld assembly of brake pedal

3. Pedal pad 4. Bolt
5. Flat washer 6. Liner
7. Return spring of brake pedal 8. Brake nylon liner
9. Spacer 10. Flange nut
 Chassis Volume BR-5

Dismantlement Steps BR001

1. Dismount the front inner trimming. (See the
Dismantlement and Reassembly of
Inner Trimming for reference.)
2. Dismount the stop lamp switch.

3. Dismount the lock pin to disconnect it and BR002

the vacuum booster.

4. Loosen the fixing nuts of brake pedal.

BR003
(There are 3 fastening bolts.)
Attention: 2
When dismounting (1), use the hexagon
socket head cap screw to fix (B) lest (B) might
follow it to turn.

When dismounting (2), use the hexagon BR004

socket head cap screw to fix (A) lest (A) might
follow it to turn.
B

A
5. Take out the brake pedal.
BR005
 Chassis Volume BR-6

Check after Dismantlement

1. Basic Check
① Check weather the straight pin of master cylinder at the upside of brake pedal is
distorted.
② Check: whether the brake pedal is curved or damaged; whether there are crevices on
the welded spare parts.
③ Replace the spare parts of brake pedal, if any unacceptable condition is found.
④ Check whether the lock pin and the brake nylon liner are damaged and distorted.
Replace the clevis pin which is damaged or distorted.

2. Check of Stop Lamp Switch

Connect a multimeter to the stop lamp switch,
and check whether the switch is closed when
the sliding pole of switch is pressed or Closed
Opened
released. The switch shall be considered
normal, if:
It is not opened with the pole pressed within
4mm from the marginal face of switch shell,
whereas it is closed with the pole released.

Reassembly
The sequence for reassembly is just contrary to that for dismantlement.
1. Check whether the brake pedal works favorably. A desirable brake pedal shall need
little effort when it is pressed or released.
2. Adjust the height of the brake pedal after mounting its spare parts.
3. Ensure the clearance between brake pedal and brake stopper switch bolt at
0.5~1mm.
Chassis Volume BR-7
 Chassis Volume BR-8

Check and Adjustment of Brake Pedal

Free Stroke of Brake Pedal
1. With the engine stopping, step on the brake
pedal for twice~3 times. With the vacuum in
vacuum booster removed, press the pedal by
hand, and then confirm whether the
movement length (free stroke) is within the
standard range before the resistance is felt.

Standard Value: 3~8mm

2. Adjust the free stoke, in case it exceeds the
standard range. Replace the failed spare parts,
if necessary.

Check and Adjustment for Clearance

between Brake Pedal and Footrest
1. Take away the foot pad which is under the
brake pedal.

2. With the engine started, step on the brake

pedal with a force at 490N, and measure the
clearance between the brake pedal and the
footrest.

Standard Value: 90mm or more

3. If the clearance is beyond the standard range,
check: whether there is air in the braking
pipelines; whether the clearance between
friction lining and brake disk is too long;
whether the parking brake lags. Adjust or
replace the unsatisfactory spare parts in
accordance with the requirement.

4. Place the foot pad back to its original position.

 Chassis Volume BR-9

Brake Fluid

Check of Brake Fluid for its Level Height

Ensure that the height of brake fluid level is within
the specified range (between MAX and MIN
MAX
marks).

1. Observe whether it is of leakage around the MIN

store solution tank with eyes.

2. If the fluid level looks too low, check whether

the braking system is of leakage. Release the
brake pedal and observe whether the brake
alarm lamp is out. If the light is still on, check
whether the braking system is of leakage.
 Chassis Volume BR-10

Discharging and Filling

Precautions against Deflation:
1. Only after air in spare parts and circuits has been removed can the hydraulic braking
system work normally and the purpose of deflation be achieved. Notice that: the
brake fluid must be clean and unused, and shall have been statically placed for 24
hours at least.
2. If the wrong brake fluid, despite any reasons, has been applied to the braking system,
the braking pipelines and all components must be rinsed by the undefiled brake fluid
and a new oil seal shall be installed for components.
3. Never reuse the brake fluid which is discharged out of the braking system.
4. In the course of deflation, the brake fluid level must be kept as high as at least 1/2 of
the store solution tank.
5. Before working, ensure that: all oil pipes and hoses all firm; all joint are tightened; all
deflation screw are closed. Especially, do not have the brake fluid contact the vehicle
paint; otherwise, the smooth face of paint will be serious damaged. Rinse the paint by
cold water, if the paint gets smeared by the brake fluid.
6. Find out the ultimate reason, correct the condition, and then proceed with the
deflation, if the brake fluid has been lost away from the master cylinder due to the
system leakage.
7. In the event that only a part of the hydraulic system has been taken down and proper
measures have been applied to prevent more loss of brake fluid, it is only needed to
deflate such a part.
8. In need of deflating the whole braking system, the following sequence shall be abided
by:
① Right rear brake;
② Left front brake;
③ Left rear brake;
④ Right front brake
9. To deflate the braking system, clean the neighboring areas of deflation screws at first,
with the deflation pipe put on. Fill the store solution tank with the brake fluid till the
tank is full of the fluid, if necessary.
10. If the vacuum arises in the braking system, quickly and consecutively step on the
pedal to destroy the vacuum.

Deflation Method:
The deflation shall be conducted by means of the special filling tools for brake fluid, which
are provided by JAC.
Chassis Volume BR-11
 Chassis Volume BR-12

Steps for Discharging and Filling:

Attention:

Filling Volume of Brake Fluid:

Provided that the filling is completed by the special machine in one time, the filling volume
of brake fluid shall be approximately 630ml.
1. Plug the ethene pipe onto the deflation valve.

2. Step on the brake pedal, release the deflation valve, and then slowly discharge the
brake fluid.

3. Rinse the inside of store solution tank, and fill it with new brake fluid.

4. Release the deflation valve, slowly step the brake pedal to the end and then release it;
repeat this course every other 2~3 seconds, till the new brake fluid effuses; then, step
on the pedal to close the deflation valve. Repeat the same operation to every wheel.
5. Carry out the deflation.

Attention:
 During the deflation, notice the liquid level in store solution tank.
 Before the operation, turn off the ignition switch, disconnect the joint of ABS actuator
and electrical unit (control device) or break off the cable from the cathode port of
storage battery.
Chassis Volume BR-13
 Chassis Volume BR-14

Brake Fluid Level Sensor

1. Confirm the mounting position of brake fluid

level sensor.

2. The sensor shall be considered normal, if:

It is not opened with the floater surface being

flush with or more than 2mm below the “MIN”,

whereas it is closed with the floater surface

being less than 4mm below the “MIN”.

 Chassis Volume BR-15

Braking Pipeline and Hose

Hydraulic Pipeline Diagram

1. Main cylinder of brake and vacuum booster assembly 2. Brake pedal

3. Wheel 4. Wheel speed sensor
5. Wheel cylinder 6. Braking pipeline
Attention:
① All braking pipelines and hoses shall not be overly curved, distorted or elongated.
② Ensure that all braking pipelines and hoses, despite the clockwise or anticlockwise
steering of vehicle, shall not disturb other components.
③ Braking pipelines and hoses are important components, which shall be always
dismantled and then whose fixing shall be tightened once again if the there is brake
fluid leakage. If any component is found damaged, it shall be replaced with a new
one.
④ Do not splash the brake fluid onto the painted surface, otherwise the latter will be
harmed. If the fluid splashes to the painted surface of vehicle body, rinse the surface
by clean water.
⑤ When braking pipelines and hoses are disconnected, cover their opening ends lest
the dust might come in.
⑥ Fill the new “DOT 4”brake fluid.
⑦ Do not reuse the brake fluid which has been discharged.

Dismantlement for Braking Pipe

Dismantlement Steps:
1. Discharge the brake fluid.
(See the Dismantlement for Brake Fluid in
this chapter for reference.) BR006
2. Disconnect the joint of master cylinder and
braking pipe.
Attention:
The braking pipe disconnected shall be
marked.
The specified tightening torque shall be met
 Chassis Volume BR-16

during the reassembly.

Tightening Torque: 18~30N·m
 Chassis Volume BR-17

3. Dismount the active carbon canister and its

BR007
support.

4. Disconnect all braking pipe joints of the ABS, BR008

and take out two braking pipes which connect
the main cylinder of brake and the ABS.

Attention:
The braking pipe disconnected shall be
marked.
The specified tightening torque shall be met
during the reassembly. BR009
Tightening Torque: 18~30N·m

5. Take out the clip, and then disconnect the

joint which connects the braking pipe of front
wheel and the braking hose. Take out the
braking pipe of front wheel.

BR010

6. Take off the fastening bolt of pipeline.

BR011
7. Take out the clip, and disconnect the joint
which connects the braking hose of rear
wheel and the braking pipe.
Tightening Torque: 25~30N·m BR011
 Chassis Volume BR-18

8. Dismount both front and rear underframes. (See the Dismantlement and
Reassembly for Front and Rear Underframes for reference.)
9. Take the rear braking pipe.

Reassembly
The steps for reassembly are just opposite to those for dismantlement. In the course of
reassembly, all oil pipe joints shall be screwed down to the extent that the specified
tightening torque requires.

Check of Braking Pipeline and Braking Hose before Dismantlement and

Reassembly
Dismantlement Steps: BR012
1. Discharge the brake fluid. (See the
Dismantlement for Brake Fluid in this
chapter for reference.)

2. Use the spanner for oil pipe nut to disconnect

the braking pipe and the braking hose.

Tightening Torque: 25~30N·m

3. Dismount the perforation bolt, and then take BR013

off the braking hose from the brake tongs.

Tightening Torque: 25~30N·m

4. Dismount the clip, and then disconnect the

BR014
braking hose from the vehicle.
Attention:
Take care of the mounting direction of clip,
when conducting the reassembly.

Reassembly
1. Align the braking hose with the protrusive section of spare part of brake tongs, mount
the hose, and then screw down the connecting bolt.
Attention:
No repetitive use of the copper washer is allowed.
 Chassis Volume BR-19

2. Connect the braking hose with the braking pipe. Temporarily tighten the oil pipe nut
by hand. Use the clip to fix them on the support.
3. Use the cuff for oil pipe nut to screw down them.
4. Fill the new brake reassembly and release the air.

Check of Braking Pipeline and Braking Hose after Dismantlement and

Reassembly
Dismantlement Steps:
1. Discharge the brake fluid. BR015

2. Use the spanner for oil pipe nut to disconnect

the braking pipe and the braking hose.

Tightening Torque: 25~30N·m

3. Dismount the connecting bolt, and then take

off the braking hose from the spare part of
BR016
brake tongs.
Tightening Torque: 25~30N·m

4. Dismount the clip, and then disconnect the

braking hose from the vehicle.
Reassembly
1. Mount the fixing device of braking hose at the locating hole for spare parts of brake
tongs, and then screw down the connecting bolt.
Attention:
No repetitive use of the copper washer is allowed.
2. After fixing the braking hose to vehicle by clip, connect the braking hose with the
braking pipe. After temporarily tighten the oil pipe nut by hand, use the cuff for oil pipe
nut to screw down them.
3. Fill the new brake reassembly and release the air.

Check after Reassembly:

Attention:
Re-tighten the joint of braking pipe and braking hose, if it gets leaky; if any spare
parts are found damaged, replace them in time.
1. Check whether the braking pipe, the braking hose and the joint leak fluid, get damaged,
twisted, distorted or loose, and contact other spare parts.
2. With the engine running, apply the braking force for 5 seconds, and then check whether
 Chassis Volume BR-20

spare parts leak fluid.

Main Cylinder of Brake

Dismantlement and Reassembly

Dismantlement Steps:
Check of Vehicle Body

Check for Leakage

Check whether the mounting faces of main cylinder and store solution tank and the
braking pipe joint are leaky.
Attention:
Do not splash the brake fluid onto the painted surface; otherwise, the latter will be
harmed. If the fluid splashes to the painted surface, rinse the surface by clean
water.
1. Discharge the brake fluid. (See the Dismantlement for Brake Fluid for reference.)
2. Dismount the joint of wire harness for brake fluid level sensor.
BR017

3. Use the spanner for oil pipe nut to disconnect the braking pipe of master cylinder.

Tightening Torque: 18~30N·m BR018

 Chassis Volume BR-21

4. Dismount the fixing nut of master cylinder, and then take off the components of
master cylinder from the vehicle

BR019

Check after Dismantlement

Check whether the mounting faces of main cylinder and store solution tank and the
braking pipe joint are leaky.

Reassembly
Attention:
① Fill the new “DOT 4”brake fluid.
② Do not reuse the brake fluid which has been discharged.
1. Mount the components of master cylinder at the vacuum booster and tighten the nut.
In the meantime, the O-ring and its neighboring area in the inner chamber of vacuum
booster, along side with the side interior wall of vacuum booster, shall be coated with
silicon grease.

Attention:
① Do not damage the sliding face of main piston push rod, nor let any foreign
substances fall onto it.
② Do not use the O-ring again and again.
2. Mount the braking pipe to the components of master cylinder, and temporarily screw
down the oil pipe nut by hand.
3. Use the cuff for oil pipe nut to tighten the braking pipe nut.
4. Install the joint of wire harness for brake fluid level switch.
5. Fill the new brake fluid and release the air.

Disassembly and Assembly

Attention:
It is unnecessary to disassemble components
 Chassis Volume BR-22

of master cylinder. Replace the master

cylinder assembly, if it is broken.
 Chassis Volume BR-23

Vacuum Booster
Dismantlement and Reassembly

1. Vacuum booster 2. Nut 3. Intake joint and one-way valve assembly

Dismantlement Steps:
Attention:

① When dismantling or reassembling the vacuum booster, do not curve or distort

the braking pipe.
② The damaged clevis pin, if any, shall be replaced.
③ Do not damage the screw thread of fastening bolt for vacuum booster. If the
vacuum booster slants during the reassembly, the division plate may damage
the screw thread.
1. Dismount the cowl cover plate. (See the Dismantlement and Reassembly for Inner
Trimming for reference.)
2. Take off the vacuum hose from the vacuum
BR020
booster.

3. Dismount the master cylinder of brake. (See

the Dismantlement for Master Cylinder of
Brake for reference.)
4. Take off the lock pin and the straight pin from
the brake pedal.
5. Take off the nuts which are on the vacuum booster and the spare parts of brake
 Chassis Volume BR-24

pedal.
6. Dismount the vacuum booster from the front heat insulating mattress of engine cabin.
Check after Dismantlement

Check of Output Rod for Length

1. Force a vacuum pressure at -66.7kPa to the vacuum booster by the manual vacuum
pump.
2. Check the extended length of output rod.
Reassembly
Input Rod
1. Loosen the locknut and adjust the length of
input rod to keep the length B (see the picture)
within the standard range.
2. Adjust the length (B) into the specified value,
screw down the locknut, and then mount the Locknut
vacuum booster onto the front division plate.
Attention:
A pad, all the time, shall be placed between the vacuum booster and front division
plate.
3. Install the vacuum booster and spare parts of brake pedal, and screw down them to
the extent of specified torque.
4. Connect the brake pedal with the vacuum booster.
5. Install the master cylinder of brake.
6. Install the vacuum hose.
7. Adjust the free height and stroke of brake pedal.
8. Screw down the input rod locknut to the extent of specified torque.
9. Install the cowl cover plate.
10. Fill the new brake fluid and release the air.
Check of Vacuum Booster:

1. Have the engine runs for 1~2 minutes and then stop it; later, step on the brake pedal
for several times with a normal force. If the pedal can be stepped to the end only for
the first time and the height of pedal gradually rises for the following times, it is
indicated that the vacuum booster works normally. If the height of pedal remains
unchanged, the vacuum booster may have been damaged.
2. With the engine off, step on the brake pedal for several times; after confirming that
the pedal gradually rises, step on the pedal to start the engine. At this time: it is
confirmed that the vacuum boost works normally, if the pedal slightly declines; the
vacuum pedal may have been damaged, if the pedal moves upwards.
3. With the engine running, step on the brake pedal to stop engine. Under this
circumstance: it is revealed that vacuum boost works normally, if the height of pedal
 Chassis Volume BR-25

keeps unchanged in 30 seconds; the vacuum pedal may have been damaged, if the
pedal moves upwards.
4. Check the vacuum hose, the one-way valve the vacuum booster, if the result of any
foresaid check is unacceptable. Providing that the result is found acceptable, the
vacuum booster shall be deemed to be in good condition.
 Chassis Volume BR-26

Vacuum Pipeline
Dismantlement and Reassembly

Check

Visual Check

Check whether the assemblage is correct and there are damages and cracks.

Check of One-way Valve

Check for Airtightness

 Use the manual vacuum pump to check.
 If the vacuum hose and the one-way valve
get troubled, replace the spare parts of
Intake Joint and One-way Valve
vacuum hose and the one-way valve. Assembly
 Chassis Volume BR-27

Front Disc Brake

On-Vehicle Check of Friction Wafer
Check of Brake Disk for Abrasion

Check the thickness of brake disk via the check

hole on the trunk.
Use the ruler for check, if necessary.

Dismantlement and Reassembly for Brake Disk

Dismantlement Steps:
Caution:

In order to minimize the loss which may be engendered by motes or other matters in air,
the clamping tongs and the friction lining of brake shall be cleaned by the vacuum cleaner.
1. Jack up the front of vehicle, and take off two front wheels.

2. Disconnect the joint of wire harness for friction lining thickness sensor.

BR021

3. Take down the fastening bolt for brake tongs

BR022
body, and bind the brake tongs body to the
vehicle.

Attention:
Do not have the friction lining dropped onto
the ground.
After the brake tongs has been dismantled, do
not step on the brake pedal.
Tightening Torque: 90~110N·m
 Chassis Volume BR-28

4. Screw off the brake disk stop bolt, and take

down the brake disk. BR023

Tightening Torque: 20~25N·m

Reassembly Steps

The steps for reassembly are just opposite to those for dismantlement.
 Chassis Volume BR-29

Dismantlement and Reassembly for Components of Brake

Tongs
Dismantlement and Reassembly

1. Front brake tongs body 2. Interior friction block of the front brake
tongs
3. Exterior friction block of the front brake tongs

Dismantlement Steps:
1. Use tools to dismount the tyres of front
wheels.
2. Discharge the brake fluid.
3. Screw off the fastening bolt for braking hose,
BR024
and take out the braking hose.

Attention:
Take care of installation of the two gaskets.
Tightening Torque: 25~30N·m

4. Dismount the set bold for supporting torsional

BR025
arm, and then take off the components of
brake tongs.
Attention:
Do not have the friction lining dropped onto
 Chassis Volume BR-30

the ground.
After the brake tongs have been dismantled,
do not step on the brake pedal.
Tightening Torque: 20~33N·m
 Chassis Volume BR-31

Reassembly Steps
Attention:

① Fill the new “DOT 4”brake fluid.

② Do not reuse the brake fluid that has been discharged.
1. Mount the components of brake tongs to the vehicle, and screw the fastening bolt for
supporting torsional arm to the extent of specified torque.
Attention:
Keep the joint faces amongst steering knuckle, components of brake tongs, bolts
and washers away from water or engine oil.
2. Mount the braking pipe to the components of brake tongs, and screw down the
connecting bolt to the extent of specified torque.
Attention:
① Do not use the copper washer for connecting bolt again and again.
② Align the braking hose with the screw hole for components of brake tongs, and
then connect them.
3. Fill the new brake fluid and release the air. (See the Deflation and Filling for Brake
Fluid for reference.)
4. Check the rotation resistance of front disk brake.
5. Install tyres.
Attention:
Before installing the brake tongs, check whether there are oily filths on the brake
shoe. If a few filths are found, they shall be immediately grinded and eliminated by
the thin sand paper. Replace the brake tongs or the friction lining, when the area of
oily filths seems large.
 Chassis Volume BR-32

Disassembly and Assembly for Components of Brake Tongs

Disassembly and Reassembly:

1. Deflation screw 2. Screw for guide

pin
3. Front brake tongs body 4. Guide pin
5. Brake tongs support 6. Friction lining
7. Oil seal for piston 8. Piston
9. Dustproof cover for guide 10. Dustproof ring
pin

Attention:
① When dismounting the trunk, do not step on the brake pedal lest the piston
might shoot out.
② Do not dismount the bolts of supporting torsional arm and braking hose, unless
disassembling or replacing the components for brake tongs. Otherwise,
suspend up the brake tongs body by the cord to avoid entangling the brake
hose.
③ Do not damage the dustproof cover for piston.
 Chassis Volume BR-33

④ In case the gasket has been terribly corroded, replace it by a new one.
⑤ The gasket and the inner gasket cover shall be replaced, every time the brake disk is
replaced.
⑥ Ensure that there is no brake fluid on the brake disk.
 Chassis Volume BR-34

Dismantlement Steps:
Attention:

When disassembling or assembling the components of trunk, do not dismount the

supporting torsional arm, the brake disk, the gasket, the inner gasket cover and the
brake disk holder.
1. Dismount the sliding pin, and then take off the trunk from the supporting torsional
arm. Supporting
Torsional Arm
2. If necessary, dismount the brake disk, the
gasket, the inner gasket cover and the brake
disk holder from the supporting torsional arm.
Attention:
① When dismounting the brake disk holder
from the supporting torsional arm, pull up
the rack in accordance with the arrow
direction (see the picture) so as to Brake Disk Holder

prevent damages.
② Do not make the brake disk, the gasket,
the inner gasket cover and the brake disk
holder fall from the supporting torsional
arm.
3. Dismount the sliding pin and the dustproof
cover for sliding pin.
Place a wood block as shown in the picture,
and then blow the fixing hole for connecting
bolt to dismount the piston and the dustproof
cover for piston.
Attention:
Do not have your finger clamped by the piston.
4. Use a flat-head screwdriver to dismount the Piston
Gasket Ring
piston gasket ring from the trunk.
Attention:
Do not damage the interior wall of trunk.
Check after Disassembly
Cylinder Body
Attention:
① Use the new brake fluid to rinse the trunk.
Do not apply mineral oils such as the
gasoline and the kerosene.
 Chassis Volume BR-35

② Check whether the interior wall of cylinder is abraded or damaged. In case of

any undesired condition, replace the cylinder.
 Chassis Volume BR-36

Front Brake Tongs Body

Check whether the front brake tongs body is abraded, creviced or damaged. In the event
of any foresaid unwanted condition, replace the front brake tongs body.
Piston
Attention:
① Check whether the surface of piston is corroded, abraded or damaged. If any
forementioned undesirable condition is found, replace the piston.
② Do not polish the sliding surface of piston by the sand paper, as the surface
has a galvanized coating.

Sliding Pin, Pin Bolt, and Dust Cover for Pin

Check whether the sliding pin, the pin bolt and the dustproof cover for pin are abraded,
creviced or damaged. Replace them, if any abrasion, crevice or damage is detected.
Reassembly:
Piston Gasket
1. Coat the piston gasket ring with the rubber Ring

lubricating grease, and install the former into the

trunk.
Attention:
Do not use the piston gasket ring again and
again.

Dust Cover for Piston

2. Coat the piston with the brake fluid, and Piston
spread the rubber lubricating grease to the
dustproof cover for piston. Use the dustproof
cover to shroud the end opening of piston, and
then fix the side margin of trunk on dustproof
cover to the groove of trunk.

Attention:
No repetitive use of dustproof cover is allowed.
3. With your hand stretching into the trunk, insert the side margin of dustproof cover for
piston to the groove of piston.
Attention:
Press down the piston with a uniform force, and adjust the application point lest the
interior wall of trunk might be chafed.
4. Install the sliding pin and the dustproof cover for sliding pin to the supporting torsional
arm.
5. Install the interior gasket and the interior gasket cover to the interior brake disk, and
mount the exterior gasket to the exterior brake disk.
 Chassis Volume BR-37

Attention:
The interior gasket cover shall be firmly mounted according to its fixing direction.
6. Install the brake disk holder, and the Brake Disk
Holder
Supporting Supporting
Torsional Arm Torsional Arm

components for interior and exterior brake

disk to the supporting torsional arm.
Attention:
The brake disk holder shall be assembled so
firmly that it will not be pull up by the
supporting torsional arm.
Brake Disk Holder
7. When installing the brake disk, press the
piston and then mount the trunk to the
supporting torsional arm.
Attention:
With the tools for disk brake piston (general maintenance tools) applied, it is easy
to press the piston.
8. Screw down the bolt for sliding pin.
Remarks:
The friction lining of brake has an abrasion alarm device, which alarms to remind the
driver when the thickness of friction lining decreases to 2mm as a result of abrasion.
Check the thickness of friction lining via the check hole on brake tongs body.
Standard value: 14.0mm <for front >, 12.0mm <for rear>
Threshold value: 2.0mm
Attention:
① If the abrasion has been beyond the threshold value, the friction linings at both
sides, as well as the brake wafers used for wheels which are at the other side,
shall be replaced at the same time.
② Check the conditions of piston and guide pin, provided that frictions at left and
right sides are obviously different in thickness.
Check of Assembled Brake Disk
Visual Check
Check whether the surface of brake disk is unevenly abraded, creviced, or badly damaged.
If any unwanted foresaid condition is found, replace the brake disk.
Attention:
During the overhaul for disk brake, strictly keep the disk brake in the tolerable
range of overhaul value so as to ensure the
satisfactory running of brake. Before
re-repairing and reprocessing the surface of
brake disk, check the following conditions.
1. Fix brake disks at (2 positions or more) on the
wheel hub with wheel nuts.
2. Check the run-out by the scale disk indicator.
 Chassis Volume BR-38

[Measuring shall be carried out at the place

10mm away from the inside margin of brake
disk.]
Threshold value: 0.03mm.
Attention:
Before measuring, ensure that the axial
clearance of wheel bearing is within the
specified value.
3. If the run-out exceeds the threshold value, it is
available to find out the position for minimum
run-out by turning the brake disk and the
wheel hub for a hole and then fixing them.
① Before dismounting the brake disk, use a
chalk to make marks at two sides of wheel
bolts, which are placed on the side of largest
run-out.
② Take off the brake disk; lay the dial gauge head as shown in the picture; then, move
the wheel hub along the axial direction and measure the run-out.
Threshold value: 0.05mm
Reassemble the steering knuckle of wheel hub and check spare parts, in case the run-out
is equal to or more than the threshold value.
③ Install the brake disk at the position 180ºaway from the chalk mark and check the
run-out of brake disk once again, if the
run-out remains within the specified
threshold value.
4. Replace the brake disk, in the event that the
run-out still exceeds the abrasion threshold
value in despite of all forementioned steps.
Check for Thickness
Check the thickness of brake disk by the
micrometer caliper. Replace the brake disk, if the
remaining thickness is less than the abrasion
threshold value.
Standard Value:22mm <for front>, 10 mm <for rear>
Threshold value:20.4mm <for front>, 8.4mm <for rear>
Check of Brake Disk
Item Remarks
 If the vehicle has not run for a long time, the brake disk,
devoid of contact with the friction lining, will rust and cause
Scuff, rust and
noise and tremble.
abrasion of brake disk
 The brake disk, in a short period, will not contact the friction
lining normally, if grooves and scuffs on the brake disk
 Chassis Volume BR-39

(which are caused as a result of excessive abrasion) are

not eliminated before the reassembly for new friction lining.
When the run-out or deflection of brake disk is beyond the
Run-out or deflection tolerance, the resistance against brake pedal will increase due
to the recoil from piston.
Change in thickness The pedal will be caused to fluctuate, tremble or run-out, if the
(parallelity) thickness of brake disk changes.
Given the excessive hot temperature and the improper
Curve and distortion
treatment during the overhaul, curve and distortion will befall the
(flatness)
brake disk.
 Chassis Volume BR-40

Rear Disk Brake

On-Vehicle Check of Friction Wafer
Check of Brake Disk for Abrasion
Check the thickness of brake disk via the check
hole on trunk.
Use the ruler for check, if necessary.

Dismantlement and Reassembly for Brake Disk

Dismantlement Steps:
Caution:
In order to minimize the loss which may be engendered by motes or other matters
in air, the clamping tongs and the friction lining of brake shall be cleaned by the
vacuum cleaner.
Attention:
① When dismounting the trunk, do not step on the brake pedal lest the piston
might shoot out.
② Do not dismount the bolts of supporting torsional arm and braking hose, unless
disassembling or replacing the components for brake tongs. Otherwise,
suspend up the brake tongs body by the cord to avoid entangling the brake
hose.
③ Do not damage the dustproof cover for piston.
④ The gasket and the inner gasket cover shall be replaced, every time the brake
disk is replaced.
⑤ Ensure that there is no brake fluid on the
brake disk. BR026

1. Discharge the brake fluid.

2. Loosen the adjusting nut for parking braking

pull wire.

3. Jack up the bottom of vehicle, and take down two wheels.

 Chassis Volume BR-41

4. Take off the clip which fixes the parking

braking pull wire at the brake tongs body; BR027
loosen an end of pull wire from the support,
and lay the pull wire aside.

5. Screw down the fastening bolt for wheel hub

bearing, and take off the brake disk assembly.
Tightening Torque: 56~70N·m
BR028

6. Take down the fastening bolt for brake tongs

body, and bind the brake tongs body to the
BR029
vehicle.

Attention:
Do not have the friction lining dropped onto
the ground.
After the brake tongs has been dismantled, do
not step on the brake pedal.
Tightening Torque: 56~70N·m

BR030

7. Screw off the brake disk stop bolt, and take

down the brake disk.
Tightening Torque: 20~25N·m

Reassembly Steps
The steps for reassembly are just opposite to those for dismantlement.
After the reassembly, fill the new brake fluid and then adjust the stroke of parking brake.
 Chassis Volume BR-42

Dismantlement and Reassembly for Components of Brake

Tongs
Dismantlement and Reassembly

1. Rear brake tongs body 2. Interior friction block of the rear brake
tongs
3. Exterior friction block of the front brake tongs

Dismantlement Steps:
1. Jack up the vehicle, and dismount the tyres of BR031
rear wheels.
Note:
Loosen the tyre fastening bolts before jacking up
the vehicle.
Tightening Torque: 86~116N·m
 Chassis Volume BR-43

2. Discharge the brake fluid.

(See the Discharging for Brake Fluid in this chapter for reference.)
 Chassis Volume BR-44

3. Take out the clip, dismount the connecting BR032

bolt, and then disconnect the braking hose
from the components of brake tongs.
Tightening Torque: 25~30N·m

4. Release the manual brake, take off the clip

BR033
for parking braking pull wire, and then
disconnect the parking braking pull wire.

5. Take off the fastening bolt for supporting

BR034
torsional arm, and then dismount the
components of brake tongs.

Attention:
Do not have the friction lining dropped
onto the ground.
After the brake tongs has been
dismantled, do not step on the brake
pedal.
Tightening Torque: 20~33N·m

Reassembly Steps
Attention:
① Fill the new “DOT 4”brake fluid.
② Do not reuse the brake fluid which has been discharged.

1. Install the components of brake tongs to the vehicle, and then tighten the fastening
bolt for supporting torsional arm.
 Chassis Volume BR-45

Attention:
Before installing the components of brake tongs, wipe off engine oil and water from
all fixed faces of the rear axle, the components of brake tongs, the screw threads,
the bolts and the washers.

2. Install the L-shape pin for braking hose to the components of brake tongs as shown in
the picture, and then tighten the connecting bolt with the specified torque.

Attention:
Connecting Bolt
Do not use the copper washer for connecting
bolt again and again.

3. Fill the new brake fluid and release the air.

4. Check the rotation resistance of rear disk brake.

5. Install tyres.
 Chassis Volume BR-46

Disassembly and Assembly for Components of Rear Brake

Tongs
Disassembly and Reassembly

1. Screw for guide pin 2. Brake tongs support

3. Return spring for parking braking 4. Support for parking braking pull wire
5. Dustproof ring 6. Piston
7. Oil seal for piston
Attention:
When disassembling or assembling the components of trunk, do not dismount the
supporting torsional arm, the brake disk, the gasket, the inner gasket cover and the
brake disk holder.

Disassembly Steps:
1. Dismount the sliding pin, and then take off
the trunk from the supporting torsional arm.
2. Dismount the bolt for sliding pin from the
supporting torsional arm
3. As is shown in the picture, use a flat-head
 Chassis Volume BR-47

screwdriver to dismount the snap ring from the

trunk.
4. Place a wood block as shown in the picture,
and then blow the fixing hole for connecting
bolt to dismount the piston and the dustproof
cover for piston.
Attention:
Do not have your finger clamped by the piston.

5. Use a flat-head screwdriver to dismount the

piston gasket ring from the trunk.
Attention: Piston Gasket Ring
Do not damage the interior wall of trunk.

Check after Disassembly

Cylinder Body
Attention:
① Use the new brake fluid to rinse the trunk. Do not apply mineral oils such as the
gasoline and the kerosene.
② Check whether the interior wall of cylinder is abraded or damaged. In case of
any undesired condition, replace the cylinder.
Rear Brake Tongs Body
Check whether the rear brake tongs body is abraded, creviced or damaged. In the event
of any foresaid unwanted condition, replace the rear brake tongs body.
Piston
Attention:
① Check whether the surface of piston is corroded, abraded or damaged. If any
forementioned undesirable condition is found, replace the piston.
② Do not polish the sliding surface of piston by the sand paper, as the surface
has a galvanized coating.
Pin Bolt and Dust Cover for Pin
Check whether the pin bolt and the dustproof cover for pin are abraded, creviced or
damaged. Replace them, if any abrasion, crevice or damage is detected.

Reassembly: Piston Gasket Ring

1. Coat the piston gasket ring with the rubber

lubricating grease, and install the former
into the trunk.
Chassis Volume BR-48
 Chassis Volume BR-49

Attention:
No repetitive use of the piston gasket ring is allowed.

2. Coat the piston with the brake fluid, and Dust Cover for Piston
Piston
spread the rubber lubricating grease to the
dustproof cover for piston. Use the
dustproof cover to shroud the end opening
of piston, and then fix the side margin of
trunk on dustproof cover to the groove of
trunk.
Attention:
No repetitive use of dustproof cover is allowed.
3. With your hand stretching into the trunk,
insert the side margin of dustproof cover for
piston to the groove of piston.
Snap Ring
Attention:
Press down the piston with a uniform force,
and adjust the application point lest the Snap Ring
interior wall of trunk might be chafed.

4. Use the snap ring to fix the dustproof cover for

piston.
Attention:
① Ensure that the dustproof cover is firmly fixed in the groove of trunk.
② No repetitive use of the snap ring is allowed.
5. Fill the PBC between the gasket cover and
the gasket. Install the interior gasket and
the interior gasket cover to the interior brake
disk, and mount the exterior gasket on the Brake Disk Supporting
Holder Supporting
Torsional Arm
exterior brake disk. Torsional Arm

6. Install the brake disk holder, and the

components for interior and exterior brake
disk to the supporting torsional arm.

Attention:
The brake disk holder shall be assembled so
Brake Disk Holder
firmly that it will not be pull up by the
supporting torsional arm.

7. Install the bolt for sliding pin to the supporting torsional arm.
8. Install the trunk to the supporting torsional arm, and screw down the bolt for sliding
 Chassis Volume BR-50

pin with the specified torque.

 Chassis Volume BR-51

Check of Brake Disk

Visual Check

Check whether the surface of brake disk is

unevenly abraded, creviced, or badly damaged.
If any unwanted foresaid condition is found,
replace the brake disk.

Check for Run-out Quantity

1. Fix brake disks at (2 positions or more) on the
wheel hub with wheel nuts.

2. Check the run-out by the scale disk indicator.

[Measurement shall be carried out at the place
10mm away from the inner margin of brake
disk.]
Note:
Before measuring, ensure that the axial
clearance of wheel bearing is within the
specified value.

3. If the run-out exceeds the threshold value, it is

available to find out the position for minimum
run-out by turning the brake disk and the
wheel hub for a hole and then fixing them.

4. Replace the brake disk, in the event that the

run-out still exceeds the abrasion threshold
value in despite of all forementioned steps.

Check for Thickness

Check the thickness of brake disk by the

micrometer caliper. Replace the brake disk, if the
remaining thickness is less than the abrasion
threshold value.
Chassis Volume BR-52
 Chassis Volume BR-53

Common Trouble and Countermeasure

Trouble Possible Cause Countermeasure

There is grease or oil on the
With the brake pressed Replace the friction lining.
surface of friction lining.
down, the vehicle is drawn
The poor contact befalls the
to a side. Correct the friction lining.
friction lining.
The brake fluid become Refill or replace the brake
insufficient or deteriorates. fluid.
There is air in the braking
Let the air out.
system.
The brake disc becomes too
hot due to the friction of
friction lining.
The poor contact befalls the
friction lining. Correct it.
The braking force is
insufficient. The vacuum booster fails.

The braking pipeline is

jammed.
There is grease or oil on the
surface of friction lining.
The pressure limiting valve
Replace it.
fails.
The spare part of friction
lining becomes ill.
There is air in the braking
Let the air out.
system.

The friction lining is abraded.

The vacuum rose is broken

The stroke of brake pedal Replace it.
off.
increase. (The clearance
between brake pedal and The master cylinder fails.
footrest decreases.)
The brake fluid is leaked. Correct it.

The clearance between push

rod and master cylinder is too Adjust it.
long.
The parking brake has not
The brake lags.
been released completely.
Correct it
The circumfluence hole of
master cylinder is jammed.
The parking brake is
Readjust it.
improperly adjusted.
 Chassis Volume BR-54

Trouble Possible Cause Countermeasure

The clearance between push
rod and master cylinder is
improper.
The return spring for master
cylinder piston fails.
Replace it.
The return spring for brake
pedal is abraded.

The sliding part is short of

Lubricate it.
lubrication.

The parking brake pull wire

gets stuck.
Replace it.
The brake chamber of wheel
or the brake tongs gets stuck.
Adjust the stroke of parking
The stroke of parking brake brake handle, or check the
handle is too long. path of parking brake pull
wire.
The friction lining of brake is
Replace it.
abraded.
The wheel is disturbed by the
With brake clutched, there brake tongs.
is scraping or grinding The brake disk is disturbed
noise. by the dustproof cover. Correct or replace it.
The brake guard plate is
curved and distorted.
The brake disk is cracked.
The disk brake fails in
braking, or the silencing
Replace it.
gasket for friction lining is
damaged.
The friction lining or the brake
disk is abraded or bruised.
Correct or replace it.
The spare part of friction
With the brake clutched,
lining is ill.
there is squealing or
There are burrs on the disk
creaking noise. Rinse the disk brake, or
brake or the brake tongs is
eliminate the burrs.
rusty.
The friction lining is dirty,
greasy, impure or abraded Rinse or replace it.
off.
The brake pedal or the push
Adjust it.
rod for booster is ill.
 Chassis Volume BR-55

Trouble Possible Cause Countermeasure

The brake is disturbed by the
curved or distorted guard
plate.
The vacuum booster, the Replace it.
master cylinder or the brake
chamber of wheel is poor in
respect of restoration.
The brake is loose or carries
Re-tighten it.
foreign bodies.
With the brake The friction lining inside
declutched, there is brake tongs is in an improper
creaking noise. position. Correct it.
The support is improperly
installed.
The disk brake is rusty or
gets stuck.
The wheel bearing is Lubricate or replace it.
abraded, damaged or short
of lubrication.
The brake pedal or the push
Adjust it.
rod for booster is ill.
There are rubbles or other
foreign bodies in the wheel Remove rubbles and such.
cover.

The wheel nut loosens.

Re-tighten it.
The installation bolt for disk
With the brake
brake loosens.
declutched, there is
The wheel bearing is
rattling or vibrating noise.
abraded, damaged or devoid Lubricate or replace it.
of lubrication.
The adjusting gasket for disk
Replace it.
brake is ill.
The brake pedal or the push
Replace it.
rod for booster is ill.
 Chassis Volume PB-1

Overview
Components Diagram

The parking braking, i.e. the manual braking in common parlance, is mainly intented to

prevent the vehicle from moving when the vehile is parked or needs to be temporarily

parked. The Parking brake, in all vehicles, takes the form of mechanical rear-wheel

braking structure. With respect to JAC Benjoy, a cam control mechanism is added to the

rear-wheel disk brake so as to achive the parking braking. This vehicle employs the

operation mode of parking brake handle, and the parking brake handle is by the side of

driver’
s cab.

Overhaul Specifications
Item Standard Value

Thickness of rear brake disk 10

Run-out of rear brake disk 0.03

Parking brake handle pulled by force of 5~7 teeth

200N
Chassis Volume PB-2
 Chassis Volume PB-3

Precautions:
① Do not splash the brake fluid onto any painted surface; or else, the painted

surface will be damaged. In case the brake fluid splashes onto the painted

surface, immediately sweep away the fluid with clean water.

② Do not use mineral oils (e.g. gasoline and kerosene), otherwise the rubber spare

parts in hydraulic system will be marred.

③ Use the spanner for oil pipe nut to dismantle or install oil pipes.

④ It is required to check the torque, in case of installing the brake oil pipes.

⑤ Before the operation, turn off the ignition switch, and disconnect the electrical

joint of ABS actuator and the electrical unit (control device) or the cathode

cable of storage battery.

⑥ When dismounting the tyres, take care of the installing torques.

⑦ When dismounting the components of brake tongs, do not step on the brake

pedal.
⑧ After the reassembly of parking brake, adjust the free stroke of parking brake.

Preparations
General Maintenance Tool
Name Drawing Illustration

Electric Used for dismounting the spare

tools parts of rear brake tongs and the wheels

Chassis Volume PB-4
 Chassis Volume PB-5

Parking Braking System

On-vehicle Check
Attention:
During such a check, the vehicle may suddenly move to jeopardize you or other
people or cause property loss. Therefore, suffcient space must be provided against
the possible forward movement of vehicle. The operator must get ready to
immediately step on the conventional brake, if the vehicle is about to move.
Park the vehicle on an appropriate precipitous slope, and let the head of vehicle
face the declivitous direction. With your foot stepping on the brake pedal, tighten
the parking brake.
Check the holding ability of parking brake: With the engine running and the gearbox
shifted to neutral position (N), slowly release force acted on the brake pedal till the
vehicle stops completely only by the praking brake.

Parking Brake Handle

Free Stroke of Parking Brake Handle:
Adjust the parking brake wiredrawing, and calculate “L”, the end distance of wiredrawing.
Note:
L shall be within a range of 19~21mm.
Inspection of Spare Parts
1. Ensure that the fixing conditions (e.g. tighteness and clearance) of every element are
normal.
2. Check whether the device assembly is curved, damaged and craviced. Replace the
assembly, if any of foresaid undesirable conditions appears.
3. Check whether the parking brake wiredrawing is abraded and damaged. Replace the
wiredrawing, if any of foresaid undesirable conditions is found.
4. Note whether the switch of parking brake alarm light works normally. If the switch
acts abnormally, check or replace it.
Adjustment:
If the stoke of parking brake handle does not meet the standard value, adjust the stroke in
accordance with the following steps.
1. Dismount the inner trimming mat of central control unit. (See the Dismantlement
and Reassembly for Inner Trimming for reference.)
2. With the parking brake handle put down, insert right and left joints of parking brake
wiredrawing to the mounting hole of balancing plate for parking brake handle (as
shown in the picture). After the reassembly of wiredrawing, screw dowm the
adjusting nut and ensure the distance “L”between nut and end of wiredrawing within
 Chassis Volume PB-6

19~21mm.
3. With the adjustment completed, 6~8 teeth shall be pulled up if a pulling force of 200N
perpendicular to the handle is applied to the parking brake handle.
 Chassis Volume PB-7

Screw Threaded
Pull Rod

Adjusting Nut

Joints of Parking
Brake Wiredrawing
Parking Brake
Handle Assembly

Attention:

① If the number of rabbets engaged by the brake lever is less than the standar

value, it is indicated that the wiredrawing has been excessively tightened. Thus,

it is required that the brake lever be adjusted to meet the standard value.

② After the stroke of brake lever has been properly adjusted, raise the bottom of

vehicle by the jack. With the praking brake handle being in the release position,

rotate the rear wheels and ensure that the rear brake is no sluggish.
 Chassis Volume PB-8

Parking Brake Control

Dismantlement and Reassembly

1. Parking control handle assembly 2. Left wiredrawing assembly of parking

brake

3. Right wiredrawing assembly of parking brake 4. Bolt, spring mattress subassembly

5. Clip

Dismantlement Steps: PB001

1. Dismount the inner console as shown in the

picture.

(See the Dismantlement and Reassembly

for Inner Trimming for reference.)

2. Screw off the stroke adjusting nut for parking

PB002
brake handle.
Chassis Volume PB-9
 Chassis Volume PB-10

3. Screw off 4 bolts of support rack.

PB003

4. Unfix the left and right wiredrawing assembly

PB004
of parking brake.

Unscrew the adjusting nut for parking brake

so as to take out the wiredrawing.

5. Dismount the parking brake handle assembly.

Check after Dismantlement:

Check whether the parking brake handle and the wiredrawing are loose and distorted.

Replace them, if the foresaid undesirable conditions appear.

Reassembly Steps:
Steps for reassebmly is just contrary to those for dismantlement.

Attention:

After the reassembly, adjust the stroke of paring brake handle.

Dismantlement for Parking Brake Wiredrawing

1. Dismount the central console.
PB005
(See the Dismantlement for Body

Console for reference.)

 Chassis Volume PB-11

2. Jack up the vehicle, use tools to dismount the

PB006
rear wheels and completely release the

parking brake handle assembly.

Attention:
Before jacking up the vehicle, unscrew the set

bolts for tyre..

3. Loosen the manual adjusting nut, and take PB007

down one end of parling brake handle

wiredrawing.

PB008
4. Dismount the clip, which fixes the left and

right parking brake handle wiredrawings on

the brake tongs body of rear disk brake; take

dowmthe other end of wiredrawing.

5. Dismount the set bolts which fix left and right

PB009
wiredrawings on the chassis, and take out the

left and right wiredrawing assembly of parking

brake.

Note:
There are 6 set bolts in total on right and left sides.

Check
 Chassis Volume PB-12

Check whether left and right parking brake handle wiredrawing are scraped and broken.
Replace them, if the foresaid unwelcome conditions are found.
 Chassis Volume PB-13

Brake Disk of Rear Wheel

Dismantlement and Reassembly

Dismantlement Steps: PB010

1. Jack up the vehicle, and use tools to

dismount rear wheels.

Attention:

Before jacking up the vehicle, loosen the

fixing nuts of vehicle.

2. Screw off selt bolts of the steering knuckle PB011

and wheel hub assembly.

Tightening Torque: 56~70N▪m

3. Take down the set bolt for brake tongs, and

then hang the brake tong to a place where PB012

does not hinder the operation.

Attention:
Do not have the brake disk dropped to the
ground.
After dismounting the brake disk, do not step
on the brake pedal.
 Chassis Volume PB-14

Tightening Torque: 56~70N▪m

 Chassis Volume PB-15

4. Unscrew the brake disk stop bolt, and take out PB013

the brake disk.

Tightening Torque: 20~25N▪m

5. Take away the brake disk. PB014

Check after Dismantlement

1. Check whether the surface of brake disk is
scraped and the friction wafer is overly
abraded.

2. Check the jump or deflection.

Check for Jump
1. Dismount the support rack for brake tongs,
then raise the brake tongs assembly and use
the steel wire rope and such to fasten
assembly.

2. Lay the dial gauge head at the place approximately 5mm away from the periphery of
brake disk, and then measure the jump of brake disk.

Limit Value: 0.03mm

Remark:
In order to fix the brake disk to the wheel hub, nuts shall be screwed down.
3. Check the change of thickness (parallelity).

Reassembly Steps:
Steps for reassembly is just contrary to those for dismantlement.
 Chassis Volume PB-16

Attention:
Do not have the brake disk smeared by the brake fluid.
 Chassis Volume ABS-1

Overview
The wheel rotation speed sensors (mounted at wheels) collect rotation speed signals of
four wheels and then send the signals to the electronic control unit, by which the
deceleration of vehicle and the skid of wheels, as well as the rotation speed of every
wheel, are accordingly calculated.
The ABS (Anti-lock Braking System) electronic control unit, on the basis of calculated
parameters, achieves the anti-lock effect for wheels by virtue of the hydraulic control unit,
which adjusts the braking pressure in the course of braking. Even though the ABS falls
inoperative, the electronic braking force distribution system can still adjust the braking
force of rear wheels. Therefore, rear wheels will not be locked earlier than front wheels
and the safety for vehicle is ensured.
Every time the ignition switch is turned on, the ABS will automatically implement the
self-checking. During this course, if any trouble is detected, the electronic control system
will automatically interrupt the functions of ABS and lighten the ABS alarm lamp; at this
time, the braking system works as if it were not equipped with the ABS.
In case of braking on the unsafe roads, the ABS controls the braking hydraulic pressure of
four wheels so as to prevent wheels from being locked.
Benefits of ABS:
 The ABS enhances not only the ability of vehicle to detour the obstacles but also the
braking capacity of vehicle against abrupt circumstances.
 The ABS enables the vehicle to retain the control stability and the steering ability,
even though the vehicle is under the emergency braking or on a curved road.
If any trouble takes place, the accompanying self-diagnosis function and self-protection
system of ABS can be applied. The hydraulic electronic control unit (HECU) receives
signals (e.g. vehicle speed, traveling direction and road conditions) from sensors on
wheels. According to such signals, the control unit will figure out the optimal idle running
proportion for wheels.

Precautions:
Pay attention to the following general items when maintaining the ABS, or else the
ABS may get damaged.
1. Before conducting the electric welding, disconnect the electronic braking control unit
(EBCU) wire harness from the EBCU.
2. Spare parts of ABS are especially sensitive to electromagnetic interferences (EMI).
Therefore, notice the wiring, the position, the installation and the orientation of all
spare parts of ABS, and heed whether the interference befall wires, joints, clamps
and brackets.
3. Do not use the fast charger to energize storage batteries when the engine runs or
batteries are not disconnected yet, or else batteries may become invalid or spare
parts of ABS may get damaged.
4. Turn off the ignition switch, and then disconnect the storage batteries.
5. Disconnect the wire harness of ABS assembly from the ABS control module, by
which the ignition switch is turned off.
6. Never try to modify any spare part of ABS. All spare parts of ABS can be maintained
only via replacement.
7. Never hang spare parts of suspension on wires of wheel rotation speed sensor, lest
the sensor wiredrawing may get damaged.
8. It is forbidden to place the ABS control module under the environment whose
temperature is above 105℃.
 Chassis Volume ABS-2

9. Never apply the petroleum-based fluid into the main cylinder of brake, nor use the
recipient which has contained the petroleum-based fluid before, as the petroleum will
cause rubber spare parts in hydraulic braking system to expand.
10. During the operation towards ABS, it is normal that the brake pedal lightly vibrates
and the machine noise is heard.
11. After turning on the ignition switch and starting the vehicle, it is also normal that brake
pedal vibrates or the working noise from motor of HCU (Hydraulic Control Unit) is
heard.
12. When the vehicle with ABS travels on bumpy, rubbly or snowed (deep new snow)
roads, its braking distance may be longer than that of non-ABS vehicle.
13. If the ABS alarm lamp or other alarm lamps indicate errors, necessary information
(namely troubles corresponding to conditions) shall be collected from the customers,
and the probable reason shall be found out before the commencement of diagnosis
and maintenance. Beside the electrical system, the operation of vacuum booster, the
height of brake fluid and the possible leakage of fluid shall be checked.
14. If tyres of different sizes and types are not used under the correct combination, or the
brake disk is not the genuine spare parts from JAC (Jianghuai Automobile Co., Ltd.),
the braking distance or the braking stability may deteriorate.
15. Troubles or errors may take place on the ABS, if the radio, the antenna, or the
antenna lead-in wire (including lead-in wire) is placed in the vicinity of control module
unit.

Precautions for Braking System

1. The recommended brake fluid is “DOT 4”.
2. Do not reuse the brake fluid which has been discharge.
3. Do not splash the brake fluid to the painted surface.
4. Use the clean brake fluid to clean or rinse the master cylinder and brake tongs.
5. Do not use mineral oils (e.g. kerosene and gasoline), or else the rubber spare parts in
hydraulic system will be damaged.
6. Use the spanner for oil pipe nut, when dismantling or installing oil pipes.
7. Heedfully check the tightening torque, when installing brake oil pipes.
8. Before the overhaul, turn off the ignition switch, and disconnect the joint of ABS
control system or disconnect the storage battery cable from the cathode.
9. The joint face of brake shall be whetted, on condition that: the surface of brake has
been repair or the brake disk has been replaced; or the brake sheet has been
replaced; or the flaccid braking appears despite the short mileage.

Preparations
Special Tool for Maintenance
Drawing No. Name Illustration
 Chassis Volume ABS-3

Used for diagnosing troubles of

X-431 Diagnostic Instrument
ABS
 Chassis Volume ABS-4

System Description
System Illustration

Electrical Schematic Diagram (ABS/EBD)

Control Circuit

Attention: This diagram is for reference, so that customers shall add their complementary explanation to
the diagram.

Description for ABS:

At present, JAC Benjoy is equipped with Delphi DBC7.4 Anti-lock Braking System (ABS),
which is used to furthest abate the skidding of wheels at the time of abrupt braking. The
working principle of ABS is as follows: by means of monitoring the speed of every wheel,
the ABS controls the brake fluid pressure towards every wheel during the braking so as to
ensure the stable direction and favor the better steering ability of vehicle.
 Chassis Volume ABS-5

ABS Functions:
The ABS functions to inspect the rotation of wheel under the condition of braking. The
ABS protects brake tongs of four wheels via electrons, enhancing the stability and agility
for the abrupt braking.
1. If the electrical is interrupted, the protected mode against failure will start, and the
ABS falls into the non-operating state with the ABS alarm lamp lighting. (An actual
illustration for instrument lamp is provided herein.)
2. It is available to use the special JAC diagnostic instrument to diagnose the electrical
system of ABS.
3. In the course of braking, the brake pedal may lightly vibrate and the machine noise
may be heard, but such are normal phenomena of an ABS at work.
EBD Functions:
The electronic braking force distribution (EBD) system, also a proportioning system, is
applied to keep the stability of vehicle during the braking. Given normal braking conditions,
the EBD ensures the equal wheel speed, which the effective balanced braking needs. In
case of difficult braking, as the mass of vehicle transfers to front wheels, rear wheels need
smaller braking pressure, the EBD will take advantage of rear pressurizing and
depressurizing valves of ABS to provide the effective braking and ensure the stability of
vehicle by means of holding the braking pressure which rear wheels require. The red ABS
alarm lamp (it shall be the stop lamp, to be validated on spot.) will light, if following
troubles arise.
1. Either wheel speed sensor of two rear wheels fails to operate.
2. None of the electromagnetic valves operates.
3. The storage batteries are open circuited or the grounding is short circuited.
4. The ECU grounding is open circuited or the storage batteries are short circuited.
5. The ignition switch is open circuited or the grounding is short circuited.
6. The internal troubles of ECU arise.
7. The electromagnetic power relay fails.
Protection Functions against Trouble
As far as the ABS/EBD, if electrical troubles of ABS happen, the ABS alarm lamp will light;
if electrical troubles of EBD arise, the braking alarm lamp and the ABS alarm lamp will
shine.
Meanwhile, the ABS will fall into a certain condition of following protection functions
against troubles.
1. For ABS troubles, the EDB is activated only, with the state of vehicle being same to
that of non-ABS vehicle.
2. For EBD troubles, neither EBD nor ABS is applicable, with the state of vehicle being
same to that of non-ABS and non-EBD vehicle.
 Chassis Volume ABS-6

Hydraulic Diagram of System

Stock Solution
Tank

Main Oil
Cylinder

Output Valve
Output Valve

Oil
Pump
Input Input
Input Input Output Electromagnetic
Electromagnetic
Electromagnetic Electromagnetic Valve
Electromagnetic Valve
Valve Valve Valve

Output Output
Output
Electromagnetic Electromagnetic
Electromagnetic
Valve Valve
Valve

Input Pump Input Pump

Slave Slave
Cylinder of Slave Cylinder Slave Cylinder of Cylinder of
Right Front of Left Rear Right Rear Wheel Left Front
Wheel
Wheel Wheel
 Chassis Volume ABS-7

Anti-lock Braking Mode

In the course of braking, if wheels skid, the ABS will comes into the anti-lock braking mode.
During the anti-lock braking, the pressure for hydraulic circuit of every wheel is under
control to prevent the wheel from skidding. Each wheel (i.e. every front wheel and every
rear wheel) employs the single hydraulic and the specific valves. The ABS is capable to
decrease, keep, and increase the hydraulic pressure for braking of each wheel, but it is
unable to increase the pressure beyond the value which the master cylinder transfers
during the braking. In the course of braking, a series of fast pulses on the brake pedal are
palpable. These pulses arise from the change of valve positions, which is according to the
specified rotation speed of wheel. Such pulses appear as soon as the anti-lock braking is
performed; they stop on the condition that the normal braking is implemented or the
vehicle has been completely halted. As a result of the fast circular operation of
electromagnetic valve, the clicking or cracking sound is audible. Provided that the
anti-lock braking is started on the dry road, wheels will give out the intermittent acute
sound. Actually, the appearance of those sounds and pulse shall be considered normal
when the anti-lock braking is executed. Under the condition of normal braking, the
operation for brake pedal in an ABS vehicle is no different from that in a non-ABS vehicle.
The stability of vehicle, alongside with the shortest braking distance, can be obtained by
means of keeping the uniform force on the brake pedal which is tread.

Keeping Pressure
Once the ECU finds wheels skidding, it will close the inlet valves and the outlet valve in
HCU to insulate the system. In this way, the pressure on brake can be kept stable, so that
the hydraulic pressure is unable to decrease or increase.

Decreasing Pressure
Under the pressure keeping mode, if the ECU still detects that wheels are skidding, it will
decrease the pressure of affected wheels by means of opening the inlet valve and closing
the outlet valve; in this case, the redundant fluid/pressure is temporarily stored into the
accumulator in HCU till the pump propels the brake fluid back to the oil tank of main
cylinder.

Increasing Pressure
Under the pressure keeping or pressure decreasing mode, if the ECU catches the skid of
wheels abating, it will increase the pressure of affected wheels by the pressure from main
cylinder. In this case, the inlet valve is opened, the outlet valve is closed, and partial or
whole pressure from main cylinder of brake is applied to wheels.
 Chassis Volume ABS-8

Distribution Diagram for Terminals and Pins of ECU Wire Harness

Connector

Pins and Their Significations:

Code Signification of Pin

1 Grounding

8 Keyword 2000 (K-line) communication

12 Low speed (left rear wheel)

13 High speed (left rear wheel)

16 Ignition

24 Low speed (right front wheel)

25 Braking alarm lamp

27 High speed (left front wheel)

28 Low speed (left front wheel)

31 Motor grounding

38 ABS alarm lamp

39 High speed (right front wheel)

41 Brake switch

42 High speed (right rear wheel)

43 Low speed (right rear wheel)

46 Storage battery

Trouble Diagnosis
How to carry out the trouble diagnosis for the quick and precise repair?
 Chassis Volume ABS-9

1. For carrying out the trouble diagnosis, it is foremost that the operator be acquainted
with a variety of systems (including control and mechanisms) of vehicle.
2. Before the diagnosis, it is also very important to understand the complaint from
customers.
First, repeat and completely see the trouble.
Then, carefully inquire the customer about the complaint. In some special
circumstance, it is necessary to drive the vehicle with the customer so as to check the
trouble.
3. In order to thoroughly solve the trouble, the check for trouble must be started at the
incipient stage. So far as the intermittent trouble, it is rather significant to repeat the
trouble according to the conversation with customers and the previous cases. Do not
carry out the check based on some particular cases. Since most intermittent troubles
arise from the poor contact, jiggling the doubtful wire harnesses or joints shall be an
efficacious solution.
4. After the diagnosis, it is required to execute the command “Clear Trouble Code”.
 Chassis Volume ABS-10

Flow Chart for Trouble Diagnosis

Check and confirm the troubled areas.

Confirm the “Precautions”and the Method for Fast

Diagnosis so as to find out Troubles as soon as possible.

Execute the preliminary check.

The ABS trouble lamp is on or

not?

Y
N Y
The diagnostic instrument Check the ABS actuator and the wire harnesses of
displays “ABS”or not? electric unit and data link ports.

Execute the self-checking

program.

Execute the trouble

diagnosis program.
Check and repair troubled spare
parts. Abnormal
Y
Abnormal

Clear the self-diagnosis result, and drive the vehicle at a speed

Confirm troubles.
of 30km/h or higher for more than 1 minute.

Normal Normal

Execute the self-diagnosis

again.

End the check.

 Chassis Volume ABS-11

Information and Flow of Diagnosis

1. Self-diagnosis:
The ECU applies the self-diagnosis for the system. In addition, the ECU can detect
and insulate the system troubles. Once a trouble is found, the ECU will set a
diagnostic trouble code (DTC) (which represents the trouble), switch on the ABS
alarm lamp, and turn off the ABS within a certain ignition period (if necessary).
2. Display of DTC:
The ECU makes use of the scanning tool to display DTCs.
3. Clearance of DTC:
DTCs in ECU memory can be cleared by two means, i.e.:
① Scanning tool method, and
② Ignition period default
Whichever way is adopted, it is required to confirm whether the system operation is
normal and the DTC reappears after the clearance steps has been finished. It is
forbidden to clear the DTC in manner of unplugging the ECU connector,
disconnecting the storage battery cable or extincting the engine, exclusive of the
circumstance that no recurrence of trouble after a 100-time ignition is set as the
default.
4. Mostly, the intermittent troubles or the poor-contact intermittent troubles arise
from:
① The wrong electric wiring;
② The wrong electric connection; and
③ The sluggish relay or electromagnetic valve.
5. Initialization Sequence
The ECU executes the initialization test at the beginning of every ignition period.
When executing the initialization test, the ECU gives priority to the electromagnetic
valve and then the pump motor to check whether spare parts operate regularly. If any
trouble is detected, the ECU will set the corresponding DTC. During the initialization
test, some actions can be heard and felt, but such actions are portions of the normal
operation of system. If the ECU has no signal input to the brake switch (with the
operator’ s foot leaving the brake pedal), the ECU will immediately execute the
initialization after it starts. During the starting, if the signals is input to the brake switch
(with the operator’ s foot treading the brake pedal), the ECU will not implement the
initialization until no signal is input to the brake switch (with the operator’ s foot leaving
the brake pedal) or the vehicle speed reaches 16km/h.

Diagnostic Circuit Check

System Description
The diagnostic circuit is competent to detect any problem which results from troubles
of ABS/EBD. After the diagnostic circuit gives off the information, the maintenance
technician shall diagnose the ABS/EBD troubles. The diagnostic circuit will direct the
technician to the next step for diagnosis. The ECU sends the serial data via port 8,
receives the constant voltage of storage battery via port 46, and convert such voltage
into the ignition voltage via port 16. The grounding port of ECU is coded as 1.
Diagnosis Process
Steps for maintaining the ABS/EDB are described as follows:
 Chassis Volume ABS-12

1. Check whether any mechanical trouble relevant to the braking system arises in
the vehicle.
(1) Check whether level of brake fluid in stock solution tank is correct;
(2) Check whether the brake fluid of main cylinder is contaminated;
(3) Check whether the main cylinder of brake/ the HCU is leaky.
(4) Check the braking spare parts of all wheels;
(5) Confirm whether the braking is sluggish;
(6) Confirm whether the braking is stable (with out backward draught or forward
rush);
(7) Check whether the brake shoe is abraded/ damaged;
(8) Check whether the wheel bearing is damaged;
(9) Check the wheel speed senor/ the wire harness;
(10) Check whether the joint of wheel speed sensor/ the ring gear of wheel speed
sensor is damaged; check the depth/ the abrasion of the tyre pattern;
(11) Give a road test to the vehicle, and confirm the actual conditions for the
correction.
2. Execute the diagnostic circuit check, with the operation conducted according to
the applicable trouble diagnosis diagrams. After all system troubles have been
eliminated, clear ABS DTCs.
Step Diagnosis Yes No
1． If possible, connect or install spare parts which has
been disconnected or dismantled.
Go to Go to Step
1 2． Ignite and then stop the engine.
Step 2 4
3． Install the applicable diagnostic instrument to the DLC,
and make the instrument communicate with the ECU.
Go to Go to Step
2 Is there any currently or previously saved trouble code?
Step 3 7
1． Record the current trouble code.
2． Record the previous DTCs.
3． Record reinforced historical data, such as:
Times set for every DTC,
Times since every DTC had been set first time,
3 Times since every DTC had been set last time,
The speed at the time of setting DTC, and
Other reinforced data which are helpful for the
diagnosis.
4．Do not clear DTCs before the information has been
recorded from the diagnostic instrument.
Does the diagnostic instrument communicate with other Go to Go to Step
4
modules which are in the same data circuit? Step 5 6
Go to the ECU trouble diagram regarding “No
5
Communication with ECU”.
6 Go to connector unit 50 for data link in electric part.
1． Extinct the engine.
2． Wait for 10 seconds. Go to Go to Step
7
3． Ignite and then stop the engine. Step 8 9
4． After the ignition, observe the orange ABS lamp.
Does any lamp still light? Go to Go to Step
8
Step 9 10
Go to the trouble diagram for the corresponding lamps
9
“opened”.
10 Go to the trouble diagram regarding “Inefficacious Lamp”.
Chassis Volume ABS-13
 Chassis Volume ABS-14

Common Troubles and Analysis of ABS

1. No Communication with ECU

Ignition Power
Switch Supply

Circuit Description
The ECU sends and receives the serial data via terminal 8, converts the ignition via
terminal 16, and receives the voltage of storage battery via terminal 46. The grounding
port of ECU is coded as 1.

Diagnosis Help
Typical reasons to these troubles may be as follows:
1. Ports are under poor contact,
2. ECU terminal 1 is ungrounded,
3. ECU terminal 46 is devoid of without storage battery voltage,
4. ECU terminal 16 is devoid of without ignition voltage,
5. The data circuit is opened/grounded, and
6. The data circuit bears high resistance.
 Chassis Volume ABS-15

2. Inefficacious ABS Alarm Lamp/No DTC

Power Supply

Ignition
Switch

ABS Alarm Lamp

Lighting
Module Group
Braking alarm lamp

Circuit Description
The ECU controls the amber ABS alarm lamp to act by means of driving the low-order
output of vehicle lamp ports. When the ignition switch is closed, the storage battery
provides the voltage to instrument panel terminals and ECU terminal 16; and ECU
terminal 46 is electrified all the time. Under the default condition, the lamp driving module
turns on the amber ABS alarm lamp and provides the grounding path for this lamp. When
directing the ABS lamp to close, the ECU grounds the control circuit of ABS alarm lamp,
making the lamp driving unit open the grounding path for the bulb. With the ignition switch
being closed, the ECU turns on the ABS alarm lamp for 3 seconds to check the bulb.
Once any trouble in ABS is found out, the ECU immediately activates the ABS alarm lamp,
which reminds the driver of the fact that the ABS needs maintaining.

Diagnosis Help
Typical reasons to these troubles may be as follows:
1. The ABS lamp bulb is troubled/ the socket loosens,
2. The fuse of instrument panel is opened,
3. The instrument/ the lamp driving module is troubled,
4. The ECU is troubled, and
5. The circuit between ECU and instrument is grounded.
 Chassis Volume ABS-16

3. ABS Alarm Lamp Being on/No DTC

Power Supply

Ignition
Switch

ABS Alarm Lamp

Lighting
Module Group
Braking Alarm
Lamp

Circuit Description:
The ECU controls the amber ABS alarm lamp to act by the lamp driving module inside
instrument. When the ignition switch is closed, the storage battery provides the voltage to
instrument panel terminals and ECU terminal 16; and ECU terminal 46 is electrified all the
time.
Under the default condition, the lamp driving module turns on the amber ABS alarm lamp
and provides the grounding path for this lamp.
When directing the ABS lamp to close, the ECU grounds the control circuit of ABS alarm
lamp, making the lamp driving unit open the grounding path for the bulb. With the ignition
switch being closed, the ECU turns on the ABS alarm lamp for 3 seconds to check the
bulb. Once any trouble in ABS is found out, the ECU immediately activates the ABS alarm
lamp, which reminds the driver of the fact that the ABS needs maintaining.

Diagnosis Help
Typical reasons to these troubles may be as follows:
1. The circuit between instruments and ECU is open,
2. The ECU is devoid of grounding,
3. The circuit between instrument and ECU is short,
4. The instrument/the lamp driving module is troubled, and
5. The ECU is troubled.
 Chassis Volume ABS-17

4. Braking Alarm Lamp on/No DTC Settings

Power Supply
Ignition
Switch

ABS Alarm Lamp

Lighting
Module Group
Braking Alarm
Lamp

Circuit Description:
The ECU controls the amber ABS alarm lamp to act by the lamp driving module inside
instrument. When the ignition switch is closed, the storage battery provides the voltage to
instrument panel terminals and ECU terminal 16; and ECU terminal 46 is electrified all the
time. Under the default condition, the lamp driving module turns on the braking alarm lamp
and provides the grounding path for this lamp.
When directing the braking alarm lamp to close, the ECU grounds the control circuit of
ABS alarm lamp, making the lamp driving unit open the grounding path for the bulb.
With the ignition switch being closed, the ECU turns on the braking alarm lamp for 3
seconds to check the bulb. Once any trouble in conventional braking system or in DBC 7.4
ABS is found out, the ECU immediately activates the braking alarm lamp, which reminds
the driver of the fact that the conventional braking system or the DBC 7.4 ABS needs
maintaining.
Diagnosis Help:
Typical reasons to these troubles may be as follows:
1. The emergency brake switch is troubled,
2. The level of brake fluid is excessively low, or the brake fluid switch is troubled,
3. Troubles listed in DTC C0055, C0065 or C0067 (see the Diagnostic Trouble Code
(DTC) List) occur,
4. The EBD become failed due to following troubles in ABS:
① Two coaxial wheel speed sensor are inefficacious,
② The storage battery is open circuited, or the grounding is short circuited,
③ The motor grounding is short circuited, or storage battery is short circuited,
④ The ECU is open circuited, or the storage battery is short circuited, and
⑤ The ignition is open circuited, or the grounding is short circuited.
5. The instrument and the ECU are open circuited,
6. The circuit between vehicle lamp ports is troubled,
7. The instrument is troubled, or
8. The ECU is troubled.
 Benjoy Maintenance Manual — Chassis Volume ABS-18

5．Inefficacious Braking Alarm Lamp/No DTC

Power Supply

Ignition
Switch

ABS Alarm Lamp

Lighting
Module Group
Braking Alarm
Lamp

Circuit Description:
The ECU controls the amber braking system alarm lamp to act by the lamp driving module
inside instrument.
When the ignition switch is closed, the storage battery provides the voltage to instrument
panel terminals and ECU terminal 16; and ECU terminal 46 is electrified all the time.
Under the default condition, the lamp driving module turns on the braking alarm lamp and
provides the grounding path for this lamp.
When directing the braking alarm lamp to close, the ECU grounds the control circuit of
ABS alarm lamp, making the lamp driving unit open the grounding path for the bulb.
With the ignition switch being closed, the ECU turns on the braking alarm lamp for 3
seconds to check the bulb. Once any trouble in conventional braking system or in EBD
system is found out, the ECU immediately activates the braking alarm lamp, which
reminds the driver of the fact that the conventional braking system or the EBD system
needs maintaining.

Diagnosis Help:
Typical reasons to these troubles may be as follows:
1. The bulb is troubled/ the socket loosens,
2. The fuse of instrument panel is opened,
3. The instrument is troubled,
4. The ECU is troubled, or
5. The circuit between ECU and Instruments is grounded.
 Benjoy Maintenance Manual — Chassis Volume ABS-19

ABS Trouble Code List

Trouble
Trouble Description
Code
C0011 Troubled ABS Alarm Lamp
C0012 Troubled Braking alarm lamp
C0014 Poor-contact Electromagnetic Relay or Open-circuit Coil
C0017 Troubled Grounding of Pump Motor
C0018 Short Circuited Pump Motor and Battery, or Motor Grounding under Open
Circuit/with High Resistance
C0021* Speed of Left Front Wheel Equal to 0kph
C0022* Speed of Right Front Wheel Equal to 0kph
C0023* Speed of Left Rear Wheel Equal to 0kph
C0024* Speed of Right Rear Wheel Equal to 0kph
C0025 Excessive Speed Change of Left Front Wheel
C0026 Excessive Speed Change of Right Front Wheel
C0027 Excessive Speed Change of Left Rear Wheel
C0028 Excessive Speed Change of Right Rear Wheel
C0032 Open-circuit Left Front Wheel Speed Sensor, or Short Circuited Grounding/
Storage Battery
C0033 Open-circuit Rear Front Wheel Speed Sensor, or Short Circuited Grounding/
Storage Battery
C0034 Open-circuit Left Rear Wheel Speed Sensor, or Short Circuited Grounding/
Storage Battery
C0035 Open-circuit Right Rear Wheel Speed Sensor, or Short Circuited Grounding/
Storage Battery
C0036 Excessively-high Voltage
C0037 Excessively-low Voltage
C0042 Open-circuit Pump Motor
C0043 Inoperative Pump Motor
C0055 Internal Trouble
C0056 Open-circuit System Relay All the Time
C0061 Troubled Left Front Pressurizing Electromagnetic Valve
C0062 Troubled Left Front Depressurizing Electromagnetic Valve
C0063 Troubled Right Front Pressurizing Electromagnetic Valve
C0064 Troubled Right Front Depressurizing Electromagnetic Valve
C0065 Troubled Left Rear Pressurizing Electromagnetic Valve
C0066 Troubled Left Rear Depressurizing Electromagnetic Valve
C0067 Troubled Right Rear Pressurizing Electromagnetic Valve
C0068 Troubled Right Rear Depressurizing Electromagnetic Valve
C0091 Inoperative Brake Pedal under Deceleration
C0093 Inoperative Brake Pedal under Deceleration within Last Ignition Period
C0094 Inoperative Brake Pedal without Deceleration
C0095* Troubled Brake Switch
C0118 Troubles Relevant to Left Rear Depressurizing Valve
C0121 Troubles Relevant to Right Rear Depressurizing Valve
C0122 Troubles Relevant to Depressurizing Valves or Front Pressurizing Valve
C0127 Inoperative Brake Pedal without Deceleration during Last Ignition Period
C0151 Excessively-long Time for Depressurizing Left Front Wheel
 Benjoy Maintenance Manual — Chassis Volume ABS-20

C0152 Excessively-long Time for Depressurizing Right Front Wheel

C0153 Excessively-long Time for Depressurizing Left Rear Wheel
C0154 Excessively-long Time for Depressurizing Right Rear Wheel
C0191 No Starting Current for Pump Motor
C0192 Pump Motor under Overcurrent
C0194 Short Circuited Pump Motor

Analysis for Trouble Codes

C0011- Troubled ABS Alarm Lamp
Circuit Description
The ECU outputs the low level to pin 38, and the other end of its port supplies the low level
to the lamp driving module or the lamp on instrument. Despite either of foresaid cases, the
output level inactivated is heightened, whereas the output level activated is lowered.
Conditions for Setting DTC
With the ignition switch closed, DTC C0011 is set, and:
1. With the lamp driving output voltage rising to exceed the to-be-determined (TBD)
voltage, the short circuit trouble of storage battery in output circuit of ECU pin 38 is
detected, meanwhile, and the information “Lamp Driving Output On = Low Driving”is
indicated; and
2. The open circuit of output circuit of ECU pin 38 or the short circuit of grounding
causes the output circuit voltage to be grounded; with the lamp driving output voltage
being lower than the TBD voltage, the open circuit trouble or the short circuit trouble
of grounding is detected, meanwhile, the information “Lamp Driving Output Off = High
Externality”is indicated.
If the output of ABS alarm lamp has been troubled for 30ms, such a trouble shall be set.
Actions for Setting DTC
The DTC shall be saved in the ECU.
Conditions for Clearing DTC
If the conditions for setting DTC C0011 no longer exist, it is available to clear the DTC by
the corresponding diagnostic instrument.
If the DTC has not appeared in 100 consecutive periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
Typical reasons to DTC C0011 may be as follows:
1. The circuit between ECU pin 38 and vehicle lamp port is opened,
2. The grounding between ECU pin 38 and vehicle lamp port is short circuited,
3. The circuit between the ECU pin 38 and vehicle lamp port and the storage battery are
short circuited, or
4. The ECU is troubled.
 Benjoy Maintenance Manual — Chassis Volume ABS-21

C0011- Troubled ABS Alarm Lamp

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 5
2 1. Extinct the engine; Go to Go to
2. Disconnect the wire harness of ECU; Step 6 Step 3
3. Ignite the engine;
4. Connect ECU wire harness port 38 with the
grounding of vehicle body by a fused jumper.
Is the amber ABS alarm off?
3 1. Extinct the engine; Less than Go to Go to
2. Still disconnect the wire harness of ECU; 2Ω Step 4 Step 7
3. Dismantle the instrument assembly from the
instrument panel;
4. Disconnect the color instrument wire harness
from the instrument assembly;
5. Connect ECU wire harness port A2 with the
port of (color) instrument wire harness by an
ohmmeter.
Is the resistance within the specified range?
It is necessary to add some steps to check the
short circuit trouble of storage battery in vehicle
wire harness.
4 Replace the instrument assembly. Go to
Complete the repair? Step
10
5 Execute the diagnostic check for circuit.
6 Replace the ECU. Go to
Complete the maintenance? Step
10
7 Before the ECU is replaced, it is necessary to
execute some check with regard to the ECU
grounding.
8 Repair the open circuit or high resistance trouble Go to
between ECU and instrument. Step
Complete the repair? 10
9 Repair the short circuit trouble of storage battery Go to
of wire harness. Step
Complete the repair? 10
10 Clear the DTC by the diagnostic instrument. Go to System
Is the DTC reset? Step 1 OK

C0012- Troubled Braking alarm lamp

Circuit Description
The ECU outputs the low level to pin 25, and the other end of its port supplies the low level
to the lamp driving module or the lamp on instrument. Despite either of foresaid cases, the
 Benjoy Maintenance Manual — Chassis Volume ABS-22

output level inactivated is heightened, whereas the output level activated is lowered.
Conditions for Setting DTC
With the ignition switch closed, DTC C0012 is set, and:
1. With the lamp driving output voltage rising to exceed the to-be-determined (TBD)
voltage, the short circuit trouble of storage battery in output circuit of ECU pin 38 is
detected, meanwhile, the information “Lamp Driving Output On = Low Driving”is
indicated; and
2. The open circuit of output circuit of ECU pin 38 or the short circuit of grounding causes
the output circuit voltage to be grounded; with the lamp driving output voltage being
lower than the TBD voltage, the open circuit trouble or the short circuit trouble of
grounding is detected, meanwhile, the information “Lamp Driving Output Off = High
Externality”is indicated.
If the output of ABS alarm lamp has been troubled for 30ms, such a trouble shall be set.

Actions for Setting DTC

The DTC shall be saved in the ECU.

Conditions for Clearing DTC

If the conditions for setting DTC C0012 no longer exist, it is available to clear the DTC by
the corresponding diagnostic instrument.
If the DTC has not appeared in 100 consecutive periods, it is allowed to be cleared from
the historical data.

Diagnosis Help
Typical reasons to DTC C0012 may be as follows:
1. the lamp driving output is open circuited,
2. the grounding of lamp driving output is open circuited, or
3. the ABS lamp driving and the storage battery are short circuited.
 Benjoy Maintenance Manual — Chassis Volume ABS-23

C0012- Trouble Braking Alarm Lamp

Step Diagnostic Action Expected Value Yes No
1 Complete the diagnostic circuit check? Go Go to
to Step 6
Step
2
2 1. Test the storage battery load.(see the Maintenance The storage Go Go to
Manual for Storage Battery for reference) battery shall be to Step 7
2. Check the charging system. (see the Maintenance able to keep the Step
Manual for Starter and Charging System for voltage above 3
reference) 9.6V for 10
3. Execute the additional load test. seconds, with the
Do storage battery, charging system and additional load current no higher
pass the test? than 30mA.
3 1. Extinct the engine. Go Go to
2. Disconnect both anode and cathode of the storage to Step 8
battery. Step
3. Disconnect the wire harness from the ECU. 4
4. Check whether the following wire harnesses are
under good connection.
 The wiring of battery terminal
 The cathodic cable to engine block / chassis
 The anodic cable to electromagnetic valve of
starter/ or to terminal box
 ECU ports 16, 46, and 1
 The ECU grounding cable to chassis grounding
Are all connections foresaid good?
4 1. Keep the ECU disconnected. Less than 2Ω Go Go to
2. Keep the storage battery cable disconnected. to Step 9
3. Connect an ohmmeter with ECU wire harness Step
terminal 1 and the cathode of storage battery cable. 5
Is the resistance value within the specified range?
5 1. Reconnect the storage batter cable. Voltage of Go Go to
2. Keep the ECU disconnected. storage battery to Step
3. Ignite the engine. Step 10
4. Measure voltages of ECU wire harness terminals 16 11
and 46 by a voltmeter.
Are voltages of these two terminals within the specified
range?
6 Execute the diagnostic circuit check.
7 Repair the charging system Go
and/or to
recharge/replace the storage battery Step
and/or 12
find out and repair the reason of excessive additional use.
Complete the repair?
8 Repair the port and/or the connector, if necessary. Go
Complete the repair? to
Step
12
9 Find and repair the reason of high resistance between Go
cathodic cable of storage battery and ECU wire harness to
connector. Step
Complete the repair? 12
10 Find and repair the reason of low voltage on ECU ports. Go
Complete the repair? to
Step
 Benjoy Maintenance Manual — Chassis Volume ABS-24

12
11 Replace the ECU. Go
Complete the repair? to
Step
12
12 Clear the DTC by the diagnostic instrument. Go System
Is the DTC reset? to OK
Step
1
C0014- Poor-contact Electromagnetic Relay or Open-circuit
Coil

Circuit Description
The electromagnetic relay is an indispensable part for the ECU. The voltage of battery is
continuously provided to the relay switch via terminal 46. When the ignition switch is
closed, the voltage of battery will be supplied to the relay coil from terminal 16, and then
the ECU grounds the circuit of relay coil to close the relay and offer voltage for
electromagnetic valves and motors. As long as the ignition switch is turned on, the relay
shall be in the closed state; or else, the relay shall be disconnected for the DTC setting.

Conditions for Setting DTC

With the ignition switch and the relay closed, DTC C0014 arises if the ignition voltage is
higher than 10.5V and the voltage for switching relay falls less than 8.0V within 1/4 second.
Those values shall be changed, subject to the specified settings by customer.

Actions for Setting DTC

1. The electromagnetic relay is switched off, and the battery voltage no longer stays at
electromagnetic valves and pump motors.
2. The ABS becomes inoperative, and the ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0014 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
Typical reasons to DTC C0014 may be as follows:
1. The voltage of storage battery is weak, or the storage battery has discharged,
2. The terminal of storage battery is loose or rusty,
3. The engine block from battery is poorly grounded,
4. The fuse of ABS is under poor contact or loosens,
5. ECU terminals 16, 46, and 1 are under poor contact,
6. The voltage of ECU terminal 46 is too low, or
7. The internal troubles of ECU arise.
Benjoy Maintenance Manual — Chassis Volume ABS-25
 Benjoy Maintenance Manual — Chassis Volume ABS-26

C0014- Poor-contact Electromagnetic Relay or Open-circuit Coil

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 6
2 1. Execute the load test for the storage load battery.(see The storage Go to Go to
section regarding storage battery in maintenance battery shall be Step 3 Step 7
manual) able to keep
2. Check the charging system. (see starter and charging the voltage
system in maintenance manual) above 9.6V for
3. Execute the additional load test. 10 seconds,
Do storage battery, charging system and additional load with the current
pass the test? no higher than
30mA.
3 1. Extinct the engine. Go to Go to
2. Disconnect both anode and cathode of the storage Step 4 Step 8
battery.
3. Disconnect the wire harness from the ECU.
4. Check whether the following connections are in good
condition.
 The wiring of battery
 The cathodic cable to engine block/chassis
 The anodic cable to electromagnetic valve of
starter/or to terminal box
 ECU ports 16, 46, and 1
 The ECU grounding cable to chassis
grounding
Are all connections foresaid good?
4 1. Keep the ECU disconnected. Less than 2Ω Go to Go to
2. Keep the storage battery cable disconnected. Step 5 Step 9
3. Connect an ohmmeter with ECU wire harness
terminal 1 and the cathode of storage battery cable.
Is the resistance value within the specified range?
5 1. Reconnect the storage batter cable. Voltage of Go to Go to
2. Keep the ECU disconnected. storage battery Step 11 Step 10
3. Ignite the engine.
4. Measure voltages of ECU wire harness terminals
16 and 46 by a voltmeter.
Are voltages of these two terminals within the specified
range?
6 Execute the diagnostic circuit check.
7 Repair the charging system Go to
and/or Step 12
recharge/replace the storage battery
and/or
find out and repair the reason of excessive additional
use.
Complete the repair?
8 Repair the port and/or the connector in accordance with Go to
the requirement. Step 12
Complete the repair?
9 Find and repair the reason of high resistance between Go to
cathodic cable of storage battery and ECU wire harness Step 12
connector.
Complete the repair?
10 Find and repair the reason of low voltage on ECU ports. Go to
Complete the repair? Step 12
11 Replace the ECU. Go to
Complete the repair? Step 12
12 1. Clear the DTC by the diagnostic instrument. Go to System
Is the DTC reset? Step 1 OK
Benjoy Maintenance Manual — Chassis Volume ABS-27
 Benjoy Maintenance Manual — Chassis Volume ABS-28

C0017- Pump Motor with Power Open Circuited

Circuit Description
The pump motor is placed in the HCU (hydraulic control unit). The voltage of pump motor
is provided by ECU terminal 46, controlled by a stationary power terminal driver, and the
pump motor is grounded via ECU terminal 31.

Conditions for Setting DTC

Only when the key is regulated to the position “ON”, the pump motor runs and the ECU
finds an open circuited pump motor can DTC C0017 be set.

Actions for Setting DTC

1. The ECU disconnects the power supply of pump motor,
2. DTC C0017 is saved,
3. The ABS becomes inoperative,
4. The ABS alarm lamp is turned on, and
5. The red braking alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0017 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.

Diagnosis Help
Typical reasons to DTC C0011 may be as follows:
1. The pump motor is inserted to the wire harness, or the connector (terminal 46) gets
disconnected or poorly contacted, and
2. The ECU is troubled.
 Benjoy Maintenance Manual — Chassis Volume ABS-29

C0017- Pump Motor with Open Power Circuit

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go Go to
to Step 4
Step
2
2 1. Extinct the engine. Voltage of Go Go to
2. Disconnect the wire harness from the ECU. storage to Step 3
3. Ignite the engine. battery Step
4. Measure the voltage of ECU wire harness terminal 46 by a 5
voltmeter.
Is the voltage value within the specified range?
3 Find and repair the reason of high resistance/open circuit Go
between cathode of storage battery and terminal 46 of ECU wire to
harness connector. Step
Complete the repair? 6
4 Complete the diagnostic circuit check.
5 Replace the ECU. Go
Complete the repair? to
Step
6
6 1. Clear the DTC by the scanning tool. Go System
Is the DTC reset? to OK
Step
1
C0018- Short Circuit between Pump Motor and Battery/Grounded Motor
under Open Circuit or with High Resistance
Circuit Description
The pump motor is placed in the HCU (hydraulic control unit). The voltage of pump motor
is provided by ECU terminal 46, controlled by a stationary power terminal driver, and the
pump motor is grounded via ECU terminal 31.
Conditions for Setting DTC
Only when the key is regulated to the position “ON”, the pump motor runs and the ECU
finds an open circuited pump motor can DTC C0017 be set.
Actions for Setting DTC
1. The ECU disconnects the power supply of pump motor,
2. DTC C0018 is saved,
3. The ABS becomes inoperative,
4. The DRP becomes inoperative,
5. The ABS alarm lamp is turned on, and
6. The red braking alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0018 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
Typical reasons to DTC C0018 may be as follows:
1. Terminal 31 is under poor contact,
 Benjoy Maintenance Manual — Chassis Volume ABS-30

2. The grounding circuit of terminal 31 is short and with no voltage,

3. The grounding circuit of terminal 31 is open,
4. The grounding circuit of terminal 31 suffers from high resistance when grounded.
5. The ECU is troubled.
 Benjoy Maintenance Manual — Chassis Volume ABS-31

C0018- Short Circuited Pump Motor and Battery/Grounded Motor under Open
Circuit or with High Resistance
Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 8
2 1. Extinct the engine. Less than Go to Go to
2. Disconnect the ECU wire harness from the ECU. 1V Step 3 Step 9
3. Ignite the engine.
4. Connect a voltmeter with terminal 31 of ECU wire
harness terminal and the grounding of vehicle body.
Is the voltage value within the specified range?
3 1. Extinct the engine. Less than Go to Go to
2. Disconnect the cathode of storage battery cable. 2Ω Step 4 Step 10
3. Keep the ECU wire harness disconnected from the
ECU.
4. Connect an ohmmeter with the cathode of storage
battery cable and terminal 31 of ECU wire harness.
Is the resistance value within the specified range?
4 1. Along the cathode of storage battery to the engine block Go to Go to
and/or the connection of chassis grounding, check Step 5 Step 11
whether these places are clean and the connection is
firm.
2. From terminal 31 of ECU wire harness, along the circuit,
find out the circuit grounding position to chassis, check
whether this position is clean and the connection is firm.
Are they clean and firm?
5 1. Keep the ECU wire harness disconnected from the Go to Go to
ECU. Step 6 Step 12
2. Dismantle the ECU from the HCU.
3. Check whether damage, corrosion, poor contact or
brake fluid spillage arises.
Are the terminal and the connector OK? Is there damage,
brake fluid or corrosion in the cabin?
6 Connect an ohmmeter with HCU terminals 1 and 2. Less than Go to Go to
Is the resistance reading of pump motor within the specified 2Ω Step 7 Step 13
range?
7 Replace the ECU. Go to
Complete the repair? Step
14
8 Execute the diagnostic circuit check.
9 Find and repair the reason to short circuit of grounding circuit Go to
of terminal 31. Step
Complete the repair? 14
10 Find and repair the reason of excessively high resistance Go to
between grounding circuit of ECU terminal 31 and grounding Step
of vehicle body. 14
Complete the repair?
11 Repair the poorly-grounded connection, if necessary. Go to
Complete the repair? Step
14
12 1. If necessary, replace the ECU and/or the HCU, when the Go to
damage and/or the corrosion arise. Step
2. Replace the ECU and the HCU, if the brake fluid leakage 14
arises.
Complete the repair?
 Benjoy Maintenance Manual — Chassis Volume ABS-32

13 Hydraulic Control Unit (HCU) Go to

Complete the repair? Step
14
14 1. Clear the DTC by the scanning tool. Go to System
Is the DTC reset? Step 1 OK
 Benjoy Maintenance Manual — Chassis Volume ABS-33

C0021- Input Signal Value of Left Front Wheel Speed Sensor Equal
Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTCs.

Conditions for Setting DTC

So far as setting DTC C0021, the following conditions are indispensable.
1. DTC C0032, or C0033, or C0034, or C0035 does not appear right now,
2. The ABS becomes inoperative,
3. The brake switch is turned off, and
The value shown by left front wheel speed senor is equal to 0, whereas that indicated by
other rest wheel speed sensors is higher than 8km/h in 2.5 second at least.

Conditions for Clearing DTC

1. If the conditions for setting DTC C0021 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.

Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short,
or contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping
performance of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.
If it is reflected by drivers that the ABS alarm lamp only lights under the wet environments
(e.g. rain, snow, and washing), thoroughly check all wheel speed sensors to see whether
water penetration befalls them. If the DTC does not appear right now, analogize the effect
of water penetration by the following means: (1) spray the suspicious areas by the brine
whose concentration is 5%; (2) then, test the vehicle with a speed over 24km/h (15 mile/h)
under a variety of road conditions (e.g. bumpy and tortuous). If the DTC arises, replace
the doubtable wire harnesses and/or sensors.
The resistance of wheel speed sensor shall be measure under the condition of room
temperature, because the resistance increases as the temperature rises.
The recurrence of DTC 0021, as well as the incorrect diagnosis and the evitable
 Benjoy Maintenance Manual — Chassis Volume ABS-34

replacement for spare parts, may be caused, provided that such steps foresaid is
implemented neither carefully nor fully.
C0021- Input Signal Value of Left Front Wheel Speed Sensor Equal to 0
Step Diagnostic Action Expected Value Yes No
1 Complete the diagnostic circuit check? Go Go to
to Step 12
Step
2
2 1. Extinct the engine. Go Go to
2. Check whether the left front wheel speed sensor, to Step 3
the wire harness, and the gear ring suffer from Step
the physical damage. 13
Is any physical damage found out?
3 Set DTC C0032 as a current code or a historical Go Go to
code? to Step 4
Step
14
4 1. Connect the scanning tool, and select data lists. Go Go to
2. Monitor the wheel speed sensor. to Step 15
3. Test the vehicle at a speed of 24 km/h (15 Step
mile/h), and then gradually reduce the vehicle 5
speed to 0. Repeat such an action for several
times.
Is DTC C0021 reset? Or does the speed of left front
wheel abruptly fall to 0 before the vehicle completely
stops?
5 1. Extinct the engine. No less than 100mV Go Go to
2. Jack up and moderately support the vehicle. to Step 6
3. Disconnect the ECU wire harness from the ECU. Step
4. Connect the voltmeter with ECU wire harness 16
terminals 27 and 28.
5. Select the scale of AC millivolt.
6. Rotate the left front wheel and observe the
voltmeter. (The voltage shall increase, as the
wheel speed rises.)
Is the AC voltage value within the specified range?
6 1. Disconnect the left front crossover wire harness 800~1,600Ω (the Go Go to
from the left front wheel speed sensor. resistance changes, to Step 17
2. Connect the ohmmeter with two terminals of left subject to the Step
front wheel speed sensor. temperature and the 7
Is the resistance value within the specified range? requirement of
customer.)
7 1. Keep the left front crossover wire harness No less than 100mV Go Go to
disconnected from the left front wheel speed to Step 17
sensor. Step
2. Connect the voltmeter with two terminals of left 8
front wheel speed sensor.
3. Select the scale of AC millivolt.
4. Rotate the left front wheel and observe the
voltmeter. (The voltage shall increase, as the
wheel speed rises.)
Is the AC voltage value within the specified range?
8 1. Disconnect the left front crossover wire harness OL (open circuit) Go Go to
from the ABS module wire harness. to Step 18
2. Keep the ECU wire harness disconnected from Step
the ECU. 9
3. Connect the ohmmeter with ECU wire harness
terminals 27 and 28.
Is the resistance value is within the specified range?
9 1. Keep the ECU wire harness disconnected from Less than 2Ω Go Go to
the ECU. to Step 19
2. Keep the left front wire harness disconnected Step
from the ABS module wire harness. 10
3. Connect the ohmmeter with ECU wire harness
terminal 27, and then with ABS module wire
harness terminal A.
 Benjoy Maintenance Manual — Chassis Volume ABS-35

Is the resistance value is within the specified range?

10 1. Keep the ECU wire harness disconnected from Less than 2Ω Go Go to
the ECU. to Step 20
2. Keep the left front wire harness disconnected Step
from the ABS module wire harness. 11
3. Connect the ohmmeter with ECU wire harness
terminal 28, and then with ABS module wire
harness terminal B.
Is the resistance value is within the specified range?
11 1. Replace the left front wheel speed crossover wire Go System
harness. to OK
2. Test the vehicle at different kinds of speed on Step
various roads. 16
Is DCT C0021 reset?
12 Before carrying out the fault tree analysis, execute the
diagnostic circuit check.
13 Repair the damaged left front wheel speed sensor, Go
the crossover wire harness and/or gear ring. to
Complete the repair? Step
21
14 Before executing diagnosis steps listed in this table,
diagnose DTC C0032.
15 The DTC C0021 is intermittent. See the Diagnosis
Help.
16 Replace the ECU. Go
Complete the repair? to
Step
21
17 Replace the left front wheel speed sensor. Go
Complete the repair? to
Step
21
18 Find and repair the trouble of short circuit between Go
these two circuits. to
Complete the repair? Step
21
19 Repair the open circuit or the high resistance between Go
terminals 27 and A. to
Complete the repair? Step
21
20 Repair the open circuit or the high resistance between Go
terminals 28 and B. to
Complete the repair? Step
21
21 Clear the DTC by the scanning tool. Go System
When the conditions for setting DTC are met, is the to OK
DTC reset? Step
1

C0022- Input Signal Value of Right Front Wheel Speed Sensor Equal to 0
Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTCs.
Conditions for Setting DTC
So far as setting DTC C0022, the following conditions are indispensable.
1. DTC C0032, or C0033, or C0034, or C0035 does not appear right now,
2. The ABS becomes inoperative,
3. The brake switch is turned off, and
 Benjoy Maintenance Manual — Chassis Volume ABS-36

4. The value shown by right front wheel speed senor is equal to 0, whereas that
indicated by other rest wheel speed sensors is higher than 8km/h (5 mile/h) in 2.5
second at least.
Actions for Setting DTC
1. DTC C0022 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0022 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from the
historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short, or
contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping performance
of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.

C0022- Input Signal Value of Right Front Wheel Speed Sensor Equal to 0
Step Diagnostic Action Expected
Yes No
Value
1 Complete the diagnostic circuit check? Go to
Go to
Step
Step 2
12
2 1. Extinct the engine.
2. Check whether the right front wheel speed sensor, the Go to
Go to
wire harness, and the gear ring suffer from the physical Step
Step 3
damage. 13
Is any physical damage found out?
3 Set DTC C0033 as a current code or a historical code? Go to
Go to
Step
Step 4
14
4 1. Connect the scanning tool, and select data lists.
2. Monitor the wheel speed sensor.
3. Test the vehicle at a speed of 24 km/h (15 mile/h), and Go to
Go to
then gradually reduce the vehicle speed to 0. Repeat Step
Step 5
such an action for several times. 15
Is DTC C0022 reset? Or does the speed of right front wheel
abruptly fall to 0 before the vehicle completely stops?
5 1. Extinct the engine. No less than
2. Jack up and moderately support the vehicle. 100mV
3. Disconnect the ECU wire harness from the ECU. Go to
Go to
4. Connect the voltmeter with ECU wire harness terminals Step
Step 6
24 and 39. 16
5. Select the scale of AC millivolt.
6. Rotate the right front wheel and observe the voltmeter.
 Benjoy Maintenance Manual — Chassis Volume ABS-37

(The voltage shall increase, as the wheel speed rises.)

Is the AC voltage value within the specified range?
6 1. Disconnect the right front crossover wire harness from 800~1,600Ω
the right front wheel speed sensor. (the
2. Connect the ohmmeter with two terminals of right front resistance
wheel speed sensor. changes, Go to
Go to
Is the resistance value within the specified range? subject to the Step
Step 7
temperature 17
and the
requirement
of customer.)
7 1. Keep the right front crossover wire harness No less than
disconnected from the right front wheel speed sensor. 100mV
2. Connect the voltmeter with two terminals of right front
Go to
wheel speed sensor. Go to
Step
3. Select the scale of AC millivolt. Step 8
17
4. Rotate the right front wheel and observe the voltmeter.
(The voltage shall increase, as the wheel speed rises.)
Is the AC voltage value within the specified range?
8 1. Disconnect the right front crossover wire harness from OL (open
the ABS module wire harness. circuit)
2. Keep the ECU wire harness disconnected from the Go to
Go to
ECU. Step
Step 9
3. Connect the ohmmeter with ECU wire harness 18
terminals 24 and 39.
Is the resistance value is within the specified range?
9 1. Keep the ECU wire harness disconnected from the Less than 2Ω
ECU.
2. Keep the right front wire harness disconnected from the Go to Go to
ABS module wire harness. Step Step
3. Connect the ohmmeter with ECU wire harness terminal 10 19
39, and then with ABS module wire harness terminal A.
Is the resistance value is within the specified range?
10 1. Keep the ECU wire harness disconnected from the Less than 2Ω
ECU.
2. Keep the right front wire harness disconnected from the Go to Go to
ABS module wire harness. Step Step
3. Connect the ohmmeter with ECU wire harness terminal 11 20
24, and then with ABS module wire harness terminal B.
Is the resistance value is within the specified range?
11 1. Replace the right front wheel speed crossover wire
harness. Go to
System
2. Test the vehicle at different kinds of speed on various Step
OK
roads. 16
Is DTC C0022 reset?
12 Before carrying out the fault tree analysis, execute the
diagnostic circuit check.
13 Repair the damaged right front wheel speed sensor, the Go to
crossover wire harness and/or gear ring. Step
Complete the repair? 21
14 Before executing diagnosis steps listed in this table,
diagnose DTC C0033.
15 The DTC C0021 is intermittent. See the Diagnosis Help.
16 Replace the ECU. Go to
Complete the repair? Step
21
17 Replace the right front wheel speed sensor. Go to
Complete the repair? Step
21
18 Find and repair the trouble of short circuit between these Go to
two circuits. Step
Complete the repair? 21
19 Repair the open circuit or the high resistance between Go to
terminals 39 and A. Step
Complete the repair? 21
20 Repair the open circuit or the high resistance between Go to
 Benjoy Maintenance Manual — Chassis Volume ABS-38

terminals 24 and B. Step

Complete the repair? 21
21 Clear the DTC by the scanning tool.
Go to System
When the conditions for setting DTC are met, is the DTC
Step 1 OK
reset?

C0023- Input Signal Value of Left Rear Wheel Speed Sensor Equal to 0
Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTCs.
Conditions for Setting DTC
So far as setting DTC C0023, the following conditions are indispensable.
1. DTC C0032, or C0033, or C0034, or C0035 does not appear right now,
2. The ABS becomes inoperative,
3. The brake switch is turned off, and
4. The value shown by left rear wheel speed senor is equal to 0, whereas that indicated
by other rest wheel speed sensors is higher than 8km/h (5 mile/h) in 2.5 second at
least.
Actions for Setting DTC
1. DTC C00023 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0023 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short,
or contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping
performance of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.

C0023- Input Signal Value of Left Rear Wheel Speed Sensor Equal to 0
Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go Go to
 Benjoy Maintenance Manual — Chassis Volume ABS-39

to Step 12
Step
2
2 1. Extinct the engine. Go Go to
2. Check whether the left rear wheel speed sensor, the to Step 3
wire harness, and the gear ring suffer from the physical Step
damage. 13
Is any physical damage found out?
3 Set DTC C0034 as a current code or a historical code? Go Go to
to Step 4
Step
14
4 1. Connect the scanning tool, and select data lists. Go Go to
2. Monitor the wheel speed sensor. to Step 15
3. Test the vehicle at a speed of 24 km/h (15 mile/h), and Step
then gradually reduce the vehicle speed to 0. Repeat 5
such an action for several times.
Is DTC C0023 reset? Or does the speed of left rear wheel
abruptly fall to 0 before the vehicle completely stops?
5 1. Extinct the engine. No less than Go Go to
2. Jack up and moderately support the vehicle. 100mV to Step 6
3. Disconnect the ECU wire harness from the ECU. Step
4. Connect the voltmeter with ECU wire harness terminals 16
13 and 12.
5. Select the scale of AC millivolt.
6. Rotate the left rear wheel and observe the voltmeter.
(The voltage shall increase, as the wheel speed rises.)
Is the AC voltage value within the specified range?
6 1. Disconnect the left rear crossover wire harness from the 800~1,600Ω Go Go to
left rear wheel speed sensor. (the to Step 17
2. Connect the ohmmeter with two terminals of left rear resistance Step
wheel speed sensor. changes, 7
Is the resistance value within the specified range? subject to the
temperature
and the
requirement
of customer.)
7 1. Keep the left rear crossover wire harness disconnected No less than Go Go to
from the left rear wheel speed sensor. 100mV to Step 17
2. Connect the voltmeter with two terminals of left rear Step
wheel speed sensor. 8
3. Select the scale of AC millivolt.
4. Rotate the left rear wheel and observe the voltmeter.
(The voltage shall increase, as the wheel speed rises.)
Is the AC voltage value within the specified range?
8 1. Disconnect the left rear crossover wire harness from the OL (open Go Go to
ABS module wire harness. circuit) to Step 18
2. Keep the ECU wire harness disconnected from the ECU. Step
3. Connect the ohmmeter with ECU wire harness terminals 9
13 and 12.
Is the resistance value is within the specified range?
9 1. Keep the ECU wire harness disconnected from the ECU. Less than 2Ω Go Go to
2. Keep the left rear wire harness disconnected from the to Step 19
ABS module wire harness. Step
3. Connect the ohmmeter with ECU wire harness terminal 10
12, and then with ABS module wire harness terminal A.
Is the resistance value is within the specified range?
10 1. Keep the ECU wire harness disconnected from the ECU. Less than 2Ω Go Go to
2. Keep the left rear wire harness disconnected from the to Step 20
ABS module wire harness. Step
3. Connect the ohmmeter with ECU wire harness terminal 11
13, and then with ABS module wire harness terminal B.
Is the resistance value is within the specified range?
11 1. Replace the left rear wheel speed crossover wire Go System
harness. to OK
2. Test the vehicle at different kinds of speed on various Step
roads. 16
Is DTC C0023 reset?
12 Before carrying out the fault tree analysis, execute the
 Benjoy Maintenance Manual — Chassis Volume ABS-40

diagnostic circuit check.

13 Repair the damaged left rear wheel speed sensor, the Go
crossover wire harness and/or gear ring. to
Complete the repair? Step
21
14 Before executing diagnosis steps listed in this table,
diagnose DTC C0034
15 The DTC C0023 is intermittent. See the Diagnosis Help.
16 Replace the ECU. Go
Complete the repair? to
Step
21
17 Replace the left rear wheel speed sensor. Go
Complete the repair? to
Step
21
18 Find and repair the trouble of short circuit between these two Go
circuits. to
Complete the repair? Step
21
19 Repair the open circuit or the high resistance between Go
terminals 12 and A. to
Complete the repair? Step
21
20 Repair the open circuit or the high resistance between Go
terminals 13 and B. to
Complete the repair? Step
21
21 Clear the DTC by the scanning tool. Go System
When the conditions for setting DTC are met, is the DTC to OK
reset? Step
1

C0024- Input Signal Value of Right Rear Wheel Speed Sensor Equal to 0
Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTCs.
Conditions for Setting DTC
So far as setting DTC C0024, the following conditions are indispensable.
1. DTCs C0032, or C0033, or C0034, or C0035 does not appear right now,
2. The ABS becomes inoperative,
3. The brake switch is turned off, and
4. The value shown by left rear wheel speed senor is equal to 0, whereas that indicated
by other rest wheel speed sensors is higher than 8km/h (5 mile/h) in 2.5 second at
least.
Actions for Setting DTC
1. DTC C00024 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0024 no longer exist, it is available to clear the DTC
 Benjoy Maintenance Manual — Chassis Volume ABS-41

by the corresponding scanning tool.

2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from the
historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short, or
contaminated,
2. Check whether terminals are distorted and damaged, and
3. Use the reserved anodic/cathodic terminals to check whether terminals connected with
leads are correct.

C0024- Input Signal Value of Right Rear Wheel Speed Sensor Equal to 0
Ste Diagnostic Action Expected Yes No
p Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step
12
2 1. Extinct the engine. Go to Go to
2. Check whether the right rear wheel speed sensor, the wire Step 13 Step 3
harness, and the gear ring suffer from the physical damage.
Is any physical damage found out?
3 Set DTC C0035 as a current code or a historical code? Go to Go to
Step 14 Step 4
4 1. Connect the scanning tool, and select data lists. Go to Go to
2. Monitor the wheel speed sensor. Step 5 Step
3. Test the vehicle at a speed of 24 km/h (15 mile/h), and then 15
gradually reduce the vehicle speed to 0. Repeat such an
action for several times.
Is DTC C0024 reset? Or does the speed of right rear wheel
abruptly fall to 0 before the vehicle completely stops?
5 1. Extinct the engine. No less Go to Go to
2. Jack up and moderately support the vehicle. than Step 16 Step 6
3. Disconnect the ECU wire harness from the ECU. 100mV
4. Connect the voltmeter with ECU wire harness terminals 42
and 43.
5. Select the scale of AC milivolt.
6. Rotate the right rear wheel and observe the voltmeter. (The
voltage shall increase, as the wheel speed rises.)
Is the AC voltage value within the specified range?
6 1. Disconnect the right rear crossover wire harness from the 800~1,600 Go to Go to
right rear wheel speed sensor. Ω (the Step 7 Step
2. Connect the ohmmeter with two terminals of right rear wheel resistance 17
speed sensor. changes,
Is the resistance value within the specified range? subject to
the
temperatur
e and the
requiremen
t of
customer.)
7 1. Keep the right rear crossover wire harness disconnected No less Go to Go to
from the right rear wheel speed sensor. than Step 8 Step
2. Connect the voltmeter with two terminals of right rear wheel 100mV 17
speed sensor.
3. Select the scale of AC millivolt.
4. Rotate the right rear wheel and observe the voltmeter. (The
voltage shall increase, as the wheel speed rises.)
Is the AC voltage value within the specified range?
8 1. Disconnect the right rear crossover wire harness from the OL (open Go to Go to
 Benjoy Maintenance Manual — Chassis Volume ABS-42

ABS module wire harness. circuit) Step 9 Step

2. Keep the ECU wire harness disconnected from the ECU. 18
3. Connect the ohmmeter with ECU wire harness terminals 42
and 43.
Is the resistance value is within the specified range?
9 1. Keep the ECU wire harness disconnected from the ECU. Less than Go to Go to
2. Keep the right rear wire harness disconnected from the ABS 2Ω Step 10 Step
module wire harness. 19
3. Connect the ohmmeter with ECU wire harness terminal 43,
and then with ABS module wire harness terminal A.
Is the resistance value is within the specified range?
10 1. Keep the ECU wire harness disconnected from the ECU. Less than Go to Go to
2. Keep the right rear wire harness disconnected from the ABS 2Ω Step 11 Step
module wire harness. 20
3. Connect the ohmmeter with ECU wire harness terminal 42,
and then with ABS module wire harness terminal B.
Is the resistance value is within the specified range?
11 1. Replace the right rear wheel speed crossover wire harness. Go to Syste
2. Test the vehicle at different kinds of speed on various roads. Step 16 m OK
Is DTC C0024 reset?
12 Before carrying out the fault tree analysis, execute the diagnostic
circuit check.
13 Repair the damaged right rear wheel speed sensor, the crossover Go to
wire harness and/or gear ring. Step 21
Complete the repair?
14 Before executing diagnosis steps listed in this table, diagnose
DTC C0035.
15 The DTC C0024 is intermittent. See the Diagnosis Help.
16 Replace the ECU. Go to
Complete the repair? Step 21
17 Replace the right rear wheel speed sensor. Go to
Complete the repair? Step 21
18 Find and repair the trouble of short circuit between these two Go to
circuits. Step 21
Complete the repair?
19 Repair the open circuit or the high resistance between terminals Go to
43 and A. Step 21
Complete the repair?
20 Repair the open circuit or the high resistance between terminals Go to
42 and B. Step 21
Complete the repair?
21 Clear the DTC by the scanning tool. Go to Syste
When the conditions for setting DTC are met, is the DTC reset? Step 1 m OK

C0025- Left Front Wheel Speed Sensor under Excessive Change

Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTC.
Conditions for Setting DTC
So far as setting DTC C0025, the following conditions are indispensable.
1. DTC C0032, or C0033, or C0034, or C0035 does not appear right now,
2. The brake switch is turned off, and
3. The acceleration or deceleration of left front wheel is beyond the reasonable limit.
Actions for Setting DTC
1. DTC C00025 is saved,
2. The ABS becomes inoperative, and
 Benjoy Maintenance Manual — Chassis Volume ABS-43

3. The ABS alarm lamp is turned on.

Conditions for Clearing DTC
1. If the conditions for setting DTC C0025 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short,
or contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping
performance of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.

C0025- Left Front Wheel Speed Sensor with Excessive Change

Ste Diagnostic Action Expected Yes No
p Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 step
12
2 Set DTC C0032 as a current DTC or a historical DTC? Go to Go to
Step 13 Step 3
3 1. Extinct the engine. Go to Go to
2. Check whether the left front wheel speed sensor and the Step 14 Step 4
crossover wire harness are damaged.
3. Thoroughly and fully check the left front gear ring to see
whether it is damaged (creviced, tooth-lost, and loose)
Is any physical damage found out?
4 1. Park the vehicle. Go to Go to
2. Connect the scanning tool, and select data lists. Step 15 Step 5
3. Monitor the wheel speed sensor.
4. Drive the vehicle, and monitor the wheel speed sensor
under the condition that the engine runs but the vehicle
does not move.
5. Lightly tread the throttle pedal to raise the idle running
speed of engine.
Is the DTC C0025 reset? Or in the presence of running engine
and unmoving vehicle, is the speed reading of left front wheel
over 0km/h?
5 1. Keep the scanning tool connected. Go to Go to
2. Monitor the wheel speed sensor. Step 6 Step
3. Test the vehicle by accelerating to the maximum speed 16
and then gradually decelerating to 0. Repeat this action for
several times.
Is the DTC C0025 reset? Or during the driving, is the speed
change of left front wheel, compared that of any one amongst
the rest wheels, is over 5km/h (3mile/h)?
6 1. Park the vehicle and extinct the engine. 800~1,600Ω Go to Go to
2. Jack up and moderately support the vehicle. (the Step 7 Step
3. Disconnect the left front crossover wire harness from the resistance 17
left front wheel speed sensor. changes,
4. Connect the ohmmeter with two terminals of left front subject to
wheel speed sensor. the
 Benjoy Maintenance Manual — Chassis Volume ABS-44

Is the resistance value within the specified range? temperature

and the
requirement
of customer.)
7 1. Keep the crossover wire harness disconnected from the No less than Go to Go to
wheel speed sensor. 100mV Step 8 Step
2. Connect the voltmeter with two terminals of left front wheel 17
speed sensor.
3. Select the scale of AC millivolt.
4. Rotate the left front wheel, and observe the voltage
displayed on voltmeter.
Is the AC voltage value within the specified range?
8 1. Disconnect the ECU wire harness from the ECU. Less than Go to Go to
2. Disconnect the left front crossover wire harness from the 2Ω Step 9 Step
ABS module wire harness. 18
3. Connect the ohmmeter with ECU wire harness terminal 28,
and then with ABS module wire harness terminal B.
Is the resistance value within the specified range?
9 1. Keep the ECU wire harness disconnected from the ECU. Less than Go to Go to
2. Keep the crossover wire harness disconnected from the 2Ω Step 10 Step
ABS module wire harness. 19
3. Connect the ohmmeter with ECU wire harness terminal 27,
and then with ABS module wire harness terminal A.
Is the resistance value within the specified range?
10 1. Keep the ECU wire harness disconnected from the ECU. OL (open Go to Go to
2. Keep the crossover wire harness disconnected from the circuit) Step 11 Step
ABS module wire harness. 20
3. Connect the ohmmeter with ECU wire harness terminals
27 and 28.
Is the resistance value within the specified range?
11 1. Replace the left front crossover wire harness. Go to Syste
2. Test the vehicle at different speeds on various roads. Step 21 m OK
Is DTC C0025 reset?
12 Execute the diagnostic circuit check before making the trouble
diagram for DTC C0025.
13 Prepare the diagnosis diagram for DTC C0032 before making
the trouble diagram for DTC 0025.
14 Repair the damage left front wheel speed sensor, the crossover Go to
wire harness and/or the gear ring. Step 22
Complete the repair?
15 The reason to DTC C0025 is that the ignition noise coupling Go to
has been induced to the circuit of left front wheel speed sensor. Step 22
Check whether the ABS module wire harness and/or the left
front crossover wire harness have potential ignition noise
sources, such as the conducting wires of spark plug. Lay out
the conducting wires again, as the case may be.
Complete the repair?
16 DTC C0025 is intermittent. See the Diagnosis Help.
17 Replace the left front wheel speed sensor. Go to
Complete the repair? Step 22
18 Repair the open circuit or high resistance between terminals 28 Go to
and B. Step 22
Complete the repair?
19 Repair the open circuit or high resistance between terminals 27 Go to
and A. Step 22
Complete the repair?
20 Repair the short circuit between two conducting wires. Go to
Complete the repair? Step 22
21 Replace the ECU. Go to
Complete the repair? Step 22
22 Clear the DTC by the scanning tool. Go to Syste
When the conditions for setting DTC C0025 are met, is this Step 1 m OK
DTC reset?

C0026- Right Front Wheel Speed Sensor under Excessive Change

Circuit Description
 Benjoy Maintenance Manual — Chassis Volume ABS-45

During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTCs.
Conditions for Setting DTC
So far as setting DTC C0026, the following conditions are indispensable.
1. DTC C0032, or C0033, or C0034, or C0035 does not appear right now,
2. The brake switch is turned off, and
3. The acceleration or deceleration of right front wheel is beyond the reasonable limit.
Actions for Setting DTC
1. DTC C00026 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0026 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short,
or contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping
performance of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.
 Benjoy Maintenance Manual — Chassis Volume ABS-46

C0026- Right Front Wheel Speed Sensor with Excessive Change

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 step 12
2 Set DTC C0033 as a current DTC or a historical DTC? Go to Go to
Step 13 Step 3
3 1. Extinct the engine. Go to Go to
2. Check whether the right front wheel speed sensor and Step 14 Step 4
the crossover wire harness are damaged.
3. Thoroughly and fully check the right front gear ring to
see whether it is damaged (creviced, tooth-lost, and
loose)
Is any physical damage found out?
4 1. Park the vehicle. Go to Go to
2. Connect the scanning tool, and select data lists. Step 15 Step 5
3. Monitor the wheel speed sensor.
4. Drive the vehicle, and monitor the wheel speed
sensor under the condition that the engine runs but
the vehicle does not move.
5. Lightly tread the throttle pedal to raise the idle running
speed of engine.
Is the DTC C0026 reset? Or in the presence of running
engine and unmoving vehicle, is the speed reading of right
front wheel over 0km/h?
5 1. Keep the scanning tool connected. Go to Go to
2. Monitor the wheel speed sensor. Step 6 Step
3. Test the vehicle by accelerating to the maximum 16
speed and then gradually decelerating to 0. Repeat
this action for several times.
Is the DTC C0026 reset? Or during the driving, is the
speed change of right front wheel, compared that of any
one amongst the rest wheels, is over 5km/h (3mile/h)?
6 1. Park the vehicle and extinct the engine. 800~1,600Ω Go to Go to
2. Jack up and moderately support the vehicle. (the Step 7 Step
3. Disconnect the right front crossover wire harness from resistance 17
the right front wheel speed sensor. changes,
4. Connect the ohmmeter with two terminals of right front subject to the
wheel speed sensor. temperature
Is the resistance value within the specified range? and the
requirement
of customer.)
7 1. Keep the crossover wire harness disconnected from No less than Go to Go to
the wheel speed sensor. 100mV Step 8 Step
2. Connect the voltmeter with two terminals of right front 17
wheel speed sensor.
3. Select the scale of AC millivolt.
4. Rotate the right front wheel, and observe the voltage
displayed on voltmeter.
Is the AC voltage value within the specified range?
8 1. Disconnect the ECU wire harness from the ECU. Less than 2Ω Go to Go to
2. Disconnect the right front crossover wire harness from Step 9 Step
the ABS module wire harness. 18
3. Connect the ohmmeter with ECU wire harness
terminal 24, and then with ABS module wire harness
 Benjoy Maintenance Manual — Chassis Volume ABS-47

terminal B.
Is the resistance value within the specified range?
9 1. Keep the ECU wire harness disconnected from the Less than 2Ω Go to Go to
ECU. Step 10 Step
2. Keep the crossover wire harness disconnected from 19
the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminal 39, and then with ABS module wire harness
terminal A.
Is the resistance value within the specified range?
10 1. Keep the ECU wire harness disconnected from the OL (open Go to Go to
ECU. circuit) Step 11 Step
2. Keep the crossover wire harness disconnected from 20
the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 24 and 39.
Is the resistance value within the specified range?
11 1. Replace the right front crossover wire harness. Go to System
2. Test the vehicle at different speeds on various roads. Step 21 OK
Is DTC C0026 reset?
12 Execute the diagnostic circuit check before making the
trouble diagram for DTC C0026.

13 Prepare the diagnosis diagram for DTC C0033 before

making the trouble diagram for DTC 0026.
14 Repair the damage right front wheel speed sensor, the Go to
crossover wire harness and/or the gear ring. Step 22
Complete the repair?
15 The reason to DTC C0026 is that the ignition noise Go to
coupling has been induced to the circuit of right front Step 22
wheel speed sensor.
Check whether the ABS module wire harness and/or the
right front crossover wire harness have potential ignition
noise sources, such as the conducting wires of spark plug.
Lay out the conducting wires again, as the case may be.
Complete the repair?
16 DTC C0026 is intermittent. See the Diagnosis Help.
17 Replace the right front wheel speed sensor. Go to
Complete the repair? Step 22
18 Repair the open circuit or high resistance between Go to
terminals 24 and B. Step 22
Complete the repair?
19 Repair the open circuit or high resistance between Go to
terminals 39 and A. Step 22
Complete the repair?
20 Repair the short circuit between two conducting wires. Go to
Complete the repair? Step 22
21 Replace the ECU. Go to
Complete the repair? Step 22
22 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0026 are met, is Step 1 OK
this DTC reset?
Benjoy Maintenance Manual — Chassis Volume ABS-48
 Benjoy Maintenance Manual — Chassis Volume ABS-49

C0027- Left Rear Wheel Speed Sensor under Excessive Change

Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTCs.
Conditions for Setting DTC
So far as setting DTC C0027, the following conditions are indispensable.
1. DTC C0032, or C0033, or C0034, or C0035 does not appear right now,
2. The brake switch is turned off, and
3. The acceleration or deceleration of left rear wheel is beyond the reasonable limit.
Actions for Setting DTC
1. DTC C00027 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0027 no longer exist, it is available to clear the
DTC by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short,
or contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping
performance of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.
 Benjoy Maintenance Manual — Chassis Volume ABS-50

C0027- Left Rear Wheel Speed Sensor with Excessive Change

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 step 12
2 Set DTC C0034 as a current DTC or a historical DTC? Go to Go to
Step 13 Step 3
3 1. Extinct the engine. Go to Go to
2. Check whether the left rear wheel speed sensor and Step 14 Step 4
the crossover wire harness are damaged.
3. Thoroughly and fully check the left rear gear ring to
see whether it is damaged (creviced, tooth-lost, and
loose)
Is any physical damage found out?
4 1. Park the vehicle. Go to Go to
2. Connect the scanning tool, and select data lists. Step 15 Step 5
3. Monitor the wheel speed sensor.
4. Drive the vehicle, and monitor the wheel speed sensor
under the condition that the engine runs but the vehicle
does not move.
5. Lightly tread the throttle pedal to raise the idle running
speed of engine.
Is the DTC C0027 reset? Or in the presence of running
engine and unmoving vehicle, is the speed reading of left
rear wheel over 0km/h?
5 1. Keep the scanning tool connected. Go to Go to
2. Monitor the wheel speed sensor. Step 6 Step
3. Test the vehicle by accelerating to the maximum speed 16
and then gradually decelerating to 0. Repeat this action
for several times.
Is the DTC C0027 reset? Or during the driving, is the
speed change of left rear wheel, compared that of any
one amongst the rest wheels, is over 5km/h (3mile/h)?
6 1. Park the vehicle and extinct the engine. 800~1,600Ω Go to Go to
2. Jack up and moderately support the vehicle. (the resistance Step 7 Step
3. Disconnect the left rear crossover wire harness from changes, 17
the left rear wheel speed sensor. subject to the
4. Connect the ohmmeter with two terminals of left rear temperature
wheel speed sensor. and the
Is the resistance value within the specified range? requirement of
customer.)
7 1. Keep the crossover wire harness disconnected from No less than Go to Go to
the wheel speed sensor. 100mV Step 8 Step
2. Connect the voltmeter with two terminals of left rear 17
wheel speed sensor.
3. Select the scale of AC millivolt.
4. Rotate the left rear wheel, and observe the voltage
displayed on voltmeter.
Is the AC voltage value within the specified range?
8 1. Disconnect the ECU wire harness from the ECU. Less than 2Ω Go to Go to
2. Disconnect the left rear crossover wire harness from Step 9 Step
the ABS module wire harness. 18
3. Connect the ohmmeter with ECU wire harness
terminal 12, and then with ABS module wire harness
terminal B.
 Benjoy Maintenance Manual — Chassis Volume ABS-51

Is the resistance value within the specified range?

9 1. Keep the ECU wire harness disconnected from the Less than 2Ω Go to Go to
ECU. Step 10 Step
2. Keep the crossover wire harness disconnected from 19
the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminal 13, and then with ABS module wire harness
terminal A.
Is the resistance value within the specified range?
10 1. Keep the ECU wire harness disconnected from the OL (open Go to Go to
ECU. circuit) Step 11 Step
2. Keep the crossover wire harness disconnected from 20
the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 12 and 13.
Is the resistance value within the specified range?
11 1. Replace the left rear crossover wire harness. Go to System
2. Test the vehicle at different speeds on various roads. Step 21 OK
Is DTC C0026 reset?
12 Execute the diagnostic circuit check before making the
trouble diagram for DTC C0026.
13 Prepare the diagnosis diagram for DTC C0034 before
making the trouble diagram for DTC 0027.
14 Repair the damage left rear wheel speed sensor, the Go to
crossover wire harness and/or the gear ring. Step 22
Complete the repair?
15 The reason to DTC C0027 is that the ignition noise Go to
coupling has been induced to the circuit of left rear wheel Step 22
speed sensor.
Check whether the ABS module wire harness and/or the
left rear crossover wire harness have potential ignition
noise sources, such as the conducting wires of spark
plug. Lay out the conducting wires again, as the case
may be.
Complete the repair?
16 DTC C0027 is intermittent. See the Diagnosis Help.
17 Replace the left rear wheel speed sensor. Go to
Complete the repair? Step 22
18 Repair the open circuit or high resistance between Go to
terminals 12 and B. Step 22
Complete the repair?
19 Repair the open circuit or high resistance between Go to
terminals 13 and A. Step 22
Complete the repair?
20 Repair the short circuit between two conducting wires. Go to
Complete the repair? Step 22
21 Replace the ECU. Go to
Complete the repair? Step 22
22 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0027 are met, is Step 1 OK
this DTC reset?
Benjoy Maintenance Manual — Chassis Volume ABS-52
 Benjoy Maintenance Manual — Chassis Volume ABS-53

C0028- Right Rear Wheel Speed Sensor under Excessive Change

Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTC.
Conditions for Setting DTC
So far as setting DTC C0028, the following conditions are indispensable.
1. DTC C0032, or C0033, or C0034, or C0035 does not appear right now,
2. The brake switch is turned off, and
3. The acceleration or deceleration of right rear wheel is beyond the reasonable limit.
Actions for Setting DTC
1. DTC C00028 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0028 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from the
historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short,
or contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping
performance of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.
 Benjoy Maintenance Manual — Chassis Volume ABS-54

C0028- Right Rear Wheel Speed Sensor with Excessive Change

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 step 12
2 Set DTC C0035 as a current DTC or a historical DTC? Go to Go to
Step 13 Step 3
3 1. Extinct the engine. Go to Go to
2. Check whether the right rear wheel speed sensor and Step 14 Step 4
the crossover wire harness are damaged.
3. Thoroughly and fully check the right rear gear ring to
see whether it is damaged (creviced, tooth-lost, and
loose)
Is any physical damage found out?
4 1. Park the vehicle. Go to Go to
2. Connect the scanning tool, and select data lists. Step 15 Step 5
3. Monitor the wheel speed sensor.
4. Drive the vehicle, and monitor the wheel speed
sensor under the condition that the engine runs but the
vehicle does not move.
5. Lightly tread the throttle pedal to raise the idle
running speed of engine.
Is the DTC C0028 reset? Or in the presence of running
engine and unmoving vehicle, is the speed reading of
right rear wheel over 0km/h?
5 1. Keep the scanning tool connected. Go to Go to
2. Monitor the wheel speed sensor. Step 6 Step
3. Test the vehicle by accelerating to the maximum 16
speed and then gradually decelerating to 0. Repeat this
action for several times.
Is the DTC C0028 reset? Or during the driving, is the
speed change of right rear wheel, compared that of any
one amongst the rest wheels, is over 5km/h (3mile/h)?
6 1. Park the vehicle and extinct the engine. 800~1,600Ω Go to Go to
2. Jack up and moderately support the vehicle. (the resistance Step 7 Step
3. Disconnect the right rear crossover wire harness from changes, 17
the right rear wheel speed sensor. subject to the
4. Connect the ohmmeter with two terminals of right temperature
rear wheel speed sensor. and the
Is the resistance value within the specified range? requirement of
customer.)
7 1. Keep the crossover wire harness disconnected from No less than Go to Go to
the wheel speed sensor. 100mV Step 8 Step
2. Connect the voltmeter with two terminals of right rear 17
wheel speed sensor.
3. Select the scale of AC millivolt.
4. Rotate the right rear wheel, and observe the voltage
displayed on voltmeter.
Is the AC voltage value within the specified range?
8 1. Disconnect the ECU wire harness from the ECU. Less than 2Ω Go to Go to
2. Disconnect the right rear crossover wire harness from Step 9 Step
the ABS module wire harness. 18
3. Connect the ohmmeter with ECU wire harness
terminal 43, and then with ABS module wire harness
terminal B.
 Benjoy Maintenance Manual — Chassis Volume ABS-55

Is the resistance value within the specified range?

9 1. Keep the ECU wire harness disconnected from the Less than 2Ω Go to Go to
ECU. Step 10 Step
2. Keep the crossover wire harness disconnected from 19
the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminal 42, and then with ABS module wire harness
terminal A.
Is the resistance value within the specified range?
10 1. Keep the ECU wire harness disconnected from the OL (open Go to Go to
ECU. circuit) Step 11 Step
2. Keep the crossover wire harness disconnected from 20
the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 43 and 42.
Is the resistance value within the specified range?
11 1. Replace the right rear crossover wire harness. Go to System
2. Test the vehicle at different speeds on various roads. Step 21 OK
Is DTC C0028 reset?
12 Execute the diagnostic circuit check before making the
trouble diagram for DTC C0028.
13 Prepare the diagnosis diagram for DTC C0035 before
making the trouble diagram for DTC 0028.
14 Repair the damage right rear wheel speed sensor, the Go to
crossover wire harness and/or the gear ring. Step 22
Complete the repair?
15 The reason to DTC C0028 is that the ignition noise Go to
coupling has been induced to the circuit of right rear Step 22
wheel speed sensor.
Check whether the ABS module wire harness and/or
the right rear crossover wire harness have potential
ignition noise sources, such as the conducting wires of
spark plug. Lay out the conducting wires again, as the
case may be.
Complete the repair?
16 DTC C0028 is intermittent. See the Diagnosis Help.
17 Replace the right rear wheel speed sensor. Go to
Complete the repair? Step 22
18 Repair the open circuit or high resistance between Go to
terminals 43 and B. Step 22
Complete the repair?
19 Repair the open circuit or high resistance between Go to
terminals 42 and A. Step 22
Complete the repair?
20 Repair the short circuit between two conducting wires. Go to
Complete the repair? Step 22
21 Replace the ECU. Go to
Complete the repair? Step 22
22 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0028 are met, is Step 1 OK
this DTC reset?
Benjoy Maintenance Manual — Chassis Volume ABS-56
 Benjoy Maintenance Manual — Chassis Volume ABS-57

C0032- Left Front Wheel Speed Sensor under Open or Short Circuit
Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTCs.

Conditions for Setting DTC

After the ignition, DTC C0032 can be set as long as the ECU finds that the left front wheel
speed sensor is open circuited, or short circuited against the ground or the storage
battery.

Actions for Setting DTC

1. DTC C00032 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0032 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short,
or contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping
performance of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.
 Benjoy Maintenance Manual — Chassis Volume ABS-58

C0032- Left Front Wheel Speed Sensor under Open or Short Circuit
Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Step Go to
2 Step
14
2 1. Extinct the engine. Go to Step Go to
2. Check whether the left front wheel speed sensor, 15 Step 3
the crossover wire harness and the gear ring suffer
from physical damage.
Is any physical damage found out?
3 Test the vehicle at different speeds on various roads. Go to Step Go to
Is DTC C0032 reset? 4 Step
16
4 1. Park the vehicle and extinct the engine. 800~1,600Ω Go to Step Go to
2. Jack up and moderately support the vehicle. (the 5 Step
3. Disconnect the left front crossover wire harness resistance 17
from the left front wheel speed sensor. changes,
4. Connect the ohmmeter with terminals A and B of subject to the
left front wheel speed sensor. temperature
Is the resistance value within the specified range? and the
requirement
of customer.)
5 1. Keep the left front crossover wire harness OL (open Go to Step Go to
disconnected from the wheel speed sensor. circuit) 6 Step
2. Connect the ohmmeter with terminal A of left front 17
wheel speed sensor, and then with the grounding
of vehicle body.
Is the resistance value within the specified range?
6 1. Disconnect the ECU wire harness from the ECU. Less than 2Ω Go to Step Go to
2. Disconnect the left front crossover wire harness 7 Step
from the ABS module wire harness. 18
3. Connect the ohmmeter with ECU wire harness
terminal 28, and then with ABS module wire
harness terminal B.
Is the resistance value within the specified range?
7 1. Keep the ECU wire harness disconnected from the Less than 2Ω Go to Step Go to
ECU. 8 Step
2. Keep the left front crossover wire harness 19
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 27, and then with ABS module wire
harness terminal A.
Is the resistance value within the specified range?
8 1. Keep the ECU wire harness disconnected from the Less than 1V Go to Step Go to
ECU. 9 Step
2. Keep the left front crossover wire harness 20
disconnected from the ABS module wire harness.
3. Connect the voltmeter with ECU wire harness
terminals 28, and then with grounding of vehicle
body
Is the voltage value within the specified range?
9 1. Keep the ECU wire harness disconnected from the Less than 1V Go to Step Go to
ECU. 10 Step
2. Keep the left front crossover wire harness 21
disconnected from the ABS module wire harness.
 Benjoy Maintenance Manual — Chassis Volume ABS-59

3. Connect the voltmeter with ECU wire harness

terminals 27, and then with grounding of vehicle
body
Is the voltage value within the specified range?
10 1. Keep the ECU wire harness disconnected from the OL (open Go to Step Go to
ECU. circuit) 11 Step
2. Keep the left front crossover wire harness 22
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 28, and then with grounding of vehicle
body
Is the resistance value within the specified range?
11 1. Keep the ECU wire harness disconnected from the OL (open Go to Step Go to
ECU. circuit) 12 Step
2. Keep the left front crossover wire harness 23
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 27, and then with grounding of vehicle
body
Is the resistance value within the specified range?
12 1. Keep the ECU wire harness disconnected from the OL (open Go to Step Go to
ECU. circuit) 13 Step
2. Keep the left front crossover wire harness 24
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 28 and 27.
Is the resistance value within the specified range?
13 1. Replace the left front wheel speed crossover wire Go to Step System
harness. 25 OK
2. Test the vehicle at different speeds on various
roads.
Is DTC C0032 reset?
14 Execute the diagnostic circuit check.
15 Repair the damaged left front wheel speed sensor, the Go to Step
crossover wire harness and/or the gear ring. 26
Complete the repair?
16 DTC C0032 is intermittent. See the Diagnosis Help.
17 Replace the left front wheel speed sensor. Go to Step
Complete the repair? 26
18 Repair the open circuit or the high resistance between Go to Step
terminals 28 and B. 26
Complete the repair?
19 Repair the open circuit or the high resistance between Go to Step
terminals 27 and A. 26
Complete the repair?
20 Repair the short circuit of voltage between terminals 28 Go to Step
and B. 26
Complete the repair?
21 Repair the short circuit of voltage between terminals 27 Go to Step
and A. 26
Complete the repair?
22 Repair the short circuit of grounding between terminals Go to Step
28 and B. 26
Complete the repair?
23 Repair the short circuit of grounding between terminals Go to Step
27 and A. 26
Complete the repair?
 Benjoy Maintenance Manual — Chassis Volume ABS-60

24 Repair the short circuit between two circuits. Go to Step

Complete the repair? 26
25 Replace the ECU. Go to Step
Complete the repair? 26
26 Clear the DTC by the scanning tool. Go to Step System
When the conditions for setting DTC C0032 are met, is 1 OK
this DTC reset?
 Benjoy Maintenance Manual — Chassis Volume ABS-61

C0033- Right Front Wheel Speed Sensor under Open or Short Circuit
Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTC.
Conditions for Setting DTC
After the ignition, DTC C0033 can be set as long as the ECU finds that the right front
wheel speed sensor is open circuited, or short circuited against the ground or the storage
battery.
Actions for Setting DTC
1. DTC C00033 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0033 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short,
or contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping
performance of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.
 Benjoy Maintenance Manual — Chassis Volume ABS-62

C0033- Right Front Wheel Speed Sensor under Open or Short Circuit
Step Diagnostic Action Expected Value Yes No
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step
14
2 1. Extinct the engine. Go to Go to
2. Check whether the right front wheel speed sensor, Step 15 Step 3
the crossover wire harness and the gear ring suffer
from physical damage.
Is any physical damage found out?
3 Test the vehicle at different speeds on various roads. Go to Go to
Is DTC C0033 reset? Step 4 Step
16
4 1. Park the vehicle and extinct the engine. 800~1600Ω (the Go to Go to
2. Jack up and moderately support the vehicle. resistance Step 5 Step
3. Disconnect the right front crossover wire harness changes, subject 17
from the right front wheel speed sensor. to the
4. Connect the ohmmeter with terminals A and B of temperature and
right front wheel speed sensor. the requirement
Is the resistance value within the specified range? of customer.)
5 1. Keep the right front crossover wire harness OL (open circuit) Go to Go to
disconnected from the wheel speed sensor. Step 6 Step
2. Connect the ohmmeter with terminal A of right 17
front wheel speed sensor, and then with the
grounding of vehicle body.
Is the resistance value within the specified range?
6 1. Disconnect the ECU wire harness from the ECU. Less than 2Ω Go to Go to
2. Disconnect the right front crossover wire harness Step 7 Step
from the ABS module wire harness. 18
3. Connect the ohmmeter with ECU wire harness
terminal 24, and then with ABS module wire
harness terminal B.
Is the resistance value within the specified range?
7 1. Keep the ECU wire harness disconnected from the Less than 2Ω Go to Go to
ECU. Step 8 Step
2. Keep the right front crossover wire harness 19
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 39, and then with ABS module wire
harness terminal A.
Is the resistance value within the specified range?
8 1. Keep the ECU wire harness disconnected from the Less than 1V Go to Go to
ECU. Step 9 Step
2. Keep the right front crossover wire harness 20
disconnected from the ABS module wire harness.
3. Connect the voltmeter with ECU wire harness
terminals 24, and then with grounding of vehicle
body
Is the voltage value within the specified range?
9 1. Keep the ECU wire harness disconnected from the Less than 1V Go to Go to
ECU. Step 10 Step
2. Keep the right front crossover wire harness 21
disconnected from the ABS module wire harness.
3. Connect the voltmeter with ECU wire harness
terminals 39, and then with grounding of vehicle
body
 Benjoy Maintenance Manual — Chassis Volume ABS-63

Is the voltage value within the specified range?

10 1. Keep the ECU wire harness disconnected from the OL (open circuit) Go to Go to
ECU. Step 11 Step
2. Keep the right front crossover wire harness 22
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 24, and then with grounding of vehicle
body
Is the resistance value within the specified range?
11 1. Keep the ECU wire harness disconnected from the OL (open circuit) Go to Go to
ECU. Step 12 Step
2. Keep the right front crossover wire harness 23
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 39, and then with grounding of vehicle
body.
Is the resistance value within the specified range?
12 1. Keep the ECU wire harness disconnected from the OL (open circuit) Go to Go to
ECU. Step 13 Step
2. Keep the right front crossover wire harness 24
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 24 and 39.
Is the resistance value within the specified range?
13 3. Replace the right front wheel speed crossover wire Go to System
harness. Step 25 OK
4. Test the vehicle at different speeds on various
roads.
Is DTC C0033 reset?
14 Execute the diagnostic circuit check.
15 Repair the damaged right front wheel speed sensor, Go to
the crossover wire harness and/or the gear ring. Step 26
Complete the repair?
16 DTC C0033 is intermittent. See the Diagnosis Help.
17 Replace the right front wheel speed sensor. Go to
Complete the repair? Step 26
18 Repair the open circuit or the high resistance between Go to
terminals 24 and B. Step 26
Complete the repair?
19 Repair the open circuit or the high resistance between Go to
terminals 39 and A. Step 26
Complete the repair?
20 Repair the short circuit of voltage between terminals 24 Go to
and B. Step 26
Complete the repair?
21 Repair the short circuit of voltage between terminals 39 Go to
and A. Step 26
Complete the repair?
22 Repair the short circuit of grounding between terminals Go to
24 and B. Step 26
Complete the repair?
23 Repair the short circuit of grounding between terminals Go to
39 and A. Step 26
Complete the repair?
24 Repair the short circuit between two circuits. Go to
Complete the repair? Step 26
25 Replace the ECU. Go to
 Benjoy Maintenance Manual — Chassis Volume ABS-64

Complete the repair? Step 26

26 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0033 are met, is Step 1 OK
this DTC reset?
 Benjoy Maintenance Manual — Chassis Volume ABS-65

C0034- Left Rear Wheel Speed Sensor under Open or Short Circuit
Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTCs.

Conditions for Setting DTC

After the ignition, DTC C0034 can be set as long as the ECU finds that the left rear wheel
speed sensor is open circuited, or short circuited against the ground or the storage
battery.

Actions for Setting DTC

1. DTC C00034 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0034 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short,
or contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping
performance of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.
 Benjoy Maintenance Manual — Chassis Volume ABS-66

C0034- Left Rear Wheel Speed Sensor under Open or Short Circuit
Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step
14
2 1. Extinct the engine. Go to Go to
2. Check whether the left rear wheel speed sensor, the Step 15 Step 3
crossover wire harness and the gear ring suffer from
physical damage.
Is any physical damage found out?
3 Test the vehicle at different speeds on various roads. Go to Go to
Is DTC C0034 reset? Step 4 Step
16
4 1. Park the vehicle and extinct the engine. 800~1,600Ω Go to Go to
2. Jack up and moderately support the vehicle. (the resistance Step 5 Step
3. Disconnect the left rear crossover wire harness from changes, 17
the left rear wheel speed sensor. subject to the
4. Connect the ohmmeter with terminals A and B of temperature
left rear wheel speed sensor. and the
Is the resistance value within the specified range? requirement of
customer.)
5 1. Keep the left rear crossover wire harness OL (open Go to Go to
disconnected from the wheel speed sensor. circuit) Step 6 Step
2. Connect the ohmmeter with terminal A of left rear 17
wheel speed sensor, and then with the grounding of
vehicle body.
Is the resistance value within the specified range?
6 1. Disconnect the ECU wire harness from the ECU. Less than 2Ω Go to Go to
2. Disconnect the left rear crossover wire harness from Step 7 Step
the ABS module wire harness. 18
3. Connect the ohmmeter with ECU wire harness
terminal 12, and then with ABS module wire
harness terminal B.
Is the resistance value within the specified range?
7 1. Keep the ECU wire harness disconnected from the Less than 2Ω Go to Go to
ECU. Step 8 Step
2. Keep the left rear crossover wire harness 19
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 13, and then with ABS module wire
harness terminal A.
Is the resistance value within the specified range?
8 1. Keep the ECU wire harness disconnected from the Less than 1V Go to Go to
ECU. Step 9 Step
2. Keep the left rear crossover wire harness 20
disconnected from the ABS module wire harness.
3. Connect the voltmeter with ECU wire harness
terminals 12 and then with grounding of vehicle
body
Is the voltage value within the specified range?
9 1. Keep the ECU wire harness disconnected from the Less than 1V Go to Go to
ECU. Step 10 Step
2. Keep the left rear crossover wire harness 21
disconnected from the ABS module wire harness.
 Benjoy Maintenance Manual — Chassis Volume ABS-67

3. Connect the voltmeter with ECU wire harness

terminals 13, and then with grounding of vehicle
body
Is the voltage value within the specified range?
10 1. Keep the ECU wire harness disconnected from the OL (open Go to Go to
ECU. circuit) Step 11 Step
2. Keep the left rear crossover wire harness 22
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 12, and then with grounding of vehicle
body
Is the resistance value within the specified range?
11 1. Keep the ECU wire harness disconnected from the OL (open Go to Go to
ECU. circuit) Step 12 Step
2. Keep the left rear crossover wire harness 23
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 13, and then with grounding of vehicle
body.
Is the resistance value within the specified range?
12 1. Keep the ECU wire harness disconnected from the OL (open Go to Go to
ECU. circuit) Step 13 Step
2. Keep the left rear crossover wire harness 24
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 12 and 13.
Is the resistance value within the specified range?
13 1. Replace the left rear wheel speed crossover wire Go to System
harness. Step 25 OK
2. Test the vehicle at different speeds on various
roads.
Is DTC C0034 reset?
14 Execute the diagnostic circuit check.
15 Repair the damaged left rear wheel speed sensor, the Go to
crossover wire harness and/or the gear ring. Step 26
Complete the repair?
16 DTC C0034 is intermittent. See the Diagnosis Help.
17 Replace the left rear wheel speed sensor. Go to
Complete the repair? Step 26
18 Repair the open circuit or the high resistance between Go to
terminals 12 and B. Step 26
Complete the repair?
19 Repair the open circuit or the high resistance between Go to
terminals 13 and A. Step 26
Complete the repair?
20 Repair the short circuit of voltage between terminals 12 Go to
and B. Step 26
Complete the repair?
21 Repair the short circuit of voltage between terminals 13 Go to
and A. Step 26
Complete the repair?
22 Repair the short circuit of grounding between terminals Go to
12 and B. Step 26
Complete the repair?
23 Repair the short circuit of grounding between terminals Go to
13 and A. Step 26
Complete the repair?
 Benjoy Maintenance Manual — Chassis Volume ABS-68

24 Repair the short circuit between two circuits. Go to

Complete the repair? Step 26
25 Replace the ECU. Go to
Complete the repair? Step 26
26 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0034 are met, is Step 1 OK
this DTC reset?
 Benjoy Maintenance Manual — Chassis Volume ABS-69

C0035- Right Rear Wheel Speed Sensor under Open or Short Circuit
Circuit Description
During the rotation of wheels, the wheel speed sensor engenders the AC voltage, which
rises as wheels rotate faster. Through twisted pair wires, the wheel speed sensor is
connected to the ECU, which calculates the wheel speed as per frequencies of AC signals.
Twist can abate the disturbance which may arise from noise against setting DTCs.
Conditions for Setting DTC
After the ignition, DTC C0035 can be set as long as the ECU finds that the right rear wheel
speed sensor is open circuited, or short circuited against the ground or the storage
battery.
Actions for Setting DTC
1. DTC C00035 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0035 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 ignition periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
If intermittent DTCs are found, circuits and connectors shall be checked thoroughly in
following ways:
1. Dismantle the protective conduit and check whether the circuits are damaged, short,
or contaminated,
2. Check whether terminals are distorted and damaged,
3. Use the reserved anodic/cathodic terminals to check the contact keeping
performance of terminals, and
4. Take off terminals from the connector and check whether terminals connected with
leads are correct.
 Benjoy Maintenance Manual — Chassis Volume ABS-70

C0035- Right Rear Wheel Speed Sensor under Open or Short Circuit
Step Diagnostic Action Expected Value Yes No
1 Complete the diagnostic circuit check? Go to Go to
Step Step 14
2
2 1. Extinct the engine. Go to Go to
2. Check whether the right rear wheel speed sensor, Step Step 3
the crossover wire harness and the gear ring suffer 15
from physical damage.
Is any physical damage found out?
3 Test the vehicle at different speeds on various roads. Go to Go to
Is DTC C0035 reset? Step Step 16
4
4 1. Park the vehicle and extinct the engine. 800~1,600Ω (the Go to Go to
2. Jack up and moderately support the vehicle. resistance Step Step 17
3. Disconnect the right rear crossover wire harness changes, subject 5
from the right rear wheel speed sensor. to the temperature
4. Connect the ohmmeter with terminals A and B of and the
right rear wheel speed sensor. requirement of
Is the resistance value within the specified range? customer.)
5 1. Keep the right rear crossover wire harness OL (open circuit) Go to Go to
disconnected from the wheel speed sensor. Step Step 17
2. Connect the ohmmeter with terminal A of right rear 6
wheel speed sensor, and then with the grounding of
vehicle body.
Is the resistance value within the specified range?
6 1. Disconnect the ECU wire harness from the ECU. Less than 2Ω Go to Go to
2. Disconnect the right rear crossover wire harness Step Step 18
from the ABS module wire harness. 7
3. Connect the ohmmeter with ECU wire harness
terminal 43, and then with ABS module wire
harness terminal B.
Is the resistance value within the specified range?
7 1. Keep the ECU wire harness disconnected from the Less than 2Ω Go to Go to
ECU. Step Step 19
2. Keep the right rear crossover wire harness 8
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 42, and then with ABS module wire
harness terminal A.
Is the resistance value within the specified range?
8 1. Keep the ECU wire harness disconnected from the Less than 1V Go to Go to
ECU. Step Step 20
2. Keep the right rear crossover wire harness 9
disconnected from the ABS module wire harness.
3. Connect the voltmeter with ECU wire harness
terminals 43 and then with grounding of vehicle
body
Is the voltage value within the specified range?
9 1. Keep the ECU wire harness disconnected from the Less than 1V Go to Go to
ECU. Step Step 21
2. Keep the right rear crossover wire harness 10
disconnected from the ABS module wire harness.
3. Connect the voltmeter with ECU wire harness
terminals 42, and then with grounding of vehicle
body
 Benjoy Maintenance Manual — Chassis Volume ABS-71

Is the voltage value within the specified range?

10 1. Keep the ECU wire harness disconnected from the OL (open circuit) Go to Go to
ECU. Step Step 22
2. Keep the right rear crossover wire harness 11
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 13, and then with grounding of vehicle
body
Is the resistance value within the specified range?
11 1. Keep the ECU wire harness disconnected from the OL (open circuit) Go to Go to
ECU. Step Step 23
2. Keep the right rear crossover wire harness 12
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 42, and then with grounding of vehicle
body.
Is the resistance value within the specified range?
12 1. Keep the ECU wire harness disconnected from the OL (open circuit) Go to Go to
ECU. Step Step 24
2. Keep the right rear crossover wire harness 13
disconnected from the ABS module wire harness.
3. Connect the ohmmeter with ECU wire harness
terminals 43 and 42.
Is the resistance value within the specified range?
13 1. Replace the right rear wheel speed crossover wire Go to System
harness. Step OK
2. Test the vehicle at different speeds on various 25
roads.
Is DTC C0035 reset?
14 Execute the diagnostic circuit check.
15 Repair the damaged right rear wheel speed sensor, the Go to
crossover wire harness and/or the gear ring. Step
Complete the repair? 26
16 DTC C0035 is intermittent. See the Diagnosis Help.
17 Replace the right rear wheel speed sensor. Go to
Complete the repair? Step
26
18 Repair the open circuit or the high resistance between Go to
terminals 43 and B. Step
Complete the repair? 26
19 Repair the open circuit or the high resistance between Go to
terminals 42 and A. Step
Complete the repair? 26
20 Repair the short circuit of voltage between terminals 43 Go to
and B. Step
Complete the repair? 26
21 Repair the short circuit of voltage between terminals 42 Go to
and A. Step
Complete the repair? 26
22 Repair the short circuit of grounding between terminals Go to
43 and B. Step
Complete the repair? 26
23 Repair the short circuit of grounding between terminals Go to
42 and A. Step
Complete the repair? 26
24 Repair the short circuit between two circuits. Go to
Complete the repair? Step
 Benjoy Maintenance Manual — Chassis Volume ABS-72

26
25 Replace the ECU. Go to
Complete the repair? Step
26
26 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0035 are met, is Step OK
this DTC reset? 1
 Benjoy Maintenance Manual — Chassis Volume ABS-73

C0036- System under Low Voltage

Circuit Description
This circuit is used to monitor the level of voltage which is provided to the ECU. If the
voltage falls below a certain level, not all functions of system can be ensured. During the
operation of ABS, several common conditions will cause the voltage of storage battery to
decline. Therefore, before operating the ABS, the voltage shall be monitored so as to
ensure a desirable charge condition; also, such a monitoring is applicable for the ABS
operation when the voltage is likely to slumps.

Conditions for Setting DTC

DTC C0036, without the ABS operation or during the initialization, can be set only when
the vehicle speed is higher than 8km/h and voltages of ignition terminal 16 and the
storage batter terminal 46 are lower than 10.5V. DTC C0036, with ABS operation, can be
set only if the ignition voltage and the storage battery voltage are respectively less than
10.5V and 9.0V.
Actions for Setting DTC
1. DTC C00036 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0036 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
Typical reasons to DTC C0036 may be as follows:
1. The voltage of storage battery is weak or used up.
2. The storage battery terminal is under poor contact.
3. The assembled equipment in factory or added equipment after sales (additional load)
leads out the excessive voltage from the storage battery.
4. The grounding of storage is poor on the cylinder body or chassis.
5. The ECU terminal is under poor contact.
6. The ECU is poorly grounded.
7. The charging system (engine) is troubled.
Circuits and connector shall be thoroughly checked, as the heedless and incomplete
check towards wirings and conductors may cause the evitable replacement of spare parts
and the unsuccessful troubleshooting.
 Benjoy Maintenance Manual — Chassis Volume ABS-74

C0036- System under Low Voltage

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 6
2 1. Test the storage battery load.(see the Maintenance The storage Go to Go to
Manual for Storage Battery for reference) battery shall Step 3 Step 7
2. Check the charging system. (see the Maintenance be able to
Manual for Starter and Charging System for keep the
reference) voltage above
3. Execute the additional load test. 9.6V for 10
Do storage battery, charging system and additional load seconds, with
pass the test? the current no
higher than
30mA.
3 1. Extinct the engine. Go to Go to
2. Disconnect both anode and cathode of the storage Step 4 Step 8
battery.
3. Disconnect the wire harness from the ECU.
4. Check whether the following wire harnesses are
under good connection.
 The wiring of battery terminal
 The cathodic cable to engine block/chassis
 The anodic cable to electromagnetic valve of
starter/or to terminal box
 ECU ports 16, 46, and 1
 The ECU/EBCM grounding cable to chassis
grounding
Are all connections foresaid good?
4 1. Keep the ECU disconnected. Less than 2Ω Go to Go to
2. Keep the storage battery cable disconnected. Step 5 Step 9
3. Connect an ohmmeter with ECU wire harness
terminal 1 and the cathode of storage battery cable.
Is the resistance value within the specified range?
5 1. Reconnect the storage batter cable. Voltage of Go to Go to
2. Keep the ECU disconnected. storage Step 11 Step
3. Ignite the engine. battery 10
4. Measure voltages of ECU wire harness terminals 16
and 46 by a voltmeter.
Are voltages of these two terminals within the specified
range?
6 Execute the diagnostic circuit check.
7 Repair the charging system Go to
and/or Step 12
recharge/replace the storage battery
and/or
find out and repair the reason of excessive additional
use.
Complete the repair?
8 Repair the port and/or the connector, if necessary. Go to
Complete the repair? Step 12
9 Find and repair the reason of high resistance between Go to
cathodic cable of storage battery and ECU wire harness Step 12
connector.
Complete the repair?
10 Find and repair the reason of low voltage on ECU ports. Go to
Complete the repair? Step 12
11 Replace the ECU. Go to
Complete the repair? Step 12
12 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0036 are met, is Step 1 OK
 Benjoy Maintenance Manual — Chassis Volume ABS-75

this DTC reset?

C0037- System under High Voltage

Circuit Description
This circuit is used to monitor the level of voltage which is provided to the ECU. If the
voltage falls below a certain level, the system may get damaged.
Conditions for Setting DTC
With the voltage provided to terminal 46 exceeding 17V per second, DTC C0037 can be
set only when the vehicle speed is higher than 8km/h (5mile/h).
Actions for Setting DTC
1. DTC C00037 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.

Conditions for Clearing DTC

1. If the conditions for setting DTC C0037 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from the
historical data.
Diagnosis Help
Typical reasons to DTC C0037 may be as follows:
1. The charging system is troubled,
2. There is poor contact, or
3. The ECU is troubled.

C0037- System under High Voltage

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 4
2 1. Connect a voltmeter with the anode and the cathode Less than Go to Go to
of storage battery. 17.0V Step 3 Step 5
2. Key off all fittings.
3. Start the engine.
4. With the engine running at 2000rpm for several
seconds, monitor the voltage of voltmeter.
Is the voltage value within the specified range?
3 1. Connect the scanning tool, and select the ABS data Less than Go to Go to
list. 17.0V Step 6 Step 7
2. With the engine running at 2000rpm for several
seconds, monitor the voltage of storage battery
shown in ABS data list.
Is the voltage value within the specified range?
4 Execute the diagnostic circuit check.
5 See the Diagnosis for Starter and Charging System.
6 The condition is intermittent. See the Diagnosis Help and
the Diagnosis for Starter and Charging System.
7 Replace the ECU. Go to
Complete the repair? Step 8
 Benjoy Maintenance Manual — Chassis Volume ABS-76

8 Clear the DTC by the scanning tool. Go to System

When the conditions for setting DTC C0037 are met, is this Step 1 OK
DTC reset?

C0042- Pump Motor under Open Circuit

Circuit Description
The pump motor is placed in the HCU (hydraulic control unit). The voltage of pump motor
is provided by ECU terminal 46, controlled by a stationary high-voltage measuring driver,
and the pump motor is grounded via ECU terminal 31.
Conditions for Setting DTC
Only when the ignition switch is regulated to the position “ON”, the pump motor is shut off
and the ECU finds an open circuited pump motor or a motor circuit with high resistance
can DTC C0042 be set.
Actions for Setting DTC
1. DTC C00042 is saved,
2. The ABS becomes inoperative, and
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0042 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from the
historical data.

Diagnosis Help
Typical reasons to DTC C0042 may be as follows:
1. The circuit between pump motor and ECU connector is open or suffers from high
resistance,
2. The circuit of pump motor is open, or
3. The ECU is troubled.
 Benjoy Maintenance Manual — Chassis Volume ABS-77

C0042- Open-circuit Pump Motor

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? ---- Go to Go to
Step 2 Step 4
2 1. Extinct the engine. ---- Go to Go to
2. Disconnect the ECU. Step 3 Step 5
3. Dismantle the ECU from the HCU.
4. Check whether the connector between HCU and ECU
suffers from damage, corrosion, poor-contact terminals
and brake fluid leakage.
Are terminals and connector OK? Is there damage, brake
fluid or corrosion in the hole?
3 Connect the ohmmeter with HCU terminals 1and 2. Less than Go to Go to
Is the resistance value of pump motor within the specified 2Ω Step 6 Step 7
range?
4 Execute the diagnostic circuit check.
5 1. If damage and/or corrosion are found, replace the ECU Go to
and/or the HCU (as the case may be). Step 8
2. If brake fluid leakage is found, replace the ECU and the
HCU.
Complete the repair?
6 Replace the ECU. Go to
Complete the repair? Step 8
7 Replace the HCU. Go to
Complete the repair? Step 8
8 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0042 are met, is this Step 1 OK
DTC reset?
 Benjoy Maintenance Manual — Chassis Volume ABS-78

C0055- ECU with Internal Trouble

Circuit Description
This DTC is used for ascertaining the possible internal troubles of ECU.
Conditions for Setting DTC
DTC C0055 shall be set when the internal components/microprocessor is likely to bear
faults.
Actions for Setting DTC
1. The electromagnetic relay, the power supply of pump motor and solenoid are
switched off,
2. The ABS is inoperative,
3. DTC C0055 is saved, and
4. The ABS alarm lamp and the braking alarm lamp are switched on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0055 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from the
historical data.
Diagnosis Help
1. When displayed on the scanning tool, DTC C0055 shall be followed by two digits (XX),
which are required to be recorded along with other visible DTCs.
2. Before carrying out fault tree analysis for DTC C0055, eliminate the trouble relevant
to low voltage, driving performance or other electric apparatuses.
3. Ensure that complex formed by ECU and HCU is reliable and firm and there is no
corrosion, leakage and/or damage.

C0055- ECU with Internal Trouble

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 5
2 1. Install the scanning tool. Go to Go to
2. With the engine shut down, ignite the engine. Step 6 Step 3
3. Observe the DTC information by the scanning tool.
Beside C0055, does the scanning tool display any
current or historical DTC?
3 1. Extinct the engine. Go to Go to
2. Disconnect the ECU wire harness form the ECU. Step 7 Step 4
3. Check whether the connector is damaged and
corroded and terminals contact each other.
Is there any trouble found?
4 Replace the ECU. Go to
Complete the repair? Step 8
5 Execute the diagnostic circuit check.
6 Perform the relevant diagnosis for other DTCs.
7 Repair the trouble according to requirements. Go to
Complete the repair? Step 8
8 Clear the DTC by the scanning tool. Go to System
 Benjoy Maintenance Manual — Chassis Volume ABS-79

When the conditions for setting DTC C0055 are met, is Step 1 OK
this DTC reset?
C0056- System Relay Always On
Circuit Description
This DTC is used for ascertaining the possible internal troubles of ECU. When activated
(switched on), the ECU relay provides the power for the solenoid of electromagnetic valve
and the pump motor.
Conditions for Setting DTC
DTC C0056 shall be set when the internal troubles are likely to appear.
Actions for Setting DTC
1. The ABS alarm lamp is not turned on,
2. DTC C0056 is saved, and
3. The ABS still functions.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0056 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from the
historical data.
Diagnosis Help
1. Before carrying out fault tree analysis for DTC C0056, eliminate the trouble relevant
to low voltage, driving performance or other electric apparatuses.
2. Ensure that complex formed by ECU and HCU is reliable and firm and there is no
corrosion, leakage and/or damage.
3. A possible reason to DTC C0056 may be that internal troubles take place in the
internal relay of ECU.
C0056- System Relay Always On
Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 5
2 1. Install the scanning tool. Go to Go to
2. With the engine shut down, ignite the engine. Step 6 Step 3
3. Observe the DTC information by the scanning tool.
Beside C0056, does the scanning tool display any
current or historical DTC?
3 1. Extinct the engine. Go to Go to
2. Disconnect the ECU wire harness form the ECU. Step 7 Step 4
3. Check whether the connector is damaged and
corroded and terminals contact each other.
Is there any trouble found?
4 Replace the ECU. Go to
Complete the repair? Step 8
5 Execute the diagnostic circuit check.
6 Perform the relevant diagnosis for other DTCs.
7 Repair the trouble according to requirements. Go to
Complete the repair? Step 8
8 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0056 are met, is Step 1 OK
 Benjoy Maintenance Manual — Chassis Volume ABS-80

this DTC reset?

C0061, C0062, C0063, C0064, C0065, C0066, C0067 and C0068
-Pressurizing/ Depressurizing Electromagnetic Valves under Open/Short
Circuit
Circuit Description
Pressurizing or depressurizing coils are inseparable members of ECU. With the ignition
switch regulated to the position “ON”, the storage battery supplies power to these coils
and then the solenoid relay is closed. If necessary, the ECU controls electromagnetic
valves by means of grounding circuits of corresponding coils.
Conditions for Setting DTC
When the ECU is open circuited or short circuited against the ground, or any pressurizing
or depressurizing coil gets short circuited against the power supply, the corresponding
DTC shall be set.
Actions for Setting DTC
1. The electromagnetic is switched on, and the power supply of electromagnetic valves
is switched off.
2. The corresponding DTCs are saved.
3. The ABS is inoperative, and the ABS alarm lamp is switched on.
4. The EBD is inoperative, and the braking alarm lamp is switched on (for DTCs C0065
and C0067 only).
Conditions for Clearing DTC
1. If the conditions for setting DTC C0061 via C0068 no longer exist, it is available to
clear the DTC by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.

Diagnosis Help
Ensure that complex formed by ECU and HCU is reliable and firm and free of corrosion.
Since coils of electromagnetic valves form part of whole ECU, any DTC set with regard to
these coils is usually expressed as an internal trouble of ECU.
 Benjoy Maintenance Manual — Chassis Volume ABS-81

C0061, C0062, C0063, C0064, C0065, C0066, C0067 and C0068 -

Pressurizing/Depressurizing Electromagnetic Valves under Open/Short Circuit
Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Step 2 Go to Step 5
2 1. Extinct the engine. Go to Step 6 Go to Step 3
2. Check whether the ECU and the
HCU suffer from physical
damages?
Is any physical damage found out?
3 1. Disconnect the ECU wire harness Go to Step 7 Go to Step 4
from the ECU.
2. Dismantle the ECU from the HCU.
3. Check whether inner chambers of
HCU and ECU suffer from brake
fluid leakage, corrosion and/or
damage.
Is there no damage, corrosion, or brake
fluid leakage in inner chambers?
4 1. Install the scanning tool. Go to Step 8 For intermittent
2. With the engine shut down, ignite troubles, go to
the engine. Step 5.
3. Clear the DTC by the scanning tool.
4. With the DTC running, drive the
vehicle.
5. Is the DTC reset as the current
DTC?
5 Execute the diagnostic circuit check. Go to the System OK
Is any trouble found? corresponding
step.
6 Replace damaged components. Go to Step 9
Complete the repair?
7 Replace the ECU and the HCU. Go to Step 9
Complete the repair?
8 Replace the ECU. Go to Step 9
Complete the repair?
9 Clear the DTC by the scanning tool. Go to Step 1 System OK
When the conditions for setting DTC are
met, is the DTC reset?

C0091- Inoperative Brake Pedal under Deceleration

Circuit Description
The ECU monitors and recognizes three input states of brake switch for corresponding
system operation, namely the high output, low output and the open output. The brake
switch signals are provided by the vehicle.
Conditions for Setting DTC
DTC C0091 shall be set when the following conditions are met.
1. The vehicle is ignited,
2. The brake pedal is inoperative,
3. The braking control is inefficacious when the vehicle moves,
4. The vehicle speed is over 24km/h,
 Benjoy Maintenance Manual — Chassis Volume ABS-82

5. The vehicle deceleration is over 11.5km/h within 1 second for two consecutive times.
6. Five conditions hereinbefore are met twice.

Actions for Setting DTC

DTC C0091 is saved by the ECU.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0091 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from the
historical data.
Diagnosis Help
Typical reasons to DTC C0091 maybe that:
1. The output voltage of brake application sensor is below the requirement of braking.
2. The internal troubles of brake application sensor arise.

C0091- Inoperative Brake Pedal under Deceleration

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 5
2 Tread the brake pedal. Go to Go to
Does any stop lamp (including the central high-mounted stop Step 6 Step 3
lamp (CHMSL) or the tertiary stop lamp) bulb fail to operate?
3 1. Extinct the engine. Less than Go to Go to
2. Disconnect the ECU wire harness from the ECU. 2Ω Step 4 Step 7
3. Use the suitable cable to install a general commutator
box between ECU wire harness and ECU.
4. Connect a voltmeter with commutator box terminal 41,
and then with commutator box terminal 1 or the
grounding of vehicle body.
Is the voltage value within the specified range?
4 Replace the ECU. Go to
Complete the repair? Step 8
5 Execute the diagnostic circuit check.
6 With the brake pedal tread, dismantle and test the plug/the Go to
non-shining bulb. Replace the bulb/the plug. Repair the Step 8
grounding, if necessary.
Complete the repair?
7 Check all groundings, bulbs and plugs of rear stop lamp to Go to
see whether they suffer from poor condition/high resistance. It Step 8
is forbidden to connect the 5V reference voltage of ECU to the
low voltage (below 2V).
Complete the repair?
8 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0091 are met, is this Step 1 OK
DTC reset?
 Benjoy Maintenance Manual — Chassis Volume ABS-83

C0093- Inoperative Brake Pedal under Deceleration during Last Ignition

Period
Circuit Description
The ECU monitors and recognizes three input states of brake switch for corresponding
system operation, namely the high output, low output and the open output. The brake
switch signals are provided by the vehicle.
Conditions for Setting DTC
DTC C0093 shall be set if DTC C0091 fails at the conclusion of last ignition period.
Actions for Setting DTC
DTC C0093 is saved by the ECU.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0093 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
Typical reasons to DTC C0093 may be as follows:
1. The brake pedal is found inoperative under deceleration at the end of testing.

C0093- Inoperative Brake Pedal Under Deceleration During Last Ignition Period
Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 5
2 Tread the brake pedal. Go to Go to
Does any stop lamp (including the central high-mounted stop Step 6 Step 3
lamp (CHMSL) or the tertiary stop lamp) bulb fail to operate?
3 1. Extinct the engine. Less than Go to Go to
2. Disconnect the ECU wire harness from the ECU. 2Ω Step 4 Step 7
3. Use the suitable cable to install a general commutator
box between ECU wire harness and ECU.
4. Connect a voltmeter with commutator box terminal 41,
and then with commutator box terminal 1 or the
grounding of vehicle body.
Is the voltage value within the specified range?
4 Replace the ECU. Go to
Complete the repair? Step 8
5 Execute the diagnostic circuit check.
6 With the brake pedal tread, dismantle and test the plug/the Go to
non-shining bulb. Replace the bulb/the plug. Repair the Step 8
grounding, if necessary.
Complete the repair?
7 Check all groundings, bulbs and plugs of rear stop lamp to Go to
see whether they suffer from poor condition/high resistance. It Step 8
 Benjoy Maintenance Manual — Chassis Volume ABS-84

is forbidden to connect the 5V reference voltage of ECU to the

low voltage (below 2V).
Complete the repair?
8 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0093 are met, is this Step 1 OK
DTC reset?
 Benjoy Maintenance Manual — Chassis Volume ABS-85

C0094- Brake Pedal with Virtual Trouble during No Deceleration

Circuit Description
The ECU monitors and recognizes three input states of brake switch for corresponding
system operation, namely the high output, low output and the open output. The brake
switch signals are provided by the vehicle.
Conditions for Setting DTC
DTC C0094 DTC C0094 shall be set when the following conditions are met.
1. It is felt that the brake pedal is acting,
2. The vehicle speed is over 40km/h,
3. The vehicle acceleration is over 8km/h, and
4. Three conditions hereinbefore last for 2 second or longer.
Actions for Setting DTC
DTC C0094 is saved by the ECU.

Conditions for Clearing DTC

1. If the conditions for setting DTC C0094 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.

Diagnosis Help
Typical reasons to DTC C0094 may be as follows:
1. The output voltage of brake application sensor is below the requirement of braking,
2. Drivers like to tread the brake pedal twice at the time of braking, or
3. The internal troubles of brake application sensor arise.
 Benjoy Maintenance Manual — Chassis Volume ABS-86

C0094- Brake Pedal in Virtual Trouble during No Deceleration

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 5
2 Tread the brake pedal. Go to Go to
Does any stop lamp (including the central high-mounted stop Step 6 Step 3
lamp (CHMSL) or the tertiary stop lamp) bulb fail to operate?
3 1. Extinct the engine. Less than Go to Go to
2. Disconnect the ECU wire harness from the ECU. 2Ω Step 4 Step 7
3. Use the suitable cable to install a general commutator
box between ECU wire harness and ECU.
4. Connect a voltmeter with commutator box terminal 41,
and then with commutator box terminal 1 or the
grounding of vehicle body.
Is the voltage value within the specified range?
4 Replace the ECU. Go to
Complete the repair? Step 8
5 Execute the diagnostic circuit check.
6 With the brake pedal tread, dismantle and test the plug/the Go to
non-shining bulb. Replace the bulb/the plug. Repair the Step 8
grounding, if necessary.
Complete the repair?
7 Check all groundings, bulbs and plugs of rear stop lamp to Go to
see whether they suffer from poor condition/high resistance. It Step 8
is forbidden to connect the 5V reference voltage of ECU to the
low voltage (below 2V).
Complete the repair?
8 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0094 are met, is this Step 1 OK
DTC reset?

C0095- Brake Switch under Open Circuit (Parking Lamp under Open
Circuit)
Circuit Description
This DTC, used for ascertaining the open circuited parking lamp switch, prevents the
parking lamp switch from inputting signals to the ECU when the brake is applied. When
the ECU sends the low-current 5V transducing voltage to the rear brake lamp through the
input circuit of brake switch, if the circuit of rear brake lamp is intact, such a voltage shall
be lessened through the bulb of rear brake switch (for below 1V) and then grounded.
Once the brake switch is turned on, the store battery voltage shall be provided to the rear
brake lamp and the ECU so as to make the brake lamp light. If the voltage is too low (less
than 1V) or too high (more than storage battery voltage), ECU will be incapable to
determine the state of brake switch and DTC C0095 shall be accordingly set.
Conditions for Setting DTC
DTC C0095, after the initialization, shall be set on condition that the voltage at input end of
brake switch reaches 2~5 V within 2 seconds.
Actions for Setting DTC
The ABS functions.
 Benjoy Maintenance Manual — Chassis Volume ABS-87

Conditions for Clearing DTC

1. If the conditions for setting DTC C0095 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
Typical reasons to DTC C0095 may be as follows:
1. Bulb filaments of one or more parking lamps are open circuited,
2. Connection of one or more bulbs of parking lamps and/or socket is loose,
3. Groundings of one or more parking lamps are loose or open circuited,
4. The input terminal of brake switch is under poor contact or gets open circuited, or
5. The input circuit of brake switch for terminal 41 is open.

C0095- Open-circuit Brake Switch (Open-circuit Parking Lamp)

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 5
2 Tread the brake pedal. Go to Go to
Does any stop lamp (including the central high-mounted stop Step 6 Step 3
lamp (CHMSL) or the tertiary stop lamp) bulb fail to operate?
3 1. Extinct the engine. Less than Go to Go to
2. Disconnect the ECU wire harness from the ECU. 2Ω Step 4 Step 7
3. Use the suitable cable to install a general commutator
box between ECU wire harness and ECU.
4. Connect a voltmeter with commutator box terminal 41,
and then with commutator box terminal 1 or the
grounding of vehicle body.
Is the voltage value within the specified range?
4 Replace the ECU. Go to
Complete the repair? Step 8
5 Execute the diagnostic circuit check.
6 With the brake pedal tread, dismantle and test the plug/the Go to
non-shining bulb. Replace the bulb/the plug. Repair the Step 8
grounding, if necessary.
Complete the repair?
7 Check all groundings, bulbs and plugs of rear stop lamp to Go to
see whether they suffer from poor condition/high resistance. It Step 8
is forbidden to connect the 5V reference voltage of ECU to the
low voltage (below 2V).
Complete the repair?
8 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0095 are met, is this Step 1 OK
DTC reset?
 Benjoy Maintenance Manual — Chassis Volume ABS-88

C0118, C0121 - Troubles Relevant to Rear Pressurizing Electromagnetic

Valve
Circuit Description
Pressurizing or depressurizing coils are inseparable members of ECU. When the ignition
switch and the electromagnetic valve relay are turned on, the storage battery supplies
power to these coils and then the solenoid relay is closed. If necessary, the ECU controls
electromagnetic valves by means of grounding circuits of corresponding coils.
Conditions for Setting DTC
DTC C0118 shall be set, when a pulse width modulation (PWM) command has been sent
to left rear pressurizing electromagnetic valve and the relevant feedback input inspection
proves that the hardware signals is consistent with the software command (The PWM
command is 2khz with a 30% duty ratio and lasts for 1ms.). Also, DTC C0118 shall be set,
when a pulse width modulation (PWM) command has been sent to right rear pressurizing
electromagnetic valve and the relevant feedback input inspection proves that the
hardware signals is consistent with the software command (The PWM command is of
2khz with a duty ratio of 30% and lasts for 1ms.).
Actions for Setting DTC
1. DTC C0118 is saved,
2. The ECU makes the ABS inoperative,
3. The ECU makes the EBD inoperative,
4. The ECU saves the DTC C0118, and
5. The ABS alarm lamp and the braking alarm lamp light.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0118 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from the
historical data.
Diagnosis Help
Typical reasons to DTCs C0118 may be as follows:
The internal troubles of ECU arise.
C0118, C0121- Troubles Relevant to Rear Pressurizing Electromagnetic Valve
Ste Diagnostic Action Expecte Yes No
p d Value
1 Complete the diagnostic circuit check? Go to Step 2 Go to Step 5
2 1. Extinct the engine. Go to Step 6 Go to Step 3
2. Check whether the ECU and the HCU suffer
from physical damages?
Is any physical damage found out?
3 1. Disconnect the ECU wire harness from the Go to Step 7 Go to Step 4
ECU.
2. Dismantle the ECU from the HCU.
3. Check whether inner chambers of HCU and
ECU suffer from brake fluid leakage,
corrosion and/or damage.
Is there no damage, corrosion, or brake fluid
leakage in inner chambers?
4 1. Install the scanning tool. Go to Step 8 For
2. With the engine shut down, ignite the engine. intermittent
3. Clear the DTC by the scanning tool. troubles, go
4. With the DTC running, drive the vehicle. to Step 5.
5. Is the DTC reset as the current DTC?
5 Execute the diagnostic circuit check. Go to the System OK
Is any trouble found? corresponding
step.
 Benjoy Maintenance Manual — Chassis Volume ABS-89

6 Replace damaged components. Go to Step 9

Complete the repair?
7 Replace the ECU and the HCU. Go to Step 9
Complete the repair?
8 Replace the ECU. Go to Step 9
Complete the repair?
9 Clear the DTC by the scanning tool. Go to Step 1 System OK
When the conditions for setting DTC C0118 or
C0121 are met, is the DTC reset?

C0122- Troubles Relevant to Depressurizing or Front Pressurizing

Electromagnetic Valve
Circuit Description
Pressurizing or depressurizing coils are inseparable members of ECU. When the ignition
switch and the electromagnetic valve relay are turned on, the storage battery supplies
power to these coils and then the solenoid relay is closed. If necessary, the ECU controls
electromagnetic valves by means of grounding circuits of corresponding coils.
Conditions for Setting DTC
DTC C0122 shall be set, when a pulse width modulation (PWM) command has been sent
to left rear pressurizing electromagnetic valve and the relevant feedback input inspection
proves that the hardware signals is consistent with the software command (The PWM
command is 2khz with a 30% duty ratio and lasts for 1ms.).
Actions for Setting DTC
1. The ECU saves DTC C0122,
2. The ECU makes the ABS inoperative,
3. The ECU makes the EBD inoperative,
4. The ECU saves DTC C0122, and
5. The ABS alarm lamp and the braking alarm lamp light.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0122 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
A typical reason to DTC C0122 may be that:
The internal troubles of ECU arise.

C0122- Troubles Relevant to Depressurizing or Front Pressurizing Electromagnetic Valve

Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Step 2 Go to Step 5
2 5. Extinct the engine. Go to Step 6 Go to Step 3
6. Check whether the ECU and the
HCU suffer from physical damages?
Is any physical damage found out?
3 7. Disconnect the ECU wire harness Go to Step 7 Go to Step 4
from the ECU.
 Benjoy Maintenance Manual — Chassis Volume ABS-90

8. Dismantle the ECU from the HCU.

9. Check whether inner chambers of
HCU and ECU suffer from brake
fluid leakage, corrosion and/or
damage.
Is there no damage, corrosion, or brake
fluid leakage in inner chambers?
4 10. Install the scanning tool. Go to Step 8 For intermittent
11. With the engine shut down, ignite troubles, go to
the engine. Step 5.
12. Clear the DTC by the scanning tool.
13. With the DTC running, drive the
vehicle.
14. Is the DTC reset as the current
DTC?
5 Execute the diagnostic circuit check. Go to the System OK
Is any trouble found? corresponding
step.
6 Replace damaged components. Go to Step 9
Complete the repair?
7 Replace the ECU and the HCU. Go to Step 9
Complete the repair?
8 Replace the ECU. Go to Step 9
Complete the repair?
9 Clear the DTC by the scanning tool. Go to Step 1 System OK
When the conditions for setting DTC
C0122 are met, is the DTC reset?

C0127- Brake Pedal with Virtual Trouble under No Deceleration during

Last Ignition Period
Circuit Description
The ECU monitors and recognizes three input states of brake switch for corresponding
system operation, namely the high output, low output and the open output. The brake
switch signals are provided by the vehicle.
Conditions for Setting DTC
DTC C0127 shall be set, if the setting for “Brake Pedal in Virtual Trouble during No
Deceleration”is unsuccessful when the last ignition period ends.
Actions for Setting DTC
ECU saves DTC C0127.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0127 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
A typical reason to DTC C0127 may be that:
1. The brake pedal is found acting at the end of testing.

C0127- Brake Pedal with Virtual Trouble under No Deceleration during Last Ignition
 Benjoy Maintenance Manual — Chassis Volume ABS-91

Period
Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 5
2 Tread the brake pedal. Go to Go to
Does any stop lamp (including the central high-mounted stop Step 6 Step 3
lamp (CHMSL) or the tertiary stop lamp) bulb fail to operate?
3 5. Extinct the engine. Less than Go to Go to
6. Disconnect the ECU wire harness from the ECU. 2Ω Step 4 Step 7
7. Use the suitable cable to install a general commutator
box between ECU wire harness and ECU.
8. Connect a voltmeter with commutator box terminal 41,
and then with commutator box terminal 1 or the
grounding of vehicle body.
Is the voltage value within the specified range?
4 Replace the ECU. Go to
Complete the repair? Step 8
5 Execute the diagnostic circuit check.
6 With the brake pedal tread, dismantle and test the plug/the Go to
non-shining bulb. Replace the bulb/the plug. Repair the Step 8
grounding, if necessary.
Complete the repair?
7 Check all groundings, bulbs and plugs of rear stop lamp to Go to
see whether they suffer from poor condition/high resistance. It Step 8
is forbidden to connect the 5V reference voltage of ECU to the
low voltage (below 2V).
Complete the repair?
8 Clear the DTC by the scanning tool. Go to System
When the conditions for setting DTC C0127 are met, is this Step 1 OK
DTC reset?

C0151, C0152, C0153, C0154- Excessively-long Time for Depressurizing

Wheels
Circuit Description
The ECU monitors and recognizes three input states of brake switch for corresponding
system operation, namely the high output, low output and the open output. The brake
switch signals are provided by the vehicle.
The ECU monitors the ON/OFF state of every electromagnetic valve and judge whether
the depressurizing time of ABS is too long. This trouble means that the ECU is incapable
to prevent wheels from side skidding by means of reducing pressure of one wheel.
Conditions for Setting DTC
DTC C0151 shall be set when the following conditions are met:
1. The ABS commands to depressurize the left front wheel, and
2. The speed of left front wheel is lower than 5km/h within 1 second.
DTC C0152 shall be set when the following conditions are met:
3. The ABS commands to depressurize the right front wheel, and
4. The speed of right front wheel is lower than 5km/h within 1 second.
DTC C0153 shall be set when the following conditions are met:
 Benjoy Maintenance Manual — Chassis Volume ABS-92

5. The ABS commands to depressurize the left rear wheel, and

6. The speed of left rear wheel is lower than 5km/h within 1 second.
DTC C0154 shall be set when the following conditions are met:
7. The ABS commands to depressurize the right rear wheel, and
8. The speed of right rear wheel is lower than 5km/h within 1 second.
 Benjoy Maintenance Manual — Chassis Volume ABS-93

Actions for Setting DTC

1. The ABS is inoperative,
2. The ABS alarm lamp is turned on, and
3. The ECU saves DTC 0151.
Conditions for Clearing DTC
1. If the conditions for setting DTCs no longer exist, it is available to clear DTCs by the
corresponding scanning tool.
2. If the current DTC does not appeared in 100 consecutive driving periods, the ECU
shall automatically clear this DTC.
Diagnosis Help
Typical reasons to these DTCs may be as follows:
1. The hydraulic device is contaminated,
2. The signal of wheel speed sensor is intermittent,
3. The electromagnetic is sticky,
4. The basic braking system suffers from excessive braking pulling force or great
resisting force, or
5. The suspension system is irregular.
C0151, C0152, C0153, C0154- Excessively-long Time for Depressurizing Wheels
Step Diagnostic Action Expected Value Yes No
1 Complete the diagnostic circuit check? Go to Step 2
2 1. Install the scanning tool. Go to the Go
2. Ignite the engine, but the engine is shut corresponding to
down. flow diagram for Step
3. Observe the parameter information of ABS DTC. 3
DTC by the scanning tools.
Does the scanning tool display any DTC which is
related to action of wheel speed sensor or of
electromagnetic valve?
3 When the vehicle decelerates from 56km/h to Go to the DTC Go
0km/h, use the scanning tool to monitor data of list, as the speed to
all wheel speed sensor displayed on ABS. of affect wheels Step
Is speed of any wheel stable? Or does any wheel changes 4
run intermittently? excessively.
4 Check the basic braking system according the Go to Step 7 Go
following conditions: to
 Is the brake fluid contaminated? Step
 Is the braking excessively sluggish? 5
 Is the suspension system irregular?
Are conditions foresaid found and corrected?
5 1. Clear the DTC by the scanning tools. For intermittent Go
2. Pressurize the brake pedal by treading. troubles, see the to
3. Activate corresponding depressurizing Diagnosis Help. Step
valves by the scanning tool. 6
Does the brake pedal decline?
6 Execute the proper procedure: Go to Step 7
 Replace the HCU.
Complete the repair?
7 1. Clear the DTC by the scanning tool. Go to Step 2
2. Test the vehicle, and make it perform an
action of ABS braking.
 Benjoy Maintenance Manual — Chassis Volume ABS-94

Is the DTC reset?

 Benjoy Maintenance Manual — Chassis Volume ABS-95

C0166- Longitudinal Acceleration beyond Range

C0167 DTC- Longitudinal Acceleration with Off-track Error
Circuit Description
The single accelerometer is controlled through ignition. Acceleration is described as the
voltage connected with the ECU through pin 10. The grounding pin of sensor connects
with the ECU sensor and returns to pin 44.
Conditions for Setting DTC
DTC C1066 shall be set, if the switch is on, and the open circle, the short circuit against
grounding or the short circuit against storage battery is detected by the ECU when the
longitudinal acceleration is input.
Actions for Setting DTC
1. DTC C1066 is saved.
2. The ABS is inoperative.
3. The ABS braking alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0166 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 consecutive driving periods, the ECU shall
automatically clear the DTC from the historical data.
Diagnosis Help
When diagnosing the intermittent DTC, make a thorough check on the wires and
connectors. This check shall include the following items:
1. Remove protected pipelines and check wire harness for breakage, short circuit and
contamination;
2. Check for incorrect connection and/or broken terminals; and
3. Remove terminals from connectors to check whether the terminal connection is
correct for the coil.
 Benjoy Maintenance Manual — Chassis Volume ABS-96

C0166- Longitudinal Acceleration beyond Range

C0167 DTC- Longitudinal Acceleration with Off-track Error
Step Diagnostic Action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to the
Step 2 Diagnosis
System
Check.
2 1. Install diagnostic instrument. 0.15-4.85 V Go to Go to
2. Turn on the ignition switch, and shut down the Step 6 Step 3
generator.
3. Use the diagnostic instrument to check input
signals of longitudinal acceleration sensor in the data
list.
Is the voltage value displayed by the diagnostic
instrument within the specified range?
3 1. Shut down the engine. 0.15V Go to Go to Step 10
2. Disconnect the connection of longitudinal Step 4
acceleration sensor.
3. Turn on the ignition switch, and shut down the
generator.
4. Observe the input parameter of longitudinal
acceleration by the diagnostic instrument.
Is the voltage value displayed by the diagnostic
instrument lower than the specified range?
4 1. Turn off ignition switch. 4.85V Go to Go to Step 8
2. Connect a 3-ampere fuse jumper with signal Step 5
circuit of longitudinal acceleration sensor and
ignition circuit of longitudinal acceleration
sensor.
3. Turn on the ignition switch, and shut down the
generator.
4. Observe the input parameter of longitudinal
acceleration by the diagnostic instrument.
Is the voltage value displayed by the diagnostic
instrument lower than the specified range?
5 1. Disconnect the fuse jumper. 9V Go to Go to Step 7
2. Use a digital universal meter to measure the Step 12
voltage value between low reference circuit of
longitudinal acceleration sensor and ignition
circuit of longitudinal acceleration sensor.
Is the voltage value displayed by the diagnostic
instrument higher than the specified range?
6 Is the input parameter of longitudinal acceleration 2.3-2.7V Go to Go to Step 11
sensor displayed by the diagnostic instrument within diagnosis
the specified range? help
7 Measure a 5V reference circuit of longitudinal Go to Go to Step 13
acceleration sensor to see whether short circuit Step 1 6
occurs due to this voltage. See the Testing and
Repair of Circuit in section Circuit System for
reference.
8 Test the ignition circuit of longitudinal acceleration Go to Go to Step 9
sensor to detect the following states: Step 16
 Open circuit;
 Short circuit against grounding; and
 High resistance.
 Benjoy Maintenance Manual — Chassis Volume ABS-97

See the Testing and Repair of Circuit in section

Circuit System for reference.
Have you found and corrected these states?
9 Test the signal circuit longitudinal acceleration Go to Go to Step 13
sensor to detect the following states: Step 16
 Open circuit;
 Short circuit against grounding; and
 High resistance.
Circuit test and circuit repair of reference circuit
system
Have you found and corrected these states?
10 Measure the signal circuit of longitudinal acceleration Go to Go to Step 13
sensor to see whether short circuit occurs due to the Step 16
voltage.
Have you found and corrected this state?
11 Test the low reference circuit of longitudinal Go to Go to Step 12
acceleration sensor to detect the following states: Step 16
 Open circuit; and
 High resistance.
Have you found and corrected these states?
12 Check whether wire harness connectors of Go to Go to Step 14
longitudinal acceleration sensor are under incorrect Step 16
connection.
Have you found and corrected this state?
13 Check whether wire harness connectors of electronic Go to Go to Step 15
braking control module (EBDM) are under incorrect Step 16
connection.
Have you found and corrected this state?
14 Replace the longitudinal acceleration sensor Go to
Have you completed the repair? Step 16
15 Replace the ECU of ABS. See the Replacement of Go to
Electronic Control Unit (ECU) for reference. Step 16
Have you completed the repair?
16 1. Clear the DTC by diagnostic instrument. Go to System OK
2. Start the vehicle, under the state of the driving Step 2
DTC being within the specified range.
Benjoy Maintenance Manual — Chassis Volume ABS-98
 Benjoy Maintenance Manual — Chassis Volume ABS-99

C0191- No Starting Current for Pump Motor

Circuit Description
When pump motor is working, the ECU, by virtue of the pump motor circuit, can detect that
the current is higher/lower than fixed threshold value.
Conditions for Setting DTC
DTC C0191 shall be set, if the current does not exceed the threshold value with pump
having run for 100ms.
Actions for Setting DTC
1. The ABS is inoperative.
2. The ECU saves DTC C0191.
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0191 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
Typical reasons to DTC C0191 may be as follows:
1. The pump motor coil suffers from high resistance, and
2. The pump motor grounding suffers from high resistance.
 Benjoy Maintenance Manual — Chassis Volume ABS-100

C0191- No Starting Current for Pump Motor

Step Diagnostic action Expected Yes No
Value
1 Complete the diagnostic circuit check? Go to Step Go to
2 Step 7
2 1. Extinct the engine. Less than 2 Go to Step Go to
2. Disconnect the cathodic cable of storage battery. ohm 3 Step 7
3. Disconnect the ECU wire harness from the ECU.
4. Connect an ohmmeter with the cathodic cable of
storage battery and the ECU wire harness
terminal 31.
Is the resistance value within the specified range?
3 1. Along the cathodic cable of storage battery, Go to Step Go to
check whether the engine block and/or the 4 Step 8
chassis grounding connections are clean and
firm.
2. From terminal 31 of ECU wire harness, along the
circuit, find out the circuit grounding position to
the chassis and check whether this position is
clean and connected firm.
Are all connections clean and firm?
4 1. Keep the ECU wire harness disconnected. Go to Step Go to
2. Dismantle the ECU from the HCU. 5 Step 9
3. Check whether the connector of ECU and HCU
suffers from damage, corrosion, poor contact or
brake fluid leakage.
Are the terminal and the connector OK? Is there
damage, brake fluid or corrosion in the cabin?
5 Connect an ohmmeter with HCU terminals 1 and 2. Less than 2 Go to Step Go to
Is the resistance reading of pump motor within the ohm 10 Step 11
specified range?
6 Execute the diagnostic circuit check.
7 Find and repair the reason of high resistance between Go to Step
ECU grounding circuit and chassis grounding. 12
Complete the repair?
8 Repair poor contact. Go to Step
Complete the repair? 12
9 1. If there is breakage and/or corrosion, the ECU Go to Step
and/or the HCU when necessary. 12
2. If there is leakage of brake fluid, replace the ECU
and the HCU.
Complete the repair?
10 Replace the ECU. Go to Step
Complete the repair? 12
11 Replace the HCU. Go to Step
Complete the repair? 12
12 Clear the DTC by the scanning tool. Go to Step
Is the DTC reset? 12

C0192- Pump Motor under Overload

Circuit Description
When pump motor is working, the ECU, by virtue of the pump motor circuit, can detect that
the current is higher/lower than the fixed threshold value.
Conditions for Setting DTC
 Benjoy Maintenance Manual — Chassis Volume ABS-101

Set DTC C0192 when the following conditions are met:

1. The pump motor runs.
2. After the pump motor runs, the current exceeds the threshold value for 100
milliseconds.
3. The current is above the threshold value for 11 microseconds.
Actions for Setting DTC
1. The ABS is inoperative.
2. The ECU saves DTC C0192.
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0192 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
Typical reasons to DTC C0192 may be as follows:
1. The pump motor coil suffer from low resistance, and
2. The Electric motor or the pump is not clamped, and needs extra torque to rotate.
C0192- Pump Motor under Overload
Step Diagnostic Action Expected Value Yes No
1 Complete the diagnostic circuit check? Go to Step 2 Go to Step 5
2 Connect the scanning tool. Go to Step 8 Go to Step 3
1. Use scanning tools to activate the
pump motor.
Is any abnormal noise heard during the
course of testing motor?
3 1. Extinct the engine. 100-200 milliohm Go to Step 4 Go to Step 8
2. Disconnect the cathodic cable of
storage battery.
3. Disconnect the ECU wire harness
from the ECU.
4. Dismantle the ECU from the HCU.
5. Connect an ohmmeter with
terminals 1 and 2 of HCU motor
connector.
Is the resistance value within the
specified range?
4 1. Connect an ohmmeter with terminal More than 100 Go to Step 6 Go to Step 8
1 and the HCU shell. kilohm
2. Connect an ohmmeter with terminal
2 and the HCU shell.
Is the resistance value in every step
within the specified range?
5 Execute the diagnosis circuit check.
6 Replace the ECU. Go to Step 7
Complete the repair?
7 Clear the DTC by the scanning tool. Go to Step 8 System OK
Is the DTC reset?
8 Replace HCU Go to Step 9
Complete the repair?
 Benjoy Maintenance Manual — Chassis Volume ABS-102

9 Clear DTC with scanning tools Go to Step 2 System OK

Is the DTC reset?

C0194- Pump Motor under Short Circuit

Circuit Description
By virtue of the pump motor circuit, the ECU can detect out that current is higher/lower
than the fixed threshold value.
Conditions for Setting DTC
DTC C0194 shall be set when the following conditions are met:
1. The pump motor runs, and
2. After the pump motor runs, the current exceeds the threshold value for 0.15
millisecond.
Actions for Setting DTC
1. The ABS is inoperative.
2. The ECU saves DTC C0194.
3. The ABS alarm lamp is turned on.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0194 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
Typical reasons to DTC C0194 may be as follows:
1. The Resistance of pump motor coil is extremely low, and
2. The grounding of high-potential end of pump motor is short circuited.
C0194- Pump Motor with Short Circuit
Step Diagnostic Action Expectation Yes No
Value
1 Complete the diagnostic circuit check? Go to Go to
Step 2 Step 5
2 Connect the scanning tool. Go to Go to
1. Use scanning tools to activate the pump motor. Step 8 Step 3
2. Is any abnormal noise heard during the course of
testing motor?
3 6. Extinct the engine. 100-200 milliohm Go to Go to
7. Disconnect the cathodic cable of storage battery. Step 4 Step 8
8. Disconnect the ECU wire harness from the ECU.
9. Dismantle the ECU from the HCU.
10. Connect an ohmmeter with terminals 1 and 2 of
HCU motor connector.
Is the resistance value within the specified range?
4 3. Connect an ohmmeter with terminal 1 and the More than 100 Go to Go to
HCU shell. kilohm Step 6 Step 8
4. Connect an ohmmeter with terminal 2 and the
HCU shell.
Is the resistance value in every step within the
specified range?
5 Execute the diagnosis circuit check.
6 Replace the ECU. Go to
Complete the repair? Step 7
 Benjoy Maintenance Manual — Chassis Volume ABS-103

7 Clear the DTC by the scanning tool. Go to System

Is the DTC reset? Step 8 OK
8 Replace HCU Go to
Complete the repair? Step 9
9 Clear DTC with scanning tools Go to System
Is the DTC reset? Step 2 OK
C0198- Incorrect Output of Pulse Width Modulation for Insufficient
Ignition on Bumpy Road
Circuit Description
The pulse width modulation signal for ignition loss on bumpy road provides the information
of bumpy road calculated by ABS controller and gives out this information to the power
assembly controller. The pulse width modulation signal is at ECU pin 38.
Conditions for Setting DTC
DTC C0198 shall be set, when the switch is turned on and the open circuit of pulse
width modulation signal, the short circuit against grounding and the short circuit
against width storage battery on bumpy roads are detected by the ECU.
Actions for Setting DTC
DTC C0198 is saved.
Conditions for Clearing DTC
1. If the conditions for setting DTC C0194 no longer exist, it is available to clear the DTC
by the corresponding scanning tool.
2. If the DTC has not appeared in 100 driving periods, it is allowed to be cleared from
the historical data.
Diagnosis Help
When the intermittent DTC is diagnosed, make a thorough check on the connection of
wire harnesses and connectors. This check shall include the following items:
1. Dismantle protective ducts, and check whether the circuit is damaged, short circuited
and contaminated,
2. Check whether terminals are distorted and damaged,
3. Check the contact keeping performance of terminals, and
4. Take off terminals from the connector, and check whether pressed lead wire terminals
are unfirm.
 Benjoy Maintenance Manual — Chassis Volume ABS-104

C0198- Incorrect Output of Pulse Width Modulation for Ignition Loss on Bumpy
Road
Step Diagnostic Action Expectation Yes No
Value
1 Complete the diagnostic circuit check? Go to Step Go to the
2 Diagnosis
System
Check.
2 1. Turn off the ignition switch. 5%-95% Go to Step Go to Step
2. Disconnect the connection of ABS ECU wire 3 4
harness.
3. Install a storage box which can store pulse width
modulation signal for ignition loss on bumpy road.
4. Turn on the ignition switch.
5. Use the diagnostic instrument to confine duty ratio
within 5%-95%.
6. Measure the AC duty ratio between bumpy-road
insufficient ignition signal circuit and good
grounding circuit.
Is duty ratio within the prescribed range?
3 Measure the frequency of direct current between 121-134 Hz Go to Step Go to Step
bumpy-road ignition loss signal circuit and good 6 4
grounding circuit.
4 1. Turn off the ignition switch. Voltage of Go to Step Go to Step
2. Disconnect the storage box. storage 8 5
3. Turn on the ignition switch and shut down the battery
generator.
4. Measure the voltage between bumpy-road ignition
loss signal circuit and good grounding circuit.
Is the measured voltage approximate to the specified
value?
5 1. Turn off the ignition switch. Go to Step Go to Step
2. Disconnect the wire harness connection of power 11 8
assembly control module.
3. In the following cases, check the bumpy-road
ignition loss signal circuit:
 Short circuit against storage battery, and
 Short circuit against grounding.
Have you found and corrected these states?
6 1. Turn off the ignition switch. Go to Step Go to Step
2. Disconnect the wire harness connection of power 11 7
assembly control module.
3. In the following cases, check the needed torque
signal circuit:
 Open circuit; and
 High resistance.
Have you found and corrected these states?
 Benjoy Maintenance Manual — Chassis Volume ABS-105

7 Check whether the wire harness of power assembly Go to Step Go to Step

control module under poor contact. 11 9
Have you found and corrected this state?
8 Check whether the ECU wire harness ABS under poor Go to Step Go to Step
contact. 11 10
Have you found and corrected this state?
9 Replace the engine control module--- power assembly Go to Step
control module. 11
Complete the repair?
10 Replace the ABS ECU. See the Replacement of Go to Step
Electronic Control Module (ECM) for reference. 11
Complete the repair?
11 1. Clear the DTC by the diagnostic instrument. Go to Step System
2. Start the vehicle, under the state of the DTC being 2 OK
within the specified range.
Is the DTC reset?
 Benjoy Maintenance Manual — Chassis Volume ABS-106

Basic Check for ABS

1. Check the level of fluid in stock solution tank.
Basic Check 1:
Check the level and leakage of brake fluid and the thickness of brake disk. Add the brake
fluid, if its level is found low.
2. Check whether any leakage take places in the braking pipeline, the ABS actuator and
the area around electric unit (control unit). If the leakage is found, conduct the
following check:
(1) Screw down the oil pipe nut of pipeline to the extent of specified tightening torque
(18~30N·m), if the joint position of ABS actuator and electric unit (control unit)
loosens. Later, recheck the condition and ensure that the brake fluid leakage no
longer appears.
(2) If the oil pipe nut at joint position and the threaded section of actuator are damaged,
replace them by new ones. Then, recheck the condition and ensure that the brake
fluid leakage no longer appears.
(3) If the leakage is found at other place besides the joint position of actuator, use a
clean cloth to wipe away the leakage and then recheck the condition. If the leakage
still arises, replace the damaged spare parts.
(4) If the leakage is found at actuator body, use a clean cloth to wipe away the leakage
and then recheck the condition. If the leakage still arises, replace the ABS actuator
and the electric unit (control unit).
Attention:
Do not disassemble the ABS actuator and the electric unit (control unit), with the
exception of special requirements.
3. Check whether (front and rear) brake disks are abraded.
Basic Check 2:
Check for Storage Battery and Loose Power Circuit Ends
Check whether the anodic/cathodic end and the grounding end become loose. At the
same time, confirm whether the voltage of storage battery is normal.
Basic Check 3:
Check for ABS Alarm Lamp and Braking alarm lamp
1. Ensure that the ABS alarm lamp is turned on for approximately 1 second and the brake
alarm light brighten, when the ignition switch is turned on. If those lamps do not light,
they shall be checked by the diagnostic instrument.
2. Check: whether the ABS alarm lamp goes out when the ignition switch has been
turned on for nearly 1 second; and whether the braking alarm lamp is out. If those
lamps still lights, the self-diagnosis shall be executed.
3. If the ABS alarm lamp does not go out within 10 second posterior to startup of engine,
the self-diagnosis for ABS actuator and electric unit (control unit) shall be executed.
4. After the completion of self-diagnosis, it is required to clear the self-diagnosis result.
Attention:
 Benjoy Maintenance Manual — Chassis Volume ABS-107

The braking alarm lamp is turned on when the parking braking is implemented (with the
switch turned on) and the brake fluid level sensor works (with the brake fluid being
insufficient).
 Benjoy Maintenance Manual — Chassis Volume ABS-108

Wheel Speed Sensor

Dismantlement and Installation

ABS001 ABS002

Front Wheel Rear Wheel

Dismantlement Steps:
Front Wheels
1. Raise the vehicle by the jack.
ABS003
2. Disconnect the sensor wire harness.
Attention:
The sensor wire harness is in the engine cabin.

1. Screw down the set bolt of sensor, and then

ABS004
slowly take out the sensor.

Attentions:
Do not forcibly drag the wire harness of wheel
speed sensor.
Heed the clearance between wheel speed
sensor and wheel hub.

ABS005

Rear Wheels
1. Jack up the vehicle, and dismount tyres of rear
wheels by tools.
Attention:
Unscrew the set bolts of tyres before jacking
up the vehicle.
 Benjoy Maintenance Manual — Chassis Volume ABS-109

2. Disconnect the ABS wire harness joint. ABS006

1. Screw down the set bolt of sensor, and then

slowly take out the sensor.

ABS007
Attentions:
Do not forcibly drag the wire harness of wheel
speed sensor.
Heed the clearance between wheel speed
sensor and wheel hub.

Check after Dismantlement

Check to ensure that no foreign bodies such as
metallic scraps are in the sensor mounting hole or
on the surface of brake disk.

Installation Steps:
Pay attention to the following items and screw down the bolts to the extent of specified
tightening torque.
Replace the wheel speed sensor, if there is any condition falling short to standard.
1. Before installing the front sensor, totally impact the pressed support and its rubber
clamp till they are locked well, lest the sensor wire harness would twist. Install the
protecting sleeve keyway to the support according to the yellow line which is on the
wire harness toward the opening of support. After the installation, the wire harness
shall not twist.
2. Having been installed, the wire harness shall not twist.
 Benjoy Maintenance Manual — Chassis Volume ABS-110

Sensor Rotor
Dismantlement and Installation

ABS008 ABS009

(Front Wheel) (Rear Wheel)

Dismantlement Steps:
Front Sensor Rotor
Since the sensor rotor can not be disassembled, the wheel hub, the bearing assembly and
the sensor shall be dismantled as integration.
(See the Dismantlement for Front Suspension for reference.)
Rear Sensor Rotor
Since the sensor rotor can not be disassembled, the wheel hub, the bearing assembly and
the sensor shall be dismantled as integration.
(See the Dismantlement for Rear Suspension for reference.)
 Benjoy Maintenance Manual — Chassis Volume ABS-111

ABS Assembly
Dismantlement and Installation for ABS Assembly

Dismantlement Steps:
Installation Position for ABS Assembly
The ABS assembly is at the left side of engine cabin.
1. Turn off the ignition switch, and disconnect
ABS010
the cathode of storage battery.

2. Take off the wire harness of ABS assembly.

(Draw the ABS fixing snapin, and then
disconnect the ABS wire harness.)
ABS011

3. Tread the brake pedal for more than 60mm

and fix it by the pedal clamp. In this way, the
centre valve of master cylinder closes up so
that the brake fluid will not effuse from the
outlet when is ABS is opened.
 Benjoy Maintenance Manual — Chassis Volume ABS-112

4. Take off ABS brake pipes which are on the

ABS012
HCU and connected with the master cylinder,
make some marks and shortly stop up outlets
A B
by plugs.

ABS013

5. Take off brake fluid pipes 1~4 which lead to

corresponding wheels, make some marks
and shortly stop up outlets by plugs.

1 2 3 4

ABS014

6. Take off bolts, which fix the ABS assembly on

the support.

7. Dismount the whole ABS assembly from the

support.

Installation:
The steps for installation are just contrary to those for dismantlement.
Attention:
Braking pipeline joint which connects with ABS hydraulic adjuster shall be screwed
to the extent of specified tightening torque.
Tightening Torque: 18~30N·m
Only when the braking pipe is to be installed, can the plug for hydraulic opening on
 Benjoy Maintenance Manual — Chassis Volume ABS-113

ABS assembly be dismounted, so as to avoid foreign bodies from entering the

braking system.
1. Install the ABS assembly to the support, and screw the assembly with the specified
tightening torque.
2. Dismount the plug for hydraulic opening, and install the braking pipe so as to confirm
the correct pipe connection.
3. Install the braking pipe which leads to the master cylinder.
4. Screw down the braking pipe with the specified tightening torque.
5. Fill the stock solution tank with the new brake fluid till the fluid level reaches the
position “MAX”; then, deflate the ABS by specified means.
6. With the ignition switch turned on, the effect that the ABS alarm lamp goes on for 1.7
seconds and then goes out shall be made.
7. Clear the DTC memory, and then see whether the DTC reappears.
8. Finally, drive the car to validate functions of ABS. It is required that the rebound of
pedal be palpable.

Note:
Replace the ABS assembly, in case of a faulty ABS master cylinder.
 Benjoy Maintenance Manual — Chassis Volume ABS-114

Deflation for ABS

The Automatic Deflation Program for ABS shall be executed, once the
following conditions appear.
1. It is impossible to achieve the intended height or perception of brake pedal by the
traditional deflation method for wheel cylinder.
2. The HCU (hydraulic control unit) is replaced.
3. The extreme loss on brake fluid takes place.
4. It is suspected that the ABS has inhaled air.
This program employs the diagnostic instrument to run valves and pumps of ABS and
eliminate air from the secondary circuits. Usually, these secondary circuits are closed, but
they will be opened during the initialization of vehicle startup and the application of ABS.
The automatic deflation program opens these secondary circuits, and makes all air flow to
the wheel cylinder and collected in the HCU, where the air can be eliminated from the
ABS.
Automatic Deflation Program
Necessary Items:
1. The diagnostic instrument with correct software;
2. The brake fluid;
3. The jack;
4. The deflation bottle with hose, which is used for reclaiming the brake fluid of vehicle;
5. The proper safety facilities, including safety glasses; and
6. Two maintenance staff – one that treads the brake pedal and controls the diagnostic
instrument; the other one keeps the level of hydraulic oil in main chamber of main
cylinder, and open/close the deflation screws in accordance with the process of
diagnostic instrument.
Preliminary Check
1. Check the charge state of storage battery. Maintain storage battery and charging
system, subject to the actual requirement.
2. Connect the diagnostic instrument, and select current and historical DTCs. Before
executing the deflation program for ABS, repair all DTCs.
3. Check whether the appearance is damaged and any leakage occurs. Carry out the
maintenance, if necessary.
Actions before Deflation
1. Start the engine.
2. Connect the diagnostic instrument to achieve the communication between it and
ABS.
3. Jack up the vehicle and properly support it.
Deflation on Vehicle
Attention:
The automatic deflation program can be terminated whenever the key “EXIT” on
diagnostic instrument is pressed.
1. Select the “Automatic Deflation Program”on diagnostic instrument, and acts in the
light of instruction. (See actual diagnostic instrument program for reference)
2. In the course of basic deflation and automatic deflation, it is necessary to manually
tread the brake pedal and keep the level of brake fluid in main cylinder.
3. When deflating a wheel, ensure that the hose connect with the deflation screw and air
 Benjoy Maintenance Manual — Chassis Volume ABS-115

is evacuated to the chamber with brake fluid. Such a chamber shall be kept 30mm
higher than the bolt of hose full of brake fluid, in order to prevent air from going into
the braking pipelines again.
4. The first step is basic deflation, which must be done before the automatic deflation so
as to obtain the intended height and feeling of brake pedal and ensure the best
performance of ABS.
5. It is the first step of automatic deflation to rotate pumps and depressurizing valves for
30 seconds or so. During this step, deflation bolts don’ t need opening and closing, but
the brake pedal shall be pressurized and depressurized continuously.
6. Within the next step, the diagnostic instrument requires the maintenance staff to open
one deflation bolt and then repeatedly checks pressurizing valves and pump motors
for approximately 30 seconds. During this course, the brake pedal shall be
pressurized and depressurized continuously.
7. The diagnostic instrument dittoes Step 6 to deflate the rest deflation bolts.
8. When the automatic deflation program is ends, the diagnostic instrument displays the
corresponding information.
9. Tread the brake pedal to measure its height and feeling. Repeat Steps 1~8 till the
conditions of brake pedal become acceptable.
Attention:
During the repeated operation, the automatic deflation program may temporarily stop and
come into the “Waiting by mean of Cool Down”mode. Such a program will not proceed
until the timer is overtime; in addition, it is impossible for the program to skip this process.
Diagnosis Steps on Vehicle:
1. Enter the Trouble Diagnosis System for JAC Cars.
Trouble Diagnosis
System for JAC Cars

Developed by LAUNCH Tech Co.,

Ltd.
Online Login

Start

Exit Original BOX Help

Version Informatio
n
Start

Select Diagnosis Software Version

2. Select the Special V10.01 Complete System of JAC Cars.
All Systems of JAC Cars

All systems of JAC cars made in

2007 or earlier can be diagnosed by
this program.

Previous Next Page OK

Page

Back Help

Start
Benjoy Maintenance Manual — Chassis Volume ABS-116
 Benjoy Maintenance Manual — Chassis Volume ABS-117

3. Enter the automatic deflation program. Carry out the operation in accordance with
system prompts. Deflation Mode

Deflation mode has been launched.

Please operate in accordance with
system prompts.

Yes No

Start

4. Execute the first step of system deflation. Deflation Mode

Step 1: Close all deflation bolts, tread

brake pedal, and then click “Yes”to
continue.

Yes No

Start

5. The deflation is now going.

Deflation Mode

Deflation mode is now going.

Pumps have been started.
This process lasts for 20 seconds.

First Page of Diagnosis

Start
 Benjoy Maintenance Manual — Chassis Volume ABS-118

6. Complete Step 1 Deflation Mode

Step 1 is completed.

OK

Start

7. Proceed to Step 2 for deflation. Deflation Mode

Step 2:
Deflation for right rear wheel is now
launched.
Connect the oil discharge pipe,
Open right rear deflation bolt, and
then tread brake pedal.

OK

Start

Deflation Mode
8. The deflation is now going.

Deflation mode is now going.

Pumps have been started.
This process lasts for 20 seconds.

First Page of Diagnosis

Start
 Benjoy Maintenance Manual — Chassis Volume ABS-119

9. Proceed to Step 3 for deflation Deflation Mode

Step 3:
Deflation for left rear wheel is now
launched.
Connect the oil discharge pipe,
Open left rear deflation bolt, and
then tread brake pedal.

OK

Start

Deflation Mode
10. The deflation is now going.

Deflation mode is now going.

Pumps have been started.
This process lasts for 20 seconds.

First Page of Diagnosis

Start

Deflation Mode
11. Complete Step 3.

Step 3 is completed.

OK

Start
 Benjoy Maintenance Manual — Chassis Volume ABS-120

Deflation Mode
12. Proceed to Step 4 for deflation.

Deflation mode is now going.

Pumps have been started.
This process lasts for 20 seconds.

First Page of Diagnosis

Start

13. The deflation is now going. Deflation Mode

Step 4:
Deflation for left front wheel is now
launched.
Connect the oil discharge pipe,
Open left front deflation bolt, and
then tread brake pedal.

OK

Start

14. Complete Step 4. Deflation Mode

Step 4 is completed.

OK

Start
 Benjoy Maintenance Manual — Chassis Volume ABS-121

15. Proceed to Step 5 for deflation. Deflation Mode

Step 5:
Deflation for right front wheel is now
launched.
Connect the oil discharge pipe,
Open right front deflation bolt, and
then tread brake pedal.

OK

Start

Deflation Mode
16. The deflation is now going.

Deflation mode is now going.

Pumps have been started.
This process lasts for 20 seconds.

First Page of Diagnosis

Start

17. Complete the whole deflation process. Deflation Mode

Deflation is all over.

OK

Start
 Chassis Volume PS-1

Overview
Hydraulic steering gear which responds to engine rotating speed has been adopted in all
models of vehicles. Its characteristics are as follows: three-spoke steering wheel is
adopted; steering column has damper and gradient steering mechanism; blade-type
steering driving gear of oil pump with oil flow-control system for steering gear and the rack
and pinion structural model with the whole rod system have been used.

Overhaul Specifications
Item Specification

Gearbox Steering gear casing model Rack and pinion

Oil pump model Blade type

Oil pump Displacement (ml/r) 8.5

Max. pressure (kgf/m3) 90+8

Boundary
Item Standard value
value
Not more than
Halted state of engine －
15
Steering wheel gap mm
Hydraulic pressure
30 30
working condition
Interior wheel 37°45′16″±1°30′ －
Steering angle
Exterior wheel 29°46′16″±1°30′ －
Starting torque of ball joint of steering tie rod end Nm 0.5~2.5 －
Static steering power N Less than 34 －
Allowable differential of fluctuation N Less than 5.9 －
Relief pressure of oil
8.8~9.6 －
pump
No-load pressure 0.8~1.0 －
Oil pump pressure Mpa
Maintaining hydraulic
pressure of steering 8.8~9.6 －
gear
Operating pressure of oil ON→ OFF 1.5~2.0 －
pressure switch of power
OFF→ ON 0.7~1.2 －
steering Mpa
Total preload of pinion Nm 0.7~1.4 －
Revolving resistance of steering tie rod ball joint N 8~20 －
Revolving torque of steering tie rod ball joint Nm 2~5 －
Side gap of oil pump belt pulley assembly mm － 0.1
 Chassis Volume PS-2

Precautions
Precautions for Secondary Restriction System (SRS):
The pre-tensioners of airbag and safety belt as well as the safety belt are used at the
same time, which could prevent drivers and the front passengers from injury due to
collision or decrease the severity. Please refer to the SRS section of this manual for
details on how to maintain this system correctly.

Caution:
1. All maintenance operation can only be executed by maintenance service center of
authorized JAC dealership, in order to decrease the possibility of personal injury in the
collision due to the failure of SRS system.
2. Improper maintenance, including improper dismantlement and reassembly for SRS
system, may result in system malfunction and cause personal injury accident. Please
refer to SRS section of this manual for dismantling means of spiral cable and safety
airbag module.
3. Except the operations illustrated in this manual, it is not allowed to test any circuit of
SRS system with electrical test equipment. SRS circuit wire harness can be identified
by yellow wire harness or wire harness joint.

Precautions for Steering System:

① When the steering system fails, please check item by item according to the specified
checking steps and methods in the determining criterion of trouble. Don’ t replace the
components at random.
② Ensure that vehicles are landed on the ground and unloaded before dismantlement of
steering. Screw down for the last time and check the positioning of wheel.
③ Please pay attention to the following precautions in dismantlement process.
1. Clean up the external surface of steering gear thoroughly before dismantlement.
2. Dismantlement shall be carried out in the clean working area. It is extremely important
to keep inner parts from being polluted by dust or other foreign substance.
3. In order to carry out assembly process more simply and correctly, please lay the
dismantled parts on parts rack in order.
4. Use nylon cloth or paper to clean parts; wiping cloth for ordinary plant will leave
chopped cloth behind which may affect the normal operation of parts.
5. Please don’ t use the unusable parts repeatedly.
6. Please apply specified lubricating grease on prescribed parts before assembly.
 Chassis Volume PS-3

Preparations
Lubricant
Item Specified lubricant Qty.
Bearing
O-ring
Oil seal
Power PSF-3 As specified
Special tools
steering
oil Pinion and valve assembly
seals
Bellows Silicon lubricating
As specified
grease
Oil for power steering gear PSF-3 0.95kg
Flow control valve
Armature, blade, cam ring and
Oil pump
friction surface of pump PSF-3 As specified
housing
O-ring
Sealant and Cement
Specified sealing
Item rubber and binding Remarks
agent
End plug screw
Power Screw of supporting cover of Half-dry
3MATD product No.
steering gear power steering rack sealing
8663 or similar variety
housing Dustproof cover edge for ball rubber
joint of steering tie rod end

Special Tools for Maintenance

Name No. Tool Purpose
Drawing
For the
die of
dismantlement
steering JAC-T1D002
of steering
wheel Drawing die of steering
die
wheel

Drawing
For disconnection Ball
Drawing
die of joint
die
of ball joint of front Cord
steering
JAC-T1D003 end control arm
driving
and steering Nut
rod
knuckle
system
Detector
for power For measurement
steering JAC-T1D005 of power steering
hydraulic oil pressure
pressure
 Chassis Volume PS-4

Power Steering Liquid

Check the Liquid Level
1. Place the car on horizontal and flat road and start Liquid level
the engine. Rotate the steering wheel for several change：Within 5mm

times until the oil temperature increases to about

50— 60℃.
2. With the engine running, rotate the steering wheel
to the left and right till the end and repeat this
movement for several times until the liquor
becomes steady. Engine is Engine is
3. Check if the oil in the oil can is frothy or milkiness running stopped.

like. Check the liquor difference when the engine

is stopping and running. If liquor differential is
more than 5mm, then exhaust the air.
Check Liquor Leakage
Check if there is any leakage, crack, damage,
looseness or abrasion.
1. Keep the engine running until the temperature of
the oil in power steering oil can achieve about
50~60℃ and then keep the engine running at idle
speed.
2. Turn the steering wheel from the dead center on
the left side to the dead center at right side for
several times.
3. Turn the steering wheel clockwise/anti-clockwise to the end center and stay for 5
seconds to check if there is any oil leakage.
Attention:
Keeping the steering wheel on the dead center for more than 15 seconds may
cause damage to the pump.
4. If the leakage is found on the joint, loose and then fasten the oil pipe nut again.
Fastening it excessively would cause damage to the O ring washer or the joint.
5. If the leakage is arising from the oil pump, please check the oil pump.
6. Check if there is any accumulated oil on the dust cover of the steering gear.
Replacement of Steering Fluid
1. Lift the front wheel and support it with jack.
2. Dismantle the induction oil pipe and oil return pipe on the oil pump and discharge the
hydraulic oil into the container.
3. Dismantle the joint of the oil return pipe of the steering gear and discharge the
hydraulic oil into the container.
4. Turn the steering wheel to the two limit positions for several times to discharge all the
oil in the oil cylinder on the both sides of steering gear (the oil is discharged from the
oil return port of the steering gear).
5. Dismantle the oil pipes and discharge all the remaining oil in the pipes.
 Chassis Volume PS-5

6. Connect one end (pay attention to the direction) of the high pressure flowline of
hydraulic steering pump with the oil inlet of the traverser and fasten the nut.
7. Connect one end (pay attention to the direction) of the oil return pipe assembly with
the oil outlet of the traverser, fasten the nut and fix it with 4 bolts along the engine and
the front beam.
8. Fix the support rack of the power steering oil can on the corresponding position on the
front girder of engine cabin with 2 bolts.
9. Connect hose on the lower half part of power steering oil can with the oil return pipe
assembly and connect the flowline of the oil can with the power steering pump with
pipe clamp respectively, and then fix the power steering oil can on the oil can support
rack.
10. Connect the other end of the high pressure flowline of the power steering pump with
the power steering pump and fix it with perforation bolt and gasket (copper gasket is
set outside and plastic gasket inside. Backward setting is forbidden.).
11. Add the new steering fluid.
12. Start the engine, then the oil level would decrease. Stop the engine and charge oil
immediately until the oil level is between MIN and MAX. Then start the engine again
and turn the steering wheel to the dead center for less than 5 seconds.
13. Close the engine. Recheck if the oil level in the oil can is between MIN and MAX. If
not, oil shall be added.
Air Release of Hydraulic System
1. Lift the front wheels with jack and bear them with rigid support.
2. Revolve the oil pump belt by hand for several times.
3. Turn the steering wheel to the left & right till the end and repeat it for 5~6 times.
4. Cut off the high voltage cable, and then turn the steering wheel to the left & right till
the end and repeat it for 5~6 times (take 15~20 seconds) while operating the starting
motor intermittently.
Attention:
① Add the steering gear oil during the course of air release to prevent the oil level
from falling below the low position of the filter.
② Release the air when the engine is running. The air would be stopped and
sucked into the oil. Thus the air could only be released while the crankshaft is
revolving.
5. Connect the ignition cable and start up the engine (idle speed).
6. Turn left/right the steering wheel until there is no air bubble in the oil can.
7. Make sure that the steering gear oil doesn’ t appear Change of oil level：
milky and the oil level has increased to the position within 5mm

specified by the dipstick.

8. Make sure that the change of oil level is small when
turning left/right the steering wheel.
9. Check if the change of the oil level is within 5mm
when the engine is stopping & running.
Attention: When engine is When engine is
running stopping
① If the change of oil level exceeds 5mm, the air
 Chassis Volume PS-6

would not be deflated from the system

completely. Thus it shall be clear completely.
② If the oil level increases suddenly when the engine has stopped, it indicates
that the air has not been deflated completely.
③ If the air is not deflated completely, there would be abnormal noise generated from
the oil pump and the flow control valve. This trouble would shorten the ages of oil
pump etc.

Steering Wheel
Check the Gap of Steering Wheel
1. Make the front wheels run forward straightly
when the engine is running (hydraulic system
is operating).
2. Turn left/right the steering wheel slightly and
measure the gap on the circle of steering
wheel before the steering wheel begins to
move.
Checking Standard for Free Stroke: 0-30mm
3. When the gap exceeds the high-point, it is necessary to check the gap between the
steering shaft joint and the steering linkage. Adjust or replace relevant parts according
to the specific condition.
4. If the gap is still beyond the high-point value, turn the steering wheel dead ahead and
set 5N load on the circle of the steering wheel, and then check the gap again.
Standard Value (gap of steering wheel when the engine is stopped): less than 15mm
Attention:
If the gap exceeds the standard value, you shall dismantle the steering gear casing
and check the total torque of pinion.

Check the Self-righting Capacity of Steering Wheel

This test shall be operated when the vehicle is running
on the road and the following actions shall be
taken for checking it.
1. Check the driving “feel”by operating slow turn
and quick turn to make sure there is no
difference between the steering effort needed
for turning between left and right and the
self-righting effort of the steering wheel.
2. When the vehicle is running at the speed of 20~30km/h, turn the steering wheel for
90°and release it after 1 or 2 seconds. If the steering wheel gets back above 70°
subsequently, the self-righting capacity could be considered good.
Remark:
While turning the steering wheel rapidly, the vehicle would be felt “heavy”temporarily, but
this is not an abnormal condition (this condition is caused by insufficient oil supply of the
oil pump under the idle speed mode).
 Chassis Volume PS-7

Check the Static Steering Effort of Steering Wheel

1. Stop the vehicle on the flat road and turn the steering wheel to the right ahead
position.
2. Start up the engine and adjust its running
speed to 1,000±100r/min.
Attention:
After checking the running speed of the engine, be
sure to get it back to the standard idle speed.
3. Connect one spring balance with the outer circle of the steering wheel to measure the
steering effort needed for turning from the position right ahead to right/left (within 1.5
circle). Besides, you shall also check if there is any obvious fluctuation of the steering
effort needed.
Standard value:
Steering effort: less than 34N
Allowance fluctuation: less than 5.9N
4. If the effort measured exceeds the standard value, please check and adjust referring
to the descriptions of troubleshooting.
Check Steering Angle of Front Wheels
1. Set the front wheels on the testing device of turning
radius to measure the steering angle.
Standard value:
Interior wheel: 37°45′16″±1°30'
Exterior wheel: 29°46′34″±1°30'
2. If the steering angle is not within the range of standard
value, it may be because that the toe-in is incorrect.
Adjust the toe-in and then check the steering angle
again.
3. Adjustment of steering angle:
When the steering angle exceeds the standard value, loosen the locknut of left/right
steering tie rods and revolve the left/right tie rods separately with spanner to adjust the
steering angle to the standard value. Then fasten the locknut to the fastening torque
45~55N·m. When adjusting the length of left/right tie rods, please pay attention to that the
length of them shall be the same (opposite direction). (As the following figure shows)
 Chassis Volume PS-8

End of bellows
assembly slot Locknut
波纹管装配槽端部 锁紧螺母

104mm

Note: when the steering angle of interior wheel exceeds the standard value, revolve the
tie rode on this side outwards to extend the steering angle of interior wheel; when the
steering angle of exterior wheel exceeds the standard value, revolve the tie rode on this
side outwards to reduce the steering angle of exterior wheel.
1. The toe-in, other parameters of four-wheel alignment and steering angle adjustment
are connected with each other;
2. The camber angle and castor angle which are preset before leaving the factory shall not be
adjusted;
3. If the camber is not within the range of standard value, please check and replace the
distorted/curving/damaged parts;
 Chassis Volume PS-9

Dismantlement and reassembly

Dismantlement
1. Cut off negative anchoring wire of storage
battery and wait for more than 3 minutes. PS001

2. Dismantle the upper and the lower protective

PS002
covers of steering column.

3. Insert right-angled screwdriver into the small

PS003
hole at the lower part of steering wheel.
Rotate the screw driver for 90°. Take out the
steering wheel cover assembly when the
steering wheel cover pops out to the driver’s
side. (It includes the driver safety airbag
module.)

4. Screw off the fixing nut of steering wheel.

Tightening Torque: 60~100N•m PS004
 Chassis Volume PS-10

5. Lift up the steering wheel, cut off the horn wire

harness and the clock spring wire harness. PS005

6. Take out steering wheel from the spline of PS006

steering shaft.
Note:
Follow the direction as shown in the picture.

Reassembly
The reassembly procedure is reverse to the dismantlement procedure.
 Chassis Volume PS-11

Steering Column

Dismantlement and reassembly

1. Power steering gear assembly 2. Steering column assembly

3. Steering wheel assembly 4. Protective column assembly of steering
column

Dismantlement Steps: PS007

1. Cut off negative anchoring wire of storage

battery and wait for more than 3 minutes.

2. Dismantle the upper and the lower protective

PS008
covers of steering column.
 Chassis Volume PS-12

3. Insert right-angled screwdriver into the small

hole at the lower part of steering wheel. PS009
Rotate screw driver 90°. Take out steering
wheel cover assembly. (It includes driver
safety airbag module).

4. Loosen the steering wheel nut.

PS010

5. Lift up the steering wheel and cut off the horn

wire harness and the clock spring wire
harness.
PS011

6. Take out steering wheel from the spline of

steering shaft.
Note:
PS012
Follow the direction as shown in the picture.
 Chassis Volume PS-13

7. Dismantle the lower protective cover of

console on driver’s side. PS013
(Please refer to console dismantlement)

8. Unscrew the three fixing bolts of combined PS014

switch.

9. Dismantle the wire harness joint which links PS015

to the combined switch. Cut off the wire
harness and then take out the combined
switch.

10. Cut off the wire harness which links to the PS016
ignition lock core.
 Chassis Volume PS-14

11. Dismantle the connecting bolt of universal PS017

joint of steering column from the lower side
of cab. Cut off the connection between the
steering column and steering gear.

12.Dismantle the four locknuts which fix steering

column to instrument interior framework. PS018

PS019

13. Lower the steering column and take out PS020

steering column from the cab.
 Chassis Volume PS-15

Inspection after Dismantlement

1. Check if there is any crack, distortion or damage on steering column. If so, it shall be
replaced.
2. Check if the spline gear of steering shaft is abraded or broken. If so, they shall be
replaced.

Reassembly
The reassembly procedure is reverse to the dismantlement procedure.

Inspection after Reassembly

With the wheel being straightly forward, rotate the steering wheel to check its sensitivity.
 Chassis Volume PS-15

Power Steering Gear

Dismantlement and Reassembly

40~55N•m

56-70 N•m

1. Cutting ferrule-type float hexagon bolt 2. I-type all-metal hexagon

locknut
3. Joint of steering tie rod end and steering knuckle
4. Connecting stiffening plate II for auxiliary frame
5. Mounting panel support I for front suspension arm
6. Welding assembly components for underframe
7. Clamp for sucker and oil return pipe of the power steering gear
8. Bolt 9.Power steering gear assembly

Dismantlement Steps PS021

1. Discharge the power steering liquid in the
power steering oil can.
Note:
Discharge the power steering liquid refering to the replacement of power
steering liquid described in this chapter.
2. Dismantle the front wheel tyres with tools (left,
right).
Tightening Torque: 86~116 N•m
Chassis Volume PS-16
 Chassis Volume PS-17

3. Dismantle the air filter and the air channel

(intake). PS022

4. Dismantle charcoal canister. PS023

(Take out the charcoal canister as shown in
the illustration.)

5. Loosen the oil pipe joint nut and cut off the high
and low oil pipes at steering gear. PS024
Attention:
Pay attention to the reassembly for washer.

6. Dismantle the fixing bolt connected with the

power steering gear.
PS025

7. Lift the vehicle and dismantle the central flow stop plate.
Attention:
 Chassis Volume PS-18

Please be careful when lifting the car.

 Chassis Volume PS-19

8. Screw off the mounting nut at the lower part of PS026

front antiways bar assembly and take off it from
the stabilizer bar.

9. Screw off the mounting nut at the upper part of

the front antiways bar and take off it from the PS027
damper stay.

10.Lift the car, screw off the fixing nut of the PS028
mounting panel support rack for front
suspension arm and dismantle the mounting
panel supports (left, right).

11. Screw off the fixing bolt of underframe

connection stiffening plate and dismantle the PS029
underframe connection stiffening plate.

12.Screw off the fixing bolt of engine bracket plate

and dismantle the engine bracket plate PS030
assembly.
 Chassis Volume PS-20

13.Screw off the fixing nut and dismantle the

forepart exhaust pipe. PS031

PS032

14.Dismantle the fixing bolt of dog plate for front PS033

antisway bar. Dismantle the front antisway bar,
the dog plate for front antisway bar and the dog
plate liner of the front antisway bar.

15.Unscrew the nut and dismantle the ball joint PS034

connecting the steering tie rod and the steering
knuckle.

16. Dismantle the 4 fixing nuts of steering gear.

PS035
 Chassis Volume PS-21

17.Lower the steering gear and take out steering

gear slowly from the right side of car. PS036

Inspection after Dismantlement PS037

1. Inspect the Total Torque of Pinion.
Screw the pinion with tools at the speed of
4~6 seconds/circle to check the total torque of
pinion.
Standard Value: 0.7－1.4Nm
［Torque Variation: 0.4Nm］
Remark
1. Dismantle the bellows from the rack casing during the measure process. Measure the
torque of pinion during the whole stroke of rack.
2. If the value measured is not within the standard value range, you shall firstly adjust
the bearing cover of rack and then check the total startup torque of pinion again.
3. If the total startup torque can not be adjusted to be within the standard range by
adjusting the bearing cover of rack, you shall check the bearing cover of rack, the
bearing spring of rack and the rack bearing. Replace the parts if necessary.

2. Check Oscillation Resistance of Steering

Tie Rod PS038
① Make the tie rod oscillate rapidly for 10 times.
② Measure the oscillation resistance of steering
tie rod with the spring.
Standard Value: 8－20N [2－5Nm]
③ If the value measured exceeds the standard
value, the steering tie rod assembly shall be
replaced.
④ Even if the measured value is below the
standard value, but the steering tie rode
oscillates stably without excessive large gap,
and then the tie rode could still be used.
Reassembly
The reassembly procedure is reverse to the dismantlement procedure.
Inspection after Reassembly
1. Check if the steering wheel is sensitive when it is straightly forward.
 Chassis Volume PS-22

2. Check the location of front wheel.

 Chassis Volume PS-23

Power Steering Pump

Dismantlement and Reassembly

Components Diagram

External members of steering gear rack

Flat nut

1. Oil supply tube 2. O-ring 3. Locknut for steering tie rod end
4. Steering tie rod end 5. Dustproof cover 6. Bellows snap-in
7. Bellows collar 8. Bellows 9. Steering tie rod
10. Cane washer 11. Locknut 12. Rack supporting cover
13. Rack supporting cover 14. Rack bearing 15. End plug
16. Self-locking nut 17. Valve casing assembly 18. Oil seal
19. Pinion and valve assembly 20. Sealing ring 21. Ball bearing
22. Oil seal 23. Valve casing 24. Circlip
25. Rack stopper turnbuckle 26. Rack liner 27. Rack
28. O-ring 29. Oil seal 30. Sealing ring
31. O-ring 32. Ball bearing 33. Needle bearing
34. Oil seal 35. Supporting washer 36. Rack cover
 Chassis Volume PS-24

Dismantlement Procedure PS039

1. Dismantle the steering tie rod/vane washer.

Loosen the vane washer which is used to fix
the steering tie rod and the rack with chisel.

2. Dismantle the bearing cover of rack. PS040

PS041
3. Dismantle the oil seal/pinion and the valve
assembly. Dismantle the pinion by hammering
it with plastic hammer.

4. Dismantle the sealing ring. PS042

Cut sealing ring, auto pinion, valve assembly
and rack to dismantle them.
Attention:
When cutting the seal ring, please be careful to
avoid causing damage to the pinion and valve
assembly/rack.

PS043 Socket

5. Dismantle the bearing/oil seal.

Dismantle the oil seal and ball bearing from
valve casing with a sleeve.
 Chassis Volume PS-25

6. Dismantle the spring ring. PS044

① Screw the limit turnbuckle for rack clockwise till Gear Rack Limit
the spring ring end stretches from the slot of Swivel Nut

rack cover.
② Screw the limit turnbuckle of rack
anti-clockwise to dismantle the spring ring.

Gear Rack
Spring
Ring

7. Dismantle rack. PS045

Pull out the rack slowly and take out the limit
turnbuckle and the liner of rack.

8. Dismantle the oil seal.

Bend the oil seal partly and dismantle it from PS046
the rack liner.
Attention: Gear Rack Shell
It is required to avoid the damage of press
matching surface for oil seal.

9. Dismantle the ball bearing.

PS047 Copper Bar

Ball Bearing

10. Dismantle needle bearing. PS048

Attention:
Don’t stretch the tool excessively to avoid the
damage of the inside of casing.

Needle Bearing
 Chassis Volume PS-26

11. Dismantle the oil seal/bearing washer.

Dismantle the bearing washer and oil seal PS049
from the gear shell with a tube or similar tools. Tube

Attention:
Be careful to avoid the damage of inner
surface of gear casing rack.

Bearing Washer

Oil Seal

Inspection after Dismantlement. PS050

1. Rack Inspection
① Check if the rack surface is abraded or
damaged.
② Check if the contact surface of oil seal is
abraded or damaged.
③ Check if rack is bended or distorted.
④ Check if the oil seal ring is damaged or
abraded.
⑤ Check if the oil seal is damaged or abraded.
2. Check of Pinion and Valve Assembly PS051
① Check if there is any crack, damage,
shedding or distortion on the gear surface of
the gear shaft of pinion and valve assembly. If
there is any trouble, the pinion and valve
assembly shall be replaced.
② Check if the bearing of pinion and valve
assembly is cracked or revolves inflexibly. If
so, a new bearing shall be mounted.
③ Check if the seal ring is damaged or abraded.
If necessary, the new seal ring shall be
mounted.
Attention:
① Be careful not to cause damage to the valve cover during the replacement
process.
② Mount the new seal ring on the tool and swell it.
③ Mount the seal ring swelled on the valve of valve core assembly and shape it.
3. Check for Bearing
① Check if there is seizure or other abnormal noise during the course of bearing
rotation.
② Check if the gap is too big.
③ Check if the needle of needle bearing is lost.
4. Check for Other Parts
① Check if there is any damage on the inner surface of power cylinder for rack casing
 Chassis Volume PS-27

body.
② Check if there is any damage, crack or aging on the dust cover.
③ Check if there is any rough abrasion or deterioration on the rack bearing.
④ Check if there is any rough abrasion on the rack liner.
 Chassis Volume PS-28

Assembly Steps PS052

1. Mount the bearing washer/oil seal. Mounting Tool Guide Sleeve

Oil Seal
Bearing Washer Stick

2. Mount the needle bearing/ball bearing.

PS053
Needle Bearing

Ball Bearing

3. Mount the oil seal /o-ring. PS054

① Smear a layer of specified oil on the outer
side of oil seal and O-ring.
Specified Oil: automatic transmission oil ATF Ⅲ
② Mount the oil seal by pressing with tool until
touching the rack liner end. O-ring

PS055

4. Mount rack.
① Smear a flat of universal lubrication on the
surface of rack.
Attention:
Prevent lubrication from blocking the passage
of rack. Passage

PS056
Oil Seal
② Mask the surface of rack with tool.
③ Smear specified oil on the tool.
Specified Oil: automatic transmission oil ATF
Ⅲ
④ Leveling the center of oil seal with rack to
Bearing
prevent the retainer spring from sliding. Insert Washer
the rack slowly from the side of power cylinder.
Chassis Volume PS-29
 Chassis Volume PS-30

5. Mount rack liner PS057

Wind the vinyl tape on rack end and smear a
layer of specified oil, and then mount the gear
liner and limit turnbuckle for rack.
Specified Oil: automatic transmission ATF Ⅲ
Vinyl Tape
Attention:
Gear Rack
Prevent the oil seal retainer from sliding out. Liner

6. Mount the spring ring.

Insert the spring ring into the limit turnbuckle PS058
Spring Ring Spring Ring
for rack through the power cylinder. Screw the
limit turnbuckle clockwise to insert the spring
ring deeply.
Attention:
Insert the spring ring into the limit turnbuckle role
Slot
while screwing the limit turnbuckle for rack Slot

clockwise.
7. Mount the oil seal/ball bearing.
PS059

Bearing
Oil Seal

PS060
8. Reassembly for sealing ring.
As the seal ring would open during the course
of reassembly, you shall contract the spring
ring with special tool or depress it by hand to
tighten it after the reassembly.

PS061
9. Mount the oil seal.
Depress the oil seal into the valve casing with
tool.
Attention:
To prevent the matching surface of valve
casing from seal malfunction, the upper About 1mm
surface of the oil seal shall stretch out 1mm
 Chassis Volume PS-31

from the rim of valve casing.

 Chassis Volume PS-32

10.Mount the end plug.

① Smear specified sealant on the threaded PS062 End
End Plug
portion of end plug. Plug
Specified Sealant:
3MATD product No. 8661 or equivalent variety
② Fix the threaded portion of end plug on 2
positions with plunger trip.
Sealant

11. Adjust the total torque of pinion. PS063

① Set the rack on the neutral position. Screw
down the bearing cover for rack to 15Nm.
② Revolve the pinion shaft clockwise at the
speed of 4~6 seconds/circle with tool on the
neutral position and reverse the bearing cover
of rack for 30~60°to adjust the torque to be
the standard value.

PS064

③ Revolve the pinion at the speed of 4~6

seconds/circle with tool to check the total
torque of it.
Standard Value: 0.7－1.4Nm
［Torque variety: 0.4Nm］
Attention:
① Set the standard value to its maximum during the adjustment course.
② When operating the rack along the shaft, please make sure it is not gnawed or
jammed.
Note:
When it could not be adjusted within the specified steering angle, the bearing cover
parts of rack shall be checked or replaced.
④ After adjusting it well, fix the bearing cover for rack with locknut.
12.Mount the vane washer/steering tie rod
After mounting the steering tie rod on the rack,
PS065
fold the end of vane washer into the slot (2
places) of steering tie rod.
 Chassis Volume PS-33

13.Mount the bellows ring.

PS066
① Clamp the bellows ring against the concave Bellows Ring

surface of it with vice.

Concave
Surface

② Bend the concave surface of bellows with a PS067

plastic hammer or similar tool as shown in the
picture.

14.Mount the dust cover. PS068

15.Mount the steering tie rod end. PS069

End of Bellows
Screw in the steering tie rod end and set its Assembly Slot Locknut
length as shown in the picture. And then fix it
with locknut.
 Chassis Volume PS-34

Power Steering Pump

Dismantlement & Reassembly

1. Power steering belt 2. Oil inlet hose

3. Oil pipe 4. Oil pump
5. Support for power steering pump

Dismantlement Steps:
1. Cut off the negative anchoring wire of storage
battery. PS070

2. Discharge or drain out the power steering fluid

from power steering oil can.
 Chassis Volume PS-35

Note:
Discharge power steering fluid referring to the replacement of power steering fluid
described in this chapter.

3. Unscrew the adjusting bolt of steering belt PS071

tension pulley and dismantle the steering belt
from belt pulley for oil pump.
Attention:
Pay attention to the mounting adjustment of
bolt during the reassembly course.

PS072
4. Cut off the wire harness joint of oil pressure
switch.

PS073
5. Unscrew the bolt and release the oil pipe joint.
Attention:
Before dismantling the oil pipe, please set a
container under the oil pump to collect the rest
oil in it. This measure could prevent other parts
from oil pollution.
Tightening Torque: 55~65 N•m

6. Loosen the hose clamping band and take off

the oil inlet hose of oil pump. PS074
Attention:
Before dismantling the oil pipe, please set a
container under the oil pump to collect the rest
oil in it. This measure could prevent other parts
from oil pollution.
Chassis Volume PS-36
 Chassis Volume PS-37

7. Dismantle 3 fixed bolts from the support rack PS075

of oil pump.
Note:
Two of the fixed bolts are behind the belt
pulley.

8. Take out the steering oil pump from engine

hatch.

Reassembly
The reassembly procedure is reverse to the dismantlement procedure.
Take the following operations after reassembly:
① Charge the power steering fluid again.
② Adjust the tension of belt.
③ Deflate the air for the oil circuit of steering system.
④ Check the pressure of oil pump.
 Chassis Volume PS-38

Dismantlement & Reassembly

Oil: Oil of Automatic Transmission

AFT III
Seal Parts for oil Pump Oil Pump Elements

Dismantlement Steps:
1. Pump cover 9. O-ring
2. Lock pin 10. O-ring
3. O-ring 11. Sealing washer
4. Blade 12. Joint
5. Cam ring 13. O-ring
6. Armature 14. Flow control valve
7. Side plate 15. Flow control spring
8. Oil seal 16. Oil pump body

Attention:
Don’t disassemble the flow control valve and oil pump body.
 Chassis Volume PS-39

Reassembly
PS076 Joint Pump Cover
1. Reassembly for O-ring.
Inner Diameter
No.
×Width
1 20.5×1.5
2 63×2.3 Lateral View of
Lateral Plate
Lateral
3 42×2
4 15.3×2

2. Reassembly for armature.

Mount the armature on belt pulley assembly PS077
and set the spline hub of armature on the side
of pump cover.

3. Reassembly for cam ring. PS078

Set the side marking slot against side plate to Marking
Slot
mount the cam ring.

4. Reassembly for blade.

PS079
Mount the blade on armature and pay attention
to the mounting position.
Cotter slot towards
armature

Cam
Armature Blade ring
 Chassis Volume PS-40

Hydraulic Pipeline
Dismantlement and reassembly

1. Power steering gear assembly 2.Power steering oil can

3. Fuel injection pipe assembly 4.Cooling pipe
5. Oil return pipe for power steering gear 6. Oil return hose
7. Oil intake hose of the steering pump
8. Steady support rack of steering device 9. Vibration isolator
10. Bolt 11. Hexagon flange bolt
12. Spring mattress and flat gasket assembly for hexagon bolt
13. Bolt, spring mattress subassembly
14. I-type all-metal hexagon latch nut
15. Clamp for sucker and oil return pipe of the power steering gear
16. Ring flange nut
17. Cutting ferrule-type float hexagon bolt 18. Sealing ring

Dismantlement steps:
1. Discharge power steering fluid.
Note: discharge the power steering fluid referring to the replacement of power
steering fluid described in this chapter.

2. Dismantle the front bumper.

Note: refers to the dismantlement and reassembly for front bumper described in the
chapter of body.
 Chassis Volume PS-41

3. Dismantle the fixing bolt for cooling pipe. PS080

4. Cut off the joint of oil return pipe and hose, then PS081
take out the cooling pipe.

5. Dismantle the fixing bolt of power steering oil PS082

can and take out the power steering oil can.
Then dismantle the oil return hose and oil
intake pipe of power steering.

PS083

6. Dismantle the air filter assembly.

7. Dismantle the active carbon canister.

(take out upwards as the illustration shows.)
PS084
 Chassis Volume PS-42

8. Unscrew the joint nut of oil pipe and cut off the
high/low oil pipe at the steering gear. PS085

9. Take out the high pressure pipeline assembly and the oil return pipe of power steering
gear.

Reassembly:
The reassembly procedure is reverse to the dismantlement procedure.

Attention:

New power steering fluid shall be added after reassembly. Then exhaust for the
braking system.
 Chassis Volume PS-43

Pressure Check for Power Steering System

Check method:
1. Set the oil pressure measuring instrument in
series in the oil circuit between the oil outlet of PS086
hydraulic pump and the oil inlet of control
valve.

2. Start up the engine and operate it at low speed.

PS087
The oil pressure shall increase when closing
the throttle valve step by step.
3. If the throttle valve is closed during a short time
(less than 10 seconds), the indication of
manometer shall be the maximum working
pressure of oil pump. If the value indicated is
less than 90% of the specified value of
hydraulic pump, it indicates that the hydraulic
pump has fault.

Cause Analysis of Insufficient Oil Pressure and Troubleshooting:

1. Check if the hydraulic pipe is blocked.
2. The oil pressure is insufficient as the air is mixed in the hydraulic system. Lift the
vehicle or dismantle the pull rode joint, and then turn left/right the steering wheel for
several times. Reciprocate the piston of power cylinder from one end to the other for
several times to exhaust the air in the system from the hydraulic pipe circuit. As the
air bubble emits continually, the oil level of power steering oil can would decrease.
The power steering fluid shall be supplied in time. Stop exhausting when there is no
air bubble.
3. When the belt for steering oil pump driving is slipped or the running gear doesn’ t
articulate well, you shall adjust the belt tension or repair the running gear articulated
not so well.
4. Hydraulic pump abrasion, severe inner oil leakage, safety valve of hydraulic pump
leakage, excessive soft spring of safety valve and excessive low startup pressure.
Please renew or check the hydraulic pump, and repair the safety valve to make the
pressure for oil pumping meet the specified demands.
Chassis Volume PS-44
 Chassis Volume PS-45

Diagnosis Info and Countermeasure Procedures

Check of Power Steering System
Operate test on road before trouble diagnosis and check the following systems in
diagnosis process:
1. Suspension system
2. Wheels
3. Check if the wheel pressure is proper and the abrasion is even
4. Check if the joint of steering column and steering gear is loose or abraded
5. Check if the following parts are loosed or damaged:
① Front suspension
② Rear suspension
③ Steering device
④ Connecting rod
6. Check if the wheel is under the following conditions:
① The wheel is not round
② The wheel is not balanced
③ The wheel is bended
④ Bearing of the wheel is loosed or has noise
7. Check if the power steering system is leaked referring to the leakage of power
steering gear and steering pump
8. Check the level of power steering fluid

Trouble Judgment Standard

Step Measure Yes No
Compare the noise level with the one of a normal operating To System is
1
vehicle. Is the fizzy noise abnormally high? step 2 normal
To
2 Check the level of power steering fluid. Is it too low? To step 4
step 3
Charge the power steering system. Refers to “Charge power To System is
3
steering system over again” step1 normal
Is the frizzy noise generated from the inner part of the To
4 To step 7
vehicle? step 5
The noise may enter the passenger’ s room through the open
To
5 pore on the front part of console. Check the seal of To step 7
step6
intermediate valve. Is it damaged or mounted improperly?
To System is
6 Repair or replace the seal of intermediate valve.
step 1 normal
Make sure the hose and pipe circuit of power steering
To System is
7 system are positioned properly (don’ t touch the front part of
step 8 normal
console). If necessary, repair or replace them.
Find the source of noise with headphones. Check the power
To System is
8 steering pump and power steering gear. If necessary, repair
step 1 normal
or replace the parts.
 Chassis Volume PS-46

There is “quack-quack”sound arising from the steering device of rack

pinion
Condition Measure
No grounding for circuit of power Make sure that the disposal of power steering system
steering system. circuit is correct.
Wrong preload adjustment of Adjust the preload of bearing of power steering gear
bearing of power steering gear. according to the specification.
Fasten the screw of power steering gear to the
Looseness of power steering gear.
specified torque.
If necessary, repair or replace the steering tie rod
Looseness of steering tie rod end.
end.
Check the intermediate bearing. If necessary, repair
Looseness of intermediate bearing.
or replace it.

Diagnosis of Power Steering Gear

Fizzy noise
1. You may hear some noise when the resting vehicle is operated under normal
condition.
2. Check if there is any leakage in hydraulic system.
3. Check if there is any air in power steering system.

Leakage of Power Steering Gear and Power Steering Pump

Symptom
The following symptoms indicate that maybe there is leakage in power steering system:
1. The oil leakage to the platform plate.
2. Leaked oil could be found on the power steering gear or power steering pump.
3. When parking or cooling the vehicle, roar noise could be heard.
4. Power steering function is lost when parking the vehicle.
5. The vehicle is felt to be heavy when it is turning.

Check Procedure
Check if there is any outer leakage of power steering system according to the following
procedure:
1. Wipe and dry the doubtful area.
2. Check if the oil charged to the power steering oil can is too much.
3. Check if the power steering system has the following conditions:
① The power steering fluid is mixed with air
② Overflow
4. Check the following components:
① Hose joint
 Chassis Volume PS-47

② O-ring
5. The position which is confirmed to be the specific place of the oil leakage is not
always the leakage position of the system. Take the following actions to lookup the
leakage:
① Close the engine.
② Wipe to dry the whole power steering system.
③ Check the level of power steering fluid.
④ Start up the engine.
Attention:
The steering wheel can not be kept on link stopper even just for a short while, or else the
power steering pump would be damaged.
① Turn the steering wheel among the link stoppers for several times with the help of
your assistant.
② Conduct the leakage diagnosis for rack pinion to confirm and repair the actual leaky
position.
6. Repair according to following procedure
① Clean up the leaky position before operating dismantlement procedure.
② Replace the leaky seal ring.
③ Check if the seal surface of component is damaged.
④ Fasten the bolt to the specified torque.
Steering Steel Rebounds Greatly or Steering Mechanism is Too Loose
Trouble Check
Air in power steering system 1． Check if the power steering system is leaky
2． Recharge the air in power steering system
Loose joint between steering 1． Check the connection between steering
column and power steering gear column and power steering gear
2． If necessary, replace the connection
Maladjustment for preload of rack Fasten the preload of rack bearing to the specified
bearing value
Looseness of base frame of power 1． Check the base frame of power steering gear
steering gear 2． Screw the assembly bolt of gear wheel for
power steering gear to the specified torque
Looseness of steering tie rod 1． Check the end of steering tie rod
2． Replace the end of steering tie rod
Abrasion of wheel bearing Replace wheel bearing
Steering Wheel Turning Needs the Increased Power
Trouble Check
Serious inner leakage Check if the power steering system is leaky
Damage of valve coil pipe of 1． Clean up the power steering system
power steering gear 2． If the default still exists, replace the power
steering gear
Too low level of power steering 1． Check if the power steering system is leaky
fluid 2． Charge power steering fluid into power
steering system
 Chassis Volume PS-48

Poor Resetting of Steering Wheel

Trouble Check
Blockage of ball joint 1．Check the ball joint
2．If necessary, replace the ball joint
Locating failure of front wheel 1． Check the location of front wheel
2． If necessary, locate the front wheel
Viscous valve of power 1． Wash the power steering system
steering gear 2． Charge the power steering system again
3． Recharge the air in power steering system
4． If the fault still exists, replace power steering
system
Too high torque of Fasten the clamping bolt of intermediate steering
intermediate steering shaft shaft to the specified torque
clamp
Maladjustment for preload of Fasten the preload of rack bearing according to the
rack bearing specification
Blockage of steering column 1． Check the location of steering column
2． If necessary, adjust the location of steering
column
3． Check the base frame of steering column
4． If necessary, repair the base of steering column
5． Check the bearing of steering column
6． If necessary, replace the bearing of steering
column
Incorrect wheel pressure Charge the wheel to get the specified pressure
Steering Wheel Vibrates/Jumps When Turning
Trouble Check
Trouble of hydraulic system 1. For hydraulic system diagnosis, refers to the
measuring program of power steering system
2. If necessary, repair the hydraulic system
Too low level of power If necessary, add power steering fluid
steering fluid
Viscous valve of power 1. For power steering system cleanup, refers to
steering gear washing of power steering system
2. Charge power steering fluid into power steering
system
3. Recharge the air in power steering system
4. If the symptom still exists, replace power steering
gear
Insufficient pressure for power 1. Check the power steering system
steering pump 2. If necessary, replace power steering pump
Steering Wheel Rebounds
Trouble Check
Air in power steering system 1. Check if the power steering system is leaky
2. Recharge the air in power steering system
Loose joint between steering 1. Check the connection between steering column
column and power steering and power steering gear
gear 2. If necessary, replace the connection
Maladjustment for preload of Fasten the preload of rack bearing according to the
rack bearing specified preload
Looseness of base frame of 1. Check the base frame of steering device
 Chassis Volume PS-49

Trouble Check
steering device 2. Screw the assembly bolt of power steering gear to
the specified torque
Looseness of the end of 1. Check the end of steering tie rod
steering tie rod 2. Replace the end of steering tie rod
Abrasion of wheel bearing 1. Replace the wheel bearing
2. Replace the wheel hub
Turning to One or Two Direction is Laboursome
Trouble Check
Too low wheel pressure Adjust the wheel pressure to the specified value
Blockage of pull rod of steering Check the components of steering mechanism
gear
Insufficient power steering fluid 1. Charge the power steering system
2. Check if the power system is leaky
Trouble Check
Viscous flow control valve 1. Refers to washing of power steering system
2. Replace the power steering pump
Too tight preload of rack bearing Adjust the preload of rack bearing to the specified
value
Incorrect location of front wheel Adjust the location of front wheel

Gap in Steering Mechanism is Too Big

Trouble Check
Loose or abraded joint between 1. Check if the torque of connection between
column and steering device column and steering device is correct
2. If necessary, replace the connection
Loose power steering gear Fasten the assembly bolt of power steering gear
to the specified torque
Abraded wheel bearing Replace wheel hub and bearing assembly
Looseness of steering tie rod 1. Check the steering tie rod
2. If necessary, replace the steering tie rod

Oscillation or Turning is Instable

Trouble Check
Locating failure of front wheel 1. Check the location of front wheel
2. If necessary, locate the front wheel
Locating failure of rear wheel 1. Check the location of rear wheel
2. If necessary, locate the rear wheel
Maladjustment for preload of rack Fasten the rack bearing to the specified preload
bearing
Breakage/slack of spring 1. Check if the spring is broken/slack
2. Replace broken/slack spring
Loose stabilizer shaft 1. Check the following component
●Assembly bolt
●Assembly connecting rod
2. Fasten the assembly bolt to the specified
torque
3. Fasten the assembly connecting rod to the
specified torque
Support abrasion 1. Check if the support is abraded referring to the
 Chassis Volume PS-50

Trouble Check
component check of front suspension system in
chapter for front suspension
2. If necessary, replace the support
Uneven/improper location for 1. If necessary, repair the wheel
wheel 2. If necessary, replace the wheel
3. Check the location
4. If necessary, conduct location

Turning is Instable in Braking Course

Trouble Check
Uneven/improper trimming for 1. Check the location of vehicle
castor 2. Conduct location on vehicle

Looseness of control arm 1. Check control arm

2. Replace and/or fasten the components
according to the specification
Warp of brake disk If necessary, replace brake disk
Breakage/slack of spring 1. Check spring
2. If necessary, repair spring
Abraded wheel bearing 1. Replace the bearing
2. Replace the wheel hub
Leakage of wheel brake caliper Replace the bearing or wheel hub
Power Steering Fluid is Bubbly and Looks Milky
Trouble Check
Air in power steering system 1. Check if the power steering system is leaky
2. Recharge the air in power steering system
Power steering fluid has following 1. Recharge the air in power steering system
conditions: 2. If the power steering fluid still looks bubbly
1. oil looks bubbly
2. fluid level is normal
Leakage inside the power steering 1. Check the leaky point of power steering pump
pump 2. If the leakage could not be repaired, replace
power steering pump
Too Low Pressure Caused by Steering Device
Trouble Check
Waterproof sealing leakage Check if the division plate is leaky
Score on casing bore Check if there is any score in casing hole
Support sealing leakage Check if the rack seal is leaky
Valve ring leakage Check if the valve ring is leaky
Valve sealing leakage Check if the valve seal is leaky
Too Low Oil Pressure Caused by Steering Pump
Trouble Check
Control valve jammed/ failed 1. Clean up power steering system
2. If the control valve still can not operate because
of block/malfunction, replace power steering
pump
Abraded ring of power steering 1. Check the ring of power steering pump
pump 2. If the ring of power steering pump is abraded,
 Chassis Volume PS-51

replace power steering pump

Score on the plate 1. Check the plate
2. If there is any score on the plate, replace power
steering pump
Score on thrust plate 1. Check thrust plate
2. If there is any score on the thrust plate of power
steering pump, replace power steering pump
 Chassis Volume PS-52

There is Roaring Noise in Steering Pump

Trouble Check
Too big back pressure of hose of 1. Check if the hose of power steering system is
power steering system blocked
2. If necessary, replace the hose
Too big back pressure of power 1. Check if the steering device is blocked
steering system 2. If necessary, replace power steering gear
Score on the plate 1. Check if there is any score on the plate
2. If there is, replace power steering pump
Score on the thrust plate 1. Check if there is any score on the thrust plate
2. If there is, replace power steering pump
There is score on brake plate 1. Check if there is any score on the brake plate
2. If there is, replace power steering pump
Abraded power steering pump 1. Check the ring of power steering pump
2. If the ring of power steering pump is abraded,
replace power steering pump
There is Clicking Sound or Knocking Noise in Steering Pump
Trouble Check
Shedding of grounding for Check the following conditions of high pressure
pressure circuit of power steering pipeline of power steering
system off ● If the assembly is correct
● If the gap is proper
Looseness of preload adjustment Fasten the rack bearing to the specified preload
of gear bearing
Looseness of steering device 1. Check if the reassembly for power steering
gear is correct
2. Fasten the assembly bolt of power steering
gear to the specified torque
Looseness of steering tie rod end 1. Check the end of steering tie rod
2. Replace the end of steering tie rod
Looseness of universal joint of 1. Check the universal joint of intermediate
intermediate steering shaft steering shaft
2. If necessary, replace the universal joint of
intermediate steering shaft
There is Ululant Noise in Steering Pump
Trouble Check
Too low fluid level of power 1. Check the fluid level of power steering fluid
steering fluid 2. If necessary, charge power steering fluid
Score on plate and wheel blade Replace the power steering pump
Score on electrical brush on Replace the power steering pump
power steering pump
There is Murmurous Noise in Steering Pump
Trouble Check
Damage of control valve Replace power steering pump
 Vehicle Body & Electric Appliance Volume

Preface
This Benjoy Maintenance Manual is prepared to help the technical

service personnel exactly understand and acquaint himself with

JAC cars, thus enabling them to fast and reasonably maintain JAC

cars. This Maintenance Manual consists of four volumes

respectively for the engine, chassis, vehicle body & electric

appliance, and circuit overhaul.

The volume of vehicle body and electric appliances illustrates the

technical standards for dismantlement & reassembly, detection,

commissioning, and diagnosis of all interior and exterior

accessories and each component of the electric appliance of

Benjoy car in detail. The maintenance data for the sheet metal

repair are offered in the appendix. As for the detailed basic diagram

and the wire harness layout of the electric appliances, please see

Volume 4 of the Maintenance Manual (circuit diagnosis volume).

For replacement of fittings, only the original ones recommended by

JAC can be used.

No part of this Manual may be reproduced or used in any form or by

any means without prior written license; otherwise any infraction

will be prosecuted for.

The Editor
 Vehicle Body & Electric Appliance Volume

July, 2007

Contents of Vehocle Body and Electric Appliance Volume

Interior and Exterior Trimmings

Precautions ..................................... EI-1 Trimming Plate on Upper Cover Plate of

Preparations .................................... EI-1 Front Wall......................................... EI-37
Trouble Diaganosis of Frizzle and Kluck Fender....................... ....................... EI-40
.......................................................... EI-2 Wheel Cover and Mudguard...... .... EI-43
Snap-in and Lock Catch...................... Deflector and Protecting Cover..... EI-44
.......................................................... EI-6 Outer Stripe Ornament of Car Body
Engine Hatch Cover........................ EI-9 .......................................................... EI-46
Boot Cover....................................... EI-12 Interior Trimming Plate of Door..... EI-55
Door Assembly (Front Door) ......... EI-16 Interior Trimming of Body Side ..... EI-58
Front Wind Shield..................... ...... EI-18 Sun Visor.......................................... EI-71
Rear Wind Shield..................... ....... EI-23 Ceiling. ............................................. EI-72
Front Bumper....................... ........... EI-28 Carpet............................................... EI-75
Rear Bumper...................... ............. EI-32 Interior Trimming of Boot............... EI-78
Front Retainer........................ ......... EI-36 Trimming Plate of Boot Cover ....... EI-80

Console Assembly

Precautions ..................................... IP-1 Assembly ......................................... IP-9

Trouble Diaganosis for Frizzle and Dismantlement of Console
Kluck ................................................ IP-2 Assembly........... .............................. IP-19
Console Assembly. ......................... IP-6
Disassembly Drawing of Assembly
.......................................................... IP-7
Dismantlement and Installation of
Seat

Precautions .................................... SE-1 Overview........................ .................. SE-5

Trouble Diaganosis for Frizzle and Dismantlement and Installation of Seat
Kluck ... ............................................ SE-2 .......................................................... SE-8

Body Control Module

Overview... .................................... BCM-1 Function Description.......................

Installation Position....................... .......................................................BCM-4
....................................................... BCM-1 Control of Ceiling Light ...............BCM-5
Basic Diagram for Control .......... BCM-2 Rear Window Defroster and Rear Fog
 Vehicle Body & Electric Appliance Volume

Light............. ................................. BCM-6 Time Sequence of ATA......................

.......................................................BCM-9
Electric Window....................... .... BCM-7 Dismantlement and Installation of Body
Anti-Thief Alarm (ATA).............. .. BCM-8 Control Module..........................BCM-13

Electric Door & Window, Back Mirror, Defroster and Sunroof

Precautions .................................. GW-1 Door Widowglass System............ GW-9

Preparations ................................ GW-2 Electric Back Mirror.................... .GW-15
Trouble Diaganosis of General Frizzle Back Window Defroster and
and Kluck...................................... GW-3 Heater........... .................................GW-19
Electric Window System ................. Interior Back Mirror
....................................................... GW-5 Assembly.................... ................. GW-22
Trouble Diagnosis Procedures... GW-6 Trouble Diagnosis and Troubshooting
Positions of Elements................... GW-8 of Electric Sunroof.......................GW-25
Dismantlement and Reassembly of Sunroof Assembly....................... GW-26

Door Lock Control System

Door Lock and Control System.. BL-1 Remote Control Key...................... BL-6
Diagnosis Procedure of Door Lock Dismantlement and Reassembly of
System.............. ............................ BL-4 System...........................................BL-9

Display System of Driver Information

Combined Instrument.................. DI-1 Check of Combined Instrument Parts

Introduction to Functions of .......................................................DI-11
Instrument..... ............................... DI-3 Dismantlement and Reassembly of
Display of Driver Information ..... DI-7 Combined Instrument..................DI-14

Combined Switch

Description of Combined SwitchSW-1 Dismantlement and Reassembly of

Basic Diagram for Control of Combine Combined Switch.........................SW-9
Switch............. .............................. SW-6
Check of Switch Control Conduction
....................................................... SW-8

Light Illuminating System

System Illustration....................... LT-1 Adjustment of Light..................... LT-4

 Vehicle Body & Electric Appliance Volume

Diagnosis for Light Illuminating System

....................................................... LT-5
Diagnosis Procedures of High Beam
Light and Dipped Headlight........ LT-7

Diagnosis Procedures of Front/Rear

Fog Light............. ......................... LT-9
Diagnosis Steps of Reversing Light
....................................................... LT-10
Diagnosis Steps of Stop Lamp... LT-11
 Vehicle Body & Electric Appliance Volume

Diagnosis Procedures of Steering Dismantlement and Reassembly of

Signal Light and Harzard Warning Light Illuminating System........... LT-14
Light.............. ................................ LT-12

Horn and Cigarette Lighter

Dismantlement and Reassembly of

Horn....................... ....................... WW-1 Check of Cigarette Lighter System
Check..................... ....................... WW-2 .......................................................WW-4
Adjustment ................................... WW-2 Troubles and Diagnosis Measures of
Dismantlement and Reassembly of Cigarette Lighter...... ....................WW-5
Cigarette Lighter.................... ...... WW-3

Wiper and Washer

Assembly of Wiper System Wiper/Washer System............WW-4

Positions of Elements… ........ WW-1
Washer .......................................... WW-2 Dismantlement & Reassembly of
Check of Wiper & Washer Systems Wiper System............................WW-7
....................................................... WW-3 Washing Spray Nozzle.................WW-9
Diagnosis Procedures of Washing Pump and Wiper KettleWW-11

Reversing Radar

Overview....................................... BCR-1 .......................................................BCR-6

Precautions...................... ............ BCR-2 Common Trouble Diagnosis and
Introduction to Functions ........... BCR-4 Troubleshooting...........................BCR-9
Technical Specifications of Dismantlement and Reassembly of
Components .............................. BCR-5 Components. .............................BCR-10
Principle of Controller and Judgment on Conditions of
Positions of Components......... Components ..............................BCR-16

Hi-Fi System

Hi-Fi Control System.................. AV-1 Precautions for Routine Maintenance

Common Trouble Diagnosis and and Use of Hi-Fi System .........AV-13
Troubleshooting of Hi-Fi System... AV-4
Dismantlement and Reassembly of
Hi-Fi System................. .............AV-6

Safety Belt
 Vehicle Body & Electric Appliance Volume

Precautions....................... ........SB-1 Dismantlement and Reassembly of

Dismantlement and Reassembly of Snap Ring............... .................SB-6
Front Seat Safety Belt......... ...SB-3 Dismantlement and Reassembly of
Dismantlement and Reassembly of Rear Seat Safety Belt......... .....SB-7
Safety Belt Constrictor....... ....SB-4 Check.......................... .............SB-10

Safety Secondary System

Precautions....................... ........SRS-1 Repair Steps for Airbag. ...........SRS-20

Preparations..............................SRS-6 Dismantlement and Reassembly of
Working Principle of SDM........SRS-14 Airbag System...........................SRS-24
Diagnosis of Airbag System ....SRS-17

Air Conditioner

Precautions for Air Conditioning Assembly............ ATC-28

System...................... ................. ATC-1 Sensor of Air Conditioning System....
Preparations..............................ATC-3 ....................................................ATC-29
Check of Air conditioner and Filling of Cooling System of Engine................
Refrigerant................................. ATC-5 ....................................................ATC-32
Control of Air conditioning System. Three-Phase Pressure Switch. ATC-33
.................................................... ATC-8 Dismantlement & Reassembly of Air
Illustration of Control Circuit Diagram Conditioning System................ATC-34
and PIN.......................................ATC-13 Disassembly Drawing of Condenser
Diagnosis of Auto Air conditioning Assembly............. ......................ATC-47
System.............. ......................... ATC-15 Ventilation System.....................
Description of Functions of Air ....................................................ATC-53
Conditioning System Elements Dismantlement and Installation of
.................................................... ATC-17 Dismantlement & Reassembly of
Evaporator Fan Assembly.......... Operation Panel of Air conditioner Air
.................................................... ATC-17 Outlet..........................................ATC-54
Motor of Mode Air Duct Door...ATC-24 Filter........................ ...................ATC-56
Compressor Assembly.................
.................................................... ATC-26
Control Unit of Condenser

Maintenance Data of Vehicle Body

Maintenance Data of Engine Hatch

Cover. ...................................Appendix-1 Maintenance Data of Boot. Appendix-3
Maintenance Data of Doorframe. Maintenance Data of Chassis
...............................................Appendix-2 ............................................. Appendix-4
 Vehicle Body & Electric Appliance Volume EI-1

Precautions
Precautions for Subsidiary Restraint System (SRS)
Using such supplemental restraint systems as “airbag”with safety belt can help reduce
the possibility of hurt or the degree of injury of driver and passengers at the front caused
by collision of vehicles. In the “Maintenance Manual”, information for secure maintenance
of the system is included in section SRS and SB.

Caution:
• In order to avoid the failure of SRS system, which may result in increasing the danger
of injury and death caused by collision of vehicles, all maintenances shall be done by
the authorized JAC dealership.
• Improper maintenance, including improperly dismantlement and reassembly of the
SRS system, may result in the error actions of this system, thus causing the casualty
accidents.
• SRS can not be tested at its any circuit by electric test appliance except the operation
indicated in this manual. The wire harness of SRS can be recognized by its yellow
joint.

Precautions for Operation

• After the dismantling or installing the open/close parts, please make proper
adjustment and check the operation.
• Check the lubricating oil level and the abrasion/damage situation of each part. If
necessary, please apply the lubricating grease to the parts or replace them.

Preparations
Special Tools for Maintenance
Tool Code Name Purpose Example

Tool for Tool for

JACD07 ornament ornament
dismantlement dismantlement
 Vehicle Body & Electric Appliance Volume EI-2

Trouble Diagnosis for Squeak and Kluck

Have a face-to-face talk with the clients if you can confirm the situation when the noise is
made.
● Know about the actual situation when the noise is made (or not) if you can, as the
client may be unable to provide the detailed description or source of noise.
● If there are many kinds of noise in the car, it is necessary to diagnose it and deal with
the noise concerned by the client. It is possible to drive with the client for testing.
● After identifying the kind of noise, distinguish the noise according to its characters.
Make the clients, maintenance consultant and maintenance technician come to an
agreement on noise description according to the characteristics of noise.
● Squeak- (as the noise made by tennis shoes rubbing against the clean ground)
The characteristics of squeak include the light touch/fast motion/resulting from road
condition/rough road surface=high noise/soft surface=low noise/edge of road
surface=chirp.
● Quack- (as the sound made by walking on the old wooden plate)
The characteristics of quack include touch/slow motion/rotary twist/volume differs from
materials to materials/the noise is usually made during operation.
● Kluck- (as the sound made by shaking children’ s toys)
The characteristics of kluck include fast repeated friction/vibration or similar
motion/looseness of spare parts/looseness of clamping band or lock catch/improper
gap.
● Knock- (as a knock at the door)
The characteristics of knock include the sound in cavity/ echo/ the noise made by
driving.
● Click- (as the sound made by second hand of clock)
The characteristics of click include light touch of soft objects/looseness of spare
parts/the sound may be caused by driver operation or road conditions.
● Thump- (knocks of heavy objects and silencer)
The characteristics of thump include the lighter knock/low sound caused by operation.
● Buzz- (as the sound made by a host of bees)
The characteristics of buzz include the high frequency cackle/stable touch.
● The acceptable noise levels typically differ from person to person. The noise which
you consider to be acceptable may be beyond the endurance of clients.
● The weather conditions, especially humidity and temperature, may influence the noise
level.

Noise Reproduction and Road-Test

Drive with the clients until the noise is made if it is possible. Pay attention to the other
information about noise or position on the diagnosis meter. The information can be used
to reproduce the same situation when you perform repair.
If it is easy to reproduce the noise when the road test is carried out, try to stop the car and
carry out the following operations for reproducing the noise in order to identify the source
of noise:
1) Close one door.
2) Knock at or push/pull the areas where the noise is made.
3) Raise the engine speed.
 Vehicle Body & Electric Appliance Volume EI-3

4) Reproduce the “twist”of vehicle with the lifter.

5) Use the engine load (electric load, M/T type semidetached clutch), when the vehicle
runs at an idle speed.
6) Raise the car with lifter and beat the tyres with rubber hammer.
● Drive the car for trying to reproduce the situations when the noise is made described
by the clients.
● If it is difficult to reproduce the noise, drive the car slowly on uneven or rough road
surface to increase the stresses on vehicle body.
Find Relative Maintenance Report
After confirming the phenomenon described by the clients, find if there are relative
technical maintenance reports.
If there are relative technical maintenance reports, please make maintenance by following the
steps.
Confirmation of Noise Source and Identification of Basic Causes
1. Reduce the noise range to a normal one. Find out the source of noise with listening
tools (as engine audiphone or mechanical stethoscope).
2. Reduce the noise range to a specific one, and identify the causes of noise with the
following methods:
● Dismantle the elements in the suspicious areas where the noise may be produced.
Do not overexert when dismantling the snap-in or fixer; otherwise, the snap-in or fixer
may be damaged or lost during maintenance, thus producing a new noise.
● Beat or push/pull the elements which may produce the noise.
Not overexert when beating or pushing/pulling the elements; otherwise the noise will
be temporarily eliminated.
● Touch the elements which may make the noise with hands to feel whether vibration
exists or not.
● Put a piece of paper between the elements which may make noise.
● Examine if there are marks for looseness and contact of elements.
Troubleshooting
● If it is caused by looseness of element, please screw it down.
● If it is caused by insufficient gap between elements:
– If it is possible, re-position the elements, or loosen and then re-screw them down
for detaching the elements.
– The isolation elements with suitable heat insulation cushion can be attained from
the authorized spare parts department for JAC vehicles.
Attention:
Do not overexert, as many elements are made of plastic, which are easily
damaged. Always inquire about the latest information on spare parts
from the spare parts department.
Maintenance Confirmation
Drive the car under the same conditions as that of reproducing noise, and confirm the
noise source through road test and then perform the maintenance.
Countermeasures for Squeak and Kluck
Refer to the catalog of regulations on dismantlement and reassembly of element.
Instrument Plate
 Vehicle Body & Electric Appliance Volume EI-4

Most troubles are caused by the contact between and movement of the following spare
parts:
1. Trimming cover and console
2. Console to A-pillar trimming plate
3. Console to windshield
4. Anchor pin of console
5. Wire harness behind the combined instrument
6. A/C defrosting pipe and pipe joint
Reproducing noise by beating or moving the elements or ceasing the noise by pressing
components during driving can help find the sources of the troubles. Most troubles can be
eliminated by using woolen cloth rubber belt or silicon spray (at the areas difficult to
access). And the polyurethane cushion can be used for separating the wire harness.
Attention:
Do not use the silicon spray to insulate the noise of squeak or kluck, as it
is impossible to verify the maintenance if the area is full of silicon.
Middle Control Desk
The parts for attention include:
1) the roof assembly of gear level to upper trimming plate assembly of auxiliary facial
console
2) A/C control device
3) the wire harness of hi-fi and A/C control device
The maintenance of console and sound insulation steps can also be used to the central
control board.
Door
Attention:
1. Slap produced by door and inner trimming plate
2. Trimming cover of mounting nuts on inner handle and trimming plate of door
3. Rap produced by wire harness
4. Put-put caused by the misalignment of lock catch of door while starting and stopping
the car.
Sticking, moving or pressing the spare parts can resolve many troubles when reproducing
the situations. Woolen cloth rubber belt or insulation foam blocks can be adopted to
insulate the areas to eliminate the noise.
Boot
Generally, the noise of boot is caused by looseness of lifting jack or objects in it.
In addition, pay attention to:
1. The damping block of luggage cover is improperly installed.
2. The lock catch of luggage cover is mismatched.
3. The air operated outriggers of luggage cover touch each other.
4. The license plates or support become loose.
Most of the troubles can be eliminated by adjusting, fixing or insulating the items or
elements producing the noise.
Sunroof/Vehicle Ceiling
Noise from the sunroof/vehicle ceiling areas can be regulated to:
1. Kluck or light knock caused by sunroof cover, beam, pull rod or bad sealing;
 Vehicle Body & Electric Appliance Volume EI-5

2. Shake of sun visor shaft in the support;

3. Squeak produced by the front or rear windshield’ s touching of the vehicle ceiling.
Most of the noise can be insulated by pressing the element while reproducing the
situation. The woolen cloth rubber belt is always used for insulation in maintenance.

Seat
When insulating the noise of seat, pay special attention to the position of seat and the
objects on it when the noise is produced. It is necessary to reproduce these conditions
when confirming and insulating the source of noise.
Causes for noise of seats include:
1. Head rest rod and mounting hole;
2. The squeak produced by seat cushion and seat rack;
3. Snap-in on the rear row backrest.
The noise can be insulated by moving or pressing the suspicious elements while
reproducing the noise. Most of the troubles can be eliminated by resetting elements or
using polyurethane rubber belt at the contact areas.

Under the Engine Cover

The elements under the engine cover or on the walls of engine may produce some interior
noise, and the noise will be transmitted to the passenger compartment.
Causes for transmission of the noise under engine cover include:
1. The elements installed on the walls of engine;
2. The elements passing through the walls of engine;
3. Supports and adaptors of the walls of engine;
4. Looseness of anchor pin on the radiator;
5. The engine cover and bumper are misaligned;
6. The lock catch on engine cover is mismatched.
Because the noise can transmit to the inside of vehicle, it is difficult to insulate it. The best
method is to fix, move or insulate an element at a time and to test the running vehicle. In
addition, it is possible to change the speed or load of engine for insulating the noise.
Troubles can be eliminated by adjusting, fixing or insulating the elements producing the
noise.
 Vehicle Body & Electric Appliance Volume EI-6

Snap-in and Lock Catch

Dismantlement and
Sign Pin Nail
Reassembly
Dismantlement:
Dismantle by plain screwdriver or the
tool for the dismantlement of clamping
band

Dismantlement:
Dismantle by special
caliper

Dismantlement:
Push the center pin until it is engaged.
(Don’t knock the center pin to dismantle.)

Press

Press

Installation

Dismantlement:

Plain screwdriver

Clamping Operation
band tool

Dismantlement:
 Vehicle Body & Electric Appliance Volume EI-7

Dismantlement
Sign Pin Nail
Installation
Dismantlement:

Dismantlement:
Clamping band
Clamping band Trimming A
A

Plain
Clamping band screwdriver
B Clamping band
B

Dismantlement:
Clamping band Trimming
A Plain
screwdriver
Clamping band B
(Seal ring)

Base board of
Clamping band Clamping band
A B (Seal ring)

Dismantlement:
1. Unscrew the screw by double offset
ring screwdriver
2. Take off the inner screw by plain
screwdriver

Dismantlement:
Installation:

Dismantle by
revolving 45°
 Vehicle Body & Electric Appliance Volume EI-8

Dismantlement and
Sign Pin Nail
Reassembly

Dismantlement:
Disconnect the upper connection of clamping
band by plain screwdriver and then dismantle it
by inserting the plain screwdriver between the
base board of car and clamping band.
 Vehicle Body & Electric Appliance Volume EI-9

Engine Hatch Cover

Dismantlement and Reassembly

1. Engine Hatch Cover 2. Hinge of Engine Hatch Cover (right) 3. Hinge of Engine
Hatch Cover (left)

1. Engine hatch cover 2. Hinge (right) of engine hatch cover 3. Hinge (left) of engine
hatch cover

Dismantlement Steps EI001

1. Open the cover of engine hatch and support its
Space
lock pin with applicable material to protect it from
cloth
dropping.
Caution：
The car will be damaged if there is no bar to support
the open cover of engine hatch when dismantling
the air operated outrigger of engine hatch cover.
 Vehicle Body & Electric Appliance Volume EI-10

2. Prize out the snap-in anchor with right-angled

EI002
screwdriver and pull outward the ball point,
and then dismantle the air operated outrigger.

3. Dismantle the fixed bolts of left/right engine EI003

hatch cover and take down the engine hatch
cover assembly with the help of assistant.
Fastening Torque of Hinge Bolt: 20~~30N•m

4. Screw off the fixing bolt for hinge from the

engine hatch cover assembly and divide
EI004
engine hatch cover assembly from the hinge.
Fastening Torque of Hinge Bolt: 20~30N•m

Reassembly
Install the engine hatch cover in the reverse order
to dismantlement steps.
Check and adjust the engine hatch cover after reassembly.

Check and Adjustment

1. Check if there is any surface difference between
the engine hatch cover and the fender. If so,
adjust the height of the engine hatch cover’
s
buffer block until there is no surface difference. EI005
 Vehicle Body & Electric Appliance Volume EI-11

2. Check if the gaps between the engine hatch

cover and left/right fender are the same. The gap
between the engine hatch cover and left/right
shall be set at the range of 4~5mm.
① When the gap between engine hatch cover and
fender is not even but the deviation is small, EI006
knock lightly the latch hook of engine hatch cover
with a small hammer. Check again to see if the
gap of engine hatch cover is even.
② Unscrew the 4 fixed bolts of the engine hatch
cover’
s hinge if the gap deviation between the left
and right fenders is too large. Move
upward/backward or left/right to adjust the engine
hatch cover to make the gap between engine
hatch cover and left/right fender the same. Then EI007
pre-fasten the 4 fixed bolts and fasten them after
the adjustment.

3. Check if the opening or closing of engine hatch

cover is flexible. If not, unscrew the fixed bolts of
lock and move upward/downward or left/right the
lock pin until the engine hatch cover can be
opened and closed flexibly. If the engine hatch
cover can not be buckled well, adjust it again.
Fastening Torque: 9±2 N•m
 Vehicle Body & Electric Appliance Volume EI-12

Boot Cover
Dismantlement and Reassembly

1. Boot cover 2. Hinge of boot cover(right) 3. Hinge of boot cover (left)

Dismantlement Steps
1. Open the boot cover and support it with
applicable materials to protect it from dropping. EI008
Space

cloth
 Vehicle Body & Electric Appliance Volume EI-13

2. Dismantle the inner ornament from the left side

of boot. Refer to the section of “Dismantlement of
Inner Ornaments of boot”. EI009

3. Disconnect the joint of wire harness and pull out

EI010
the wire harness from the sheet-metal part of car
body.

4. Prize out the clip with right-angled screwdriver

and pull outward the ball point of the air-operated EI011
outrigger and then dismantle the air-operated
outrigger.

5. Dismantle the fixed bolts of boot cover’

s hinge EI012
and the boot cover assembly with the help of
assistant.
Fastening Torque of Hinge Bolt: 20~30N•m
 Vehicle Body & Electric Appliance Volume EI-14

6. Screw off the fixed bolt of hinge from the boot

cover assembly and divide the boot cover from
hinge. EI013
Fastening Torque of Hinge Bolt: 20~30N•m

Reassembly
Install the boot cover in the reverse order to the
dismantlement.
Check and adjust the boot cover after reassembly.

Check and Adjustment

1. Check if there is any surface difference between
EI014

the upper surface and side wall of boot cover.

If so, adjust the height of the engine hatch
cover’
s buffer block until there is no surface
difference.
2. Check if the gap between the boot cover and
outer plate of side wall is even.
① When the gap is not even but the deviation is
small, knock lightly the latch hook of boot cover
with a small hammer. Check again to see if the
EI015
gap
of boot cover is even.

② When the gap is too large, unscrew the 4 fixed

bolts of the boot cover’
s hinge and the boot cover
simultaneously. Move the boot cover
upward/backward or left/right to make the gap
between the boot cover and the outer plate of
side wall the same. Then pre-fasten the 4 fixed EI016
bolts and fasten them after the adjustment.
 Vehicle Body & Electric Appliance Volume EI-15

3. Check if the opening or closing of boot cover is EI017

flexible. If not, unscrew the fixed bolts of lock
and move the catch upward/downward or
left/right
until the boot cover can be opened and
closed flexibly.
 Vehicle Body & Electric Appliance Volume EI-16

Door Assembly (Front Door)

Dismantlement and Reassembly
Dismantlement Steps
1. Disconnect the negative terminal line of storage
battery.
2. Dismantle the lower trimming plate of A-pillar and
then disconnect the wire harness joint of the
EI018
door.

3. Open the door and screw off the two fixed bolts
and dismantle the front door stopper.

EI019

4. Unscrew the connecting bolt of car hinge with the

help of assistant.
Then take off the pin and take down the door.
Fastening Torque of Bolts: 30~45N•m

EI020

Reassembly
Install the door assembly in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-17

Adjustment of Door
The gap between door’s upper edgy and side wall’s upper edgy shall be adjusted to
be within 17.5~18.5mm after the installation.
① When the door is relatively higher than the upper EI021
edgy of side wall, open the door for the angle of
30~45°and apply pulling force F in the direction
indicated in the left figure. Then close the door to
F
check the gap and unscrew the fixed screw of
latch hook. Knock the latch hook downward with
a hammer. Close the door until the door’
s upper
edgy and side wall’
s upper edgy are in good
coordination, and then fasten the fixed screw of
latch hook.
② When the door is relatively lower than the upper edgy of side wall, open the door for
the largest angle (front door with the angle of 68°and back door 62°) and apply pulling
force F in the direction indicated in the figure above. Then close the door to check the
gap and unscrew the fixed screw of latch hook. Knock the latch hook upward with a
hammer and then close the door until the door’
s upper edgy and side wall’
s upper
edgy are in good coordination.

After the installation of door, there shall EI022

not be any surface difference between the
outer surface of door and the car body:
① When the outside of door seems relatively
higher than the side wall outside of car body,
Inner side
loosen the fixed screw of latch hook and knock of car body

the latch hook with a hammer along the inner

side of car body. Then close the door to check
the surface difference and fasten the fixed screw
of latch hook until there is no difference between
the outside of door and the car body’
s side wall
outside. EI023

② When the outer surface of door is relatively lower

than the side wall outside of car body, unscrew Outer side
of car body
the fixed screw of latch hook and knock the latch
hook with a hammer along the outer side of car
body. Then close the door to check the surface
difference and fasten the fixed screw of latch
hook until there is no difference between the
 Vehicle Body & Electric Appliance Volume EI-18

outer surface of door and the car body’

s side wall
body.
 Vehicle Body & Electric Appliance Volume EI-19

Front Wind Shield

Dismantlement and Reassembly
Dismantlement Steps
1. Dismantle the left/right wiper rod. Refer to the
section of “Wiper and Washing Apparatus”. EI024

2. Dismantle the trimming plate on the upper cover

plate of front wall. Refer to the section of
“Dismantlement for Trimming Plate on the Upper
Cover Plate of Front Wall”.

EI025

3. Dismantle the interior back mirror. Refer to the

section of “Electric Door and Window, Back
Mirror and Sun Roof”.

EI026

4. Dismantle the upper trimming plate of A-pillar on

both sides. Refer to the section of
“Dismantlement and reassembly for upper EI027
trimming plate of A-pillar”
Vehicle Body & Electric Appliance Volume EI-20
 Vehicle Body & Electric Appliance Volume EI-21

5. Dismantle the weather seal around front

windscreen.
EI028

6. Cut the adhesive around the front windscreen by

special tool for cutting.

EI029

7. If there is any need for the installation of

windscreen, mark the localizations on the
windscreen and car body for convenient
installation. EI030

8. Dismantle the front windscreen by glass sucking

EI031
disk with the help of assistant.
 Vehicle Body & Electric Appliance Volume EI-22

9. After the dismantlement, remove the adhesive EI032

from the front windscreen and its frame by
knife blade.

Installation
1. Install the new weather seal on front EI033
windscreen.

2. Apply the base agent of adhesive with the

breadth of 20mm around the frame of front
EI034
windscreen.

Attention:
If the polyurethane adhesive is not solidified
completely, the car will bounce out the
unprotected passengers and cause damage to them.

The moisture-solidifying polyurethane adhesive shall be solidified for at least 6 hours at

the temperature of 21°C (70°F) or more with the relative humidity not below 30%. The
complete solidification of polyurethane adhesive needs at least 24 hours.

EI035
The chemosetting polyurethane adhesive shall be solidified for at least 1
hour. Don’
t touch the repaired position before the
shortest solidification time.
3. Apply the glass adhesive to the front of
windscreen by sealing robot as the figure
indicates.

The glass adhesive shall be of 10mm thickness

 Vehicle Body & Electric Appliance Volume EI-23

and 8mm breadth.

 Vehicle Body & Electric Appliance Volume EI-24

4. Align the front windscreen with the marks EI036

made before and load it in the frame with the
help of assistant.

Attention:
After the installation of windscreen, don’t
drive the car before the complete solidification
of the adhesive. Open one glass of front door
before the solidification of the adhesive to protect the windscreen from being
pushed out by car’s air pressure produced by the closure of door.

5. Sprinkle water on the front windscreen to

check if there is any leakage. With leakage EI037
occurring, dry out the front windscreen and
block the leaking position with the adhesive. If
the leakage still exists, please dismantle the
front windscreen and carry out the whole
procedure again.

6. Install the back mirror inside the car. EI038

7. Install the upper trimming plates of left/right A-pillars inside the car.

EI039
 Vehicle Body & Electric Appliance Volume EI-25

8. Install the trimming plate on the upper cover plate of front wall.

EI040

9. Install the left/right wiper rods.

EI041
 Vehicle Body & Electric Appliance Volume EI-26

Rear Wind Shield

Dismantlement and Reassembly
Dismantlement Steps

1. Dismantle the coatrack inside the car. Refer EI042

to the section of “Dismantlement of
Coatrack”.

2. Dismantle the left/right upper trimming plates EI043

of C-pillar. Refer to the section of
“Dismantlement for Upper Trimming plate of
C-Pillar”.

EI044

3. Break the connector of wire harness from the

rear window demister (one for each side, left
or right).

4. Dismantle the boot cover as necessary. Refer

EI045
Boot cover
to the section of “Dismantlement of Boot
Cover”.
Vehicle Body & Electric Appliance Volume EI-27
 Vehicle Body & Electric Appliance Volume EI-28

5. Dismantle the weather seal of rear windscreen.

EI046

6. Cut the adhesive around the rear windscreen

by special tool for cutting. EI047

EI048
7. If there is any need for the installation of
windscreen, mark the localization in the
windscreen and car body for convenient
installation.

EI049

8. Dismantle the rear windscreen by glass sucking

disk with the help of assistant.
 Vehicle Body & Electric Appliance Volume EI-29

9. After the dismantlement, remove the

EI050
adhesive from the rear windscreen and its
frame by knife blade.

Installation
EI051
1. Install the new weather seal on rear
windscreen.

EI052

2. Apply the base agent of adhesive around the

frame of rear windscreen.

Attention:
If the polyurethane adhesive is not solidified completely, the car will bounce out
the unprotected passengers and cause damage to them.
The moisture-solidifying polyurethane adhesive shall be solidified for at least 6
hours at the temperature of 21°C or more and with the relative humidity not below
30%. The complete solidification of
polyurethane adhesive needs at least 24 EI053
hours.
The chemosetting polyurethane adhesive
shall be solidified for at least 1 hour. Don’t
touch the repaired position before the shortest
solidification time.
 Vehicle Body & Electric Appliance Volume EI-30

3. Apply the glass adhesive in front windscreen by sealing robot as shown in the figure.
The thickness of glass adhesive is of 10mm thickness and 8mm breadth.
 Vehicle Body & Electric Appliance Volume EI-31

4. Align the rear windscreen with the marks

EI054
made before and load it in the frame with the help
of assistant.

Attention:
After the installation of windscreen, don’t
drive the car before the complete solidification of the adhesive.
Open one windscreen of front door before the solidification of the adhesive to
protect the windscreen from being pushed out by car’s air pressure produced by
the closure of door.
EI055
5. Sprinkle water on the front windscreen to check
if there is any leakage. If so, dry out the front
windscreen and block the leaking position
with the adhesive. If the leakage still exists,
please dismantle the front windscreen and
carry out the whole procedure repeatedly.

EI056

6. Install the boot cover.

EI057
EI057
7. Install the connector of wire harness for the
rear window demister.
Vehicle Body & Electric Appliance Volume EI-32
 Vehicle Body & Electric Appliance Volume EI-33

8. Install the upper trimming plate of C-pillar. EI058

EI059
9. Install the coatrack inside the car.
 Vehicle Body & Electric Appliance Volume EI-34

Front Bumper
Dismantlement and Reassembly

1. Front Bumper 2. Buffering Percussion Absorption Block 3. Front Bumper

Frame

Attention:
The trimming plate of bumper is made of resin material. Please protect it from brute force
and oil.

Dismantlement Steps EI060

1. Screw off the expansion snap-in. Dismantle the
upper cover plate of radiator face shield and the
front grid-brand. Refer to the section of
“Dismantlement of front grid-brand”.
 Vehicle Body & Electric Appliance Volume EI-35

2. Dismantle the front wheel and tyre. Refer to the EI061

section of “Wheel and Tyre”.

3. Dismantle the two screws fastening the front

EI062
wheel cover and front bumper as well as the
two plastic screws at the lower part to take off
the front wheel cover.

EI063

4. Dismantle the two fixed bolts from the side

EI064
wall of front bumper. (two bolts for each side,
left and right)
Vehicle Body & Electric Appliance Volume EI-36
 Vehicle Body & Electric Appliance Volume EI-37

5. Elevate the car and dismantle the 2 fixed

EI065
bolts under the front bumper.

6. Dismantle the 4 fixed bolts on the bumper. EI066

7. Release the bumper and disconnect the EI067

connector of wire harness of front fog lamp Front bumper body

and then take off the bumper.

EI068
 Vehicle Body & Electric Appliance Volume EI-38

8. Dismantle the buffering percussion absorption

blocks from the bumper frame. And put them EI069
down in order.

9. Screw off the 4 fixed bolts of the bumper frame EI070

and dismantle the bumper frame.
Fastening Torque: 24±4 N•m

Reassembly
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume EI-39

Rear Bumper
Dismantlement and Reassembly

1. Rear Bumper 2. Buffering Percussion Absorption Block 3. Rear bumper Frame

Attention:
The trimming plate of bumper is made of resin material. Please protect it from brute
force and oil.

Dismantlement Steps
1. Dismantle the two fixed screws fastening the EI071
rear wheel cover and the rear bumper (two bolts
for each side, left and right).
 Vehicle Body & Electric Appliance Volume EI-40

2. Dismantle a fixed bolt from the side wall of rear bumper (left/right side).
Fastening Torque: 9±2 N•m
EI072

3. Open the boot cover and dismantle the DVD

cabin. Refer to the section of “Sound
System”.

EI073

4. Dismantle the trimming plate of left/right side EI074

walls from boot. Refer to the section of
“Dismantlement of the Trimming Plate of
Boot”.

EI075

5. Screw out the two fixed bolts of rear bumper

reinforcement from the inside of boot.
Fastening Torque: 9±2 N•m
 Vehicle Body & Electric Appliance Volume EI-41

6. Dismantle the expansion snap-in and bolt at

EI076
the bottom of rear bumper.
Fastening Torque: 9±2 N•m

EI077

EI078
7. Dismantle the upper fixed bolts in the rear
bumper.
Fastening Torque: 9±2 N•m

EI079

8. Release the rear bumper and disconnect the

connector of reversing radar wire harness.
Take off the bumper and put it in the secure
place to protect its surface from scratch.
 Vehicle Body & Electric Appliance Volume EI-42

9. Dismantle the buffering percussion absorption EI080

block from the rear bumper frame.

EI081

EI082

10. Screw off the 4 fixed bolts from the rear bumper
and dismantle the rear bumper frame.
Fastening Torque: 23±4 N•m

Reassembly
Install the rear bumper in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-43

Front Retainer
Dismantlement Steps
1. Open the engine cover and screw off the EI083
expansion snap-in, and then dismantle the
upper cover plate of radiator face shield.

2. Break off the front grid slowly with hands and EI084
then loosen the five clips inside it.

3. Pull out the front grid-brand in the direction

towards the car head. EI085

Reassembly
Install in the reverse order to dismantlement.
 Vehicle Body & Electric Appliance Volume EI-44

Trimming Plate on Upper Cover Plate of Front Wall

Dismantlement and Reassembly

1. Plastic snap-in 2. Front windshield assembly 3. Sealing rubber strip assembly

of the front Windshield 4. Left piece assembly of trimming plate on the upper cover
plate of front wall 5. Right piece assembly of trimming plate on the upper cover plate of
front wall 6. Cover plate assembly of trimming plate on the upper cover plate of front
wall 7. A-type through-hole plastic nut 8. Head tapping screw

Dismantlement Steps:
1. Dismantle the front wiper rods (left/right).

EI086
 Vehicle Body & Electric Appliance Volume EI-45

2. Dismantle the sealing rubber strip of wiper

EI087
trimming plate.

3. Screw off the fixed screws of little cover and EI088

dismantle it.

EI089
4. Screw off the 3 plastic snap-ins from the left
plate assembly of trimming plate on the upper
cover plate of front wall.

EI090
5. Screw off the 3 plastic snap-ins from the right
plate assembly of trimming plate on the upper
cover plate of front wall.
 Vehicle Body & Electric Appliance Volume EI-46

6. Disconnect the water injector hose of wiper.

EI091
Take off the left/right piece assembly of
trimming plate on the upper cover plate of
front wall.

Reassembly:
Install in the reverse order to the dismantlement.

Attention:
When installing the trimming plate of wiper, make sure that the hidden snap-in is
aligned with the plate hole of car body and then press them in.
 Vehicle Body & Electric Appliance Volume EI-47

Fender
Dismantlement and Reassembly

Bolt

Fender

Dismantlement Steps

1. Press and push the turn light towards, and pull

out the side turn light and disconnect the EI092 towards the front
of car
connector of wire harness, and then dismantle
the side turn light.

EI093
 Vehicle Body & Electric Appliance Volume EI-48

2. Screw off the fixed screws from the wheel cover and mudguard and then dismantle
the wheel cover and mudguard. Refer to the section of “Dismantlement of Wheel
Cover and Mudguard”. EI094

3. Dismantle the front bumper. Refer to the Section

EI095
of “Dismantlement of Front Bumper”.

4. Dismantle a fixed bolt from the lower side of

EI096
fender.

EI097
5. Screw off the two fixed bolts from the Fender.
Vehicle Body & Electric Appliance Volume EI-49
 Vehicle Body & Electric Appliance Volume EI-50

6. Open the front door and then screw off the other two fixed bolts from the fender.

EI098

7. Open the engine cover and then screw off the 4 EI099
fixed bolts in the upper section of fender.

8. Dismantle the fender from the sheet metal piece of

EI100
car body.

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-51

Wheel Cover and Mudguard

Dismantlement Steps
1. Screw off the fixed nut from the wheel and then
dismantle the front wheel. EI101

2. Screw off the fixed screws from the wheel cover EI102
and mudguard.

EI103
3. Take off the wheel cover and mudguard.

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-52

Deflector and Protecting Cover

Dismantlement steps
1. Dismantle the front wheel. Refer to the section of “Wheel and Tyre”.

EI104

2. Dismantle the front wheel cover. Refer to the

section of “Dismantlement of Wheel Cover and
Mudguard”.
EI105

3. Dismantle the front bumper. Refer to the

section of “Dismantlement of Front Bumper”.
EI106
Front
bumper

Deflector

4. Dismantle the fixed bolt and nut of deflector

from the bracket of underframe.

EI107 Bracket of

Nut

Bolt
 Vehicle Body & Electric Appliance Volume EI-53

5. Screw off the fixed screws from the deflector and then dismantle it.
EI108

6. Disconnect the wire harness joint of washing

apparatus motor and the washing water pipe. EI109
Screw off the fixed bolts of washing solution
kettle and then dismantle it.

Fastening Torque: 9±2 N•m

7. Screw off the fixed bolts from the right-side EI110

protecting grill cover plate for the engine. And
then dismantle the protecting cover plate.

Fastening Torque: 9±2 N•m

8. Screw off the fixed bolts from the left-side

protecting cover plate for the engine. And then EI111
dismantle the protecting cover plate.

Fastening Torque: 9±2 N•m

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-54

Outer Stripe Ornament of Car Body

Bright Stripe Ornament of Engine Hatch Cover

Bright stripe ornament for

engine hatch cover

Sealed end

Engine hatch
cover

Grid

Dismantlement
1. Open the engine hatch cover and Screw off EI112
the 4 fixed nuts of bright stripe ornament from
the cover’
s back. And then dismantle the
bright stripe ornament.

Reassembly
Align the bolt of bright stripe ornament of engine hatch cover with the installation hole of
engine hatch. And then screw down the nut to 4N•m and fix it.
 Vehicle Body & Electric Appliance Volume EI-55

Bright Stripe Ornament of Boot Cover

Sealed end
nut

Boot cover

Bright stripe
ornament

Snap-in

Dismantlement
1. Open the boot cover and dismantle the 11 fixed
snap-ins of trimming plate. And then dismantle
the trimming plate of boot cover.

EI113

EI114
2. Screw off the 4 fixed nuts of bright stripe
ornament from the back of boot cover. Prize out
the snap-ins and then dismantle the bright stripe
ornament.

Reassembly
Align the F-type bolts and snap-in of stripe ornament for tail door with its assembly hole to
install the stripe ornament for tail door to the boot cover. Screw it down to 4N•m for fixing it
 Vehicle Body & Electric Appliance Volume EI-56

with the ending nut. And then install the trimming plate of boot cover.
 Vehicle Body & Electric Appliance Volume EI-57

Stripe Ornament of Car Roof

EI115
Dismantlement steps
1. Prize out the stripe ornament of car roof by
slotted screwdriver to disengage the stripe
from snap-in.

2. Draw up the stripe from the rear of car to the EI116

front. And then dismantle the stripe of car roof.

Illustration
After the dismantlement of the stripe, please heat
the contact surface of stripe tape by the dryer.
And then remove the gib from the side wall of
car body by the lead plier.

Reassembly
1. Clean the sticking surface of stripe by cotton cloth soaked with lead-free gasoline or
IPA.
Illustration:
If the filler strip is used, start from the sixth step.
2. Use the binary epoxy adhesive (3M-weld DP-105 or other similar products).
3. Coat the surface of snap-in tape evenly with adhesive [thickness：about 0.5mm
(0.020in)].
4. Locate the components needed in proper positions and then press fully till the
adhesive overflow from the side face of tape.
5. Pack the snap-in with tape after the pressing and hold it for a specific period
according to the following situations:
● 5~10°C (41~50°F) ---one hour or more).
● 11~ 23°C (52~73°F) ---30 minutes or more).
● 24°C or higher (75°F or higher) ---15 minutes or more).
6. Install the stripe of car body according to this order from the rear end of car roof to the
front end of it after the shortly holding.
Attention:
● Bind the clamping band with double side glue after the drying of the adhesive.
● Insert the rear end cover of filler strip firmly to the rear end cut of car roof
(according to the installation standard).
● Before the installation of windscreen clamping band, make sure that the filler
 Vehicle Body & Electric Appliance Volume EI-58

strip of the side fastener of car body have been firmly inserted and then press it
in.
● Don’t wash the car in 24 hours to keep the binding property of filler strip.
 Vehicle Body & Electric Appliance Volume EI-59

Bright Stripe Ornament for Side Wall

Dismantlement steps
1. Open the front/back door completely. EI117

EI118
2. Dismantle the snap-in and draw it outward by
snap-in detacher from the rear end of bright
stripe ornament for side wall to its front end
and then dismantle the bright stripe ornament
for side wall.

Reassembly
Install in the reverse order to the dismantlement.
Illustration:
The bright stripe ornament for side wall is the disposable part, so it can only be replaced
with the new one after the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-60

Outer Water Deflector in the Front Door

Dismantlement steps
1. Lower the door window completely.

EI119

2. Dismantle the electric rear mirror. See the

EI120
section of “Electric Door and Window”.

3. Screw off the fixed screw of the outer water EI121

deflector from the inner side of door.

3. Draw up the outer water deflector from the rear EI122

end of car to its front end and then dismantle the
outer water deflector.
Attention:
Don’t dismantle it with too much force, or it is
easy to result in the distortion of outer water
deflector and the breakage of end snap-in.
Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-61

Outer Water Deflector in the Rear Door

Dismantlement steps
1. Prize up the snap-in behind the outer water
deflector of the rear door. EI123
Attention:
During the operation, please glue the gelatin film
to the car’
s surface for protecting the surface from
scrapping accidentally.

EI124
2. Draw up the outer water stripe and
dismantle it.
Attention:
Don’t dismantle it with too much force, or it is
easy to result in the distortion of outer water
deflector and the breakage of the end snap-in.

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-62

Rubbing Strip of Door

Dismantlement Steps
1. Prize up the end of rubbing strip with slotted
screwdriver packed with the adhesive cloth. EI125
Attention:
During the operation, please glue the gelatin film
to the car’
s surface for protecting it from scrapping
accidentally.

2. Draw the rubbing strip outward from the end of

EI126
it and take it out then.

Reassembly
Tear the protective gelatin film from the new rubbing strip and then glue the strip to the
located position of the body, making sure that the rubbing strip and front/rear bumper are
on the same line.

Illustration:
The rubbing strip is the disposable piece, so it is necessary to replace with the new one
after the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-63

Stripe Ornament for Front Bumper

Dismantlement
EI127
1. Prize up the end of stripe ornament by the
slotted screwdriver packed with adhesive tape.
Then draw the stripe ornament outward and
take it out.

Reassembly
Tear the protective gelatin film from the new stripe ornament and then bind the stripe to
the located position of body, making sure that the stripe ornament for front bumper and
rubbing strip of door are on the same line.

Illustration:
The stripe ornament for front bumper is the disposable part, so it is necessary to replace
with the new one after the dismantlement.
Vehicle Body & Electric Appliance Volume EI-64
 Vehicle Body & Electric Appliance Volume EI-65

Stripe Ornament for Rear Bumper

Dismantlement
EI128
1. Prize up the end of stripe ornament for rear
bumper by the slotted screwdriver packed with
adhesive tape. Then draw the stripe ornament
front the left to right and dismantle it.

Reassembly

Tear the protective gelatin film from the new stripe ornament and then bind the stripe to
the located position of body, making sure that the stripe ornament of rear bumper and the
rubbing strip of door are on the same line.

Illustration:
The stripe ornament for rear bumper is the disposable part, so it is necessary to replace
with the new one after the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-66

Interior Trimming Plate of Door

Dismantlement Steps
1. Prize up the protecting cover of high tone horn by slotted screwdriver.

EI129

2. Prize up the blanking cover and then Screw off

its screw of internal broaching handle lock. Then EI130

dismantle the blanking cover.

EI131
3. Prize up the switch control panel of window and
then disconnect the wire harness joint. Then
dismantle the switch control panel.

EI132
 Vehicle Body & Electric Appliance Volume EI-67

4. Screw off the fixed screw under the switch of electric window.
EI133

5. Prize up the glass lens of door and then Screw

off the fixed screw. EI134

EI135

6. Prize and loosen the internal snap-ins around EI136

the inner trimming plate by the slotted

screwdriver.
Vehicle Body & Electric Appliance Volume EI-68
 Vehicle Body & Electric Appliance Volume EI-69

7. Disengage the wire harness joint behind the

EI137
inner trimming plate of door and then take out
the inner trimming plate.

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-70

Interior Trimming Plate of Body Side

Upper Trimming Plate of A-pillar
Dismantlement
1. Break off the trimming plate with hands EI138
outwards to disengage the snap-in. Then
dismantle the trimming plate of A-pillar.

EI139

Reassembly
Align the trimming plate snap-in with the locating hole and then press it into the hole and
chuck it.
 Vehicle Body & Electric Appliance Volume EI-71

Lower Trimming Plate of A-pillar

Dismantlement
1. Dismantle the self-tapping screw and through
EI140
hole snap-in cap from the lower trimming plate of
A-pillar.

EI141
2. Break off the trimming plate with hands outwards
to disengage the snap-in. And then dismantle the
lower trimming plate of A-pillar.

Reassembly
Align the trimming plate snap-in with the locating hole and then press it into the hole and
chuck it. Then screw down the self-tapping screw.
 Vehicle Body & Electric Appliance Volume EI-72

Lower Trimming Plate of B-pillar

Dismantlement
1. Dismantle the pedals of front door and rear EI142
door.

EI143

2. Dismantle the two fixed screws from the lower EI144

trimming plate of B-pillar.

EI145
3. Break off the trimming plate with hands
outwards to disengage the snap-in and then
dismantle the lower trimming plate of B-pillar.

Reassembly
Align the trimming plate snap-in with the locating hole and press it into the hole and chuck
 Vehicle Body & Electric Appliance Volume EI-73

it. Then screw down the self-tapping screws.

 Vehicle Body & Electric Appliance Volume EI-74

Upper Trimming plate of B-pillar

1. Screw off the fixed screws from the lower trimming plate of B-pillar and dismantle the
lower trimming plate of B-pillar.
EI146

2. Dismantle the two fixed screws from the upper

trimming plate of B-pillar. EI147

EI148
3. Dismantle the front safety belt. Refer to the
Section of “Safety Belt”.

EI149
4. Break off the trimming plate with hands outwards
to disengage the snap-in. Then dismantle the
lower trimming plate of B-pillar.

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-75

Lower Trimming Plate of C-pillar

Dismantlement
1. Dismantle the rear seat. See the section of EI150
“Seat”.

EI151
2. Dismantle the fixed screw and through hole C-pillar lower
trimming plate
snap-in cap from the lower trimming plate of
C-pillar.

EI152

C-pillar lower
trimming plate

EI153

3. Break off the trimming plate with hands

outwards to disengage the snap-in. Then
dismantle the lower trimming plate of C-pillar.

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-76

Upper Trimming Plate of C-pillar

Dismantlement
EI154
1. Dismantle the rear seat. See the section of
“Seat”.

EI155

2. Dismantle the lower trimming plate of C-pillar.

See the section of “Dismantlement of Lower
Trimming Plate”.

EI156

3. Dismantle the snap-in from the coatrack. And

then dismantle the coatrack.

EI157

4. Dismantle the safety belt from rear seat. See

the section of “Safety Belt”.
Vehicle Body & Electric Appliance Volume EI-77
 Vehicle Body & Electric Appliance Volume EI-78

5. Screw off the fixed screws from the upper

EI158
trimming plate of C-pillar.

6. Break off the trimming plate with hands

outwards to disengage the snap-in and then
dismantle the upper trimming plate of C-pillar.
EI159

Reassembly
Install in the reverse order to the
dismantlement.
 Vehicle Body & Electric Appliance Volume EI-79

Front Door Pedal

Dismantlement
Break off the pedal with hands outwards to EI160
disengage the snap-in and then dismantle the
front door pedal.

Reassembly
Put the pedal aligning with its installing position and after aligning its snap-in with the
locating hole, press the snap-in into the hole and chuck it.
 Vehicle Body & Electric Appliance Volume EI-80

Rear Door Pedal

Dismantlement
1. Raise the rear seat cushion and then screw EI161
off a fixed screw from the rear door pedal.

Rear door

pedal

EI162
2. Break off the pedal with hands outwards to
disengage the snap-in and then dismantle the
rear door pedal.

EI163

Reassembly
Put the pedal aligning with its installing position and after aligning its snap-in with the
locating hole, press the snap-in into the hole and chuck it.
 Vehicle Body & Electric Appliance Volume EI-81

Rubber Strip of Doorframe

Dismantlement
1. Dismantle the door pedal. Refer to the section EI164
of “Dismantlement of Door Pedal”.

2. Draw the rubber strip upward from its head

and then dismantle it.
EI165

EI166

Reassembly
Clip the control point of rubber strip into the
position displayed in the picture and insert EI167
gradually the caulking groove of rubber strip to
the sheet metal piece of body. When near the
Control
ends, insert the head into the inner trimming plate point

and then knock it firmly with rubber hammer along

the door frame.
 Vehicle Body & Electric Appliance Volume EI-82

Weather Seal on the Door

Dismantlement
1. Dismantle the snap-in of the first rubber strip of EI168
front door.

EI169 the first rubber strip

of front door

2. Dismantle the first rubber strip of front door from

caulking groove on the door.

EI170

3. Screw off the three fixed screws from the outer

protecting plate at the door and then dismantle
the outer protective plate.

EI171

outer
protecting
Vehicle Body & Electric Appliance Volume EI-83
 Vehicle Body & Electric Appliance Volume EI-84

4. Dismantle the snap-in from the secondary EI172

rubber strip of door and then dismantle the
strip.

EI173 The secondary

rubber strip of
door

Sheet-metal
of car body

5. Dismantle the snap-in of weather seal at the EI174

door’
s lower section. And then dismantle the
weather seal.

Reassembly

Install the lower weather seal, secondary rubber strip of door and the first rubber strip of
front door in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-85

Coatrack
Dismantlement
1. Lay down the backrest of rear seat and
dismantle the snap-in of the coatrack. EI175

2. Lift the coatrack and disconnect the wire EI176

harness connector of high brake lamp and
then take off the coatrack.

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-86

Sun Visor
Dismantlement Steps
1. Screw off the two fixed screws from the one
side of the sun visor. EI177

2. Disengage the wire harness. EI178

3. Screw off the other fixed screw from the other EI179
side sun visor and then dismantle it.

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-87

Ceiling
Dismantlement Steps
1. Prize up the blanking cover and then screw off
EI180
the fixed bolts from the arm rest. Then
dismantle the arm rest.

2. Dismantle the sun visor. Refer to the section

EI181
of “Dismantlement of Sun Visor”.

EI182
3. Dismantle the front ceiling light inside the car
and the central ceiling light. Refer to the
section of “Lighting System”.

EI183
 Vehicle Body & Electric Appliance Volume EI-88

4. Dismantle the rubber strip of doorframe.

EI184

5. Dismantle the upper trimming plate of

A/B/C-pillar.
EI185

EI186

EI187
 Vehicle Body & Electric Appliance Volume EI-89

6. Dismantle the fixed snap-in from the Ceiling

EI188
by snap-in detacher. Ceiling

EI189

7. Dismantle the ceiling from the car.

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-90

Floor Carpet
Dismantlement Steps

1. Dismantle the front/rear seat. Refer to the EI190

section of “Seats”.

2. Dismantle the central console. Refer to the

EI191
section of “Facial Console Assembly”.

3. Dismantle the front door pedal and rear door

EI192
pedal.

EI193
 Vehicle Body & Electric Appliance Volume EI-91

4. Screw off the three fixed bolts from the base EI194
board and dismantle the base board for the
second driver’
s seat.

EI195
6. Dismantle the left/right side A-pillar lower
trimming plate and B-pillar lower trimming plate.

EI196

7. Dismantle the fixed bolts (left/right) on the floor

from the safety belt of front seat. EI197
 Vehicle Body & Electric Appliance Volume EI-92

8. Dismantle the carpet screw and then pull out the

carpet. EI198

Carpet screw under the

instrument desk

EI199

Lower side of rear

seat

Reassembly
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-93

Interior Trimming of Boot

Dismantlement Steps
EI200
1. Open the boot cover assembly and then
dismantle the water holding rubber strip on the
rear boot cover.

2. Dismantle the two self-tapping screws and

EI201
four fixed snap-ins from the trimming plate of Self-tapping
screws
boot apron board.

Snap-in

3. Dismantle the three fixed snap-ins from the EI202

spare tyre cover plate of boot and then
dismantle the spare tyre cover plate.

Spare tyre
cover

4. Dismantle the three fixed snap-ins from the EI203

side trimming plate of boot.
 Vehicle Body & Electric Appliance Volume EI-94

5. Draw out the side trimming plate and then

EI204
disconnect the connector of wire harness. Then
dismantle the lower side trimming plate.

6. Dismantle the fixed snap-ins from the front EI205

trimming plate and then dismantle the plate.

7. Dismantle the fixed snap-ins from the ceiling

trimming plate and disengage the wire harness. EI206
Then dismantle the ceiling trimming plate of
boot.

Reassembly
Install the trimming plate of boot in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume EI-95

Trimming Plate of Boot Cover

Dismantlement Steps
1. Open the boot cover assembly
EI207
completely.

EI208

2. Dismantle the 11 fixed snap-ins from the

trimming plate by snap-in detacher. Then
take off the trimming plate of boot cover.

Reassembly
Locate the trimming plate on the boot cover and then align it with the locating hole to
install the snap-in symmetrically.
 Vehicle Body & Electric Appliance Volume IP-1

Console Assembly
Precautions
Precautions for Dismantling and Reassembling the Airbag of Supplemental Restraint
System (SRS)
Using such supplemental restraint systems as “airbag”and “safety belt pre-tensioner”with
safety belt can help reduce the possibility of hurt or the degree of injury of driver and
passengers at the front caused by collision of vehicles.
Caution:
 In order to avoid the failure of SRS system, which may result in increasing the danger of
injury and death caused by collision of vehicles, all maintenances shall be done by the
maintenance service center of the authorized JAC dealership.
 Improper maintenance, including improperly dismantlement and Reassembly of the SRS
system, may result in the error actions of this system, thus causing the casualty
accidents.
 For the dismantlement method of spiral cables and airbag modules, please refer to the
part of SRS.
 It is forbidden to test any circuit of the SRS system with electricity testing equipment,
except such operations are illustrated in this manual. The wire harness of SRS circuit is
always identified by the yellow wire harness or wire harness connector.
Precautions
 Cut off the cables of storage battery in advance.
 Cut off the lines of airbag system in advance.
 Overhauling can be started only after switching the ignition switch to LOCK position and
dismounting the cables from the negative (-) terminal of storage battery for 3 minutes, as
the SYS system is equipped with the reserve power supply.
 Avoid damaging or opening the airbag cover forcibly; otherwise adverse effects will be
caused to its performance.
 Be careful not to scratch the lining and other spare parts.
 Be careful not to make the parts damaged or deformed when dismantling or
disassembling any part, and pay attention to protect the spare parts which
may hook clothes.
 After dismounting the lining of steering wheel, put its top side upwards and reserve it on a
balanced place; further more, don’ t’put any objects on it.
 Protect the dismounted spare parts with cloth.
 If the clamping band is deformed or damaged, please replace it.
 If the non-reusable spare parts are dismounted, please replace then with new ones.
 Tighten the bolts and nuts to stipulated moment.
 Confirm each spare part operates normally after reassembly.
 It is not allowed to measure the resistance of triggering device for airbag unfolding, (as it
is may cause the airbag explosion accidentally); thus it is necessary to conform to the
relative precautions on the illustration name plate on the walls of the SRS spare parts.
 It is forbidden to electrify the controller with alternating current or direct current of more
than 20V for protecting it from damage.
 Vehicle Body & Electric Appliance Volume IP-2

Extreme danger! It is forbidden to dismantle the airbag sub-assembly and its interior gas
generator.
 Clean the sewage with the following methods.
Water Soluble Stain:
Submerge the soft cloth in water and wring it to wipe the stains; then, wipe it with soft dry
cloth.
Oil Stain:
Dissolve the complex detergent in warm water (2~3% concentration or lower), and soak the
cloth to wipe out the oil stain; then, submerge the cloth in clean water and wring it to wipe out
the detergent; at last, wipe the clean part with soft dry cloth.
 Don’ t use such organic solvent as diluent or gas.

Trouble Diagnosis for Squeak and Kluck

Have a face-to-face talk with the clients if you can to confirm the situation when the noise is
made.
● Know about the actual situation when the noise is made (or not) if you can, as the client
may be unable to provide the detailed description or source of noise.
● If there are many kinds of noise in the car, it is necessary to diagnose it and deal with the
noise concerned by the client. It is possible to drive with the client for testing.
● After identifying the kind of noise, distinguish the noise according to its characters. Make
the clients, maintenance consultant and maintenance technician come to an agreement
on noise description according to the characteristics of noise.
● Squeak- (as the noise made by tennis shoes rubbing against the clean ground)
The characteristics of squeak include the light touch/fast motion/resulting from road
condition/rough road surface = high noise/soft surface = low noise/edge of road
surface=chirp
● Quack- (as the sound made by walking on the old wooden plate)
The characteristics of quack include touch/slow motion/rotary twist/volume differs from
materials to materials/the noise is usually made during operation.
● Kluck- (as the sound made by shaking children’ s toys)
The characteristics of kluck include fast repeated friction/vibration or similar
motion/looseness of spare parts/looseness of clamping band or lock catch/improper gap.
● Knock- (as a knock at the door)
The characteristics of knock include the sound in cavity/echo/the noise made by driving.
● Click- (as the sound made by second hand of clock)
The characteristics of click include light touch of soft objects/looseness of spare parts/the
sound may be caused by driver operation or road conditions.
● Thump- (knocks of heavy objects and silencer)
The characteristics of thump include the lighter knock/low sound caused by operation.
● Buzz- (as the sound made by a host of bees)
The characteristics of buzz include the high frequency cackle/stable touch.
● The acceptable noise levels typically differ from person to person. The noise which you
consider to be acceptable may be beyond the endurance of clients.
 Vehicle Body & Electric Appliance Volume IP-3

● The weather conditions, especially humidity and temperature, may influence the noise
level.
Noise Reproduction and Road-Test
Drive with the clients until the noise is made if it is possible. Pay attention to the other
information about noise or position on the diagnosis meter. The information can be used to
reproduce the same situation when you perform repair.
If it is easy to reproduce the noise when the road test is carried out, try to stop the car and
carry out the following operations for reproducing the noise in order to identify the source of
noise:
1) Close one door.
2) Knock at or push/pull the areas where the noise is made.
3) Raise the engine speed.
4) Reproduce the “twist”of vehicle with the lifter.
5) Use the engine load (electric load, M/T type semidetached clutch), when the vehicle runs at
an idle speed.
6) Raise the car with lifter and beat the tires with rubber hammer.
● Drive the car for trying to reproduce the situations when the noise is made described by
the clients.
● If it is difficult to reproduce the noise, drive the car slowly on uneven or rough road surface
to increase the stresses on vehicle body.

Find Relative Maintenance Report

After confirming the phenomenon described by the clients, find if there are relative technical
maintenance reports.
If there are relative technical maintenance reports, please make maintenance by following the
steps.

Confirmation of Noise Source and Identification of Basic Causes

1. Reduce the noise range to a normal one. Find out the source of noise with listening tools
(as engine audiphone or mechanical stethoscope).
2. Reduce the noise range to a specific one, and identify the causes of noise with the
following methods:
● Dismantle the elements in the suspicious areas where the noise may be produced.
Do not overexert when dismantling the snapin or fixer; otherwise, the snapin or fixer may
be damaged or lost during maintenance, thus producing a new noise.
● Beat or push/pull the elements which may produce the noise.
Not overexert when beating or pushing/pulling the elements; otherwise the noise will be
temporarily eliminated.
● Touch the elements which may make the noise with hands to feel whether vibration exists
or not.
● Put a piece of paper between the elements which may make noise.
● Examine if there are marks for looseness and contact of elements.
 Vehicle Body & Electric Appliance Volume IP-4

Troubleshooting
● If it is caused by looseness of element, please screw it down.
● If it is caused by insufficient gap between elements:
– If it is possible, re-position the elements, or loosen and then re-screw them down for
detaching the elements.
– The isolation elements with suitable heat insulation cushion can be attained from the
authorized spare parts department for JAC vehicles.
 Vehicle Body & Electric Appliance Volume IP-5

Attention:
Do not overexert, as many elements are made of plastic, which are easily
damaged. Always inquire about the latest information on spare parts from
the spare parts department.
Maintenance Confirmation
Drive the car under the same conditions as that of reproducing noise, and confirm the noise
source through road test and then perform the maintenance.
Countermeasures for Squeak and Kluck
Refer to the catalog of regulations on dismantlement and installation of element.
Instrument Panel
Most troubles are caused by the contact between and movement of the following spare parts:
1. Trimming plate and console;
2. Console to A-pillar trimming plate;
3. Console to windshield;
4. Anchor pin of console;
5. Wire harness behind the combined instrument;
6. A/C defrosting pipe and pipe joint.
Reproducing noise by beating or moving the elements or ceasing the noise by pressing
components during driving can help find the sources of the troubles. Most troubles can be
eliminated by using woolen cloth rubber belt or silicon spray (at the areas difficult to access).
And the polyurethane cushion can be used for separating the wire harness.
Attention:
Do not use the silicon spray to insulate the squeak or kluck, as it is
impossible to verify the maintenance if the area is full of silicon.

Middle Control Desk

Elements to be noted:
1. The cover of gearshift lever assembly to trimming plate;
2. A/C control device;
3. Wire harness behind the sound and A/C control device.
Procedures of maintenance and sound insulation of console can also be applied to the central
control desk.
Door
Attention:
1. Slap produced by door and inner trimming plate;
2. Trimming cover of mounting nuts on inner handle and trimming plate of door;
3. Rap produced by wire harness;
4. Put-put caused by the misalignment of lock catch of door while starting and stopping the
car.
Sticking, moving or pressing the spare parts can resolve many troubles when reproducing the
situations. Woolen cloth rubber belt or insulation foam blocks can be adopted to insulate the
areas to eliminate the noise.
Boot
 Vehicle Body & Electric Appliance Volume IP-6

Generally, the noise of boot is caused by looseness of lifting jack or objects in it.
In addition, pay attention to:
1. The damping block of luggage cover is improperly installed.
2. The lock catch of luggage cover is mismatched.
3. The air operated outriggers of luggage cover touch each other.
4. The license plates or support become loose.
Most of the troubles can be eliminated by adjusting, fixing or insulating the items or elements
producing the noise.
Sunroof/Vehicle Ceiling
Noise from the sunroof/vehicle ceiling areas can be regulated to:
1. Kluck or light knock caused by sunroof cover, beam, pull rod or bad sealing;
2. Shake of sun visor shaft in the support;
3. Squeak produced by the front or rear windshield’ s touching of the vehicle ceiling.
Most of the noise can be insulated by pressing the element while reproducing the situation.
The woolen cloth rubber belt is always used for insulation in maintenance.
Seat
When insulating the noise of seat, pay special attention to the position of seat and the objects
on it when the noise is produced. It is necessary to reproduce these conditions when
confirming and insulating the source of noise.
Causes for noise of seats include:
1. Head rest rod and mounting hole;
2. The squeak produced by seat cushion and seat rack;
3. Snapin on the rear row backrest.
The noise can be insulated by moving or pressing the suspicious elements while reproducing
the noise. Most of the troubles can be eliminated by resetting elements or using polyurethane
rubber belt at the contact areas.
Under the Engine Cover
The elements under the engine cover or on the walls of engine may produce some interior
noise, and the noise will be transmitted to the passenger compartment.
Causes for transmission of the noise under engine cover include:
1. The elements installed on the walls of engine;
2. The elements passing through the walls of engine;
3. Supports and adaptors of the walls of engine;
4. Looseness of anchor pin on the radiator;
5. The engine cover and bumper are misaligned;
6. The lock catch on engine cover is mismatched.
Because the noise can transmit to the inside of vehicle, it is difficult to insulate it. The best
method is to fix, move or insulate an element at a time and to test the running vehicle. In
addition, it is possible to change the speed or load of engine for insulating the noise. Troubles
can be eliminated by adjusting, fixing or insulating the elements producing the noise.
 Vehicle Body & Electric Appliance Volume IP-7

Console Assembly
Positions of Spare Parts

K
J
B C
A

D E
F H I
G

A. Combined instrument B. Air outlet of air conditioner C. DVD control panel

D. Combined switch E. Steering wheel assembly F. Safety airbag
assembly
G. Cigarette lighter and ashtray assembly H. Air conditioning control
panel
I. Storage box J. Anti-theft indicator light K. Sunlight sensor
Vehicle Body & Electric Appliance Volume IP-8
 Vehicle Body & Electric Appliance Volume IP-9

Disassembly Drawing of Assembly

Disassembly of Main Instrument

No. Description No. Description

1 Console assembly 2 Bolt
3 Screw 4 Screw
Left demister wind pipe
5 Air pipe assembly of air conditioner 6
assembly
Air outlet pipe assembly of air
7 Right demister wind pipe assembly 8
conditioner
Glove compartment frame
9 Safety airbag assembly for the assistant driver 10
assembly
Lock core assembly of glove
11 Glove compartment assembly 12
compartment
Assembly of screw cover of
13 Latch hook of glove compartment 14
combined instrument
Storage box assembly at the
15 Lower trimming plate assembly at the driver’ s side16
driver’
s side
17 Upper panel assembly at center 18 Left air outlet assembly at center
19 Right air outlet assembly at center 20 Lower panel assembly at center
Cover plate assembly of right
21 Cover plate assembly of left end face of console 22
end face of console
Upper cover assembly of
23 Base board assembly for the assistant driver 24
combined switch
25 Lower cover assembly of combined switch 26 Screw
27 Nut 28 Bolt
Vehicle Body & Electric Appliance Volume IP-10
 Vehicle Body & Electric Appliance Volume IP-11

Disassembly of Auxiliary Instrument

1 Auxiliary console assembly 2 Screw

4 Upper trimming plate assembly of
3 Bolt
auxiliary console
5 Ash tray body assembly 6 Screw
Trimming plate assembly of manual 8 Left front extension board assembly
7
brake of auxiliary console
Right front extension board assembly 10 Front extension board support of
9
of auxiliary console auxiliary console
Connection support of front extension 12 Front-end fixed support of auxiliary
11
board support of auxiliary console console
Rear-end fixed support of auxiliary 14 Bolt
13
console
 Vehicle Body & Electric Appliance Volume IP-12

Dismantlement and Reassembly of Assembly

(A) Trimming of Control Desk Switch
1. Cut off the negative terminal of storage battery for IP001
3 minutes.

IP002

2. Insert the withdrawal tools (flat tool) and unclench

the snapin of control switch.

IP003

3. Disconnect the joint of wire harness and take off

the control switch.

IP004
 Vehicle Body & Electric Appliance Volume IP-13

(B) Front Ash Tray and Cigarette Lighter

Loosen the fixed screws of the front ash tray, and then
lift the joint of wire harness to dismantle it.
IP005

(C) Lower Cover Plate of Console (Left/Right)

1. Loosen the screws between the lower cover plate IP006

of console (left/right) and carpets.

2. Unclench the front door pedal with the flat tool and IP007
dismantle it.

3. Dismantle the fixed screws of the lower cover plate IP008

and take it off.
 Vehicle Body & Electric Appliance Volume IP-14

(D) Auxiliary Instrument

1. Properly pull the upper trimming plate of auxiliary
IP009
instrument upwards to loose it.

IP010
2. Pull the gear lever shell upwards and take the
lever off.

IP011
3. Dismantle the fixed screws of the cigarette lighter
and ash tray assembly.

IP012

4. Properly detach the air conditioning control panel

upwards, and then dismantle it and cut off the
connecting wire harness.
Vehicle Body & Electric Appliance Volume IP-15
 Vehicle Body & Electric Appliance Volume IP-16

IP013

5. Dismantle the fixed screws.

IP014

IP015
6. Dismantle the left & right extension board
assemblies of the auxiliary instrument.

IP016

7. Adjust the seats and dismantle the fixed screws of

the auxiliary instrument.
 Vehicle Body & Electric Appliance Volume IP-17

8. Dismantle the screws fixing the auxiliary

instrument onto the vehicle body. IP017

9. Raise the auxiliary instrument desk assembly.

IP018

IP019

(E) Glove Compartment Before Passengers

1. Open the glove box cover and dismantle the fixed
screws.

IP020
 Vehicle Body & Electric Appliance Volume IP-18

2. Dismantle the fixed bolts of the lock catch of glove

compartment.
IP021

IP022

3. Draw it out and cut off the relative terminals of wire

harness.

IP023

(F) Display Unit

1. Find out the U-tool.

IP024

2. Insert the U-tool into the control panel and grip it

tightly to draw out the control panel; then pull out
the wire harness to take the display unit out.
 Vehicle Body & Electric Appliance Volume IP-19

IP025

Attention:
The bayonets of U-tool should be properly inserted
until hearing the sound “bang”.
(G) Lower Trimming Plate at Driver’s Side
1. Dismantle the screws, and loosen the data
diagnosis adaptor.
IP026

IP027

IP028
 Vehicle Body & Electric Appliance Volume IP-20

2. Dismantle the wiredrawing handle of engine hatch.

IP029

3. Cut off the adaptors of inside temperature sensor

and take out the lower trimming plate.
IP030

(H) Fuse Box Cover IP031

Dismantle the fixed bolts and cut off the wire harness.

IP032

(I) Steering Wheel

1. Dismantle the upper & lower protecting covers of
steering column.
Dismantle the fixed bolts and detach the upper
and lower protecting cover.
 Vehicle Body & Electric Appliance Volume IP-21

2. Unclench the inner circlip with tools from the rear IP033
of the steering wheel cover assembly.

3. Take out the steering wheel cover assembly.

IP034

4. Dismantle the locknut of steering wheel.

IP035

5. Cut off the wire harness adaptors of horns and

spiral cables. IP036
 Vehicle Body & Electric Appliance Volume IP-22

6. Draw out the steering wheel upwards. IP037

(l) Plate Cover of Central Control Desk

2 3

1. Screw 2. Display unit

3. Grid of central ventilator 4. Plate cover
Disassembly
1. Refer to the part of dismantlement and installation of display unit to take off the display
unit.
2. Loosen the screws, and then dismantle the central ventilator grid and the plate cover.
Assembly
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume IP-23

Dismantlement of Instrument Desk Assembly

1. Dismantle the fixed bolts on the left & right sides.

IP038

IP039

2. Dismantle the fixed bolts in the middle.

IP040

IP041

3. Raise the console assembly.

 Vehicle Body & Electric Appliance Volume SE-1

Precautions
Precautions for Subsidiary Restraint System (SRS) such as “Safety
Airbag”and “Safety Belt Pre-tensioner”
With the use of subsidiary restraint system such “as Safety Air Bag”and “Safety Belt
Pre-tensioner”along with the use of safety belt, the danger of being hurt or the degree of
injury could be reduced or at least lessened to protect the driver and passengers in the
collision of car. In the “Maintenance Manual”, information for secure maintenance of the
system is included in section SRS and section SB.
Caution:
• In order to avoid the failure of SRS system, which may result in increasing the danger
of injury and death caused by collision of vehicles, all maintenances shall be done by
the maintenance service center of the authorized JAC dealership.
• Improper maintenance, including improperly dismantlement and Reassembly of the
SRS system, may result in the error actions of this system, thus causing the casualty
accidents. For the dismantlement method of spiral cables and airbag modules, please
refer to the part of SRS.
• It is forbidden to test any circuit of the SRS system with electricity testing equipment,
except such operations are illustrated in this manual. The wire harness of SRS circuit
is always identified by the yellow and/or orange wire harness or wire harness adaptor.
Notice for Service
• Cover the car body with cloth or liner to prevent it from dashing while dismantling and
installing the parts.
• Carefully remove the inner trimming, filler trip apparatus and grid etc., while
dismantling and installing them. Keep them away from the touching of oil products or
other damage.
• Apply sealant in the position as necessary while installing the parts.
• Don’ t have the sealant effused out of the parts in the use of it.
• Apply the rust protection measure for the replacement of any metal parts (such as
mechanic parts, etc.)
Precautions
• Keep the parts away from damage or deforming while dismantling or disassembling
them. Pay attention to the parts which are possible to cut the clothes.
• Pack the part with ethylene tape or clothe band to protect them while dismantling
them with screwdriver or other tools.
• Protect the dismantled parts with clothe.
• Replace the deformed or damaged clamping band.
• Replace the dismantled disposable parts with the new ones.
• Screw down the bolt and nut to the regulated torque.
• Make sure that each part is in its normal use after the reassembly.
• Clean up the sewage by the following methods.
Water Soluble Stain:
Submerge the soft cloth in water and wring it to wipe the stains; then, wipe it with soft dry
cloth.

Oil Stain:
Dissolve the complex detergent in warm water (2%~3% concentration or lower), and soak
 Vehicle Body & Electric Appliance Volume SE-2

the cloth to wipe out the oil stain; then, submerge the cloth in clean water and wring it to
wipe out the detergent; at last, wipe the clean part with soft dry cloth.
• Don’ t use such organic solvent as diluent or gas.
Trouble Diagnosis for Squeak and Kluck
Have a face-to-face talk with the clients if you can to confirm the situation when the noise
is made.
• Know about the actual situation when the noise is made (or not) if you can, as the
client may be unable to provide the detailed description or source of noise.
• If there are many kinds of noise in the car, it is necessary to diagnose it and deal with
the noise concerned by the client. It is possible to drive with the client for testing.
• After identifying the kind of noise, distinguish the noise according to its characters.
Make the clients, maintenance consultant and maintenance technician come to an
agreement on noise description according to the characteristics of noise.
• Squeak- (as the noise made by tennis shoes rubbing against the clean ground)
The characteristics of squeak include the light touch/fast motion/resulting from road
condition/rough road surface = high noise/soft surface = low noise/edge of road
surface = chirp
• Quack- (as the sound made by walking on the old wooden plate)
The characteristics of quack include touch/slow motion/rotary twist/volume differs from
materials to materials/the noise is usually made during operation.
• Kluck- (as the sound made by shaking children’ s toys)
The characteristics of kluck include fast repeated friction/vibration or similar
motion/looseness of spare parts/looseness of clamping band or lock catch/improper
gap.
• Knock- (as a knock at the door)
The characteristics of knock include the sound in cavity/echo/the noise made by
driving.
• Click- (as the sound made by second hand of clock)
The characteristics of click include light touch of soft objects/looseness of spare
parts/the sound may be caused by driver operation or road conditions.
• Thump- (knocks of heavy objects and silencer)
The characteristics of thump include the lighter knock/low sound caused by operation.
• Buzz- (as the sound made by a host of bees)
The characteristics of buzz include the high frequency cackle/stable touch.
• The acceptable noise levels typically differ from person to person. The noise which
you consider to be acceptable may be beyond the endurance of clients.
• The weather conditions, especially humidity and temperature, may influence the
noise level.
Noise Reproduction and Road-Test
Drive with the clients until the noise is made if it is possible. Pay attention to the other
information about noise or position on the diagnosis meter. The information can be used to
reproduce the same situation when you perform repair.
If it is easy to reproduce the noise when the road test is carried out, try to stop the car and
carry out the following operations for reproducing the noise in order to identify the source
of noise:
1) Close one door.
 Vehicle Body & Electric Appliance Volume SE-3

2) Knock at or push/pull the areas where the noise is made.

3) Raise the engine speed.
4) Reproduce the “twist”of vehicle with the lifter.
5) Use the engine load (electric load, M/T type semidetached clutch), when the vehicle
runs at an idle speed.
6) Raise the car with lifter and beat the tires with rubber hammer.
• Drive the car for trying to reproduce the situations when the noise is made described
by the clients.
• If it is difficult to reproduce the noise, drive the car slowly on uneven or rough road
surface to increase the stresses on vehicle body.

Find Relative Maintenance Report

After confirming the phenomenon described by the clients, find if there are relative
technical maintenance reports.
If there are relative technical maintenance reports, please make maintenance by following the
steps.
Confirmation of Noise Source and Identification of Basic Causes
1. Reduce the noise range to a normal one. Find out the source of noise with listening
tools (as engine audiphone or mechanical stethoscope).
2. Reduce the noise range to a specific one, and identify the causes of noise with the
following methods:
• Dismantle the elements in the suspicious areas where the noise may be produced.
Do not overexert when dismantling the snapin or fixer; otherwise, the snapin or fixer
may be damaged or lost during maintenance, thus producing a new noise.
• Beat or push/pull the elements which may produce the noise.
Not overexert when beating or pushing/pulling the elements; otherwise the noise will
be temporarily eliminated.
• Touch the elements which may make the noise with hands to feel whether vibration
exists or not.
• Put a piece of paper between the elements which may make noise.
• Examine if there are marks for looseness and contact of elements.
Troubleshooting
• If it is caused by looseness of element, please screw it down.
• If it is caused by insufficient gap between elements:
– If it is possible, re-position the elements, or loosen and then re-screw them down
for detaching the elements.
– The isolation elements with suitable heat insulation cushion can be attained from
the authorized spare parts department for JAC vehicles.
Attention:
Do not overexert, as many elements are made of plastic, which are easily damaged.
Always inquire about the latest information on spare parts from the spare parts
department.
Maintenance Confirmation
Drive the car under the same conditions as that of reproducing noise, and confirm the
noise source through road test and then perform the maintenance.
Countermeasures for Squeak and Kluck
 Vehicle Body & Electric Appliance Volume SE-4

Refer to the catalog of regulations on dismantlement and installation of element.

Instrument Plate
Most troubles are caused by the contact between and movement of the following spare
parts:
1. Trimming plate and console
2. Console to A-pillar trimming plate
3. Console to windshield
4. Anchor pin of console
5. Wire harness behind the combined instrument
6. A/C defrosting pipe and pipe joint
Reproducing noise by beating or moving the elements or ceasing the noise by pressing
components during driving can help find the sources of the troubles. Most troubles can be
eliminated by using woolen cloth rubber belt or silicon spray (at the areas difficult to
access). And the polyurethane cushion can be used for separating the wire harness.
Attention:
Do not use the silicon spray to insulate the noise of squeak or kluck, as it is
impossible to verify the maintenance if the area is full of silicon.
Middle Control Desk
Elements to be noted:
1. From the cover of gearshift lever assembly to trimming plate;
2. A/C control device;
3. Wire harness behind the sound and A/C control device.
Procedures of maintenance and sound insulation of console can also be applied to the
central control desk.
Door
Attention:
1. Slap produced by door and inner trimming plate;
2. Trimming cover of mounting nuts on inner handle and trimming plate of door;
3. Rap produced by wire harness;
4. Put-put caused by the misalignment of lock catch of door while starting and stopping
the car.
Sticking, moving or pressing the spare parts can resolve many troubles when reproducing
the situations. Woolen cloth rubber belt or insulation foam blocks can be adopted to
insulate the areas to eliminate the noise.
Boot
Generally, the noise of boot is caused by looseness of lifting jack or objects in it.
In addition, pay attention to:
1. The damping block of luggage cover is improperly installed.
2. The lock catch of luggage cover is mismatched.
3. The air operated outriggers of luggage cover touch each other.
4. The license plates or support become loose.
Most of the troubles can be eliminated by adjusting, fixing or insulating the items or
elements producing the noise.
Sunroof/Vehicle Ceiling
Noise from the sunroof/vehicle ceiling areas can be regulated to:
1. Kluck or light knock caused by sunroof cover, beam, pull rod or bad sealing;
 Vehicle Body & Electric Appliance Volume SE-5

2. Shake of sun visor shaft in the support;

3. Squeak produced by the front or rear windshield’ s touching of the vehicle ceiling.
Most of the noise can be insulated by pressing the element while reproducing the situation.
The woolen cloth rubber belt is always used for insulation in maintenance.
Seat
When insulating the noise of seat, pay special attention to the position of seat and the
objects on it when the noise is produced. It is necessary to reproduce these conditions
when confirming and insulating the source of noise.
Causes for noise of seats include:
1. Head rest rod and mounting hole;
2. The squeak produced by seat cushion and seat rack;
3. Snapin on the rear row backrest.
The noise can be insulated by moving or pressing the suspicious elements while
reproducing the noise. Most of the troubles can be eliminated by resetting elements or
using polyurethane rubber belt at the contact areas.
Under the Engine Cover
The elements under the engine cover or on the walls of engine may produce some interior
noise, and the noise will be transmitted to the passenger compartment.
Causes for transmission of the noise under engine cover include:
1. The elements installed on the walls of engine;
2. The elements passing through the walls of engine;
3. Supports and adaptors of the walls of engine;
4. Looseness of anchor pin on the radiator;
5. The engine cover and bumper are misaligned;
6. The lock catch on engine cover is mismatched.
Because the noise can transmit to the inside of vehicle, it is difficult to insulate it. The best
method is to fix, move or insulate an element at a time and to test the running vehicle. In
addition, it is possible to change the speed or load of engine for insulating the noise.
Troubles can be eliminated by adjusting, fixing or insulating the elements producing the
noise.

Overview
Two kinds of seats are available for the model of car: manual seat and electric seat.
Diagram for the Adjustment Function of Electric Seat
Vehicle Body & Electric Appliance Volume SE-6
 Vehicle Body & Electric Appliance Volume SE-7

Distribution and Strike Diagram for Wire harness of Electric Seat

Fixed point of harness Harness to angle

controller

Power supply to
car body

Harness to car
body

Indicating harness in
safety belt
Motor to front lifting

Motor to rear lifting

Motor to level
lifting

Strike Diagram for Wire Harness of 8-direction Seat

Specifications of Torque Value

Name of the Parts Purpose of Bolts Fastening Torque
Connecting
Bolt-M10x1.25 To connect the angle
controller/backrest/slide track. 45±5 N•M
Mounting nut in To connect the seat basin with slide
cushion frame M8 track. 21±3 N•M
Screw in lateral plate To mount the lateral plate/switch box.
ST4.8X9.5 (only for the luxurious seats) 4±0.4 N•M
To connect the surface liner
Bolt in liner supporting supporting bar with slide track. (only
bar M6X16 for passengers) 7±1 N•M
To connect the waist bracket with
Screw in waist bracket backrest steel thread. (only for
M6×16 luxurious seats) 7±1 N•M
Revolving screw in To connect the waist bracket with the
waist bracket M4×30 framework. (only for luxurious seats) 1.5±0.2 N•M
Bolt in safety bolt To fix the safety belt. 49±6 N•M

Nut in arm rest To fix the arm rest in the rear seat
M8 back. 21±3 N•M
Vehicle Body & Electric Appliance Volume SE-8
 Vehicle Body & Electric Appliance Volume SE-9

Mechanical Diagnosis List for the Front/Rear Adjuster of Seat

Symptoms Possible Causes Repair Methods
 The handle of  Repair the handle to make sure that
adjustor distorted or it can be released and locked or
bended. replaced from both sides.
Self-locking  The return spring of  Install a new adjustor.
failure of adjustor latch  Fill the latch pivot with special
adjustor broken lubricating oil. If the latch is stuck,
 The lock stuck to the please eliminate the cause or
adjustor. replace the adjustor.

 The new adjustor  Move repeatedly the seat front the

not experiencing the foremost end to the backmost to
running-in period.（in make tracks slide smoothly.
need of 20 times  Lubricate the adjustor tracks by
Moving forward running-in） special car lubricant or the products
or backward  The adjustor with the same effect.
with difficulty for lubricated  Replace the adjustor.
seat. improperly.
 The adjustor
running badly due to
the bended or
damaged tracks.
1. Move the seat forward as possible.
When the seat system is 2. Unscrew the bolt from the adjustor
The adjustor
installed, one track is to floor.
tracks in the
installed in the front and 3. Lock in the seats in the foremost
different lines
the other in the rear. position and screw down the bolt
from adjustor to floor. (20 Ｎ•ｍ)
Vehicle Body & Electric Appliance Volume SE-10
 Vehicle Body & Electric Appliance Volume SE-11

Dismantlement and Installation of Seat

Front Electric Seats

Dismantlement Steps: SE001
1. Disconnect the negative terminal from
the storage battery.

2. Dismount the electric seat pillow. SE002

SE003
3. Dismantle the fixed bolts from the seat.

SE004
 Vehicle Body & Electric Appliance Volume SE-12

SE005
4. Disconnect the relevant wire harness
under the seat

SE006

5. Take down the seat assembly.

Installation:
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume SE-13

Manual Seats
Front Seats SE007
Dismantlement Steps:
1. Dismantle the manual seat pillow of the
front passenger seats. (Press the buckle by
hand and pull out the pillow upwards)

2. Dismantle the four fixed bolts from the seat. SE008

SE009

3. Disconnect the wire harness from the

safety belt snapin and then take down the SE010

front seat assembly.

Installation:
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume SE-14

Remarks
Screw down at first the fixed nuts of the seat assembly for a moment at all the mounting
positions and then screw them down completely by the specified torque.
Fastening torque: 45~55N•m

Disassembly of Front Seat

Exploded View of Assembly

Pillow assembly
Backrest liner assembly
Headrest guide sleeve-free
end

Headrest guide
sleeve-lock
Front seat

Seat cushion liner assembly Lateral plate

(textile)-left
assembly-of left Right-side of
side driver’s seat Polyfoam
assembly-backrest
of front seats
Safety belt snap-in

Driving rod

Left -side of driver’s

seat

Connecting bolt

Lateral plate
Polyfoam assembly-of right side
assembly-left side of Framework assembly Direction manual
front seat cushion of the front seat slide track Height-adjustment
cushion, left assembly-left hand wheel
Angle controller
handle

(A) Dismantlement and Installation of Height

Adjusting Handle for Seats SE011
Dismantlement Steps:

1. Dismantle the seat (please refer to the

section of “Dismantlement of Seat”) and then
take it down from the car.
2. Align the shedding inverse with the clip and
then prize up the clip.
 Vehicle Body & Electric Appliance Volume SE-15

3. Pull out the adjusting hand wheel upwards

SE012
(two).

(B) Left/Right Lateral Plate Assembly of SE013

Seats
1. Pull out the angle controller handle with
proper force.

2. Dismantle the safety belt snapin. SE014

3. Dismantle the fixed screw from lateral

SE015
plates (three for each side, left and right)
 Vehicle Body & Electric Appliance Volume SE-16

(C) Dismantlement of Seat Cover

1. Dismantle the snapin of seat cushion.
2
The line in the picture indicates the fixed SE016
points of snapin.

4 3

SE017 SE018

SE019 SE020
 Vehicle Body & Electric Appliance Volume SE-17

SE021 SE022

SE023

2. Take off the seat cover.

Installation:
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume SE-18

Rear Seats
Dismantlement and Installation

3
4
2 2
2 2
1

(1) Cushion for rear material seat

(2) All-metal hexagon flange face locknut (by the torque of 21~25N.m)
(3) Backrest for rear plus material seat
(4) Rear seat arm rest
 Vehicle Body & Electric Appliance Volume SE-19

Seat Cushion
Dismantlement Steps:

With the rear seat stop block being drawn, raise the seat cushion upward and then
dismantle it.

SE024 Stop block of

rear seat

Seat
cushion

Dismantlement of Rear Backrest

Dismantlement Steps:
SE025

1. Unscrew the fixed screws from the rear seat

backrest.

SE026
2. Raise the rear seat backrest upward and
then pull it out.
 Vehicle Body & Electric Appliance Volume SE-20

Installation

Installation of Rear Seat Backrest Assembly

1. Raise the backrest to align the three locating cross-ins with mounting holes and then
clap them in downward.

Side backrest
SE027
assembly

Hook
Fixed steel
wire

2. Assemble the two fixed bolts under the

SE028
backrest.
Torque Value: 21~25 N·m
Vehicle Body & Electric Appliance Volume SE-21
 Vehicle Body & Electric Appliance Volume SE-22

Installation of Seat Cushion

1. Draw up the safety belt from seat cushion. SE029

SE030
Iron hook

Rear seat safety belt

2. Push the seat cushion with force into the backrest’

s lower side. When the iron hook
located in the lower front position of seat cushion has moved to the upward side of
snapin, please press the seat cushion into the snapin.
 Vehicle Body & Electric Appliance Volume BCM-1

Body Control Module (BCM)

Overview
The BCM (body control module) controls the operation of all types of electrical units
installed in a car.
• External start point: side door for driver, side door for passengers and trunk lock; it
can also be applied to wireless remote control with wireless receiver of body control
module. It has three buttons (unlocking, lockup and trunk’
s remote control unlocking
buttons).
• Internal operation point: lockup/unlocking buttons are on the side door for driver and
passengers.
• Locking range: door and trunk.

Body Control Module

Installation Position
Illustrations:
The body control module of the car is mounted under the seat of driver.
 Vehicle Body & Electric Appliance Volume BCM-2

Basic Diagram for Control

Remarks: for paraphrases of English, please refer to the illustrations of pins in

next page.
 Vehicle Body & Electric Appliance Volume BCM-3

Illustrations of BCM Computer Pin

Connector C Connector A Connector B

Output/
Code Description Code Description Output/Input
Input
Positive plate of storage
A1 A2 Earthing
battery
A3 Trunk cover switch Input A4 Open of oil tank cover Output
Switch of rear window
A5 Internal locking/unlocking Input A6 Input
demister
A7 Unlocking of trunk cover Output A8 Position light switch Input
Ascending of electric
A9 Ignition switch Input A10 Input
window of left front door
A11 Collision signal Input A12 Speed signal Input
Descending of electric widow
A13 Output A14 Light of safety state Output
of left front door
Ascending of right rear
A15 Front fog lamp switch Input A16 Output
electric window
A17 Earthing A18 Rear fog lamp Output
Descending of electric widow
A19 Output A20 Inner light Output
of right rear door
A21 Buzzer Output
Positive plate of storage
B1 B2 Left steering light Output
battery
B3 Right steering light Output B4 Rear defroster relay Output
B5 Rear fog lamp switch Input B6 Ignition relay Output
Micro switch of right
B7 micro switch of left front door Input B8 Input
front door
Micro switch of trunk
B9 Open of a single gate Input B10 Input
cover
Micro switch of left rear
B11 Micro switch of right rear door Input B12 Input
door
Locking of door with a Unlocking of door with a
B13 Input B14 Input
mechanical key mechanical key
B15 Oil tank cover switch Input B16 Unlocking of central lock Output
B17 Locking of central lock Output B18 Remote control antenna Input
Positive plate of storage
C1 C2 Earthing
battery
Ascending switch of electric Positive plate of storage
C3 Input C4
window of left front door battery
Ascending of electric
Descending of electric
C5 Input C6 window of right front Input
window of left front door
door
Descending of electric
Ascending of electric window
C7 Output C8 window of right front Input
of left rear door
door
Ascending of electric window Descending of electric
C9 Input C10 Output
of left rear door window of left rear door
C11 Descending of electric Input C12 Ascending of electric Input
 Vehicle Body & Electric Appliance Volume BCM-4

window of left rear door window of right rear door

Descending of electric
Ascending of electric window
C13 Output C14 window of right front Output
of right front door
door
Descending of electric
C15 Input
window of right rear door
Function Description
Central Lock-up
Users can control the central-controlled door lock through two external operating points:
Wireless Remote Controller
Side door for Driver and Passengers
The wireless remote controller is composed of a locking button, an unlocking button and a
trunk opening button.
There is a lock-up and unlocking switch on the side door for driver and passengers.
Lock-up and unlocking can be controlled through this switch.
1. Lock-up Function
After starting the lock-up signal through external operating point, the central-controlled
door lock system of the vehicle will be set in the lock-up state. If the side door for
driver is not closed, the external lock-up operation will be unsuccessful. Every control
point in the carriage cannot be used after the lock-up operation. Use forbiddance
function of the internal control point can be activated by giving the unlocking order
through either of the two external control points.
2. Function of Remote Control Relock
After being locked, the vehicle will be relocked automatically in 30s after receiving a
remote control unlocking request if either of the following conditions occurs.
a．Any door or trunk is opened.
b．Ignition is performed.
3. Unlocking Function
The lock-up system of the complete vehicle will be released automatically by starting
the unlocking signal through external operating point. The internal “lock-up/unlocking”
button, “open of oil tank cover”button can thus be used.
4. Control of Central-Controlled Door Lock Through Internal Lock-up and
Unlocking Buttons
When lockup and unlocking buttons are activated, the central-controlled door lock will
be set in a state opposite to the current one (reversal function).
- Unlocked vehicles will be locked.
- Locked vehicles will be released from lock-up.
5. Unlocking Function of Collided Car
A collision signal will be sent out if the car is collided after ignition, if the signal
confirmation exceeds 100ms, the whole vehicle will be released from lock-up
 Vehicle Body & Electric Appliance Volume BCM-5

automatically.
The lock-up system of car will be frozen up unless one door is opened.
6. Overheat Protection for Central-Controlled Door Lock
If the central-controlled door lock system is operated too frequently, the function of
overheat protection will be activated to protect central-controlled executive motor.
7. Open of Trunk
The trunk cover will be opened when the trunk open-up button in the carriage is
activated and the internal operating button is not in the forbiddance. The open-up
function of the trunk will be prohibited when the speed exceeds 15km/h.
8. Open of Oil Tank Cover
The oil tank cover will be opened when the open-up button of oil tank cover in the
carriage is activated and the internal operating button is not in the forbiddance state.
The open-up function of the oil tank cover will be prohibited when the speed exceeds
15km/h.

Control of Ceiling Light

Ceiling light can be controlled by two timers:
a) At least one door is to be opened: Keeping “on”
b) All the doors are closed: delay of extinguishment
1. Keeping “On”
The ceiling light will be on for 12 minutes at most if one door is kept open in order to
prevent the battery from discharging electric excessively. The ceiling light will keep on
and extinguish automatically after 12-minute duration if a door is opened.
The timer will rework when opening another door after the ceiling light keeps on for
12-minute duration or when closing a door with other doors open.
2. Delay of Extinguishment
The ceiling light will be on for 30s once all the doors are closed.
Delay of extinguishment will be activated if one of the following conditions occurs:
- Close the last door when all other doors are closed; and the vehicle is not locked
from external and ignition switch is not turned on. (The ceiling light will be
extinguished when the ignition switch is turned on.)
- Unlocking from external.
3. Release of Extinguishment Delay
Extinguishment delay will be released if one of the following conditions occurs:
- The ignition switch is turned on;
- Lock-up from external.
4. Control of Ceiling Light After Collision
If the collision switch is activated for 100ms after ignition, the ceiling light will be on for
 Vehicle Body & Electric Appliance Volume BCM-6

12minutes and another alarm light will scintillate for 12 minutes.

The ceiling light and alarm light can be turned off within 12 minutes by giving an
external unlocking order.
 Vehicle Body & Electric Appliance Volume BCM-7

Rear Window Defroster and Rear Fog Light

1. Control of Rear Window Defroster
After ignition, the rear window defroster can be started by pressing the defroster
switch. The rear window defroster will stop automatically after 20 minutes. The rear
window defroster can be stopped immediately by turning off the ignition switch or
pressing the switch button again when the rear defroster is working.
2. Rear Fog Light
When both the ignition switch and the key light (or front fog light) are turned on, an
internal relay will be activated after pressing the rear fog light switch (instantaneous
switch) for 50ms, thus to light up the rear fog light.
If the rear fog light is on, it will be turned off by pressing the switch button.
If the position light or the ignition switch is turned off, the rear fog light will be closed
too.
 Vehicle Body & Electric Appliance Volume BCM-8

Electric Window
1. Elevation of Electric Window
The electric window can be controlled by the ascending and descending buttons on
the door.
The elevation operation will be possible after the ignition switch is turned on.
Operation of rear window will be forbidden by pressing the child lock button at any
time.
After the ignition switch is turned off, the electric window can still be controlled unless
that:
1) The ignition switch is turned off over 10 minutes ago.
2) Any door is opened.
3) The door is locked up from external.
2. Child Lock Button
The child lock button can control the electric window buttons on the right front door,
left rear door and right rear door. When the child lock button is locked up, the electric
window buttons on right front, right rear and left rear doors are still effective.
3. Operation Mode
The operation modes of electric window include: manually ascend and descend,
automatically descend.
Manually ascend: the corresponding window will ascend by pressing the ascending
button of electric window for more than 300ms. And the electric window will stop
ascending by releasing the button.
Manually fall: the corresponding window will descend by pressing the descending
button of electric window for more than 300ms. And the electric window will stop
descending by releasing the button.
Automatically descend: the corresponding window will descend to the bottom by
pressing the descending button of electric window for less than 300ms, or stop
descending when the descending button is pressed again.
4. Stop of Amenity
When the ignition switch is turned off, all the electric windows will ascend to the top or
until the locking press button is released by pressing the locking button on the remote
controller for more than 1s.
5. Start of Amenity
When the ignition switch is turned off, all the electric windows will ascend to the
bottom or until the locking press button is released by pressing the locking button on
the remote controller for more than 1s.
Vehicle Body & Electric Appliance Volume BCM-9
 Vehicle Body & Electric Appliance Volume BCM-10

Anti-Theft Alarm(ATA)
General Rules:
The anti-theft alarm will be activated if someone enters the vehicle or use it illegally. The
system will activate the optics and sound alarms at the same time.
1. Activation of Alarm
The optics alarm consists of a group of flashing alarm lights. Once the alarm lights are
activated, it will flash for 101s at the frequency of 1Hz.
The sound alarm consists of ATA-alarm whistle. Once it is activated it will give an
alarm at a frequency of 27s/37sHz, with the same alarm time as that of the optics
alarm light.
2. Equipment of Anti-Theft Alarm (ATA)
The anti-theft alarm (ATA) can be set by any of external central-control points (RF
remote control, left/right front door) to give a lock-up order after the vehicle
extinguishes.
3. Release of Anti-Theft Alarm (ATA)
The ATA can be released only by the unlocking order sent by the RF remote control.
4. Anti-Theft Alarm Light(LED)
The alarm light (LED) is mounted on the door.
Once the ATA is activated, the alarm light (LED)will flash at the frequency of
20ms/1.1s, with the longest flash time of 14 days.
5. Configuration of Alarm System
After the AT is activated, the alarm will be triggered once the following input signal is
detected:
- Contact switches on four doors.
- Contact switch on the trunk.
 Vehicle Body & Electric Appliance Volume BCM-11

Time Sequence of ATA

1. ATA Setting
ATA will be activated if the vehicle is locked by remote controller RCT after all the
doors and engine covers are closed.
At the same time, the steering light will flash for time T2;
When the vehicle is locked by remote controller RCT with a door open, ATA can only
be activated after all the doors are closed.

2. ATA Cancellation
The ATA can be cancelled by releasing the lock-up through the remote controller RCT.
The steering light will flash for two times.

3. Activation of ATA
The ATA will be triggered when a door or the engine cover is opened after setting. The
steering light will flash for more than 101s at the frequency of 1Hz; the alarm whistle
will be also triggered at the same time to give an alarm at the frequency of 27s/37sHz,
 Vehicle Body & Electric Appliance Volume BCM-12

with the alarm time same as that of steering flash. The starter relay will stop working
after cancelling the anti-theft setting.

(1) Activation of ATA in Special Conditions

a) If a door or the engine cover is opened during ATA activation period, the ATA won’
t
enter another activation period.

b) If a door or the engine cover is reopened after the end of an ATA activation period, the
ATA will enter a new activation period.
 Vehicle Body & Electric Appliance Volume BCM-13

(2) Cancellation of ATA Activation by Unlocking Order from Remote Controller

The ATA activation will be stopped immediately when the lock-up is released by
pressing the unlocking key on the remote controller. The steering light will flash for
two times.

(3) Cancellation of ATA Activation by Locking Order from Remote Controller

a) The ATA activation will be stopped immediately when the car is locked up by
pressing the locking key on the remote controller. The steering light will flash for one
time. The ATA will be in the activated state after the activation period ends.
 Vehicle Body & Electric Appliance Volume BCM-14

b) Opening of At least One Door or Engine Cover

The ATA activation will become ineffective immediately when the car is locked up by
pressing the locking key on the remote controller and the starter relay will stop working.
The steering light will flash for one time after the unclosed door or engine cover is
closed and the ATA will be in the activated state as well.
 Vehicle Body & Electric Appliance Volume BCM-15

Dismantlement of Body Control Module

Dismantlement Steps
1. Disconnect the negative terminal of storage battery for more than 30s.

BCM001

2. Dismount the seat at the driver’

s side. BCM002

BCM003
=
 Vehicle Body & Electric Appliance Volume BCM-16

3. Lift the carpet upwards.

BCM004

4. Dismantle the fixed bolts of the body control module.

．

BCM005

5. Disconnect the harness connector of the

controller and take out the controller.

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume GW-1

Precautions
Precautions for “Airbag” and “Safety Belt Pre-tensioner” of Supplemental
Restraint System
Using such supplemental restraint systems as “airbag”and “safety belt pre-tensioner”with
safety belt can help reduce the possibility of hurt or the degree of injury of driver and
passengers at the front caused by collision of vehicles. For the information on proper
maintenance of the system, please refer to the SRS and SB parts of this Manual.

Caution:
 In order to avoid the failure of SRS system, which may result in increasing the danger
of injury and death caused by collision of vehicles, all maintenances shall be done by
the maintenance service center of the authorized JAC dealership.
 Improper maintenance, including improperly dismantlement and reassembly of the
SRS system, may result in the error actions of this system, thus causing the casualty
accidents.
For the dismantlement method of spiral cables and airbag modules, please refer to the
part of SRS.
 It is forbidden to test any circuit of the SRS system with electricity testing equipment,
except such operations are illustrated in this manual. The wire harness of SRS circuit
is always identified by the yellow wire harness or wire harness connector.

Disposal of Adhesive and Base Coat

 Don’
t use the expired adhesive. The storage life of this kind of product is six months
as from the date when it is produced. Strictly follow the deadline and production date
printed on the box.
 Store the base coat and adhesive in a cool and dry place, with the refrigerator as the
best choice.
 The base coat and adhesive should not be opened until the moment when they are
used. The remains should be discarded.
 Before using, please shake the container of base coat to homogenize it. If any floater
is found, please don’
t use it.
 If base coat or adhesive attaches to skin, wipe it off with gasoline or analog and clean
skin with soap.
 When using base coat and adhesive, please always follow the precautions in the
instruction manual.
 Vehicle Body & Electric Appliance Volume GW-2

Preparations
General Tools

Name Picture Function Description

Engine
Orientation of noise
audiphone

Sucking disc Holding of the door glasses

 Vehicle Body & Electric Appliance Volume GW-3

Trouble Diagnosis for Squeak and Kluck

Please refer to the catalog of regulations on dismantlement and installation of element.

Instrument Panel
Most troubles are caused by the contact between and movement of the following spare
parts:
1. Trimming plate and console
2. Console to A-pillar trimming plate
3. Console to windshield
4. Anchor pin of console
5. Wire harness behind the combined instrument
6. A/C defrosting pipe and pipe joint
Reproducing noise by beating or moving the elements or ceasing the noise by
pressing components during driving can help find the sources of the troubles. Most
troubles can be eliminated by using woolen cloth rubber belt or silicon spray (at the
areas difficult to access). And the polyurethane cushion can be used for separating
the wire harness.
Attention:
Do not use the silicon spray to insulate the squeak or kluck, as it is impossible
to verify the maintenance if the area is full of silicon.
Middle Control Desk
Elements to be noted:
1. The cover of gearshift lever assembly to trimming plate
2. A/C control device
3. Wire harness behind the sound and A/C control device
Procedures of maintenance and sound insulation of console can also be applied to the
central control desk.

Door
Attention:
1. Slap produced by door and inner trimming plate
2. Trimming cover of mounting nuts on inner handle and trimming plate of door
3. Rap produced by wire harness
4. Put-put caused by the misalignment of lock catch of door while starting and stopping
the car.
Sticking, moving or pressing the spare parts can resolve many troubles when reproducing
the situations. Woolen cloth rubber belt or insulation foam blocks can be adopted to
insulate the areas to eliminate the noise.
Boot
Generally, the noise of boot is caused by looseness of lifting jack or objects in it.
In addition, pay attention to:
1. The damping block of luggage cover is improperly installed.
2. The lock catch of luggage cover is mismatched.
3. The air operated outriggers of luggage cover touch each other.
4. The license plates or support become loose.
 Vehicle Body & Electric Appliance Volume GW-4

Most of the troubles can be eliminated by adjusting, fixing or insulating the items or
elements producing the noise.

Sunroof/Vehicle Ceiling
Noise from the sunroof/ vehicle ceiling areas can be regulated to:
1. Kluck or light knock caused by sunroof cover, beam, pull rod or bad sealing;
2. Shake of sun visor shaft in the support;
3. Squeak produced by the front or rear windshield’ s touching of the vehicle ceiling.
Most of the noise can be insulated by pressing the element while reproducing the situation.
The woolen cloth rubber belt is always used for insulation in maintenance.

Seat
When insulating the noise of seat, pay special attention to the position of seat and the
objects on it when the noise is produced. It is necessary to reproduce these conditions
when confirming and insulating the source of noise.
Causes for noise of seats include:
1. Head rest rod and mounting hole;
2. The squeak produced by seat cushion and seat rack;
3. Snapin on the rear row backrest.
The noise can be insulated by moving or pressing the suspicious elements while
reproducing the noise. Most of the troubles can be eliminated by resetting elements or
using polyurethane rubber belt at the contact areas.

Under the Engine Cover

The elements under the engine cover or on the walls of engine may produce some interior
noise, and the noise will be transmitted to the passenger compartment.
Causes for transmission of the noise under engine cover include:
1. The elements installed on the walls of engine;
2. The elements passing through the walls of engine;
3. Supports and adaptors of the walls of engine;
4. Looseness of anchor pin on the radiator;
5. The engine cover and bumper are misaligned;
6. The lock catch on engine cover is mismatched.
Because the noise can transmit to the inside of vehicle, it is difficult to insulate it. The best
method is to fix, move or insulate an element at a time and to test the running vehicle. In
addition, it is possible to change the speed or load of engine for insulating the noise.
Troubles can be eliminated by moving, adjusting, fixing or insulating the elements
producing the noise.
 Vehicle Body & Electric Appliance Volume GW-5

Electric Window System

Overview
The electric window system can electrically lift or lower the window by controlling the
switch on each door trimming plate. The main switch on the front door trimming plate at
the driver’s side enables the driver to lift or lower the window at each passenger’ s side
and lock each separate switch on the door at passenger’ s side. Only when the ignition
switch is in the position of “ON”, can the electric window system receives the voltage of
storage battery through the circuit breaker in the connection box. The electric window
system consists of the electric window switch on each door trimming plate, the BCM
control module and the electric window motor in each door. The electric window motor is
replaced with the window glass frame riser assembly. If the electric window motor needs
to be replaced, then the window glass frame riser should be also replaced.

Working Principle
Electric Window Switch
The electric window is controlled by the window/door lock switch on each front door
trimming plate. The window/door lock switch at the driver’ s side enables the driver to
control the window at the passenger’ s side. All the passenger’ s side windows receive
power supply from storage battery and grounding via the circuit of window/door lock
switch. When the lock-up switch of the electric window is in the “lock-up”position, power
supply to the storage battery of each electric window switch on the door at each
passenger’ s side will be cut off.

Electric Window Motor

The permanent-magnet reversible motor drives the glass bracket on the glass frame riser
to move by the rope-sheave mechanism. The plus plate and minus pole of the storage
battery are connected to the two terminals of the electric motor, which makes the electric
motor run in one direction. The countercurrents flowing through two identical joints will
make the motor run in the reverse direction. In addition, each electric window motor is
equipped with an integrative self-resetting circuit breaker to avoid overloading of the
electric motor.
1. Ascending of Electric Window
The electric window can be controlled by the ascending and descending buttons on
the door. When the ignition switch is on, the operation of the electric window will be
available. The operation of rear window can be prohibited at any moment by pressing
the child lock button. After the ignition switch is turned off, the electric window can still
be controlled unless that:
1) The ignition switch is turned off over 10 minutes ago.
2) Any door is opened.
3) The door is locked up from external.

1. Relock Button
Relock button can control the electric window buttons on the right front door, left rear
door and right rear door. When the relock button is locked up, the electric window
buttons on right front, right rear and left rear doors are still effective.
 Vehicle Body & Electric Appliance Volume GW-6

2. Operation Mode
The operation modes of electric window include: manually ascend and descend,
automatically descend.
Manually ascend: the corresponding window will ascend by pressing the ascending
button of electric window for more than 300ms. And the electric window will stop
ascending by releasing the button.
Manually fall: the corresponding window will descend by pressing the descending
button of electric window for more than 300ms. And the electric window will stop
descending by releasing the button.
Automatically descend: the corresponding window will descend to the bottom by
pressing the descending button of electric window for less than 300ms, or stop
descending when the descending button is pressed again.
3. Stop of Amenity
When the ignition switch is turned off, all the electric windows will ascend to the top or
until the locking press button is released by pressing the locking button on the remote
controller for more than 1s.
4. Start of Amenity
When the ignition switch is turned off, all the electric windows will ascend to the
bottom or until the locking press button is released by pressing the locking button on
the remote controller for more than 1s.
Trouble Diagnosis Procedures
All the window risers of the front doors don’t work.
Step Measure YES NOT
(1) Move the ignition switch to RUN position.
To To step
1 (2) Check whether the circuit and fuse is disconnected and whether the fuse
step 7 2
is disconnecting.
(1) Turn the ignition switch to the lock position.
(2) Turn off the left front window switch.
To To step
2 (3) Turn the ignition switch to RUN position.
step 3 5
(4) Apply a test light between the rear body harness connector and
grounding to see whether the light is on.
Apply a test light between the rear body harness connector and grounding to To To step
3
see whether the light is on. step 4 6
4 Improve the poor contact with switch or replace the left window switch.
Improve the poor contact or open circuit between the fuse
5
box and the harness connector of left side front door.
Improve the poor contact or open circuit between the fuse box and the rear
6
body harness connector.
Repair the grounding short circuit of the circuit and fuses. Is the To step
7
maintenance finished? 2

The window riser of the right side door doesn’t work.

Step Measure YES NOT
Check whether the circuit and fuse are disconnected and whether the circuit To To step
1
is open. step 7 2
(1). Turn off the right front window switch.
To To step
2 (2). Turn the ignition switch to RUN position.
step 3 6
(3). Connect the test light.
 Vehicle Body & Electric Appliance Volume GW-7

(4). Apply the test light between the right rear body harness connector X and
grounding from the back.
(5). Check whether the test light is on.
(1). Connect the test light and apply it between the rear body harness
To To step
3 connector and grounding from the back.
step 4 5
(2). Check whether the light is on.
4 Improve the poor contact with switch or replace the right window switch.
Improve the poor contact or open circuit of the circuit between the fuse box
5
and the body harness connector.
Improve the poor contact or open circuit between the fuse box and the rear
6
body harness connector.
Repair the grounding short circuit from the circuit to fuses. Is the
7
maintenance finished?
The window riser of the left side door doesn’t work.
Step Measure YES NOT
Check whether the circuit and fuse are disconnected and whether the To step
1 To step 1
circuit is open. 2
(1). Cut off the window riser motor.
(2). Apply a test light into the window regulator motor of the left front
To step
2 window from front. To step 3
10
(3).Turn the ignition switch to RUN position.
(4). Check whether the test light is on.
(1). Turn off the left front window switch.
(2). Use digital multimeter to test the circuit between the window
regulator motor of the left front window and the rear body harness To step
3 To step 4
connector first, and then test the circuit between the motor and 8
connector.
(3). Are the two circuits with continuity?
(1). Use a test light between the left front window switch and grounding
from front.
To step
4 (2). Turn the ignition switch to RUN position.
5
(3). Press the left front window switch to UP position, and then to DOWN
position. Is the test light on under these circumstances?
Turn off the left front window switch. Apply a test light between the left
To step
5 window switch and grounding from front. Is the test light on under the To step 7
9
two circumstances?
Improve the poor contact or open circuit between the left side window
6
riser motor and the window regulator motor.
7 Replace the left front window switch. Is the maintenance finished?
Improve the poor contact or open circuit of the circuit between the
8 window riser and the rear body harness connector, or test whether the
circuit between them has poor contact or open circuit.
Improve the poor contact or open circuit of the circuit
9 between the left front window switch and the rear
body harness connector.
10 Replace the left front window riser motor. Is the maintenance finished?
Repair the grounding short circuit or open circuit of To step
11
the circuit and the fuse. Is the maintenance finished? 2

Check of Electric Window System

Step Measures Normal Result Abnormal Result
1 Turn the ignition switch to RUN —— ——
position.
2 Use the switch on the control panel The operation is performed The electric window
of the left window to operate the quietly and smoothly without doesn’
t work.
left front window. clamping stagnation.
3 Use the switch on the control panel The operation of the right front The electric window
of the left window to operate the window is performed quietly doesn’
t work.
right front window. and smoothly without clamping
stagnation.
 Vehicle Body & Electric Appliance Volume GW-8

4 Use the switch on the inner handle The operation of the right front The electric window
of the right door to operate the right window is performed quietly and doesn’
t work.
front window. smoothly without clamping
stagnation.
 Vehicle Body & Electric Appliance Volume GW-9

Positions of Elements
Elevating Switch of Glass
Elevating switch of left front door glass Elevating switch of right rear
door glass

Glass Riser

Illustrations for the Pin of Electric Glass Window Switch

Terminal
Terminal
Function Description Code Function Description
Code No.
No.
Descending of the right front
1 Ascending of the right front door 2
door
3 Central-controlled lock 4 Grounding
Descending of the left front
5 The left front door rises 6
door
Descending of the right rear
7 Child lock 8
door
9 Ascending of the right front door 10 Pin unused
 Vehicle Body & Electric Appliance Volume GW-10

11 Power supply of the small light 12 Ascending of the left rear door
13 Descending of the left rear door
 Vehicle Body & Electric Appliance Volume GW-11

Dismantlement & Reassembly of Door Window Glass System

Control Switch of Front Door Glass
Dismantlement Steps:
1. Cut off the negative terminal of the storage GW001
battery.

2. Unclench the switch control panel with an GW002

open cutter.

3. Cut off the harness connector.

GW003

4. Take off the switch assembly. GW004

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume GW-12

Front Door Glass

Dismantlement Steps:
GW005
1. Lower the glass (just make the fixed bolt
that the glass riser adopts for holding the
glass point to the process hole of the door’
s
internal plate). Cut off the negative terminal
of the storage battery.

2. Dismantle the control switch panel and the

internal trimming plate of the glass window.
(Please refer to steps for dismantlement
and reassembly of body internal and
GW006
external trimmings.)
3. Loosen the fixed bolts on both sides of the
glass retaining clip of the glass riser.

GW007

4. Hold the door’

s window and uplift it from the
rear-end. Then pull the glass outwards to
get it out from the window frame.

GW008

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume GW-13

Electric Glass Riser

Dismantlement Steps:
GW009
1. Cut off the negative terminal of the storage
battery.

2. Dismantle the control switch panel of the

glass window. GW010

3. Dismantle the internal trimming plate of the

GW011
door.
(Please refer to steps for dismantlement
and reassembly of body internal and
external trimmings.)
4. Dismantle the glass
(Refer to the dismantlement steps of the
front door glass)
5. Dismantle the fixed bolts of the front glass
guide slot and the glass riser. GW012
 Vehicle Body & Electric Appliance Volume GW-14

6. Cut off the wire harness connector of the

motor, and take out the glass riser
assembly. GW013

Check After Dismantlement

Check the following items of the riser assembly.
If there is any trouble, replace it or coat it with
lubricating grease.
 Abrasion of wire
 Deformation of riser
 Lubrication of each sliding part

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume GW-15

Elevating Switch for Electric Glass of Rear Door

Dismantlement Steps:
GW014
1. Cut off the negative terminal of the storage
battery.

2. Use open tool to unclench the control panel. GW015

3. Cut off the harness connector of the control

GW016
switch.

4. Take out the elevating control switch. GW017

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume GW-16

Rear Door Glass

Dismantlement Steps:
1. Lower the glass and cut off the negative
terminal of the storage battery. GW018

2. Dismantle the control switch panel and the

internal trimming plate of the glass window.
(Please refer to steps for dismantlement and
reassembly of body internal and external
trimmings.)

GW019
3. Dismantle the fixed bolt of the glass guide slot,
dismantle the triangle glass and then push it to the
Pull it out and push
small glass. Dismantle the clamping glass bolt on forwards

the glass riser.

GW020

4. Take out the glass carefully.

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume GW-17

Electric Back Mirror

Overview:
The electric back mirror is composed of a regulating control switch and a back mirror
assembly (with electric motor). The driver can electrically adjust the two exterior back
mirrors on the front seat at his side by operating the switch on the front door’
s trimming
plate at his side. The electric back mirror receives order through the fuse in the connection
box and can’
t be supplied with power by the storage battery which is controlled by switch,
so as to keep the system in the working state in spite of the position at which the ignition
switch is set.

Disassembly Drawing of Electric Back Mirror Assembly

Mirror base of exterior
back mirror

Actuator assembly

Mirror frame

Test of Electric Back Mirror Switch and Description of Terminal

1. Cut off and isolate the negative cable of the storage battery.
2. Dismantle the electric back mirror switch.
3. Cut off the harness plug and socket on the switch.
4. Test the conduction of switch and confirm whether the switch’
s conduction at each
position is normal. If it is abnormal, then replace it according to the conditions.

Schematic diagram of lens adjusting circuit Schematic diagram of lens defrosting and steering light circuit

(Aqua)
(Red) Lens heating
Motor power for adjusting lens resistance
(Yellow/green) upwards and downwards
P = 3.3 W (Black)
Motor power for adjusting lens
(Brown) leftwards and rightwards
P = 3.3 W
Schematic diagram of assembly harness
terminal
Adjusting Direction of Lens A direction
Red Brown Yellow/Green Direction
+ - Upwards
- + Downwards
+ - Leftwards
- + Rightwards
Vehicle Body & Electric Appliance Volume GW-18
 Vehicle Body & Electric Appliance Volume GW-19

Actuator of Electric Back Mirror

Check:
1. Cut off the electric back mirror connector from the harness.
2. Connect the connection terminal with storage battery voltage and check the
corresponding movement of the mirror.

Steps for Dismantlement of Electric

Back Mirror: GW021
1. Cut off the negative terminal of the storage
battery.

2. Dismantle the protecting cover of the high GW022

tone loudspeaker.

3. Dismantle the internal trimming plate of the

door.
Please refer to the steps for dismantlement GW023

and reassembly of the internal and external

trimmings.

4. Dismantle the fixed bolts of the electric back

mirror.
(Take off the high tone loudspeaker first).
 Vehicle Body & Electric Appliance Volume GW-20

GW024
5. Cut off the connecting harness and take off
the back mirror.

Reassembly:
Reassemble it according to the reverse order of
dismantlement.
 Vehicle Body & Electric Appliance Volume GW-21

Switch of Electric Back Mirror

Dismantlement Steps:
1. Cut off the negative terminal of the storage
GW025
battery.

2. Unclench the switch panel assembly with an

open cutter. GW026

3. Cut off the harness connector.

GW027

4. Take off the switch control panel assembly

of the electric back mirror. GW028

Reassembly:
Assemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume GW-22

Rear Window Defroster and Heater

Check: Press with finger
Attention: Test probe
First wrap the tin foil around the end of the
voltmeter with test lead to avoid damaging
the heating wire. Press the tin foil with
fingers, move the tin foil along these grid
lines. Check whether there is an open circuit. Tin foil
Heating lead

1. Turn on the defroster switch and measure

the voltage of each heating wire with
voltmeter at the middle of the glass. If the
voltage displayed on the voltmeter is about
6V Normal value
6V, the heating wire of the rear window can
be considered as normal.

Fusing point

2. If there is an open circuit between the

centre and the positive pole. The voltage
will be displayed as 12V

Fusing point
3. If there is an open circuit between the
centre and the negative pole. The voltage
will be displayed as 0V
 Vehicle Body & Electric Appliance Volume GW-23

The voltage will change before and after the opening point.
4. Slowly move the test probe in the direction
where there is a possible open circuit. If the Here the voltage is 0V. Terminal
voltage appears suddenly or becomes to 0
V at a certain point, the point where the
voltage changes is just the one with open
circuit.

5. Use ohmmeter to measure the resistance When measuring from one side of the negative
terminal. (No breakpoint in the grid)
between the terminal and the centre of the
grid line, as well as that between this
terminal and the adjacent heating wire. The
Breakpoint in the grid line
resistance of the circuit with open circuit is
Centre
double that of other circuit. Move the test Positive
terminal
probe under the affected part until the
resistance changes rapidly at a certain Measuring resistance reading
is displayed as double.
point.
 Vehicle Body & Electric Appliance Volume GW-24

Repair of Heater’s Open Circuit

Repair it according to the following procedures:
1. Conductor dope.
2. Dope dilution.
3. Masking adhesive tape.
4. Silicone resin remover.
5. Use a fine brush to clean the heating wire
with open circuit. Rinse it with silicone resin
remover and attach the covering adhesive
tape to it. Shake the dope container to make
the dope evenly mixed. Use a brush to apply
the dope every other 15 minutes for 3 times in
all. Tear out the adhesive tape and ensure
the dope has been dry before electrifying. Covering adhesive tape
You’
d better scrape off the redundant
sediments after the dope becomes dry completely (about 24 hours).
Attention:
Use a soft dry cloth to wipe the glass clean or use a slightly wet cloth to wipe it
along the direction of the grid line after repair.

Switch of Rear Window Defroster

Check:
1. Cut off the negative pole of the storage
battery.
2. Remove the central control plate on the
instrument desk.
3. Cut off the connector from the rear window
defroster switch.
4. Operate the switch and check whether the
terminals are put through with the ohmmeter.
 Vehicle Body & Electric Appliance Volume GW-25

Interior Back Mirror Assembly

Disassembly Drawing of Assembly

No. Name of Part No. Name of Part

1 Base 2 Screw M6 × 12
3 Elastic retainer ring 4 Supporting thread of spring
5 Cushion of supporting rod 6 Strut cover plate
7 Supporting rod 8 Decorative cover
9 Mirror shell 10 Thimble
11 Micro-adjustment ball seat 12 Display
13 Tapping screw 14 Regulator handle
15 Mirror surface
 Vehicle Body & Electric Appliance Volume GW-26

Dismantlement Steps:
GW029
1. Cut off the negative terminal of the storage
battery.

2. Unclench the protecting cover of the

GW030
interior rearview mirror with an open cutter.

3. Cut off the harness connector. GW031

4. Push the rearview mirror assembly

GW032
downwards to get it out.

Reassembly:
GW033
Reassemble it according to the reverse order of
dismantlement.
 Vehicle Body & Electric Appliance Volume GW-27

Electric Sunroof
Overview
Electric sunroof is featured as following:
1. Manual sun visor. There is a handle in the sun visor which is used to push and close
the sun visor. The sun visor will be opened with the sliding open of the sunroof but it
needs to be closed manually.
2. The motor control module at the rear of the sunroof frame can make the sunroof glass
stay in the position of open, ventilation or close.
3. The sunroof motor control module assembly is connected to the driving tube
assembly. It has a transmission shaft for driving chains, which can rotate in two
directions.
4. The water drain channel is under the sunroof glass plate. The accumulated water
entering into the channel flows out of the car via the outfalls in the four corners of the
sunroof. The gutter moves with the sliding of the glass.
5. The sealing rubber strips for sunroof are mounted around the glass plate to seal the
clearance between the glass and car roof.
6. The sunroof harness is connected to the sunroof motor assembly and converged with
the body harness.
7. The sunroof possesses the function of thermal protection. When this function is
started, the sunroof will stop working. The sunroof will work normally after the motor
cools.
8. The sunroof doesn’ t have an anti-clamping function, but has a maximum close force
of 343N.
Maintenance of Sunroof and Function Introduction
Maintenance of Sunroof
1. Clean the sunroof surface and the sealing strip with wet clean cloth to keep the
sealing strip elastic without corrugation.
2. Pay attention to clear the foreign substances in the sunroof track.

Initialization of Sunroof
1. Press the tilting switch to make the sunroof run to the maximum tilting position. (If the
sunroof is in other position, the maximum tilting position is also required.)
2. Release the tilting switch, then press the tilting switch again for over 13s and find the
sunroof glass will tremble up and down for several times.
3. Release the tilting switch. Press the tilting switch once again within 5s. The sunroof
will automatically run for a period after 3s. (Tilting position— close position— open
position— close position). The hand should not be removed during this period. Then
the initialization ends.
4. Under the two following circumstances, the initialization needs to be done again:
A: Replacement of the sunroof motor module.
B: After being used for a period, the sunroof glass can’ t be closed to the designated
position (The long-time usage leads to abrasion clearance between the
mechanical groups). The time is always two years.
5. Function of Thermal Protection
Under various modes, if the actual running time of the sunroof motor exceeds the
specified limit running time, the motor will stop running for cooling. Its normal function
 Vehicle Body & Electric Appliance Volume GW-28

will be recovered when the specified value has been achieved and it is unnecessary
to initialize it again.
 Vehicle Body & Electric Appliance Volume GW-29

Trouble Diagnosis and Troubleshooting for Electric Sunroof

Trouble Feature Possible Causes Maintenance

Clean out the accumulated
Dust accumulation in the drain pipe.
dust in the drain pipe.
Remove the sewage by
Jam of the drain pipe. blowing into the drain
passage.
Break or disengagement of the drain
Sunroof leaks. Check the pipe device and
pipe, and damage or dehiscence of
lug contact.
the clamp.
Aging of the car roof sealing strip. Replace it.
Oversize clearance between the car
roof cover and body, and incorrect Adjust it.
assembly of the sealing strip.
There is wind Looseness or deformation of the
Tighten, adjust or replace
noise around guide plate. The clearance doesn’t
it.
sunroof. meet the requirement.
Check whether there are
There is noise Foreign substances in the guide
foreign substances in the
when moving the track.
drive cable and guide track.
sunroof covering
Looseness of the guide track and
plate. Tighten again.
cover.
Check whether there are
Foreign substances in the guide
foreign substances in the
track.
drive cable and guide track.
The motor works, Check whether the motor
Incorrect meshing of the motor pinion
but the sunroof installation is loose and the
and driving cable.
can’t be moved pinion is damaged.
or can’t be The skid force of the motor clutch
Adjust it.
moved to the reduces.
designated Improper adjustment of sunroof
position. makes its skid resistance or
interference between the sunroof Adjust or replace it.
and the drive cable/sealing strip
increase.
There is noise in Check the pinion
Incorrect meshing of the engine
the motor (when installation and tighten the
pinion and drive cable.
the sunroof is motor again.
opened or closed Wear or damage of motor pinion Replace the motor
completely, the bearing. assembly.
noise due to
clutch’
s sliding Abrasion or deformation of
Replace it.
from the motor is driving cable.
normal noise).
Vehicle Body & Electric Appliance Volume GW-30
 Vehicle Body & Electric Appliance Volume GW-31

Sunroof Assembly

Car roof

Sun roof assembly

Fixed bolt

Dismantlement Steps:
1. Cut off the negative terminal of the storage GW034
battery.

2. Dismantle the trimming pieces of car ceiling

(two sun visors, armrest, front and rear
dome lamp, upright column trimming plate).
Please refer to the part of body internal
trimming.
3. Dismantle the trimming plate and glass
surface plate.
GW035
Tightening Torque
Fixed nut of glass panel: 4～6 N·m
 Vehicle Body & Electric Appliance Volume GW-32

4. Cut off the drain pipe. GW036

5. Dismantle the fixed bolts of the sunroof and GW037

take off the sunroof assembly.

GW038
Tightening Torque
Sunroof installation bolt: 7～11 N·m
Sunroof installation nut: 4～6 N·m

Illustration:
When dismantling the sunroof assembly, take it out carefully to avoid damaging other
parts.
 Vehicle Body & Electric Appliance Volume GW-33

Disassembly Drawing of Assembly

No. Name of Part No. Name of Part

1 Sunroof frame assembly 2 Sunroof wind screen assembly
3 Sunroof sun visor assembly 4 Sunroof glass assembly
Sealing rubber strip assembly
5 6 Electric motor assembly
for sunroof
7 Sun visor stopper clip 8 Clamping screw for windshield
9 Screw 10 Front drain pipe of sunroof
11 Rear drain pipe of sunroof
 Vehicle Body & Electric Appliance Volume GW-34

Maintenance Manual for Electric Sunroof

Adjustment of Height and Opening Matching of Electric Sunroof Glass
Adjustment of Sunroof Glass Sealing
If the sunroof glass is correctly adjusted, and the glass sealing strip and car roof is
compactly matched, then the water flowing into the water drain channel will be reduced
greatly. If the sunroof glass is incorrectly adjusted, the quantity of water flowing into the
water drain channel will be very large, which may lead to water leakage or unendurable
wind shield noise.
Test the matching according to the following procedures:
1. Insert a piece of paper between the car roof and the sealing strip.
2. Close the sunroof glass.
3. Draw out the paper. If you feel certain resistance when drawing out the paper, the
matching is correct.
4. Complete the matching adjustment of all glasses and the car roof through changing
the glass’
s vertical height and alignment.

Replacement of Weather Strip of Sunroof

Dismantlement Procedures:
Open the sunroof glass completely, and then press the weather strip down slightly and
gently to set the weather strip spring in the bayonet lock clearance at the front of the track.
Pull out the springs at the two ends. Pay attention to not pull out the spring forcedly.

Reassembly Procedures:
Place the weather strip at the front of the sunroof. Make the springs at both sides point at
the bayonet lock clearance and insert them.
 Vehicle Body & Electric Appliance Volume GW-35

Replacement of Electric Sunroof Glass

Dismantlement Steps:
1. Make the sun visor fully opened.
2. Set the sunroof in the inclined ventilation position.
3. Dismantle the four screws of the sunroof (two screws on each side).
4. Dismantle the sunroof glass from the frame.

Reassembly Procedures:
1. Place the sunroof glass into the sunroof frame and make sure the glass symbol is
orientated towards the rear of the sunroof opening.

2. Mount the four fixed screws of sunroof.

3. Adjust the sunroof glass. Refer to the part of adjustment of height and opening
matching of the sunroof.
4. Open and close the sunroof to test the matching of the car roof and sunroof.
 Vehicle Body & Electric Appliance Volume GW-36

Replacement of Electric Sunroof Frame Assembly

Dismantlement Steps:
1. Make the sunroof fully closed.
2. Dismantle the canopy. Refer to the steps for replacement of canopy in the part of
internal trimming pieces.
3. Cut off the sunroof harness and body harness.
4. Disconnect the front and rear discharge hose adaptors from the sunroof frame.
5. Dismantle the nine connecting bolts from the sunroof frame to car roof.
6. Dismantle the sunroof frame from the vehicle via the door opening.

Reassembly Procedures:
1. Place the sunroof frame into the car interior via the door opening.
2. Mount the nine bolts from the sunroof frame to car roof.
3. Connect the front and rear discharge hose to the sunroof frame.
4. Connect the sunroof harness with the body harness.
5. Mount the electric sunroof switch temporarily and check the operation of the sunroof.
6. Mount the canopy. Refer to the steps for replacement of canopy in the part of internal
trimming pieces
7. Open and close the sunroof to check whether the operation of the sunroof is correct.
8. Adjust the height of the sunroof when necessary. Refer to the part of adjustment of
height and opening matching of the sunroof.
 Vehicle Body & Electric Appliance Volume GW-37

Replacement of Electric Sunroof Sun Visor

Dismantlement Steps:
1. Make the sunroof glass in the fully tilted position to dismantle the glass.
2. Press the close button again to make the sunroof mechanism group in fully close
position. Dismantle the canopy, cut off all harnesses, and dismantle all fixed bolts of
the sunroof.
3. Dismantle the limit bayonet catch (its shape is similar to screw) on the frame at the
rear of sun visor with a knife. Only on one side is with the limit bayonet catch and it
can’
t be used repeatedly.
4. Draw the sun visor backwards. When the rearward shift of the sun visor stop block is
hindered by the gutter connection assembly, press the sun visor stop block
downwards gently to make it pass the gutter connection assembly and the gutter, and
draw out the sun visor from the back.

Reassembly Procedures:
1. Insert the sun visor into the frame chute from the back, and push the sun visor. When
the forward shift of the sun visor stop block is hindered by the gutter connection
assembly, press the sun visor stop block downwards gently to make it pass the gutter
connection assembly.
2. Mount the sun visor limit bayonet catch and draw the run visor to check whether the
pulling force is suitable.
3. Fix the sunroof to the car roof, connect harness and operate the sunroof.
4. Set the mechanism group in the fully tilted position. Mount the glass and the car roof
internal trimming.
 Vehicle Body & Electric Appliance Volume GW-38

Replacement of Electric Sunroof Motor Assembly

Dismantlement Steps:
1. Dismantle the canopy. Refer to the steps for replacement of canopy in the part of
internal trimming pieces.
2. Cut off the sunroof motor assembly harness.
3. Dismantle the three fixed screws of the sunroof motor assembly.

4. Dismantle the motor assembly from sunroof.

Reassembly Procedures:
1. Mount the motor on the sunroof.
2. Push the motor assembly into the driving tube assembly directly to make them well
matched.
3. Mount the fixed screws of the sunroof motor assembly.
4. Connect the sunroof motor assembly harness to the motor assembly.
5. Check the operation of the sunroof in all positions.
6. Mount the canopy. Refer to the steps for replacement of canopy in the part of internal
trimming pieces.
 Vehicle Body & Electric Appliance Volume GW-39

Replacement of Electric Sunroof Glass Sealing Strip

Mount the sealing strip on the glass assembly. Press the joint place of the sealing strip to
the centre at the right side (marking place). Insert the straight-line parts after inserting the
part at four angles (the order is shown in Fig. A). Hammer at the tilted places with rubber
hammer gently until they are well matched with the glass. Make sure the installation
margins of the sealing strip at the four borders are basically even and the sealing strip is
smooth and level. If the edge is tilted, the location of the sealing strip should be adjusted
to make the sealing strip without looseness, corrugation and deformation. The sealing
strip should be with no looseness, corrugation and deformation, and the sealing strip in
the four corners of the glass assembly should be with no corrugation.

Schematic Diagram for Order & Method of Sealing Strip Installation

Sealing
strip
connector

Label
 Vehicle Body & Electric Appliance Volume GW-40

Reassembly Check
1. Turn on the ignition switch. Cross section place

2. Turn on the sunroof switch. Check

whether the sunroof can be
opened and closed normally and
has abnormal noise during
operation.

3. Close the sunroof and observe

the surface difference of the
clearance between the sunroof and
the exterior of car roof.

4. Check the fixed screws on both

sides of the sunroof glass. Adjust the surface difference of the clearance between the
body and it.

5. Fasten the bolts after satisfying the requirements.

 Vehicle Body & Electric Appliance Volume BL - 1

Door Lock and Control System

Overview
Electric Door Lock
There is a switch that can control all the doors on the trimming plate on driver’
s side door.
The electric door lock system can lock or unlock electrically all the doors and lifting doors
through the operation of this switch. The electric door lock system receives the storage
battery current that comes by the fuse in the terminal case. No matter where the ignition
switch is, the electric door locks are all in the operable state.
When the vehicle travels at a speed of 40 km/h with all the doors closed and accelerator
pedal tread down, BCM will lock all the doors automatically.
Central Lock/Unlocking Mechanism System
The central door lock system controls the power of door and lifting door lock and log-in
system with illumination. The central door lock system has the following characteristics:
① When the speed exceeds 40 km/h, the door will lock automatically.
② If the ignition key is in the ignition switch and the driver’
s side door is open, then door
lock switch or remote control can prevent the door from locking.
③ Optional unlocking modes for drivers: press the unlocking button on the remote control
to open all the doors. The lock core of driver’
s side door or the lock core of auxiliary
driver’
s side door can also be used to open all the door locks.
④ All the doors can be locked by pressing the locking button on the remote control.
Fastener
Door lock mechanism is driven by the reversible motor equipped on every door. The motor
of electric door lock is in the locking pin device.
Electric door lock motor can not be adjusted or repaired. If the motor is out of service or
damaged, the whole locking pin device shall be replaced.

Operating Principle
Electric Door Lock
When receiving excitation input signal of log-in the emitter without the key from door lock
switch or remote control, BCM will lock or unlock the door. All the doors for passengers
can be locked or unlocked by the mechanical button equipped on the inner trimming plate
of the door, so is the lock core of key.
Door Lock Motor
Door lock motor is controlled by the central control unit. The positive and negative poles of
storage battery are connected to the two terminals on the motor to make the motor rotate
in one direction. If the current reverses, the rotation direction will reverse, too.
Log-in through Remote Control with No Key
① Locking: press “locking”button to lock all the doors;
② Unlocking: press “unlocking”button to open all the doors;
③ Unlocking of boot: press “unlocking”button on the boot to open the boot;
 Vehicle Body & Electric Appliance Volume BL - 2

System Composition and Position Distribution

BCM Computer BL001
Position illustration:
Under the carpet that is under the driver’
s seat.

BL002

Body and Fastener of the Front Door Lock

Position illustration:
In the doorframe of the front door

BL003

BL004

Actuator of the Lock on the Rear Boot Cover

Position Illustration:
In the doorframe of the boot
 Vehicle Body & Electric Appliance Volume BL - 3

Remote Control
Illustration:
Equipped along with the car.
 Vehicle Body & Electric Appliance Volume BL - 4

Diagnostic Procedure of Door Lock System

Diagnostic Procedure of Door Lock System: Central Door Lock is out of
Service 1
Steps Processing Method Yes No
1 Inspect if the fuse is in good condition. To step 2 To step 3
2 Replace damaged fuse. To step 3
3 Inspect if other fuses are in good condition
To step 4 To step 5
according to circuit diagram.
4 Replace the damaged fuse with new one. To step 5
5 Disconnect the connector between console and lead
wire harness of the rear body. Use digital multimeter
To step 7 To step 6
to gauge the voltage around the lead wire harness
of instrument and inspect if the voltage is normal.
6 Inspect and repair the console lead wire harness
from fuse to connector. Make sure that it has no To step 7
problems.
7 Use digital multimeter to gauge the voltage of
connector (around the console lead wire harness) To step 9 To step 8
and inspect if the voltage is normal.
8 Inspect and repair the console lead wire harness
from fuse to connector. Make sure that it has no To step 9
problems.
9 Dismount the central door lock module, move the
ignition position to “ON”(switch-on) position,
move the windshield wiper switch to internal gear. To step 11 To step 10
Gauge with the digital multimeter if the pressure is
normal.
10 Inspect and repair the lead wire harness from
connector to the rear body of central door lock
To step 11
module according to circuit diagram to make sure it
has no problems.
11 Replace with new central door lock module and
To step 12
inspect if the system is normal.
12 Gauge the grounding wire of central door lock
module with digital multimeter to inspect if ground To step 13 To step 14
connection is in a good condition.
13 Disconnect the connector of lead wire harness
between the rear door and front left door (front right
door, trunk cover in the combination tail). Gauge To step 16 To step 15
the ground wire with digital multimeter to inspect if
the ground connection is in a good condition.
14 Repair the ground wire of lead wire harness of the
To step 13
rear body. Inspect if the system is normal.
15 Repair the ground wire around the connector to
To step 16
make sure it in a good grounding.
16 Disconnect the central door lock motor connector
and the switch connector at every door. Test and
inspect lead wire harness of the rear body, left front
door, right front door, rear door and trunk cover To step 17
with digital multimeter according to circuit diagram.
Make sure the harness and the system are in a
good condition.
 Vehicle Body & Electric Appliance Volume BL - 5

17 Inspect the internal structure of central door interlock

switch and central motor at every door. If necessary,
replace or repair it to ensure the system in a good
condition.

Diagnostic Procedure of Door Lock System: Central Door Lock is out of

Service 2
Steps Processing Method Yes No
1 Inspect if the fuse is in a good condition. To step 2 To step 3
2 Replace the damaged fuse. To step 3
3 Inspect if other fuses are in good conditions according
To step 4 To step 5
to circuit diagram.
4 Replace the damaged fuse with new one. To step 5
5 Disconnect the socket connector between console
and lead wire harness of the rear body. Use digital
To step 7 To step 6
multimeter to gauge if the pressure around the
instrument leads harness is normal.
6 Inspect and repair the console lead wire harness from
fuse to socket connector. Make sure that it has no To step 7
problems.
7 Use digital multimeter to gauge if the pressure of
socket connector (around the console lead wire To step 9 To step 8
harness) is normal.
8 Inspect and repair the console lead wire harness from
To step 9
fuse to connector. Make sure that it has no problems.
9 Dismount the central door lock module, move the
ignition position to “ON”(switch-on) position, move To step
To step 11
the windshield wiper switch to internal gear. Gauge 10
with the digital multimeter if the pressure is normal.
10 Inspect and repair the lead wire harness from socket
To step 11
connector to the rear body of central door lock module
and make sure it has no problems.
11 Replace with new central door lock module and To step
inspect if the system is normal. 12
12 Gauge the ground wire of central door lock module
To step
with digital multimeter to inspect if ground connection To step 13
14
is in a good condition.
13 Disconnect the socket connector of lead wire harness
between the rear door and front left door (front right
To step
door, trunk cover in the combination tail). Gauge the To step 16
15
ground wire with digital multimeter to inspect if the
ground connection is in a good condition.
14 Repair the ground wire of lead wire harness of the To step
rear body. Inspect if the system is normal. 13
15 Repair the ground wire around the socket connector To step
to make sure it in a good grounding. 16
16 Disconnect the central door lock motor socket To step
connector and the switch connector at every door. 17
 Vehicle Body & Electric Appliance Volume BL - 6

Test and inspect lead wire harness of the rear body,

left front door, right front door, rear door and trunk
cover with digital multimeter according to circuit
diagram. Make sure the harness and the system are
in a good condition.
17 Inspect the internal structure of central door interlock
switch and central motor at every door. If necessary,
replace or repair it to ensure the system in a good
condition.
 Vehicle Body & Electric Appliance Volume BL - 7

Remote Control Key

Overview
The remote control key of this car adopts potent technology of fillip mechanism, which is
made up of one lock press button, one unlocking button and boot’
s open-up button.
There are lockup/unlocking switches on the side door for driver and passengers. This
switch can be used to lock and unlock. lock Work indication unlock

Function
1. Lockup Function
When starting up lockup signal through exterior
operating point, centralized door lock system of the
vehicle will be set as locked state. If driver’ s side
door is not closed, exterior lockup operation will be Spring of key Open of boot

unsuccessful. Every control point of seats and

carriage will be forbidden to use after the lockup operation. Forbidden function of internal
control point can only be activated by unlocking order given by either of the two exterior
control points.
2. Re-lock Function of Remote Control
The vehicle will re-lock automatically in 30s when receiving a remote control
unlocking request with lockup of the vehicle if neither of the following conditions
occurs.
a. Any door or boot is opened.
b. Ignite to start.
3. Unlocking Function
The lockup system of the complete vehicle will be released automatically when
starting up unlocking signal through exterior operating point. The internal
“lockup/unlocking”button, “open of oil tank cover”button can be permitted to use at
this time.
4. Control Centralized Door Lock through Internal Lockup/Unlocking Buttons
When lockup/unlocking buttons are activated, the centralized door lock will be set as
the opposite state to the current state (reversal function).
- Unlocked vehicles are locked.
- Locked vehicles are released from lockup.
5. Comfort Closedown
Press the locking button on the remote control for more than 1s with the closedown of
ignition switch, then all the electric windows will ascend to the top until the locking
button is released.
6. Comfort Open-up
Press the unlocking button on the remote control for more than 1s with the closedown of
ignition switch, then all the electric windows will bottom out until the locking button is
released.
7. Identity Identification of Driver
Anti-theft ECU realizes legal user’ s identity identification of the vehicle by reading the
message in the electric code responder in the key handle of the car through the
inductive coil covered on the lock core of ignition switch and also transfers the result
 Vehicle Body & Electric Appliance Volume BL - 8

of identity identification to electric control module of the motor by cryptogram. It can

prevent illegal intruder from cutting off the circuit of car such as igniting circuit,
start-up motor, petrol pump, central control unit and so on. It also can prevent illegal
intruder from starting up electronic injection engine to stop the car from starting up.
 Vehicle Body & Electric Appliance Volume BL - 9

Replacement of the Remote Control Battery

The battery of remote control door lock emitter can be used for two years in regular
service conditions.
If luminous diode indicator light is not bright and the emitter is out of service at any
position within the effective range, it indicates the shortage of quantity of electricity. If the
emitter only works by approaching the vehicle, then the battery shall be replaced
immediately.
Attention
It is necessary to avoid contacting circuit board
when replacing the battery or the static transferred
to circuit board from your body can damage the
emitter.
Steps of replacing battery of remote control door
lock emitter are as follows:
1. Dismount the cover plate on the front face of
remote control key and take out the emitter.

2. Open the emitter cover carefully, take out the

old battery and mount the new one. Be sure to
make the positive pole of the battery upward.
Use one 3V battery or battery of the same
type.
Vehicle Body & Electric Appliance Volume BL - 10
 Vehicle Body & Electric Appliance Volume BL - 11

3. Cover the emitter cover and make sure the emitter cover is covered tightly in order for
waterproof.
4. Put the emitter in the remote control key and cover the cover plate.
5. Test the operation condition of the emitter.
6. Press the two buttons on the emitter at the same time for about 10 seconds, LED
indicator light will blink and extinguish.
7. Loosen the button if the indicator light extinguishes and the LED indicator light will
continue blinking here.
Continuously press the lockup and unlocking buttons for three times separately. Every
pressing time shall exceed 1.5 seconds.
 Vehicle Body & Electric Appliance Volume BL - 12

Dismantlement and Reassembly of System

BCM Computer
Dismantlement Steps:
1. Disconnect the negative terminal of the storage battery for more than 30s.

BL006

2. Dismount the driver’

s side seat.

BL007

BL008

3. Lift the carpet on the central control unit.

BL009
 Vehicle Body & Electric Appliance Volume BL - 13

4. Dismount the fixing bolt of the BCM computer. BL010

5. Disconnect harness joint of the controller and take out the controller.
Reassembly:
Assemble according to the opposite sequence to dismantlement.
 Vehicle Body & Electric Appliance Volume BL - 14

Lock Casing and Fastener of the Door.

Dismantlement Steps:
1. Disconnect negative terminal of the storage battery.

BL011

2. Dismantle lifting switch of the glass.

BL012

3. Dismantle the shade of ladder lamp.

BL013
 Vehicle Body & Electric Appliance Volume BL - 15

4. Disassemble inner trimming plate of the door.

Unclench the
protecting cover
BL014 BL015

BL016 BL017

BL018

5. Disassemble the fixing bolt of the lock and fastener assembly.

BL019
 Vehicle Body & Electric Appliance Volume BL - 16

6. Disconnect the harness joint and connecting piece, take out door lock actuator and
lock casing.

BL020

Reassembly
Assemble according to the opposite sequence to disassembly.
 Vehicle Body & Electric Appliance Volume BL - 17

Inner Handle of the Door

Dismantlement Steps:
1. Disassemble the fixing screw of the inner door handle shell and push the cover of
inner handle forward.

BL021 Unclench the

protecting cover

BL022

2. Disassemble the inner trimming plate of the door.

(Disassembly and assembly Steps: refer to
disassembly and assembly of the interior
and exterior trimmings).
3. Disconnect the connecting rod zipper and BL023
disassemble the fixed screw and bolt of
the connecting rod of the inner handle of
the door.

BL024

Reassembly:
Assemble according to the opposite sequence to disassembly.
Vehicle Body & Electric Appliance Volume BL - 18
 Vehicle Body & Electric Appliance Volume BL - 19

Outer Handle and Outer Handle Base of the Door

Dismantlement Steps:
1. Disassemble the inner trimming plate of the
door.
Dismantlement Steps: refer to disassembly
and assembly of the interior and exterior
trimmings of the body.
2. Unclench end plate on the outer handle of the BL025
door with screw driver and take it off.

3. Unclench the handle snap-in of the door with

screw driver. BL026

4. Take off the outer handle and disassemble the

fixing screw of the lock core. Take out the BL027
outer handle base of the door.

Reassembly:
Assemble according to the opposite sequence to disassembly.
Vehicle Body & Electric Appliance Volume BL - 20
 Vehicle Body & Electric Appliance Volume BL - 21

Latch Hook of the Door Lock

Dismantlement Steps:
1. Open the door.
2. Disassemble the fixing screw of the latch hook.
BL028

Reassembly:
Assemble according to the opposite sequence to disassembly.
 Vehicle Body & Electric Appliance Volume BL - 22

Controller and Lock Casing of the Boot Lock

Dismantlement Steps:
1. Open the door of the boot.
(Controller button can be used to open it, so is
the control button of the instrument console).
BL029

2. Disconnect the negative terminal of the BL030

storage battery.

BL031
3. Disassemble the trimming plate of the boot
door.

4. Disassemble the fixing bolt of the lock casing.

BL032
Fastening Torque: 24 ±4N.m

5. Disassemble the fixing screw of the boot lock controller.

Vehicle Body & Electric Appliance Volume BL - 23
 Vehicle Body & Electric Appliance Volume BL - 24

BL033

6. Disconnect the connecting piece and take out

the lock casing and controller.

Lock core
of the
trunk

Reassembly
Assemble according to the opposite sequence to disassembly.
 Vehicle Body & Electric Appliance Volume BL - 25

Lock Core of the Boot Lock

Dismantlement Steps:
1. Open the boot and dismantle inner trimming
plate of the boot.
BL035

2. Disassemble the decorative bright wisp

BL036
(four fixing bolts).

BL037

3. Disconnect the connecting rod of lock core.

BL038
 Vehicle Body & Electric Appliance Volume BL - 26

4. Disassemble the fixing bolt of the lock core. BL039

5. Take out the lock core.

Reassembly:
Assemble according to the opposite sequence to disassembly.
 Vehicle Body & Electric Appliance Volume BL - 27

Latch Hook of the Boot

Dismantlement Steps:
1. Open the door of the boot.
2. Disassemble the fixing screw of the latch
hook and take off the latch hook.

BL040

Reassembly:
Assemble according to the opposite sequence to disassembly.
Fastening Torque: 9 ±2N.m
 DI - 1

Combined Instrument
Overview
The combined instrument is located in the console which is right ahead of the driver and
above the open of the steering column. While the rest parts of the combined instrument,
including installation parts and electric connecting parts, are encapsulated in the console
which is behind the combined instrument. Besides the analogue instrument and indicator,
several alarm or warning instructions and some diagnosis information are also provided.
The instrument for this car adopts the four-meter form and the three-gun-barrel pattern. From
the left side to the right, they are tachometer, car speed meter, water temperature meter and
fuel oil meter which are in a gun barrel structure. The odometer, shown by white LTD passage
code, is set in the middle car speed meter without lighting in the background. Blue light halo is
adopted as the meter ring and back light, with white letters and red pointers. Indicator lights lie
in the verge of two side meters and the upper part of instrument separately. This arrangement
appears more directly perceived, clear, compact and concise.

Car speed meter Water temperature Fuel oil meter

Tachometer meter

Tachometer
An impulse signal with a duty ratio of 50% is input to the input terminal of speed signal to
indicate the engine speed of engine. The microprocessor measures the frequency of impulse
at the input terminal, and then drives the stepper motor according to frequency ratio
(revolution per minute).
Characteristic of Tachometer (sensor at the crankshaft position outputs 2 impulses
/revolution):
Frequency of Input Impulse Actual Speed of
Indication Error (RPM)
(Hz) Engine(RPM)
0 0 /
33.33 1,000  100
100 3,000  150
233.33 7,000  350
 DI - 2

266.67 8,000 /
Car Speed Meter
A collecting-anode open-circuit impulse signal with a duty ratio of 50% is input to the speed
terminal. The microprocessor measures the frequency of impulse received by the input
terminal, and then drives the stepper motor according to the frequency ratio to make the
pointer point at the corresponding position (km/h).
PPK value is 2,640 (4 impulses/revolution): (speed ratio of odometer is 660)
Actual Speed Sensor Impulse Indicated Speed Indication Error
(km/h) Frequency (km/h) (km/h)
0 0 0 0
60 44 61.8 - 63 0~+ 5
100 73.33 103 - 105 0~+ 5
160 117.33 164.8 - 168 0~+ 6
212 155.47 220 /

Fuel Oil Meter

The fuel oil meter adopts the resistance-type sensor, whose resistance ratio has a certain
relation with the oil level in the fuel tank. The microprocessor measures sensor’
s resistance to
the ground. Thereby, it figures out the oil volume in fuel tank, drives the stepper motor to the
corresponding position, and indicates the oil volume.
Oil Volume in Fuel
Permissible Error of Resistance Ratio of
Pointer Position Tank
Indication () Sensor ()
(L)
E 2.5 4 283  4
Alarm Oil Level 8 4 180  4
1/4 17.5 4 130  4
1/2 35 4 88  4
3/4 52.5 3 62  3
F 70 2 44  2

Coolant Thermometer
Resistance-type sensor provides the instrument with the signal of temperature of engine
coolant in the form of resistance, with the ultimate voltage of input terminal measured by the
one-piece machine.
Permissible Resistance
Actual Temperature Indicated
Dial Indication Error of Ratio of
(℃) Temperature
Pointer Sensor ()
C mark 60 C mark --- 110
1/4 travel 80 1/4 travel  3 62
1/2 travel 90 ½ travel  3 43.5
Redline
Redline Mark 115  3 25
Mark
 DI - 3

H Mark 120 H Mark --- 22

 DI - 4

Introduction to Functions of Instrument

Alarm Sign

Function Control Sign Color Control Pattern

Left steering Hardware Green High
Right steering Hardware Green High
Bright beam Hardware Blue High
Charge and discharge Hardware Red Low
Pressure of lubricating oil Hardware Red Low
Anti-theft indicator light of
Hardware Yellow High
engine
Low fuel Software Yellow Software calculation
High or not
ABS Hardware Yellow
connected.
Airbag Hardware Red Low
Engine check Hardware Yellow Low
Seat belt Software Red Software
Door opened Hardware Red Low
Small light indication Hardware Green High
Front fog lamp Hardware Green High

Alarm Sign (Continued)

Back fog lamp Hardware Yellow High

Handbrake and EBD is low with handbrake

level alarm for and brake level alarm signal is
Hardware Red
brake low connected
EBD High or not connected (note)
Indication for
abrasion of brake Hardware Red High or not connected
lining

EOBD Hardware Yellow Low

Trunk indication Hardware Yellow Low

Cruise indication Hardware Green Low

Note: When the EBD signal is high connected or not connected, the indicator light will be on;
only when the EBD doesn’
t alarm (EBD is low connected), check the signal of the handbrake
and the level alarm for brake. When signal is low connected, the alarm light will be on.
 DI - 5

Operation Instructions:
Car Speed Meter and Sub-Total of Mileage
The car speed meter displays speed by kilometer/hour (km/h). The odometer displays the
mileages the vehicle has covered.
Accumulative Total of Mileage
The total odometer can display the mileages the vehicle has so far covered.

Tachometer
The tachometer displays the engine’
s engine speed with revolution/minute as the unit.

Warning Light of Seat Belt

The light is always on before the driver fastens the seat belt. If the driver has fastened the
seat belt, it will be off.

Warning Sound of Seat Belt

A warning sound lasting for several seconds would be given out when the ignition switch is
connected to remind everybody of fastening the seat belt. If the driver has fastened the seat
belt, there will be no warning sound.
Readiness Indicator Light of Airbag
On the console there is an airbag indicator light, which displays the sign of airbag. The system
will check whether the airbag system has troubles or not. Whether the airbag system has
electric troubles will be indicated by this light. The system checks the airbag sensor, airbag
module, circuit and diagnosis module. When the vehicle is started, the light will be on for
about seven seconds and then go out, which means that the airbag system has been ready. If
the readiness indicator light of airbag does not go out after the vehicle has been started or it is
lit on while traveling, it indicates that the airbag system is abnormal.
Indicator Light of Charge System
As an item to be checked, the indicator light of charge system will be on for a short time when
the ignition switch is connected and the engine is not started, which indicates the system
works normally. When the engine has been started, the indicator light is to go out. If the
indicator light does not go out after the vehicle has been started or it is lit up while traveling, it
indicates that there is electric trouble about the charge system. All the electricity of battery will
be used up when traveling with the light on. If it is necessary to travel for a short distance with
the light on, do turn out all the accessories, such as radio and air conditioner.
Indicator Light of Anti-Skid Braking System
The warning light will be on for several seconds when the ignition switch is switched on, which
is a normal phenomenon. If the warning light keeps on, set the ignition switch at the position
of LOCK. Or, if the warning light is lit up, stop the car immediately, turn off the ignition switch,
and restart the engine to reset the system. If the warning light is on or is lit up again while
traveling, the car needs to be maintained. If the warning light of conventional braking system
hasn’
t been lit up, the car can also brake, but not perform the anti-skid brake. If the warning
 DI - 6

light of conventional braking system is also lit up, not only can the anti-skid brake not be
performed, but also the conventional braking system has troubles. When the ignition switch is
switched on, the indicator light of anti-skid braking system will be on for a short time, which is
a normal phenomenon. If the warning light is not lit up at this time, eliminate the trouble to
make it give warning whenever there are troubles.
Thermometer of Engine Coolant
When the ignition switch is switched on, the temperature of engine coolant will be displayed
by the water temperature meter.
Warning Light of Lubricating Oil Pressure
If lubricating oil pressure is too low, the warning light will be kept on after the engine has been
started or lit up while traveling, which indicates that the lubricating oil is not enough. The case
may be that the level of lubricating oil is too low or there are other troubles with the lubricating
oil. The warning light of lubricating oil may also be lit up in other three cases:
1. As an item to be checked, the warning light will be lit up when the ignition switch is
switched on and the engine does not run, which indicates that the light works normally. It
will go out after the engine has been started. If it is not be lit up when the ignition switch is
switched on, there are troubles about the fuse or bulb.
2. If the engine runs at an idle speed when there is a red light, the warning light may glimmer
and then go out. If you perform the emergency brake, the light will be on for a short time,
which is a normal phenomenon.
Warning:
Do not drive ahead when the pressure of lubricating oil is too low.
Attention:
If correct maintenance is not carried out to the lubricating oil, damage will be caused to the
engine.
Indicator Light of Bright Beam
The indicator light will be lit up whenever the bright beam distance headlamp is switched on.
Warning Lamp of Door Unclosing
When the door is not closed, this indicator light will be kept on until all the doors are closed
and locked.
Warning Lamp of Trunk Unclosing
The light will be on when the trunk is not closed tightly.
Fuel Oil Meter
Fuel oil meter will display the volume of oil left in the fuel tank when the ignition switch is
switched on. When the fuel tank is going to be empty, warning lamp of low fuel level will be lit
up. There is still a little fuel left, but you should refuel as soon as possible.
Indicator Light of Brake Shoe Abrasion
When the lining is braded to a certain extent, the indicator light of brake shoe abrasion will be
lit up to remind you of changing the brake disk.
DI - 7
 DI - 8

Instructions for Pin of Combined Instrument

SL1 (Green):

Pin Definition Pin Definition

1 Cruise 17 Anti-theft alarm
2 Front fog lamp 18 Left steering
3 Engine check 19 Bright beam
4 ABS 20 Not used
5 Airbag 21 Not used
6 Input of door-unclosing signal 22 Not used
7 Input of hand brake signal 23 Diagnosis opening
8 EBD 24 Not used
9 Input of fuel signal 25 Not used
10 Input of coolant temperature signal 26 Not used
11 Input of illumination adjusting signal 27 Sensor floor
12 Input of gear signal (PWM AT) 28 Body floor
13 Input of engine speed signal 29 Not used
14 Input of ground speed signal 30 KL15 (Ignition signal)
15 Lubricating oil pressure 31 Small light
16 Seat belt 32 KL30 (Battery)

SL2 (Blue):
Pin Definition Pin Definition
1 Not used 17 Not used
Not used Charge and discharge
2 18
indication
3 Not used 19 Reserved
4 Not used 20 Reserved
5 Not used 21 Trunk
6 Not used 22 P (Only for AT)
7 Not used 23 R (Only for AT)
8 Not used 24 N (Only for AT)
9 Not used 25 D (Only for AT)
10 Not used 26 4 (Only for AT)
11 Not used 27 3 (Only for AT)
12 Not used 28 2 (Only for AT)
13 Not used 29 1 (Only for AT)
14 Not used 30 Not used
15 Right steering 31 EOBD
16 Back fog lamp 32 Abrasion of brake shoe
 DI - 9

Display of Driver Information

Pressure of Lubricating Oil
When the signal of lubricating oil pressure input is at low, the alarm light will be lit up.
Seat belt
When the ignition switch is turned on, the buzzer and alarm LED will not act if the seat belt is
connected.
When the ignition switch is turned on, the buzzer will horn and the alarm LED will be on for
three seconds if the seat belt is disconnected. If the seat belt still cannot be connected within
three seconds, the buzzer will stop horning after three seconds, while the alarm LED will be
still on. If the seat belt is connected within three seconds, the alarm light will go out, and the
buzzer will still horn for three seconds before stop.
The seat belt will be connected when the ignition switch is turned on. If the seat belt is
unfolded in traveling, only the alarm LED will be on and the 7.3 LCD will work.
A LCD is installed in the instrument to display the total mileage, mileage sub-total and clock.
The display of clock and mileage sub-total will be switched by pressing a key.
The LCD will remain on after ignition is turned off. It is directly driven by the microprocessor. A
negative model with a drive ratio of 1:4 is adopted for the 7-character LCD display.

Colors of LCD must accord with the definitions in the valid drawings. The visible angles are:
From one side of the instrument to the other ±45°
From the head of the instrument + 1°~+ 8°
The working temperature range of LCD is - 20 to + 65C. There are no visible faults when
observing from the position of the driver. Comparative degree would be decreased if the
temperature is too high or too low.
Model: Negative
Drive ratio: 1:4
Voltage: 5V
Drive frequency: 130Hz
Gate rate: 1.732
 DI - 10

Accumulative Total of Mileage

The accumulative total of mileage is displayed in the LCD’
s lower part, with the total mileage
(0~999, 999, 999, 999km) displayed. When the full scale reading is achieved (999, 999km), it
will keep unchanged.

Mileage Sub-Total
Mileage sub-total is displayed in the LCD’
s upper part. It displays the total mileage since last
zero clearing of mileage sub-total or cut-off of battery voltage, with the display range of
0~999.9km and precision of 0.1km. If the instrument’
s power supply (the battery power supply,
but not the firing power supply) is cut off, the mileage sub-total will be cleared.

Sub-Total and Accumulative Total of Mileage

Clearance of Mileage Sub-Total

In the display mode of mileage sub-total, the present mileage sub-total will be cleared by
pushing the adjust bar for a long time (more than two seconds).
Clock
Time and clock signs are displayed in the upper part of LCD. Time is displayed in the form of
24 hours system. When the ignition is off and illumination is on, only the clock will be
displayed. After the ignition voltage is disconnected, time can also be adjusted. When the
ignition voltage is connected, LCD will display the functions before disconnecting the ignition
voltage. Within the operation temperature range of the instrument, the total precision of clock
is above 115ppm.
Clock Set
Time is displayed in the form of 24 hours system.
The model of clock set can be started by pushing the adjust bar for a long time (more than two
seconds). At this moment, the hour number and colon will scintillate with the frequency of
1Hz.
Hour Set
Under the model of hour set, hour number will increase as the adjust bar is pushed for a short
time (more than 300 milliseconds and less than 2 seconds). If the adjust bar is pushed for
more than 2 seconds, the hour number will continuously increase at the speed of 5
hours/second. At this moment, the hour number and colon will scintillate with the frequency of
1Hz.
If the adjust bar is left untouched within 5 seconds, the model of minute set will be started. At
 DI - 11

this moment, the hour number and colon will scintillate with the frequency of 1Hz, as it is
defined above.
Minute Set
Operation of minute set is the same with that of hour set.
If the adjust bar is left untouched within 5 seconds, the set model will be stopped. At this
moment, the clock display will not scintillate.
Reset of Mileage Sub-Total and Swift of Hour Set
The reset bar can be used for model switch and reset, and it is operated by being pushed
towards the instrument direction. While switching the display model, it should be pushed for a
short time (more than 300 milliseconds and less than 2 seconds).
Flow Chart of Clock and Mileage Sub-Total Set

Clock display

Push for a long

time

Push for a long

Hour set time Hour number
model increases
automatically

Push for a short time

Hour number
Not push > 5 sec
increased

Push for a short time

Push for a long time

Minute set Minute number
increases
automatically

Push for a short time Minute number

Not push > 5 sec increased

Attention:
Display of Use the following definitions:
mileage Push for a short time = < 2 Secs but > 300mS
sub-total
Push for a long time = > 2 Secs but
Push for a long time

When ignition is off, clock will be displayed on

LCD.
Reset When ignition is started again, the former function
DI - 12
 DI - 13

Gear
PRND4321 makes use of 9-character in LCD to display the gear chosen by automatic speed
changing system, with 8 display states of P, R, N, D, 4, 3, 2 and 1.

PWM AT: Directly input the PWM signal through the SL1-12 gear input lead pin. If no signal is
available, there will be no display.
AT: PRND4321 correspond with 8 input terminals respectively. The PRND high level is valid,
so is the 4321 low level. If no signal is available, there will be no display.

PRNDL State LCD Display

P (Parking) P
R (Reversing) R
N (Neutral) N
D (Driving) D
4(Four-speed) 4
3 (Third speed) 3
2 (Intermediate gear) 2
1 (First gear) 1

PRND4321 Display Example

Gear signal is PWM signal.
 DI - 14

Check of Combined Instrument Parts

Speedometer
1). Adjust the tire pressure to the fixed level.
2). Drive the car to the speedometer test device. Choose proper wedge block to support the
front wheels.
3). Check whether the speedometer point range is within standard value or not.
Attention:
Don’t tread the clutch suddenly or accelerate/decelerate at a high speed while testing.
Tire abrasion and over-inflation or under-inflation of tire will enlarge the display error.
Tachometer:
1). Connect the test tool with the diagnosis connecting joint or install a tachometer.
2). When the engine is started, compare the readings of tester and tachometer,
If the error excesses the fixed value, replace the tachometer.
Engine Speed (rpm) 750 2,000 3,000 4,000 5,000 6,000 7,000
Display Value (rpm) ±00 ±125 ±150 ±200 ±250 ±300 ±350

Attention:
If the tachometer is connected reversely, its transistor and diode will be damaged.
When disassembling and assembling the tachometer, be careful not to drop it or have
it vibrated seriously.
Fuel Oil Meter:
Check
1. Cut off the fuel delivery joint from the fuel delivery
Fuel meter
device.

Battery
2. Connect a 4W12V test bulb to the No. 3 and No. 4
terminals of the joint at the harness side.
3. Set the ignition switch at the position of “ON”and
check whether the bulb is on and whether the
tachometer pointer points to the position of “F”(full).

Fuel Sensor:
Reticule Datum Resistance Value (Ω)
E 283 ±4
Alarm oil level 180 ±4
Red zone of empty oil level 159 ±4
1/4 130 ±4
1/2 88 ±4
3/4 62 ±3
F
44 ±2

1. Use ohmmeter to measure the resistance between connector 3 and 4 under every floating
liquid level.
 DI - 15

2. Check whether the resistance changes smoothly

when the liquid level rises from “E”to “F”.

Sensor of Fuel-Quantity Insufficiency: 1. Thermally sensitive resister 3. Fuel

sensor
1. Connect a test bulb (12V, 3.4W) and a battery to 2. Fuel oil meter 5. Earthling
the sensor, and immerse the sensor into water.
2. The test light will be off when thermally sensitive
resistor is immersed into water. The test light will
be on when the sensor is taken out of water.
Illustrations:
Replace the fuel sensor assembly if troubles are
found.
Attention:
Wipe the sensor dry and reinstall it into the fuel
tank after the test is over.
Engine Coolant Thermometer:
1. Cut off the lead wire joint from the temperature
sensor of the engine coolant in the engine
compartment.
2. Set the ignition switch at the position of “ON”.
Check whether the meter hand points to the
position of “COOL”. Set the ignition switch at the
position of “OFF”.
3. Mount a test bulb (12V, 3.4W) between the
connector at the harness side and the ground. Set
the ignition switch at the position of “ON”.
4. Check whether the test bulb flashes and the
indicator points at the position of “HOT”or not.
Illustrations:
Replace the indicator if the result is not the same as above. Then recheck the system.
Engine Coolant Temperature Sensor
1. Use ohmmeter to measure the resistance between
connector 2 and the ground connection.
 DI - 16

2. Change the temperature sensor if the resistance

value is different from the table.
Graduation Line of Datum
Water Temperature Resistance
Gauge Value (Ω)
C 128
1/4 94
7/16 58
1/2 24
Red starting line 14
Oil Pressure Switch:
1. When the engine stops, check and confirm that there is current between the switch
terminal and the grounding.
2. When the engine is running, check and confirm that there is no current between the
switch terminal and the grounding.
3. Replace the switch if it does not work as required.
Oil Pressure Alarm Light:
1. Cut off the adaptor from the alarm light switch and
earth the terminal at the harness side.
2. Set the ignition switch at the position of “ON”.
Check whether the alarm light is on or not. If the alarm
light is off, test the light or check the harness.
Brake Fluid Level Alarm Switch:
1. Dismount the joint of the brake fluid reservoir switch.
2. Check whether there is current between switch terminal 1 and 2 when pushing the switch
with bar.

Parking Brake Switch

Parking brake switch is a push-pull switch which is
under the parking brake bar. Keep the parking brake
lever disengaged when adjusting, and then move the
switch up and down.
1. Make sure there is current between the terminal
and switch body when the switch is at the position
of “ON”(push pull bar is pulled up).
2. Make sure there is no current between the terminal and switch body when the switch is at
 DI - 17

the position of “OFF” (push pull bar is loosened). If the current does not meet the
requirements, replace the switch or check the grounding connections.

Dismantlement and Reassembly of Combined Instrument

Dismantlement Steps:
DI001
1. Cut off the negative terminal of the battery for
more than 30s.

DI002
2. Dismantlement of steering wheel assembly.
(Include the upper and lower trim boards of
steering stem, airbag pattern assembly and
steering wheel. As for the dismantlement steps,
please refer to the steering system or the
console assembly.)
3. Dismantlement of instrument pad.
Insert the detacher into the gap between the
console pad and the console (arrowhead), and
DI003
then loosen the bayonet lock to dismount it.

4. Remove the instrument fixed screws.

5. Pull out the instrument upwards, and cut off the

two joints of the instrument harness (green and
blue). DI004

Reassembly:
Reassemble it according to the reverse order of
dismantlement.
 Vehicle Body & Electric Appliance Volume SW-1

Combined Switch
Decription of Combined Switch

Light parts Fixed return clamp Windscreen

parts wiper parts

This combined switch has altogether three function parts:

1．Light control part
 Vehicle Body & Electric Appliance Volume SW-2

Low
High

Over
taking

Control left turning, left lane changing, right turning,

right lane changing, front light, sidelight,
overtaking light signal. In the front light-working
model, it can also realize two functions of high
beam light to low beam light and low beam light to
high beam light.

Turning and lane changing signal lights

Turning signal light control lever has two upward
positions (Right turning) and two downward
positions (Left turning). These positions are used
to give out turning and lane changing signal lights.

To give out turning signal light, you should push the control lever upwards or downwards
 Vehicle Body & Electric Appliance Volume SW-3

to the end.
When turning is finished, control lever will return automatically.
An arrowhead in the instrument stand’
s combined device will flash to display the direction
of turning or lane changing.
To give out lane changing signal light, you only have to raise or press the control lever
until the arrowhead flashes, and hold the control lever until lane changing is finished.
When you loosen the control lever, it will return automatically. If the arrowhead flashes too
quickly when you are giving out turning or lane changing signal light, signal light would be
burnt out, then other drivers can not see the signal light you give out.
If a bulb is burnt out, it needs to be changed to avoid traffic accidents. If the arrowhead
does not flash at all when you are giving out turning signal light, you should check
whether the bulb has been burnt out, then check the fuse.
Highlight /low beam light converter
Push the turning signal light / multi-functional control lever in your opposite position if you
want to change the headlight from low beam to high beam. If the ignition switch is
switched on when high beam light is switched on, then this light in the combined device
will also be on.
Push the turning signal light / multi-functional control lever in the position toward you if you
want to change the headlight from high beam light to low beam light.
Overtaking flashing
This function can enable you to give out overtaking signal to the front driver through the
use of high beam light.
When using this function, push the turning signal light / multi-functional control lever in the
position towards you until the headlight’
s high beam light is on, then loosen the control
lever to let the headlight die out.
２． Windscreen wiper control parts

Inching

Off

Intermis
sion

Under
speed

High
speed
 Vehicle Body & Electric Appliance Volume SW-4

On

Off

Automatic
return

The way of controlling windscreen wiper (washing,

inching, gap, underspeed or high-speed). When
windscreen wiper is at the gear of gap, there are
three kinds of modes for choice: high, intermediate
and low.

Use the control lever at the right of steering column to operate the front windshield
wiper, which can be operated only when the ignition switch is switched on.
HI(High): High-speed washing can be carried on when the control lever is shifted to
this position.
LO(Low): Constant underspeed cleaning can be carried on when the control lever is
shifted to this position.
INT(Gap): After turning the control lever to this position, a delayed cleaning circle
can be obtained.
 Vehicle Body & Electric Appliance Volume SW-5

Shifting the middle passage of the windshield wiper’

s control lever to the direction
of LO can extend lag time. Shifting the middle passage of the windshield wiper’
s
control lever to the direction of HI can shorten lag time. Only when control lever is
at the position of INT can cleaning speed be adjusted.

Front windshield washing solution

To wash the front windshield, pull the front windshield wiper’
s washing solution control
lever towards you when ignition switch is switched on and front windshield wiper’
s
washing solution will spray out from the windshield spray nozzle.
Caution:
In freezing weather, do not use windscreen wiper if the front windshield has not
been preheated. Otherwise, washing solution will freeze to keep out your field of
vision. When you loosen the control lever, washing apparatus will stop working,
while the windshield wiper will continue for about three circles, then it will stop
washing or recover to the washing speed you have used ahead of this.

3． Fixed return parts

They are fixed parts of windscreen wiper parts and light control parts, and can realize
close of turning light through the return clamp rotation of steering wheel when light control
parts are at the state of left turning or right turning.
Vehicle Body & Electric Appliance Volume SW-6
 Vehicle Body & Electric Appliance Volume SW-7

Basic Diagram for Control of Combined Switch

Windscreen
wiper switch
 Vehicle Body & Electric Appliance Volume SW-8

Relay
Relay

Turn signal switch

DIM-switch Light switch
 Vehicle Body & Electric Appliance Volume SW-9

Check Switch Control for Connection

Functional gear 备注

Inching

Front
Off
windscreen
wiper
Interval

Low speed

High speed

Front washing

Rated current

Functional gear Remarks

Off

Small light
Light
Headlight

Left steering/lane
changing

Steering
Middle
Right turning/lane
changing

High beam

Low beam

High
Light beam
shift
Overt
aking
Low
beam

Rated current

Disassembly and Reassembly of Combined Switch

Disassembly and Reassembly
Warning:
1. It is prohibited that airbag assembly and clock spring clamp are dismantled or repaired.
Replace them if there are any troubles discovered.
2. It is prohibited that airbag assembly and clock spring clamp are dropped or come into
contact with water, fire, oil, etc. Replace them if deformation, crack, rust and so on are
found.
3. The upper surface of airbag assembly should be placed upwards in a smooth place.
Placing materials on airbag is prohibited.
4. Airbag is prohibited to be placed in a place where temperature degree is higher than
93℃.
 Vehicle Body & Electric Appliance Volume SW-10

5. Substitute clock spring clamp with new parts after airbag is unfolded.
6. Wear gloves and safety protecting sleeve glasses when dealing with unfolded airbag.
7. Proceed strictly according to the procedures when dismantling the whole safety airbag
assembly.
8. Act gently when disconnecting the adaptor of airbag assembly and clock spring clamp.
Do not exert too much strength.
9. Place airbag assembly in a clean and dry place after being dismantled.
10. Before assembling spiral cable, adjust spiral cable to the middle position between left,
right rotations, and let it aim at the center sign, then place the bearing circle at the
center position. In addition, spiral cable’
s keytooth should aim at steering column’
s key
seat. Otherwise, spiral cable would be damaged, even airbag will become invalid and
do serious harm to the driver. When checking the spiral cable, please refer to chapters
and sections in “Safety protective system for passengers”.
11. Disconnect the storage (— ) negative connector. SW001
Attention:
Wait for at least three minutes between leads
of the storage battery being disconnected and
next action.

Disassembly procedures:
1. Disconnect the storage battery negative
connector for more than three minutes.

SW002

2. Dismantle the steering wheel airbag module.

Rotate it for 90 degrees, and pry the clamping
band with cotter pin knife.

SW003

3. Dismantle the grip nut in the middle of the

steering wheel.
 Vehicle Body & Electric Appliance Volume SW-11

4. Disconnect the auto horn wire harness and SW004

clock spring wire harness.

SW005
5. Dismantle the fixed screw of combined switch.

SW006
6. Disconnect the combined switch wire
harness and then take off the combined
switch.

SW007

Reassembly:
 Vehicle Body & Electric Appliance Volume SW-12

Re-assemble them in the opposite order of the dismantlement.

 Vehicle Body & Electric Appliance Volume LT-1

System Illustration
Arrangement and Distribution of Lighting System
Arrangement Table of Lighting

No. Part Description Qty/Car

1 Rear ceiling light assembly 1
2 Front ceiling light assembly 1
3 Indoor small light assembly 4
4 Left front door light 1
5 Right front door light 1
6 Left rear door light 1
7 Right rear door light 1
8 License light assembly 2
9 Left turn light 1
10 Right turn light 1
11 Left front fog lamp assembly 1
12 Right front fog lamp assembly 1
13 Left front combination light assembly 1
14 Right front combination light assembly 1
15 Left rear combination light assembly 1
16 Right rear combination light assembly 1
17 High position brake lamp assembly 1
 Vehicle Body & Electric Appliance Volume LT-2

Partial Light Distribution Diagram

Front headlight Combined rear

light
Front fog light
Brake light
Rear position light
Turn light Reversing light
Dipped headlight /turn light
Rear fog light
High beam light
Front position light
License light

Front headlight

Front fog light

Combined rear
light

Side turn light

Lighting Fitting Parameter

Part
No. Parameter Requirement Power
Description
High beam
Tungsten-halogen lampH1 55W
light
Dipped Irradiation light: tungsten-halogen
Front combination 55W
1 headlight lampH7
light
Position light Incandescent lamp 5W
Turn light Incandescent lamp 21W
High quality with build-in dimming motor
Turn light Incandescent lamp 21W
Stop lamp LED 3W
Reversing
Incandescent lamp 21W
Rear combination light
2
light Rear fog light Incandescent lamp 21W
Position light LED 3W
Mounting height according to
Reflex mirror
international standard
3 Front fog light Tungsten-halogen lamp 55W
4 Side turn light Incandescent lamp 5W
High position
5 LED 3W
brake lamp
6 License light Incandescent lamp 5W
Front ceiling light Incandescent lamp bulb, integrated skylight controls
7 5W×2
assembly the switch
Rear ceiling light Incandescent lamp bulb, referring to the inner
8 5W×2
assembly schematic diagram for operation guide
Indoor small light
9 Incandescent lamp 5W
assembly
10 Door light Incandescent lamp 5W
 Vehicle Body & Electric Appliance Volume LT-3

Requirements for Gap and Surface Difference between Headlight and

Circum Components

Tolerance
Circum Gap Surface
Headlight Gap of Surface
Components Tolerance Difference
Difference
Engine cover 3.0mm ±1.0mm -0.3mm ±1.0mm
Front
Front safety rod 1.0mm ±1.0mm 1.4mm ±1.0mm
headlight
Front fender 1.9mm ±1.0mm -0.3mm ±1.0mm
Rear side wall 1.0mm ±1.0mm -1.0mm ±1.0mm
Rear Rear boot cover 3.0mm ±1.0mm 0 ±1.0mm
headlight Rear safety rod 1.0mm ±1.0mm 0 ±1.0mm
Front fog
Front safety rod 2.0mm ±1.0mm
light
 Vehicle Body & Electric Appliance Volume LT-4

Adjustment of Light
Adjusting Switch

Lamp brightness adjustment of Adjusting switch for

instrument desk headlight

Test for light irradiation position and light intensity:

The irradiation position shall be adjusted within the set range, and the light intensity of
high beam single light shall be ≥18,000cd

Irradiation Position of Front Light Beam

Standard Requirement
No. Inspection Item
Left light Right light
Centre height of light H (mm)
Height h (mm)
Dipped Light-to-dark
1 h/H 0.7~0.9
beam deadline
Left offset (mm) ≤170
angle
Right offset (mm) ≤350
Centre height of light H (mm)
Height h (mm)
High
2 Light beam h/H 0.9~1.0
beam
centre Left offset (mm) ≤170 ≤350
Right offset (mm) ≤350 ≤350
 Vehicle Body & Electric Appliance Volume LT-5

Diagnosis for Light Illuminating System

1. High position brake lamp fails to work

Steps Measures Yes No

To
1 Check whether the fuse has been burnt out? To step2
step4
Connect the test light with the two ends of brake signal To
2 To step3
light. Is the test light dark or not? step5
1. Connect the test light with the two ends of central high
To
position brake signal light.
3 step6 To step7
2. Keep stamping on the brake pedals. Is the test light dark
or not?
4 Replace fuse.
5 Replace brake signal light.
6 Replace high position brake signal light.
7 Repair the loose contact circuit.

2 Ceiling light fails to work

Steps Measures Yes No

Check whether the filament of ceiling light bulb has been To
1 To step4
burnt out? step2
Check whether the fuse has been burnt out. Is anything To
2 To step5
burning out? step3
Connect the test light with the two ends (left front, right
To
3 front, left rear, right rear) of contact switch and the end of To step6
step7
headlight separately. Is the test light dark or not?
4 Replace the light bulb.
5 Replace the fuse.
6 Replace the contact switch or the headlight switch.
7 Repair the loose contact circuit.

Ceiling light is always working

Attention: Premises for keeping ceiling light working are as follows:
• Close all the car doors.
• Troubleshooting steps for the close of lighting switch closes are as follows:
– Check the contact switch in the left front side and change it in case of any
trouble.
– Check the contact switch in the right front side and change it in case of any
trouble.
– Check the contact switch in the left rear side and change it in case of any trouble.
– Check the contact switch in the right rear side and change it in case of any
trouble.
– Check the headlight switch and change it in case of any trouble.
 Vehicle Body & Electric Appliance Volume LT-6

3. Glove-box lamp fails to work

Steps Measures Yes No

Check whether the fuse has been burnt
1 To step3 To step2
out?
Check whether the filament of glove-box
2 lamp bulb has been burnt out. Is To step4 To step5
anything burning out?
Check the interior
3 Replace the fuse.
lighting system
Check the interior
4 Replace the bulb.
lighting system
Check the interior
5 Repair the loose contact circuit.
lighting system

Boot light fails to work

Steps Measures Yes No

Check whether the filament of boot light
To step To step 2
1 bulb has been burnt out. Is anything
4
burning out?
Check whether the fuse has been burnt To step
2 To step 3
out？ 5
Connect the testing light with the two
To step
3 terminals of boot light switch. Is the test To step 7
6
light dark or not?
Check the interior
4 Replace the bulb.
lighting system
Check the interior
5 Replace the fuse.
lighting system
Check the interior
6 Replace the boot light switch.
lighting system
Check the interior
7 Repair the loose contact circuit.
lighting system
Vehicle Body & Electric Appliance Volume LT-7
 Vehicle Body & Electric Appliance Volume LT-8

Diagnosis Procedures of High Beam Light and Dipped

Headlight
A: All the high beam lights and dipped headlights stop working.

Steps Measures Yes No

1
Turn the switch to “ ”position, and turn the high beam light
To To
and dipped headlight switch to high light position. Is the fuse in step2 step3
good condition？
2 Measure the fuse pressure and see whether it is normal? To To
step7 step4
3 Replace the damaged fuse please. Whether it is still damaged To To
after replacement? step7 step2
4 Check switches of high beam light and dipped
To
headlight. Make sure that they have no
step5
problem.
5 Check switches to see it that there is no problem. To
step6
6 Check the lead wire harness of instrument plate according to To
circuit diagram. step8
7 Check whether the high beam signal device is working. To
step9
8 Check high, dipped lights and its connector connecting with
To
wire harness. Confirm whether the connector is in good -
step 9
condition?
9 Confirm the wire well-connected with earth by the number pin To
of light connector. step
10
10 Separate the connector between the wire harnesses of front car To To
body. Check whether the pressure of the pin is normal? step step
11 12
11 Make sure that connector in good contact
condition and check the wire harness from
connector to the front car body according to
circuit diagram.
12 Make sure that connector in good contact condition and check
wire harness from fuse to the instrument plate of connector
according to circuit diagram.

B. Only high beam light fails to work

Steps Measures Yes No

1. Check whether the high beam signal device is working (only To To step3
 Vehicle Body & Electric Appliance Volume LT-9

for high beam)? step2

Please check lights
and the connector connecting lights with wire harness.
Make surethat To
2.
there is no problem step3
when adjusting in high
beam position.

Steps Measures Yes No

Separate the connector between instrument plate and
To
3. wire harness of front car body. Check whether the To step4
step5
pressure is normal?
Check whether the wire harness of front car body from
4. connector to high beam light is in good condition To step5
according to the circuit diagram?
Check the wire harness from fuse to the instrument plate
5.
of connector according to circuit diagram please.
Check whether fuse is in good condition. To
6. To step7
step9
Measure whether the pressure of fuse is normal? To
7. To step 8 step
11
Check the wire harness from fuse to the instrument plate
8. To step10
of connector.
Replace fuse and check whether it is still in damaged To
9. condition? To step8 step
7
10. Check connector and the wire harness of front car body. To step2
Check switches of high beam and dipped beam and the
11.
wire harness of instrument plate from switch to fuse.

C. Dipped headlight fails to work

Steps Measures Yes No

Check lights and the connector connecting lights with wire To
1.
harness. Make sure that there is no problem? step2
Check whether fuse is in good condition? To To
2. step3 step
8
Measure whether the pressure of fuse is normal? To To
3.
step4 step7
Check the connector between instrument plate and the wire To
4. harness of front car body please. Whether the measured step5
pressure is normal?
5. Check the wire harness of front car body.
6. Check the wire harness of instrument plate.
Check switches of high beam and dipped beam and the wire
7.
harness of instrument plate from switch to fuse.
 Vehicle Body & Electric Appliance Volume LT-10

Replace fuse and check whether it is still in damaged condition. To To

8.
step4 step3

D. Only one high beam light or one dipped headlight fails to work

Steps Measures Yes

Check the lights and the connector inserted to To step 2
1
wire harness please.
2 Check the fuse according to circuit diagram. To step 3
Check the connector and instrument plate or
3 the
wire harness of front car body.

Diagnosis Procedures of Front Fog Light/Rear Fog Light

Steps Measures Yes No
To To
Turn the light switch to position “ ”, and then open the step7 step2
1.
front fog light switch. Check whether the indicator of switch is
in good condition?
Check whether the No. 9 fuse is in good condition? To To
2.
step4 step3
Replace the damaged fuse. To
3.
step4
Dismount the relay of front fog light, and then measure the To To
4.
voltage of the relay. Whether the voltage is normal? step6 step 5
Check whether the wire harness of instrument plate and the
5. circuit of front fog light are normal according to circuit diagram.
Carry out the maintenance work if necessary.
Replace relay. Check whether the fog lights are normal? To
6.
step7
Please check the connector of fog lights to make sure that To
7.
there is no problem in terms of pressure and earth connecting. step 8
Check the wire harness of instrument plate from relay to fog
8.
lights according to circuit diagram.

I. Rear fog light fails to work after turning on dipped headlight

Steps Measures Yes No

Dismount the relay of rear fog light, and then turn on the
1. dipped headlight. Measure the top pin voltage of the To step3 To step2
relay. Whether the voltage is normal?
Check the lights switches and the wire harness of
instrument plate between rear fog light and relay
2.
according to circuit diagram. Carry out the
maintenance work if necessary.
3. Replace relay and check the wire harness of instrument
 Vehicle Body & Electric Appliance Volume LT-11

plate.

II. Rear fog light fails to work after turning on the front and rear fog light

Steps Measures Yes No

Turn on dipped headlight and front fog light. Open the
1 switch of rear fog light. Whether the director of the To step2 To step 6
switch is working?
Please check rear fog light and its connector
2 connecting to wire harness. Make sure that there is no To step 3 To step 11
problem in terms of pressure and earth connecting.
Check the connector between the instrument plate and
3 the wire harness of rear car body. Measure whether the To step 4 To step 5
pressure is correct.
Check the wire harness of rear car body from the
4 connector to the rear fog light. Do the maintenance
work if necessary.
Please check the wire harness of instrument plate from
5 switch to connector. Do the maintenance work if
necessary.
Dismount the switch of rear fog light. Measure the
6 pressure of wire harness. Whether the pressure is To step 7 To step 8
normal?
Please replace the switch of rear fog light. Whether the To step 3
7
rear fog light is normal?
Please replace relay, and see whether rear fog light is To step 9
8
normal?

Check the wire beam of instrument plate from relay To step

9
to switch. Make sure that there is no problem. 10
Please check the wire harness of instrument plate
10 connecting to the relay of rear fog light. Do the
maintenance works if necessary.
11 Replace rear fog light.

Diagnosis Procedures of Reversing Light

Reversing light fails to work
Steps Measures Yes No
1. Check whether fuse is in good condition? To step 3 To step2
Replace the damaged fuse. Whether the reversing
2. To step3
light is in good condition?
Check the connector between the instrument plate
3. and the rear car body. Measure whether the To step4 To step6
pressure is normal?
4. Please check the reversing light and its connector To step 5 To step 10
 Vehicle Body & Electric Appliance Volume LT-12

connecting to the wire beam. Make sure that there

is no problem.
Check the wire harness of rear car body from the
5.
connector to the reversing light.
Separate the connector of reversing light switch.
6. To step 8 To step7
Measure whether the pin pressure is normal?
Please check the wire harness of instrument plate
7.
from fuse to reversing light switch.
Please check the wire harness of instrument plate
8. from the connector of reversing light switch to the To step 9
joint. Make sure that there is no problem.
Check the stop lamp and its connector connecting
9 To step 10
to the wire beam.
Check the grounding point for the wire harness of
10 rear car body. Make sure that it is in good
grounding condition.

Diagnosis Procedures of Stop Lamp

All the stop lamps and high position stop lamps fail to work
Steps Measures Yes No
Turn the ignition switch to (ON) position. Check fuse To step
1. To step2
and see whether it is in good condition? 3
Replace fuse and check whether it is still in damaged To step
2. To step3
condition? 5
To step
3. Measure whether the voltage of fuse is normal? To step 4
5
4. Please check the wire harness of instrument plate.
Separate the connector of brake switch and check the
To step
5. brake switch. Make sure that the brake switch has no To step 6
7
problem. Measure whether the voltage is normal.
Check the wire harness of instrument plate from the
6.
brake switch to the fuse.
Check the connector between instrument plate and the
To step
7. wire harness of rear car body. Make sure that it has no
8
problem.
Please check the wire harness of rear car body from To step
8.
connector to stop lamp. 9
Please check the stop lamp and its connector To step
9
connecting to wire harness. 10
Please check the grounding point for the wire harness of
10 rear car body. Make sure that it is in good grounding
condition.
Vehicle Body & Electric Appliance Volume LT-13
 Vehicle Body & Electric Appliance Volume LT-14

Diagnosis Procedures of Turning Signal Light and Hazard Warning Light

A. All the lights stop working when turning on turning signal light or hazard
warning light

Steps Measures Yes No

Check the fuse of turning light and hazard warning light and To step To
1.
see whether they are in good condition? 3 step2
To
2. Replace the damaged fuse.
step3
Dismount flasher relay and measure the top pin pressure of To step To step
3.
the relay by using DMM. Whether the pressure is normal. 7 4
Dismount hazard warning light switch. Measure the voltage
4. of the switch by using DMM and see whether the voltage is
normal?
Please check the hazard warning light switch and the wire
5. harness of instrument plate from the hazard warning light
switch to the flasher relay.
Please check the wire harness of instrument plate from fuse
6.
to hazard warning light switch.
Check the flasher relay and make sure that it has no
To step
7. problem. Check the grounding line of the relay and make
8
sure that it is in good grounding condition.
Check the wire harness of instrument plate from relay to
hazard warning light switch and the wire harness of
To step
8. instrument plate for turning signal light. Carry out the
9
maintenance work if necessary to ensure that there is no
problem.
Check switches of the hazard warning and turning signal
To step
9 light. Please replace them if necessary to ensure that there
10
is no problem.
Please check turning signal light and its connector To step
10
connecting to wire beam. 11
Please check the wire harness of instrument plate and front, To step
11
rear car body. Carry out the maintenance work if necessary. 12
Check the connector between instrument plate and front
12
rear car body.

B. Hazard warning light fails to work, but turning signal light has no problem
Steps Measures Yes No
1. Please check whether the fuse is in good condition? To step To step2
3
2. Replace the damaged fuse and check whether the To step3
hazard warning light is normal?
3. Dismount hazard warning light switch and check it. Make To step4
sure that the switch has no problem.
4. Check whether the pressure of hazard warning light To step6 To step 5
switch is normal?
5. Please check the wire harness of instrument plate from
fuse to hazard warning light switch.
6. Check the ground connecting line of hazard warning light To step To step7
switch and see whether it is in good grounding condition? 8
7. Check the grounding line for the wire harness of
 Vehicle Body & Electric Appliance Volume LT-15

instrument plate.
8. Check the lead line from the wire harness of instrument
plate to the hazard warning light switch.
 Vehicle Body & Electric Appliance Volume LT-16

C. Turning signal light fails to work, but hazard warning light has no problem

Steps Measures Yes No

To step
1. Please check whether the fuse is in good condition? To step2
3
Replace the damaged fuse and check whether the turning
2. To step3
signal light is normal?
Dismount the hazard warning light switch and measure
To step
3. the pressure of the switch. Check whether the pressure is
5
normal?
Please check the wire harness of instrument plate from
4.
fuse to hazard warning light switch.
Check the hazard warning light switch and make sure that
5.
it has no problem.
Dismount turning signal light. Check the wire harness of
6. instrument plate from flasher relay to switch and the To step7
switch of turning signal light.
Check the wire harness of instrument plate coming from
7. the
switch of turning signal light.

D. All the lights are shining without flashing

Steps Measures Yes No

Dismount the flasher relay and check whether the lead wire
To step
1. connecting to relay is in good condition. Check the relay if
2
necessary and see whether it is normal after replacement.
Please check the wire harness system of lead line according
2.
to circuit diagram.

E. Turning signal light or hazard warning light has no problem, but the director
fails to work
I. Left (right) side— light of one side fails to work, but the other not
1. Dismount the switch of turning signal light or hazard warning light. Check it if
necessary and examine whether it is in good condition after replacement?
2. Please check the wire harness system of lead wire from switch to light.
II. Only front or rear light fails to work
1. Separate the connector and measure the voltage of pin by using DMM. Whether the
voltage is normal?
2. Check the wire harness of instrument plate coming from turning signal or hazard
warning switch connecting to the connector.
3. Check the connector and make sure that it is in good contact condition.
4. Check the wire harness of lead wire from connector to light.
5. Check the light and its connector connecting to the lead wire.
III. Only one or two light (s) fail (s) to work
 Vehicle Body & Electric Appliance Volume LT-17

1. Please check the light and its connector connecting to the wire harness of lead wire.
Make sure that light and voltage or grounding line have or has no problem.
2. Please check the wire harness of lead wire according to circuit diagram.
 Vehicle Body & Electric Appliance Volume LT-18

Dismantlement and Reassembly of Light Illuminating System

Combined Front Lamp

Dismantlement Steps:
1. Cut off the negative terminal of the storage battery.

LT001

2. Open the engine cover, and disassemble the front bumper. (referring to the
disassembly and assembly of exterior trimmings for detailed steps).
3. Disassemble the fixing bolt of front combination lamp.
LT002

LT003

LT004
 Vehicle Body & Electric Appliance Volume LT-19

4. Cut off the wire harness joint, and pull the

front combination lamp out. LT005

LT006

LT007

Reassembly:
Assemble according to the reverse order of disassembly.
 Vehicle Body & Electric Appliance Volume LT-20

Inner Bulb Replacement of Front Combination Lamp

Replacement methods for the inner bulb of front combination lamp are the same. Do it as
the follows:
1. Disassemble the front combination lamp (disassembly method is as shown above).
2. Cut off the connecting joint of bulb.
LT008

3. Depress the clip of bulb heavily and push it

forward (according to the fixed point direction LT009
of clip) until the looseness of clip.

4. Take the bulb out and replace it. Assemble it LT010

following the reverse order mentioned above.
 Vehicle Body & Electric Appliance Volume LT-21

Front Fog Light

Dismantlement Steps:
1. Cut off the negative terminal of the storage battery.LT011

2. Disassemble the fixed point of front bumper. (referring to the disassembly and
assembly of exterior trimmings for detailed disassemble steps).
3. Cut off the wire harness joint of front fog light.
LT012

4. Take down the front bumper, and disassemble the fixing bolt of front fog light.

LT013

5. Separate the front fog light from front bumper.

Reassembly:
Install it following the reverse order of disassembly.
 Vehicle Body & Electric Appliance Volume LT-22

Replacement of Front Fog Light Bulb

1. Dismount the front fog light (referring to the method mentioned above).
2. Open the rubber cover according to the mark on the cover.
LT014

3. Cut off the inner connecting joint of the bulb.

LT015

4. Depress the clip till the looseness of it.

LT016

5. Take out the bulb.

LT017
 Vehicle Body & Electric Appliance Volume LT-23

(Left or Right) Turn Light

Dismantlement Steps: LT018
1. Cut off the negative terminal of battery.

2. Press the turn light with two hands, and then

LT019
push it forward. Take it out finally. Push forward
,

3. Cut off the wire harness of turn light.

LT020

4. Take off the turn light.

Reassembly:
Assemble it following the reverse order of disassembly.
 Vehicle Body & Electric Appliance Volume LT-24

Combined Rear Lamp

Dismantlement Steps: LT021
1. Cut off the negative terminal of battery.

2. Disassemble the inner setting carpet of the

boot. (referring to the disassembly and
assembly of exterior trimmings for detailed
disassemble steps).

3. Disassemble the fixing bolt of rear combination lamp.

LT022

4. Cut off the wire harness.

LT023

5. Take out the light group. LT024

Vehicle Body & Electric Appliance Volume LT-25
 Vehicle Body & Electric Appliance Volume LT-26

Reassembly:
Assemble it following the reverse order of disassembly.
Replacement for the Bulb of Rear Combination Lamp
1. Disassemble the rear combination lamp (disassemble it following the method
mentioned above).

LT025
2. Revolve and open the lamp base according
to the mark on the lamp group base.

LT026

3. Depress the bulb and revolve it

anti-clockwise.
LT027

LT028
4. Take out the bulb. (replacement methods for
the bulb of rear combination lamp is the
same).
 Vehicle Body & Electric Appliance Volume LT-27

High Position Brake Light

Dismantlement Steps:
1. Cut off the negative terminal of battery.
LT029

2. Depress the bake seat and disassemble the

clothes tree.

LT030

3. Cut off the wire harness joint of high

position brake light on the clothes tree, and LT031
take off the clothes tree.

Reassembly:
Assemble it following the reverse order of disassembly.
Vehicle Body & Electric Appliance Volume LT-28
 Vehicle Body & Electric Appliance Volume LT-29

License Light
LT032
Dismantlement Steps:
1. Cut off the negative terminal of battery.

2. Open rear boot, and disassemble the boot

cover. (referring to the disassembly and
assembly of interior trimmings for detailed LT033
disassemble steps).
3. Disassemble the fixing bolt on the shining
block of rear boot cover, and take off the
shining block.

LT034

4. Cut off the wire harness joint of license light.

LT035

5. Press the license light assembly heavily, push

leftward, and then forward, take it out finally.
The direction is as shown in the right picture.
6. Take out rear license light.
Note: two lights (left and right) in all.
 Vehicle Body & Electric Appliance Volume LT-30

Reassembly:
Assemble it following the reverse order of disassembly.

Indoor Lamp of Wheelhouse

Dismantlement Steps:
1. Cut off the negative terminal of battery.
LT036

2. Press down heavily (as shown in the

picture), and it would spring out LT037
automatically.

3. Disassemble two fixing screws.

LT038

4. Take out the indoor lamp assembly, and cut

off the wire beam joint. LT039
 Vehicle Body & Electric Appliance Volume LT-31

5. As shown in the picture, pry-out the indoor

lamp shade with a screwdriver, and replace
the indoor lamp bulb.

LT040

Reassembly:
Assemble it following the reverse order of disassembly.
 Vehicle Body & Electric Appliance Volume LT-32

Indoor Lamp of Passenger Carriage

Dismantlement Steps:
1. Cut off the negative terminal of battery.
LT041

2. Pry out the indoor lamp shade with a flat

screwdriver. LT042

3. Disassemble the two fixing screws.

LT043

4. Take out indoor lamp assembly, and cut off

LT044
the wire harness.

Reassembly:
Assemble it following the reverse order of disassembly.
 Vehicle Body & Electric Appliance Volume LT-33

Rear Tail Box Lamp

Dismantlement Steps:
1. Cut off the negative terminal of battery.

LT045

2. Press down the back seat, and disassemble

the clothes tree.

LT046

3. Cut off the wire harness joint of rear tail lamp.

LT047

4. Take out the rear tail lamp.

Reassembly:
Assemble it following the reverse order of disassembly.
 Vehicle Body & Electric Appliance Volume LT-34

Glove-box Lamp
Dismantlement Steps: LT048
1. Cut off the negative terminal of battery.

2. Open the glove-box, and disassemble the

glove-box cover plate.
3. Disassemble the fixing bolt and screw of
glove-box. LT049

4. Disassemble the fixed bolt of glove-box lock

catch.

LT050

5. Pull out glove-box assembly, and cut off the

switch of glove-box lamp and the connecting
wire harness of bulb.

LT051
 Vehicle Body & Electric Appliance Volume LT-35

6. Take out the illuminating light of glove-box.

LT052

Reassembly:
Assemble it following the reverse order of disassembly.
 Vehicle Body & Electric Appliance Volume LT-36

Indoor Small Light Footlight

Dismantlement Steps:
1. Cut off the negative terminal of battery.
LT053

2. Cut off the wire harness terminal of footlight.

LT054

3. Take off the footlight. LT055

Reassembly:
Assemble it following the reverse order of disassembly.
 Vehicle Body & Electric Appliance Volume LT-37

Indoor Small Light Door Ladder Light

Dismantlement Steps LT056

1. Cut off the negative terminal of battery.

LT057

2. Disassemble the door inner setting plate.

(referring to the disassembly and assembly of
interior trimmings for detailed disassemble
steps).
3. Pry out the lamp shade of ladder light with
tools.

LT058

4. Revolve ladder light group, and adjust the

accurate gear position for disassembly and
assembly. Take out the light group.

LT059

Reassembly:
 Vehicle Body & Electric Appliance Volume LT-38

Assemble it following the reverse order of disassembly.

 Vehicle Body & Electric Appliance Volume WW-1

Dismantlement & Reassembly of Horn

Dismantlement Steps: WW001
1. Cut off the negative terminal of storage
battery.
2. Lift the car by lift jack and dismount the
central mudguard.
3. Dismount the mudguard of left front wheel.
4. Dismount the front bumper assembly.
5. Dismount the fixed bolt of double horn.

WW002

6. Disconnect the harness and take off the

horn.

WW003

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume WW-2

Check
1. Check the horn by connecting the
pressure terminal 1 with the grounding
terminal 2 of storage battery.
2. The horn should sound; otherwise, replace
it.

Adjustment
Push the horn and adjust the sound of the horn to a proper extent by turning the adjusting
screw.
Attention:
Coat a little of glue around the screw after adjustment to protect it from looseness.
 Vehicle Body & Electric Appliance Volume WW-3

Dismantlement & Reassembly of Cigarette Lighter

Dismantlement Steps:
1. Cut off the negative terminal of storage
battery. WW004

2. Unclench the control panel of air

conditioner with an open cutter. WW005

WW006
3. Push down the ashtray cover and
dismount the auxiliary console.

WW007
 Vehicle Body & Electric Appliance Volume WW-4

4. Dismount the fixed screws of ashtray. WW008

5. Pull the ashtray and cigarette lighter WW009

assembly upwards. And cut off the wire
harness.

WW010
6. Cut off the wire harness and take off the
cigarette lighter.

Reassembly:
Reassemble it according to the reverse order of dismantlement.

Check of Cigarette Lighter System

Step Measure Normal Result Abnormal Result
Push the cigarette lighter into The cigarette lighter The cigarette lighter fails.
cigarette lighter seat untill you would jump to the rim of
hear the sound “clatter”. cigarette lighter seat
when the negative pole
is electrified.
The light of cigarette The light of cigarette
 Vehicle Body & Electric Appliance Volume WW-5

lighter is on. lighter is off.

 Vehicle Body & Electric Appliance Volume WW-6

Troubles and Diagnosis Measures of Cigarette Lighter

Troubles:
The cigarette lighter fails.

Diagnosis Measures:
1. Check the circuit to see if the fuse burns out.
2. Connect the positive and negative terminal of the cigarette lighter with a test light to
check whether the current exists.
3. Repair the place where poor contact appears.
 Vehicle Body & Electric Appliance Volume WW-1

Wiper
Assembly of Wiper System Positions of Elements
Wiper Motor
Position description:
Inside the engine hatch.
WW001

Wiper Control Switch

Position description: WW002
Combined switch under the steering wheel.

Wiper Blade
Position description: WW003
At the front windshield.

WW004
Wiper Connecting Rod
Position description:
It is connected with the wiper blade at the front
windshield.
 Vehicle Body & Electric Appliance Volume WW-2

Washer
Position description:
It is installed on the trimming plate of the wiper.
WW005

WW006

The motor and kettle of washer are installed at the

right front lower part of the engine hatch.
 Vehicle Body & Electric Appliance Volume WW-3

Check of Wiper & Washer Systems

Step Measure Normal Result Abnormal Result
1 Set the ignition The wiper works at low speed. The washer doesn’
t
switch at the The washer would spry to the work.
position of windshield constantly if the
RUN. Keep the washer switch is kept at ON
washer switch position. When the switch is
at ON position. cut off, the washer stops
working and the wiper returns
to the stop position after
scraping for 2-4 times.
2 Set the wiper After a complete wipe, the The wiper doesn’
t work
switch at the wiper would pause for 1-22 at delay mode.
position of seconds before starting The wiper doesn’
t work
delay another scraping work. at demister/delay/low
(impulse speed mode.
mode).
3 Set the wiper The washer would spry to the The washer doesn’ t
switch at the windshield as long as the work. The wiper
position of washer switch is kept at ON doesn’t work at delay
delay. Keep position. The wipers work at mode.
the wiper low speed while the washer is The wiper doesn’
t work
switch on for spraying water and continues at demister/delay/low
1-2 seconds. wiping for 2-4 times after the speed mode.
washer switch is released.
Then the wiper returns to
impulse mode.
4 Set the wiper The washer continues working The wiper doesn’
t work
switch at at low speed. at demister/delay/low
low speed speed mode.
position.
5 Set the wiper The washer continues working The wipers don’t work
switch at high at high speed. at high speed mode
speed (HI) but at low speed
position. mode.
6 Set the wiper The wiper returns to the stop Windshield wiper
switch at OFF position at a low speed. blades can’
t stop
position. working. The wiper
keeps working.
7 Set the rear The wiper stops working for The wiper doesn’t work
wiper switch at about 8 seconds. at delay mode.
ON position. The wiper doesn’t work
at demister/delay/low
 Vehicle Body & Electric Appliance Volume WW-4

speed mode.

Diagnosis Procedures of Wiper/Washer System

Trouble mode: the wiper and washer don’t work no matter what position
is set for the wiper switch.
Step Measure Yes No
1 Check if the fuse of the wiper was damaged. To step 3 To step 2
Dismount the wiper switch to check and make sure it is To step 5 To step 4
ok. Check if the pressure between the connector of lead
2
wire harness and wiper switch is proper with digital
multimeter.
3 Replace the damaged fuse. To step 2
Please check the console lead wire harness between the To step 5
4
fuse and the wiper switch. If necessary, please repair it.
Confirm that the connectors of the wiper switch and lead To step 6
wire harness contact well.
Separate the lead wire harness from the wiper motor. Check
5
the console lead wire between the wiper switch and the fuse
according to the circuit diagram. If necessary, repair the wire
harness.
Check the wiper motor and repair it if necessary. Make To step 7 —
6 sure that the wiper motor operates well. Make sure that
the connector of the wiper motor contacts well.
Please check the grounding wire of the wiper motor at the To step 8
7
console lead wire harness and repair it if necessary.
8 Is the system in good condition?
Trouble mode: the wiper and washer don’t work only when the high
position is selected.
Step Measure Yes No
1 Please separate the lead wire harness connector from the wiper To To step
motor. Check if the pressure of the pin on the lead wire harness step 2 3
side is proper with digital multimeter.
2 Check the inner structure of the wiper motor and replace it if
necessary.
3 Dismount and check the wiper switch; make sure it operates well.
Check the console lead wire harness between the wiper switch
and the wiper motor and repair it if necessary.
Trouble mode: the wiper and washer don’t work only when the medium
position is selected.
Step Measure Yes No
1 Please separate the lead wire harness connector from the wiper To To
motor. Check if the pressure of the pin on the lead wire harness step 2 step 3
 Vehicle Body & Electric Appliance Volume WW-5

side is proper with digital multimeter.

2 Check the inner structure of the wiper motor and replace it if
necessary.
3 Dismount and check the wiper switch; if necessary, replace or To
repair it. Make sure it operates well. step 4
4 Check the console lead wire harness between the wiper switch
and the wiper motor and repair it if necessary.
Trouble mode: the wiper and washer don’t work only when the interval
position is selected.
Step Measure Yes No
Dismount the wiper relay, set the ignition switch at ON To step 4 To step 2
1 position and set the wiper switch at inner position.
Check if the pressure of the relay top pin is proper.
Dismount and check the wiper switch to make sure it is in To step 3
2 good condition. Or else replace or repair it if
necessary.
Check the console lead wire harness between the wiper To step 7
3
switch and the wiper relay and repair it if necessary.
Please check if the grounding wire connects with the To step 6 To step 5
4
ground well.
Please repair the grounding wire. Make sure it connects
5
with the ground well.
Please replace lead wire relay. Is the system in good
6
condition?
Please check the console wire harness between the To step 8 To step
7
wiper switch and the relay to make sure it works well. 10
Dismount the new wiper relay and check if the pressure To step
8
of the relay is proper with digital multimeter. 10
Please check the console lead wire harness and repair it To step
9
if necessary; Make sure it works well. 10
Please check the console lead wire harness between
10 relay and wiper motor and repair it if necessary; make
sure it works well. Is the system in good condition?

Trouble mode: the wiper blade doesn’t stop at its original position.
Step Measure Yes No
1 Dismount the wiper switch to check the inner structure of To step 2
the wiper. Repair or replace it if necessary. Make sure
it works well.
2 Cut off the wiper motor connector; Check if the pressure To step 4 To step
of the pin on the lead wire harness side is proper with 3
digital multimeter.
3 Check the console lead wire harness between the fuse To step 4
and the wiper motor according to the circuit diagram;
 Vehicle Body & Electric Appliance Volume WW-6

make sure it works well.

4 Dismount the wiper motor and check its structure; repair
or replace it if necessary. The system is in good
condition.
 Vehicle Body & Electric Appliance Volume WW-7

Trouble mode: the wiper keeps open.

Step Measure Yes No
1 Check if the fuse is ok. To step To
2 step 3
2 Replace the damaged fuse. To step
3
3 Dismount the wiper switch and check if the pressure on the To step To
switch is proper with digital multimeter. 5 step 4
4 Please check the console lead wire harness between the fuse To step To
and the wiper switch; repair it if necessary. 5 step 6
5 Please check the inner structure of wiper switch and replace To
or repair it if necessary. Make sure it works well. Is the system step
in good condition? 10
6 Please separate the wiper from the wiper motor and set the To step To
ignition switch at “ON”position. Switch the wiper switch to 7 step
the high position and check if the pressure of the pin on the 10
connector (on lead wire harness side) is proper with digital
multimeter.
7 Please check the console wire harness between the wiper To step To
switch and the relay. Make sure it works well. 8 step 9
8 Please check if the grounding wire contacts well with the
ground with the digital multimeter.
9 Dismount the wiper motor and repair or replace it. Is the To
system in good condition? step
10
10 Check the console lead wire harness between the wiper
switch and the wiper motor according to the circuit diagram; if
necessary, repair it. Make sure it works well. Is the system in
good condition?
Trouble mode: the washer doesn’t work.
Step Measure Yes No
1 Dismount the wiper/washer switch; set the washer switch at
To To
“ON”position; check if the pressure of the pin at the original
step 3 step 2
position of the switch is proper with the digital multimeter.
2 Please check the console lead wire harness between the fuse
To
and the wiper/washer switch. Repair it if necessary. Make sure
step 3
it works well.
3 Check the inner structure of the wiper switch. Repair or replace
To
it if necessary. Make sure it works well. Is the system in good
step 4
condition?
4 Mount the wiper/washer switch; separate the washer motor
connector and set the wiper/washer switch at the position of To To
“washing”. Check if the pressure of the pin on the washer motor step 6 step 5
connector (lead wire harness side) is proper with the digital
 Vehicle Body & Electric Appliance Volume WW-8

multimeter.
5 Check and repair the lead wire harness between the
To
wiper/washer and the washer motor according to the circuit
step 6
diagram.
6 Please check if the console lead wire harness between the To
wiper motor and the wiper/washer switch works well. step 7
7 Please replace the washer motor. Is the system in good
condition?
 Vehicle Body & Electric Appliance Volume WW-9

Dismantlement & Reassembly of Wiper System

Dismantlement Steps:
1. Cut off the negative terminal of storage
battery.
WW007

2. Open the engine hatch cover and

dismount the bolt protecting cover of both WW008
wiper blades.

3. Dismount the fixed nuts of both wiper WW009

blades.

WW010

4. Dismount the seal rubber strip and the

clamping band of the wiper trimming plate.
Vehicle Body & Electric Appliance Volume WW-10
 Vehicle Body & Electric Appliance Volume WW-11

WW011

5. Take off the wiper blade and the wiper

trimming plate.
WW012

6. Dismount the connecting bolt of the

connecting rod and the wiper motor. WW013

7. Cut off the wire harness, dismount the

fixed bolt of the wiper motor and take off WW014
the motor.
 Vehicle Body & Electric Appliance Volume WW-12

WW015

8. Dismount the fixed bolt of the wiper

connecting rod and take out the
connecting rod.

WW016

WW017

Reassembly:
Reassemble it according to the reverse order of dismantlement.
Attention:
After mounting the motor and the wiper connecting rod, connect the wiper motor
with the joint. Set the wiper switch at ON position to activate the wiper motor and
then turn the wiper switch at OFF position (stop automatically).
Vehicle Body & Electric Appliance Volume WW-13
 Vehicle Body & Electric Appliance Volume WW-14

Washing Spray Nozzle

Check of One-Way Valve:
Blow into the valve towards the direction at which the washing solution is sprayed out to
make sure that the airflow can only go through the valve in one way, but not in the reverse
direction (induction).
Dismantlement Steps:
1. Open the engine hatch.
2. Pull the washing spray nozzle upwards by
hand to get it out.
WW018

3. Cut off the spray nozzle pipe.

WW019

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume WW-15

Washing Pump and Wiper Kettle

Dismantlement Steps:
1. Cut off the negative terminal of storage
battery.

WW020

WW021
2. Dismount the front bumper. (refers to the
steps of Dismantlement/Reassembly of
Exterior Trimmings)
3. Cut off the wire harness connector and
spray pipe of the washing pump.

4. Loosen the fixed bolt of the kettle. WW022

Reassembly:
Reassemble it according to the reverse order of dismantlement.
Washing Pump Check
Connect the two connecting food of the washing pump with a 12V power. It’
s normal if the
washing pump works.

Wiper Washing System Check after Installation:

1. Open the wiper switch to check if each working mode of the wiper is ok.
2. Open the spray nozzle to check if the spray condition is normal.
3. If not, please adjust the spray angle of the wiper spray nozzle by the pin.
4. Check the spray condition; check if it sprays to other places.
5. If the adjustment can’ t meet the requirement, please continue to adjust till when the
requirement is satisfied.
 Vehicle Body & Electric Appliance Volume BCR-1

Reversing Radar System

Overview
This car is equipped with Park Assist System (also called Reversing Radar) which can

display the exact distance of the obstacle behind the car during parking to ensure safety.

When the car is shifted into reverse gear, the Reversing Radar begins to work. At the

moment it begins to work, the Reversing Radar will have a quick self-checking for the

whole system to ensure the normal working of every part. If any part of the system or the

whole system doesn’

t work normally, then the display component will give alarm

information and the buzzer will ring for warning. The self-check result is shown as below:

Self-Checking Result Display Unit Buzzer

Normal Display “---” Rings like “BI-BI”

Part of the system doesn’

t Lack of display or full Normal ring or continuous

work display ring

The system can’

t work No display No suggestive sound

Self-Checking Result of Reversing Radar

According to the data statistics, the normal speed of reversing is about 5km/h, namely,

1.38m/h. Considering the inertia of the car, people’

s respond speed and different road

conditions comprehensively, the detecting distance of radar is divided into three sections

which giver the driver 0.5s, 0.8s and 1.2s respectively to respond. According to the

respond time above, the driver is recommended to stop the car immediately when it is

40cm away from the nearest obstacle, namely, when the display shows 40, to ensure

enough safety space.

 Vehicle Body & Electric Appliance Volume BCR-2

Precautions:
1. Because of the location, angle, size and reflected sound quality of the object,
the echo signal may not be received. What’
s more, the signal reflected from
complicated environment may also be false. Please see the following
examples:

The driver can not get any

caution from the radar
eye and even can not see
it in the side mirror.

Obstacle B and C will be

detected sooner or later,
but A will never be
detected.

A is detected first; but

when the car is reversed
to the end, what
displayed is the distance
of B.
Maybe the nearest distance is
judged falsely when the display
shows the distance of B but not
A. Only when the nearest object
is in a dead angle can this

When the car is almost

perpendicular with a glass wall or
any other smooth surface, the
radar may not detect the object.

When the car approaches a

smooth sloping ground, the
radar may not detect the
object.

The radar may not detect

small and smooth
cylindrical rod.
Vehicle Body & Electric Appliance Volume BCR-3
 Vehicle Body & Electric Appliance Volume BCR-4

2. When the car is reversed at a high speed, the detecting exactness of the reversing

radar system will decrease. Thus, a low speed of 6km/h is recommended.

3. When the red indicator light turns on and the alarm sound rings continuously, please

stop the car immediately because there are obstacles within the 40 cm area.

4. If mud or snow is found on sensor, you can clean it with water directly but not with

sharp object, high-pressure water-jet gun or strong cleaning agent in order to avoid

damage on the sensor.

5. If the surface of the sensor is attached by water droplet after rains or car washing, its

sensitivity may decrease (about 20%). But when the water droplet drops or the water

film evaporates, its sensitivity will be recovered.

6. The sensor is very sophisticated and very difficult to be recovered if its interior is

opened without permission. Our company won’

t take the responsibility for

maintenance in such cases.

7. Reversing radar is only assistant equipment for driving. Driver still need pay attention

to all safety by himself.

 Vehicle Body & Electric Appliance Volume BCR-5

Introduction to Functions
Self-Checking Function:
When the car is shifted into reverse gear, the reversing radar begins to work. At the

moment it begins to work, the reversing radar will have a quick self-checking for the whole

system to make sure every part works normally. If any part of the system or the whole

system doesn’
t work normally, then the display will show alarm information and the buzzer

will ring for warning.

Ultrasonic Sensor
The sensor adopted is the water-proof and dirt-proof ultrasonic sensor with strong

anti-interference capability. And it has the following functions:

 When receiving the command from ECU, the sensor will send out the corresponding

ultrasonic pulse.

 Filter the received ultrasonic signals.

 Amplify the ultrasonic pulse signals which measure up to standard.

 Switch the enlarged ultrasonic pulse signals to digital signals and transfer them to ECU.

Respond Mode of Buzzer

a. A: Continuously ring. If the buzzer begins to ring continuously, the car should be backed

up 40 cm far away to stop the continuous ring; B: Rapid intermittent sound, 8±0.5Hz;

C: Intermittent sound, the ring frequency is 4±0.5Hz.

b. Display

As soon as the reversing radar starts working, the azimuth patterns of all sensors will

flash according to the area detected and the sound frequency sent out by buzzer in

this area. The flashing frequency of the continuous ring area is 16Hz. The

corresponding azimuth patterns of the broken-down sensors won’

t be displayed.
 Vehicle Body & Electric Appliance Volume BCR-6

Technical Specifications of Components

Controller Assembly
Item Specification Item Specification
1. Rated voltage DC12V 2. Operation voltage DC10.8V~15V
3. Consumption Below 3W (including 4. Operation
-20℃~80℃
power buzzer) temperature
5. Storage 6. Operation
-40℃~85℃ 40KHz±2KHz
temperature frequency
Sensor
Item Specification Item Specification
2. Operation
1. Operation voltage AC90~130 -30℃~80℃
temperature
3. Storage 4. Operation
-40℃~85℃ 40KHz±1KHz
temperature frequency
5. Effective distance 5~120±5cm 6. Detecting way Ultrasonic
Taking the sensor as a centre, the left and right angle is about 120
7. Detecting angle degrees respectively, and the upper and lower angle is about 60
degrees respectively.
Display
Item The 1st The 2nd The 3rd The 4th The 5th
Distance (5~40cm) (41~60cm) (61~80cm) (81~100cm) (101~120cm)
Continues
Rapid intermittent sound Intermittent sound
sound
Red
Orange
Display Orange Yellow
Yellow Green
Yellow Green Blue
Green Blue
Green Blue
Blue
Blue

Buzzer
Item Specification Item Specification
1. Rated voltage DC12V 2. Operation voltage DC10.8V~15V
3. Storage 4. Operation
-40℃~85℃ -20℃~60℃
temperature temperature
5. Buzzer volume 90-110dB/10cm
 Vehicle Body & Electric Appliance Volume BCR-7

Principle of Controller and Positions of Components

Basic Diagram for Computer Control of Reversing Radar
Reverse switch

Buzzer
Left reverse light

Right reverse light

Reverse signal
Reverse radar ECU

Left probe Left middle Right middle Right probe

probe probe

1. Controller (ECU) 2. Ultrasonic sensor 3. Display 4. Buzzer

 Vehicle Body & Electric Appliance Volume BCR-8

Description of Controller Pin

Schematic Diagram of Reversing Radar Controller Terminal

1. Upper cover

2. Lower cover

3. Screw

4. Foam cotton (Buffer

pad)

Description of PIN’
s Functions
No. Name and Usage of Pin No. Name and Usage of Pin
CL (signal line of left GND (ground lead of right
1 11
middle sensor) middle sensor)
GND (ground lead of left Vcc (power cord of right
2 12
middle sensor) middle sensor）
Vcc (power cord of left Vcc (power cord of left
3 13
middle sensor） sensor）
Pin R (signal line of right L (signal line of left
4 14
lead sensor) sensor)
of GND (ground lead of right GND (ground lead of left
5 15
ECU sensor) sensor)
connect Vcc (power cord of left
6 5V (Display power cord) 16
or sensor）
DATA (signal line of
7 17 NC
display)
8 BZ (control line of buzzer) 18 V-(ECU ground input line)
V+( input line of ECU
9 19 NC
power supply)
CR (signal line of right GND (ECU ground input
10 20
middle sensor) line)
 Vehicle Body & Electric Appliance Volume BCR-9

Location of Components
BCR001 Controller of Reversing
Radar
1. Radar Controller

Illustration: Under the clothes stand.

2. Display BCR002

Illustration: In the interior rear view mirror.

Display of Reversing
Radar

3. Sensor
BCR003
Illustration: On the back bumper.

Sensor of Reversing
Radar

4. Buzzer
BCR004
Note: At the lower part of the instrument panel at

the passenger side.

Buzzer of Reversing
Radar
 Vehicle Body & Electric Appliance Volume BCR-10

Common Trouble Diagnosis and Troubleshooting

No Means and Techniques Remark
Troubles Causes of Trouble
. of Maintenance s
1. Bad connection 1. Check whether the
between wire wire harness is
The system doesn’t harness and main connected to power
1
work when reversing. power supply. correctly.
2. Incorrect socket 2. Correctly connect all
connection. sockets again.
It can’t work normally Incorrect location of Correctly connect all
2 although the power socket results in the sensors sockets
indictor light is on. failure of sensor. again.
1. The system
1. Correctly install it
detects the body or
according to instructions
ground.
The buzzer and invite professional
2. False installment
continuously alarms technicians for guidance
or falling-off of
and the display shows and check if necessary.
3 sensor.
the same number; but 2. Replace the damaged
3. Damage of
there is no obstacle sensor in time.
sensor.
behind the car. 3. Check whether the
4. Damage of
wire harness is
sensor connecting
damaged.
wire.
1. Check whether the
1. The voltage of the voltage of the storage
storage battery is battery is normal.
abnormal. 2. Shut off the system
Incorrect display of the 2. Incorrect socket and correctly connect all
4
distance of obstacle. location. sockets again.
3. Interruption of the 3. Check whether the
wire harness of the sensor connecting wire
sensor. touches exhaust pipe
and silencer.
1. Check the connecting
There is no suggestive
1. False connection wire and socket of
sound when be
of buzzer. buzzer. Correctly
5 started. Other work is
2. Damage of connect the buzzer
normal and there is no
buzzer again.
alarm during working.
2. Replace the buzzer.
No display on the
1. Check the connecting
display. But there is 1. False connection
wire and socket of
suggestive sound of display.
6 display. Correctly
when being started 2. Damage of
connect display again.
and alarm during display.
2. Replace the display.
working.
 Vehicle Body & Electric Appliance Volume BCR-11

Dismantlement and Reassembly of Components

Controller of Reversing Radar
Dismantlement Steps: BCR005

1. Cut off the negative electrode of the storage

battery.

BCR006

2. Press the back seat downwards and then

dismantle the clothes stand.

BCR007

3. Cut off the connector of wire harness of the

high-mounted stop lamp on the clothes stand

and take out the clothes stand.

BCR008

4. Dismantle the mounting screw of the

reversing radar controller, cut off the wire

harness and take out the controller.

Reassembly:
Install it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume BCR-12

Display

Serial Spare Parts

Serial Number Spare Parts Name
Number Name
1 Base 2 Screw M6X12
Elastic retainer
3 4 Supporting thread of spring
ring
5 Strut pad 6 Strut cover plate
7 Strut 8 Decorative cover
9 Mirror shell 10 Thimble
Micro-adjustment
11 12 Display
ball seat
13 Tapping screw 14 Regulator handle
15 Mirror surface
Vehicle Body & Electric Appliance Volume BCR-13
 Vehicle Body & Electric Appliance Volume BCR-14

Dismantlement Steps:
BCR009
1. Cut off the negative terminal of the storage

battery.

BCR010
2. Unclench the shield of the interior rear view

mirror with open cutter.

BCR011
3. Cut off the connector of wire harness.

BCR012
4. Push out the rear view mirror assembly

downwards.

BCR013
 Vehicle Body & Electric Appliance Volume BCR-15

5. Disassemble the display assembly. BCR014

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume BCR-16

Sensor of Reversing Radar BCR015

Dismantlement Steps:
1. Cut off the negative terminal of the storage

battery.

BCR016

2. Open the door of the trunk and dismantle the

fixed bolt of rear bumper (please refer to the

section of exterior trimming).

3. Cut off the wire harness connector of the BCR017

reversing radar sensor and take off the rear

bumper.

4. Press the bayonet catch of the sensor by BCR018

hand and push it outwards forcibly to take off

the sensor.

Illustration of Sensor Dismantlement:

The sensor is embedded in an external way. Dismantlement Steps are just reverse to that

of installation. First take off the connector plug, then press the bayonet catch of the sensor

manually from the interior of protective rod and push it outwards forcibly. The sensor can

be thus taken off.

Reassembly:
 Vehicle Body & Electric Appliance Volume BCR-17

Reassemble it according to the reverse order of dismantlement.

 Vehicle Body & Electric Appliance Volume BCR-18

Buzzer
Dismantlement Steps:
BCR019
1. Cut off the negative terminal of the storage

battery.

BCR020
2. Dismantle the steering wheel assembly

(please refer to the section of steering system

for dismantlement and reassembly).

3. Dismantle the auxiliary instrument panel

(please refer to the section of interior trimming

for dismantlement and reassembly).

4. Dismantle the central instrument console assembly (please refer to the section of

interior trimming for dismantlement and reassembly).

5. Dismantle the fixed bolts of buzzer.

6. Cut off the connector of wire harness. Then take off the buzzer.

Dismantlement Instructions:
The buzzer is fixed on the buzzer support with screws and fixed to the body with

double-side glue. Detach the mounting screws with screwdriver and pull out the plug of

connector. Thus, the buzzer can be taken off.

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume BCR-19

Judgment on Conditions of Components

When the car is shifted to reverse gear, there

The basic machine is
is no suggestion for start.
damaged. Replace it.

Measure to see whether the

Y
Check whether the harness
terminal voltage of the
is well connected or not.
basic machine is 12V.

N N

The voltage is not at 12V. Connect the harness well again.

Check whether the N Connect the connectors

connectors of the basic of the basic machine
machine are connected. well again.

The connectors of the basic machine are

connected well.

Y
Check whether he
Replace the harness.
harness is damaged.

The harness is in good condition. Check again.

 Vehicle Body & Electric Appliance Volume BCR-20

When the car is shifted to reverse gear, the basic machine gives out two alarms
and the corresponding indicator light on the display turns on.

Check whether the Connect the connectors of

N
connectors of the basic the basic machine well
machine are connected well. again.

The connectors of the basic machine are connected well.

Check whether the Y

harness is damaged. Replace the harness.

The harness is in good condition.

Y
Check whether the
Replace the sensor.
sensor is damaged.

N
When the car is shifted to
Replace the basic machine.
reverse gear, check whether
it works normally.

Continue using it.

 Vehicle Body & Electric Appliance Volume BCR-21

When the car is engaged in reverse gear, the basic machine is normal in
self-check.; but when there is an obstacle behind the car, the buzzer won’t ring.

The system
N
Check whether the Obstacle is works
within the detecting range. normally.

The obstacle is within the detecting range.

N
Check whether the The system
reflective surface works
area of obstacle is normally.
big enough.
Y

The reflective surface area of obstacle is big enough.

Check whether the Y

sensor is damaged.
Replace the sensor.

The sensor is in good condition.

Replace the basic machine.

 Vehicle Body & Electric Appliance Volume AV-1

Hi-Fi Control System

Composition of Audio System:

DVD Mainframe and Remote Controller

DVD Disc Tray and U-Type Special Tool

Treble Loudspeaker and Bass Loudspeaker

Antenna Amplifier
 Vehicle Body & Electric Appliance Volume AV-2

Operation of DVD Mainframe

Operation Effect Diagram

Power switch

Menu function selection

Upwards/downwards seek function

Switch of radio band

Automatically seek and preserve

function.
DVD selection

Mute function Screen zooming function

Upward & downward directions are for

VOL control button selecting disc. Leftward & rightward
directions are for selecting music.

Play/Pause Repeat function Scan function Random play Fast reverse Fast forward
 Vehicle Body & Electric Appliance Volume AV-3

Illustration of Audio System PIN

Illustration of Audio Display System PIN

No. Function Color No. Function Color

1 Mute when there is an incoming call 9 Mains lighting supply Yellow/Black
2 Ignition line Orange 10 Memory power supply Red/Green 10A
3 Power supply ground Black 11 Automatic antenna Blue
4 Left back loudspeaker (-) Purple/Red 12 Right back loudspeaker (-) Orange/Grey
5 Left back loudspeaker (+) White/Red 13 Right back loudspeaker (+) Orange/White
6 Left front loudspeaker (-) Red/Black 14 Right front loudspeaker (-) Orange/Black
7 Left front loudspeaker (+) Red/Blue 15 Right front loudspeaker (+) Orange/Blue
8 P/BRK Brown 16 CCD

No. Function
1 Right CD signal input
2 REM
3 Ground
4 B+ Main power supply
5 BUS
6 ACC
7 Left CD signal input
8 Signal ground
 Vehicle Body & Electric Appliance Volume AV-4

Common Trouble Diagnosis and Troubleshooting of Hi-Fi System

Trouble
Troubleshooting
No. Trouble Possible Cause Can’t be
Means
Eliminated
Fuse blows out. Replace the fuse with a To step 2.
new one.
The machine is Press the reset key on To step 3.
locked up. the panel with a pointed
Audio object.
mainframe Loose or poor Insert the power supply If the trouble
1
can’ t be contact between output plug into the can’ t be
started up. power supply output mainframe socket again eliminated,
plug and mainframe or replace the output the trouble
socket. plug. lies in the
mainframe or
other parts.
The 1. Loose contact 1. Press the tray-out 1. Replace
mainframe between disc tray button of the DVD-CH. the control
can work, and mainframe If the DVD-CH can box.
but the connecting move into and out of the 2. Replace
CHR harness. tray normally and read the wire
button 2. Bad DVD-CH. the disc, it shows that harness if the
2 can’t be 3. Bad DVD control the DVD-CH is basically trouble can’ t
switched box. normal and the control be eliminated.
into DVD box may be in bad 3. Replace
state. conditions. the DVD-CH
when the
trouble can’ t
be eliminated.
Loudspeaker 1. The volume 1. Set the volume control
is mute. control button is set button at a suitable
at the min. position position. Adjust the
or the left-right left-right volume
volume balance/front-back
3 balance/front-back volume control.
volume is 2. Check the connection
improperly set. of loudspeaker wires.
2. False connection
of loudspeaker
wires.
Only the 1. No DVD disc is 1. Replace the disc with Replace the
start picture put in or the disc is a new one and put in disc tray.
4
of DVD can damaged and dirty. the disc with the label
be 2. False disc format. side downwards.
 Vehicle Body & Electric Appliance Volume AV-5

displayed, 3. Moisture of laser 2. Replace the disc.

but without head or disc. 3. Use it after some time.
pictures of
normal
play.

Trouble
Troubleshooting
No. Trouble Possible cause Can’t be
Means
Eliminated
1. Adjust the display
1. False adjustment brightness, color,
The screen is
of the screen contrast and tone to
too bright or
brightness and the central position
dark. The
5 color. again.
picture isn’
t
2. Unclear content 2. Replace with a new
clear.
of disc itself. disc.
3. Bad DVD-CH. 3. Replace the
DVD-CH.
When the DVD 1. The disc is
is being played, damaged,
there is pause, scratched, dirty and Clean the disc or Replace the
6 mess of the so on. replace it with a new disc tray.
screen, or the 2. The road for one.
sound is traveling is too
intermittent. bumpy.
The positive and
negative terminals Connect the
The sound field
of the left and right loudspeaker according
is unclear under
7 sound channels of to the wiring diagram.
the stereo
the loudspeaker are
mode.
connected
reversely.
Check whether the
There is trouble
Bad reception installation site of
with the antenna
8 of radio or antenna and
installation or
noise. connection of wire is
antenna cable.
correct.
Check whether
the installation Go to a place where
site of antenna Bad signal of the most stations can be
9
and connection designation station. received and preset
of wire is the stations.
correct.
1. False disc 1. Replace the disc
Some of new format. with a suitable one.
10 discs can’
t be 2. There are burrs 2. Scrape off the burrs
played. at the disc inside at the edge gently with
edge. a pencil.
1. Two discs are put Press the tray-out
Replace
Disc can’
t be in the same disc button for more than 2
11 the
taken out. tray. seconds and try the
DVD-CH.
2. Disc is out of the automatic open.
 Vehicle Body & Electric Appliance Volume AV-6

disc tray.

1. The direction of
the remote
controller is
incorrect during 1. Get the remote
operation. controller pointed at
2. The electricity the remote control
1. Replace
quantity of the receiver at the base of
the remote
storage battery of steering wheel during
controller.
the remote operation.
The remote 2. Replace
12 controller is 2. Replace the storage
controller fails. the remote
inadequate. battery with a new
control
3. The remote one.
receiver.
control receiver is 3. Avoid the remote
bad. control receiver being
4. The remote exposed to too strong
control receiver is luminous beam.
exposed to too
strong luminous
beam.

Dismantlement and Reassembly of Hi-Fi System

Dismantlement and Reassembly of DVD Mainframe
Dismantlement Steps:
1. Cut off the negative terminal of the storage battery.

AV001

AV002
2. Insert the U-type tool into the control panel and
hold it tightly. Pull out the control panel directly.
After the wire harness is pulled out, the display
unit can be taken out.

AV003

Attention:
The bayonet of the U-type tool should be
inserted correspondingly. It will be OK if the
sound of “Bang”is heard.
 Vehicle Body & Electric Appliance Volume AV-7

AV004

3. Cut off the wire harness connector and signal AV005

line behind the display.

4. Take out the display unit. AV006

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume AV-8

DVD Disc Tray

Dismantlement Steps:
1.Cut off the negative terminal of the storage AV007
battery.

2. Dismantle the fixed bolt of DVD disc tray AV008

rack.

3. Cut off the data connector, and take out the AV009
disc tray.
 Vehicle Body & Electric Appliance Volume AV-9

Reassembly:
Reassemble it according to the reverse order of dismantlement.

Loudspeaker
Dismantlement Steps:
1. Cut off the negative terminal of the storage AV010
battery.

2. Dismantle the controller panel of the glass AV011

window.

3. Dismantle the interior trimming plate of the AV012

door (please refer to the dismantlement and
reassembly of the interior trimming for
 Vehicle Body & Electric Appliance Volume AV-10

dismantlement steps).

4. Dismantle the fixed screw of the

loudspeaker.

5. Cut off the wire harness and take off the loudspeaker.

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume AV-11

Treble Loudspeaker
Dismantlement Steps
1. Cut off the negative terminal of the storage AV013
battery.

2. Open the door and unclench the protective AV014

cover of the treble loudspeaker with tools.

3. Dismantle the fixed nut of the treble

loudspeaker. AV015

4. Cut off the wire harness and remove the

treble loudspeaker.

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume AV-12

Antenna Amplifier
General
The antenna amplifier is an electronic circuit component, which catches and enhances the
radio frequency (RF) in the band of amplitude modulation (AM) and frequency modulation
(FM). The antenna module is mounted on the C-pillar at the right side. The module is
connected to ground with installation support and fastening pieces.

Operation Principle
The antenna module receives radio signal of amplitude modulation (AM) and frequency
modulation (FM) through the integrated radio antenna at rear window and amplifies it with
selectivity. Then the amplified signal is sent to the input end of radio through the
coaxial-cable of the body.

Diagnosis and Test of Antenna Amplifier

Phenomena Possible Causes Measures

1. Open circuit of or 1. Repair the location of open circuit
disconnection between the and connect the connector of the
antenna amplifier and the antenna amplifier to the antenna
No reception of
connector of antenna. mounted on window.
amplitude modulation
2. Open circuit or 2. Replace the antenna cable or
(AM) or weak
disconnection of cables. connect the cable again.
reception of
3. No power supply for 3. Check the fuse. If it is normal,
frequency
antenna amplifier. repair the location of open circuit of
modulation signal.
4. Separation of antenna the storage battery.
amplifier and window. 4. Connect the connector of the
module to window.
No reception of 1. Disconnection of 1. Connect the coaxial-cable again.
amplitude modulation coaxial-cable of the radio. 2. Repair or replace the
or frequency 2. Short circuit between coaxial-cable.
modulation. coaxial-cable and ground.
No reception of
amplitude modulation
Trouble of antenna
or frequency Replace the antenna amplifier.
amplifier.
modulation; weak
received signal.
 Vehicle Body & Electric Appliance Volume AV-13

Dismantlement and Reassembly of Antenna Amplifier

Dismantlement Steps:
1. Cut off the negative terminal of the storage AV016
battery.

2. Press the rear seat and dismantle the AV017

clothes stand.

3. Dismantle the fixed screw of the protective AV018

plate of C-pillar and then remove the
protective plate of the C-pillar.

4. Cut off the connecting wire harness and AV019

fastening pieces of the antenna amplifier.

5. Take off the antenna amplifier.

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume AV-14

Precautions for Routine Maintenance and Use of Hi-Fi System

Precautions for Routine Maintenance
1. Don’ t put the remote controller in places with direct sunlight to avoid trouble of storage
battery due to longtime exposure to sunlight.
2. If the disc is not used for the time being, please don’ t put it randomly or in places with
sunlight to avoid accidental scuffing and spot and deformation and aging of disc due to
longtime exposure to sunlight.
3. Never attach any labels or other protective device to discs and avoid using the recorded
discs.
4. After putting the disc into the DVD disc changer, please close the tray door (clothes
cover) in time to prevent such foreign substances as dust from coming into the machine,
to avoid decrease of the sensitivity of laser head.
5. When traveling on over-bumpy road, you’ d better to stop using DVD and especially
changing disc to avoid trouble such as “disc jammed”.
6. Don’ t dismantle the DVD without permission.

Use and Maintenance of Disc

Precautions for Use

 Please hold the disc by its edge to avoid leaving fingerprints on its surface. (As shown
in Fig. A)
 Fingerprints and spots will cause sound skip and distortion.
 Don’ t write on the volume label surface with a ball pen or other writing tools.
 Don’ t clean the disc with spraying agent for disc cleaning, gasoline, dilution, antistatic
liquid or any other solvent.
 Pay attention not to drop or warp the disc.
 Do put the disc into the special disc case when you don’ t use it.
 Don’ t attach any paper or volume label onto the disc.

 When the disc surface is dirty

 Clean it gently with a soft wet cloth (only immersed with water). (As shown in Fig.
B)
 Move the cloth from the centre to the edge while cleaning.
(If you clean the disc in a circular direction, it may cause circular scuffing, which will
result in noise.)

 If the disc is taken from a cold place to a hot place, moisture may be formed on
it.
 Vehicle Body & Electric Appliance Volume AV-15

Before using the disc, wipe off the moisture with a soft dry cloth (excluding cotton
linter).

 False Storage of Discs

The disc will be damaged if it is stored in the following ways:
 Exposed to sunshine.
 In humid or dusty place.
 Directly exposed to heat outlet or heating appliance.

 Maintenance
 If the disc surface is very dirty, please clean it with a soft dry cloth.
 Don’ t use alcohol, gasoline, dilution, cleanser or other chemical solvent.
 Don’ t use compressed air to remove the dust.

Please don’t use the following abnormal discs in order to avoid damage of DVD-CH
caused by “disc jammed”.

1. Disc which is undersize or out-of-shape.

2. Over-thick disc.

3. Bad disc.
 Vehicle Body & Electric Appliance Volume SB-1

Precautions
Precautions for Safety Airbag and Safety Belt Pre-tensioner of Subsidiary
Restraint System (SRS)
Using such supplemental restraint systems as “airbag”and “safety belt pre-tensioner”with
safety belt can help reduce the possibility of hurt or the degree of injury of driver and
passengers at the front caused by collision of vehicles.
Caution:
 In order to avoid the failure of SRS system, which may result in increasing the danger of
injury and death caused by collision of vehicles, all maintenances shall be done by the
maintenance service center of the authorized JAC dealership.
 Improper maintenance, including improperly dismantlement and Reassembly of the SRS
system, may result in the error actions of this system, thus causing the casualty
accidents. For the dismantlement method of spiral cables and airbag modules, please
refer to the part of SRS.
 It is forbidden to test any circuit of the SRS system with electricity testing equipment,
except such operations are illustrated in this manual. The wire harness of SRS circuit is
always identified by the yellow wire harness or wire harness adaptor.
 Vehicle Body & Electric Appliance Volume SB-2

Precautions for Safety Belt Repair

Attention:
• Before dismantling the pre-tensioner assembly of front seat safety belt, you shall turn off
the ignition switch and disconnect the storage battery cable, and then wait at least three
minutes.
• Don’
t check the pre-tensioner of front seat safety belt with electrical test equipment.
• Please check the system function after the replacement or re-dismantlement of
pre-tensioner assembly of front seat safety belt, or connecting again the joint of
pre-tensioner of front seat safety belt. Please refer to the section of Operation Inspection
for Airbag System for detailed description.
• Don’
t use the disintegrated retaining ring or safety belt system.
• If the fixed bolt is deformed or foreworn, please replace it.
• Don’
t lubricate the tongue depressor and snap ring.
• If there is any trouble with the components of safety belt assembly, don’
t repair them.
Just replace the whole safety belt assembly.
• If the safety belt assembly is broken, worn out or damaged, please replace the safety belt
assembly.
• When replacing the safety belt assembly, please use the real assembly of JAC.
After the Collision
Caution:
After the collision, please check the safety belt assemblies of all seats, including the
constrictor and other metal components.
It is suggested by our company that all the used safety belt assemblies in collision shall be
replaced unless there is no damage with the assembly and it can function properly. Or there
will be serious fatal accident in the collision. If the safety belt assembly not used in the
collision is found in any damage or can not function properly, please replace it. In case of the
front collision leading to the denotation of airbag, even if the safety belt is not used, the
pre-tensioner of safety belt shall be replaced.
Please replace the safety belt assembly (including the fixed bolts) in case of the
following situations:
• The safety belt is in use when the collision happens (unless the collision is very slight and
the safety belt, retractor and snap ring are not damaged and of normal function).
• The safety belt is completely damaged. (It is to say the safety belt is broken and the
retractor is bended or the chute slides).
• The fixed points of safety belt are completely damaged in the accident. So before the
dismantlement of new safety belt assembly, please check the fixed area of safety belt to
make sure that it is not damaged or deformed. Make repair as necessary.
• The fixed bolt is deformed or foreworn.
 Vehicle Body & Electric Appliance Volume SB-3

• In case of the collision leading to the denotation of airbag, even if the safety belt is not
used, the pre-tensioner of safety belt shall be replaced.
Dismantlement and Reassembly of Front Seat Safety Belt
Attention:
Before the dismantlement or installation, please make sure that the ignition switch has been
turned off and the cable of storage battery has been disconnected. And then wait at least
three minutes.

1 2

6
3

1. Nut of shoulder fixed sheet 2. Shoulder fixed plate

3. Bolt 4. Safety belt adjuster
5. Safety belt constrictor 6. Outer fixer
 Vehicle Body & Electric Appliance Volume SB-4

Dismantlement and Reassembly of Safety belt Constrictor

Dismantlement Steps:
SB001
1. Slip upward the outer fixer cover.

SB002

2. Dismantle the screws from the upper and lower

trimming device of B-pillar.

(A) Dismantle the screws of the lower trimming device

and then dismantle the device.

SB003
(B) Dismantle the screws from the upper trimming
device and then dismantle the device.

4. Dismantle the fixed nut from the shoulder fixed SB004

plate.
 Vehicle Body & Electric Appliance Volume SB-5

5. Dismantle the fixed bolts from the height adjuster of SB005

safety belt.
6. Disconnect the pre-tensioner joint from the safety
belt.

Attention:
• Insert the screwdriver packed with tape and
prize up the lock to disconnect the pre-tensioner
joint. SB006
• Connect the joint while prizing up the lock and
then press the lock.

7. Dismantle the fixed bolt from the safety belt SB007

constrictor.

8. Dismantle the safety belt assembly.

Installation of Constrictor
 Vehicle Body & Electric Appliance Volume SB-6

Install in the reverse order to the dismantlement.

Dismantlement and Reassembly of Snap Ring

SB008

Dismantlement Steps:
1. Dismantle the front seat from the car.
(A) Unscrew the front screw of front seat.

(B) Unscrew the rear screw from front seat.

SB009

2. Disconnect the wire harness from the snap ring of

safety belt.
SB010

3. Dismantle the fixed screw and then the snap ring of

safety belt.
SB011
 Vehicle Body & Electric Appliance Volume SB-7

Installation of Snap Ring

Install in the reverse order to the dismantlement.

Dismantlement and Reassembly of Rear Seat Safety Belt

Dismantlement Steps for Safety Belt of Rear Seat:

1. Dismantle the rear seat cushion.

Stop block
in rear seat

Cushion
 Vehicle Body & Electric Appliance Volume SB-8

2. Dismantle the rear fixed bolt and inner snap-in.

SB013

3. Dismantle the rear seat backrest.

SB014

4. Dismantle the trimming device of rear coatrack.

SB015
 Vehicle Body & Electric Appliance Volume SB-9

5. Dismantle the trimming devices in rear seat

backrest and C-pillar.
SB016

6. Dismantle the mounting fixed bolt in safety belt SB017

constrictor.

7. Dismantle the safety belt assembly. SB018

Installation
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume SB-10

Check
Check after Accident
After the collision, please check the constrictor, safety belt fixer, fixed block in lower cover
plate, shoulder fixed plate to see if there is any damage or deforming. It is suggested that all
the parts in safety belt shall be replaced in case of the following situations, because the
damages may lead to the fatal injury.
• after the collision
• when the mounting points have been damaged.
• when it can not operate properly.

Check of Safety Belt Constrictor

• Safety belt constrictor is the system used to lock the constrictor to protect the safety belt
from being pulled out while the car is in emergent states, for example, the sudden break.
• There are two ways for the check: static checking and dynamic checking. Check the
constrictor for its common operations according to the steps below.

Static Test
Make sure that the constrictor has been locked and the safety belt can be stopped at once
when it has been pulled outwards quickly.

Dynamic Test
Caution:
• The following tests shall be carried out in a broad and safe place without cars and
obstacles.
• The tests shall be carried out on the dry cement road. Don’
t make the tests on slippery or
unsurfaced road, public road or express highway. (They will cause traffic accident or
body injury.)
• The driver and passenger assume that the constrictor has not been locked and then
make corresponding preparations.
1. Fix the safety belts of the driver and passengers.
2. Drive at the speed of 16 kilometers/hour.
3. Inform the passengers that sudden breaking will come. The driver and passengers must
make preparations to cope with the unlocked constrictor. Then the driver treads the break
pedal completely to stop the car suddenly.
4. When the car has stopped, please make sure if the constrictor has been locked and the
safety belt has been pulled out. If the constrictor is not locked, just check the parts of
constrictor.
 Vehicle Body & Electric Appliance Volume SRS - 1

Precautions
Precautions for Airbag

With the use of Airbag along with safety belt, the danger of being hurt or the degree of
injury could be reduced or at least lessened to protect the driver and passengers when the
cars crashed together.

Warning:
• In order to lessen danger of fatal accident in the collision of car for the inactivation of
SRS, all the maintenance shall be carried out by the authorized store of JAC
franchised for repair.
• SRS could be operated by fault for improper maintenance, including incorrect
dismantlement and assemblage, which may lead to fatal accident.
• SRS can not be tested at its any circuit by electric test appliance except the operation
indicated in this manual.
1. The personnel for installing, dismantling or repairing shall receive the special training.
2. While dismantling the steering wheel, the steering wheel shall be directed rightly to
lock the clock spring assembly in right position. Or the clock spring assembly will be
damaged and the situation will become very dangerous.
3. Don’ t apply the kid-seat orientating backward in front seat.
4. Before the products rightly installed to the car, circuit is not allowed to be conducted by
non-professional personnel to avoid accident.
5. While driving, please fasten the safety belt. Only by the use of airbag along with safety
belt can the best protection be achieved in the accident. It is a wrong presumption that
by the use of airbag, people need not apply safety belt.
6. SDM is matched with the special parameters of airbag subassembly, so they shall be
used in pairs. Don’ t apply SDM or airbag subassembly of other brand to match the
airbag subassembly or ECU of JAC.
 Vehicle Body & Electric Appliance Volume SRS - 2

Precautions for Repair

• SDM is not the component that the end user needs to operate. The private
dismantlement/installation and opening the SDM are not allowed. If there is any
trouble, please refer to the authorized service and have it operated by professional
personnel.
• The replacement of SDM shall be operated by the dealer or the maintenance
merchant authorized by JAC and the trained professional personnel.
• SDM is not allowed to be installed in other cars for replacement. In its whole life cycle,
it shall be applied in the car that it has been originally installed
• When the ignition switch is turned on, the caution light in airbag will be started and
then extinguished after its flashing in the frequency of 1Hz for about 5.5 seconds.
• If the caution light in airbag is not bright with the ignition switch turned on, it illustrates
that there is trouble with the airbag.
• If the caution light in airbag is not extinguished or turned bright while driving, it
illustrates that there is trouble with the airbag and can be judged that the airbag has
not functioned.
• If the airbag expands while colliding, the SDM shall be replaced with the new.
• Before operating the airbag system and SDM,
please turn the key to “off” state and then
break off the storage battery negative pole
and pack the terminal.
• Before operating the airbag system and SDM,
please wait three minutes until the storage
capacity in SDM has been discharged
completely.
• SDM is very sensitive to collision. If the
collision or dropping happens to SDM, it shall
not be applied. SDM shall not be stored at the
temperature of above 90℃, even if for a very
short while.

• Don’t allow the connecting terminal to be

contacted with water or oil. Don’
t touch the
connecting terminal either.
 Vehicle Body & Electric Appliance Volume SRS - 3

• Airbag or pre-tensioner for the driver and passenger is not allowed to be

disassembled.
• If the airbag wire harness is found in damage,
disconnection or rustiness, don’ t repair it with
welding equipment. Replace the troubled wire
harness with the new component.

• Mount the wire harness firmly by special wire

holder to protect the wires from other
components’interference or being winded up with
them.

• If the airbag module, airbag controlling module,

the pre-tensioner or the wire harness is deformed
or damaged, please replace with the new.

• While checking the airbag system, please apply

the digital multimeter. The analogue multimeter
will activate the airbag system accidentally due to
the mini current inside it.
Vehicle Body & Electric Appliance Volume SRS - 4
 Vehicle Body & Electric Appliance Volume SRS - 5

• While checking, please apply the testing wire

harness (1). The damage in connecting
terminal will lead to the trouble. Don’
t touch
any connecting terminal of airbag with
multimeter pole directly.

• Don’ t check the airbag of driver or

passengers, or the pre-tensioner conduction
either.

• While repairing the car, please turn the ignition switch to “off”position. And then
disconnect the earth line in storage battery and wait at least 30 seconds before
working.
• The airbag is equipped with spare power supply. If the airbag is repaired in 30
seconds after the disconnection of earth line, the airbag will be inflated.
SDM shall be tested and removed with the trouble code by the diagnosis apparatus
specified by JAC. If the trouble can not be excluded, the repair personnel can not open the
SDM but return it to JAC for treatment.
 Vehicle Body & Electric Appliance Volume SRS - 6

Storage of Airbag Module

• While storing the dismantled airbag module, please don’t put any material on the
module or stack the airbag modules together. If the cushion pad of airbag is put
downward or under any object, it is possible to result in the serious accident with the
airbag being inflated for some causes.

Airbag Module for Driver

Airbag Module for Passenger

 Vehicle Body & Electric Appliance Volume SRS - 7

Preparations
Special Tool for Repair

Tool (No. and

Diagram Purpose
Name)

Expanding the
Expansion tool
airbag

The wire
Diagnosing
harness detector
detector
for every module

Check the
imitator joint of
every wire
Imitator
harness
resistance
 Vehicle Body & Electric Appliance Volume SRS - 8

Structure Illustration for SRS (Airbag)

SRS is provided as the standard equipment in order to improve the security. The system
will strengthen the security of collision by suppressing the passengers when the system
meets the powerful face collision.

SRS includes the side airbag assembly for driver, the side airbag assembly for passenger,
electrical controlling unit for SRS (SRS-ECU), caution light for airbag, airbag wire harness
and clock spring.

The side airbag assembly for driver is located in the central of the steering wheel with a
fold over airbag and a gas generator inside it.

The side airbag assembly for driver is located in the console, the right ahead of the
passenger.

The controlling unit for airbag (SDM) and its mounting retaining plate are located in the
front floor under the console. This controlling unit (SDM) monitors the airbag system with
the sensor inside it. The SRS caution indicator light in the combined device indicates the
working condition. The clock spring is under the steering wheel and fixed by screws for
steering wheel as integration.

Only the repair personnel approved by training can make repair to the parts of SRS or
those parts around it. Before the repair, the relevant personnel shall read this manual
carefully.
While repairing, please pay attention not to carry out the operation by fault, which will
leads to the explosion and expansion of airbag system by fault and so hurts the repair
personnel or driver.
Vehicle Body & Electric Appliance Volume SRS - 9
 Vehicle Body & Electric Appliance Volume SRS - 10

Position Distribution Diagram for Elements of Airbag System

Computer of Airbag
Position Illustration:
SDM is installed on the centre passage behind SRS001
the heat insulating mattress.

Spiral Cable
Position Illustration:
SRS002
Install it between the steering wheel and
combined switch.

Airbag Module Subassembly for Driver SRS003

Position Illustration
Install it on the steering wheel.

Side Airbag Module Subassembly for SRS004

Passengers
Position Illustration
Install it under the side console for passengers.
 Vehicle Body & Electric Appliance Volume SRS - 11

Pre-tensioner for Safety Belt

Position Illustration: SRS005

Lower position of B-pillar.

 Vehicle Body & Electric Appliance Volume SRS - 12

The airbag will not detonate under the following situations

(1) When the car meets the side collision beyond the angle of ± 30ºin the sidefront,
including the cross collision coming from the dead side and the end collision, the
airbag will not detonate.
(2) When the relative speed in the driving direction for car’
s collision with the stiff material
is less than 13km/h, the airbag will not detonate.
(3) When the rollover happens to the car in longitudinal axial line, the airbag will not
detonate.
(4) When the car travels and breaks regularly, or travels on uneven road, the airbag will
not detonate.
(5) When the car collides with the deformable and movable objects (such as the road
sign board, sand drift, snow drift, ice cake, safety guards on express highway, etc.)
and the collision intensity can hardly reach the condition for the detonation of airbag,
the airbag will not detonate.

Working Principles for Car’

s Airbag
1. In the present of vehicle collision, SDM (computer for airbag) tests the valve value of
the collision and then issues the ignition dictation.
2. Gas generator receives the ignition dictation.
3. Igniter tube ignites and then the supporter combustion is lit up.
4. After the supporter combustion is lit up, the high temperature produced will lead to the
ignition of gas propellant and then a great amount of gas with the high temperature
and pressure.
5. The great amount of gas will flow to the gas bag after the filtering and at last fill up the
gas bag with the forming of the gas blanket between the passengers and the inner
trimming device, which stops the passengers from colliding with the inner trimming
device and protect the passengers.
 Vehicle Body & Electric Appliance Volume SRS - 13

Working Process of Airbag:

1. The moment of collision

2. The detonation of airbag

3. Gas bag filled up

4. Protection from the safety belt and airbag

 Vehicle Body & Electric Appliance Volume SRS - 14

Control Principle Diagram of Airbag

Main airbag Assistant airbag

assembly assembly

Spiral
coil

Airbag controlling module SDM

Collision
signal

Indicator light for Side safety belt Side safety belt

the caution of tensioner for driver tensioner for
airbag Side mortise lock second driver
switch for driver

Illustration of SDM Pin

 Vehicle Body & Electric Appliance Volume SRS - 15

NO. Illustration NO. Illustration

1 Empty pin 2 Empty pin
3 Empty pin 4 Empty pin
5 Power supply of storage battery 6 Earthing
7 Work indicator light 8 Empty pin
9 Data wire for diagnosis seat 10 “+”short-circuit plate in the front
driver seat
11 “-” short-circuit plate in the front 12 Switch for the safety belt buckle of
driver seat driver
13 “+”short-circuit plate in the switch 14 BPD “-” short-circuit plate in the
of BPT driver switch of BPT driver
15 Flash code switch 16 BPT Pass “-”short-circuit plate of
switch
17 BPT Pass “+”short-circuit plate of 18 Pass “+” short-circuit plate of
switch switch in driver airbag
19 Pass “-”short-circuit plate of switch 20 Empty pin
in driver’
s airbag
21 Empty pin 22 ACS
23 Indicator light for closing in the side 26-29 Short-circuit plate
airbag of passengers
30 Empty pin 31-32 Short-circuit plate
33 34 Outlet of collision
35-36 Short-circuit plate 37 Switch for the side safety belt
buckle of passengers
38-39 Short-circuit plate 40 earth controlling of ACS
41-44 Short-circuit plate 45-50 Empty pin

Introduction for Elements of Airbag System

Control Computer for Airbag (SDM)
 Vehicle Body & Electric Appliance Volume SRS - 16

Working Principle of SDM

There is acceleration sensor of micro machine type inside SDM. It can sense the
deceleration while collision happens to the car and make the judgment that if there is the
need of detonating the airbag and pre-tensioner safety belt.

Spiral Cable
Overview
The clock spring assembly is fixed by three screws
in the steering wheel of the steering column. The
clock spring includes a flat round plastic casing.
There is a forming plastic rotor like a winding shaft
with a wheel hub in the plastic casing. There is a
big centre hole on the surface of rotor wheel hub.
The inside of plastic casing and surrounding of
winding shaft is winded up with a long band, which
is made up by several slim copper wires folded by
two layers of plastic film. The outer terminal of the
long band is linked to the connector’
s terminal,
which is aligned with the self associated connector
faced with the console. And the inner terminal is
linked to the flexible circuit conductor and the plug
board of connector, which is in the rotor wheel hob
of clock spring that faces the steering wheel.
 Vehicle Body & Electric Appliance Volume SRS - 17

Working Principle
The clock spring is a mechanical circuit component, which is applied for the continual
conduction in the fixed console wire harness and the electrical components mounted on or
inside the revolving steering wheel. As to this model of car, the rotating electrical
components include:
Side Airbag for Driver
Switch of Horn
The connector terminal fixed in the rear section of fixed clock spring box connects the
clock spring to the electric system of the car by the self associated connector in the
console wire harness. The clock spring rotor can rotate and is connected to the steering
column shaft which is cast in the rotor wheel hub. The steering signal on the lower surface
of rotor hub in clock spring cancels the bump in the cam and along with the revolving
signal in the multi-function switch cancels the contact with performer, and so the canceling
instruction for self steering signal occurs.
The two short flexible circuit conductor with yellow jacketing on the surface of rotor wheel
hub in the clock spring connects the clock spring to the side airbag for multilevel driver.
One wire harness in steering wheel connects the two plug boards of connector on the
upper surface of clock spring to the plug board of flexible circuit conductor for current
supply in the horn switch. If the car is equipped with steering wheel switch, the wire
harness will connect the switch to the steering wheel. Like the spring of real clock, the
stroke of clock spring rewinding is limited, which will be damaged for the tightly rolling up
when the steering wheel revolves in the two limit positions. In order to avoid the situation,
when mounting the clock spring to the steering column, please align it with the centre. And
then the centered clock spring will lead its rewinding to be assembled in the movable
steering components. So the rewinding can function in the designed operation range. But
if the clock spring is dismantled from the steering column or the steering shaft and
steering gear are disconnected, the clock spring rewinding may change the relative
position between the movable steering components. After the repair, the clock spring shall
be aligned with the centre again, or the rewinding will be damaged.
The clock spring can not be repaired. If there is any trouble, damage with the clock spring,
or the side airbag for driver has inflated, the clock spring shall be replaced with the new.
Vehicle Body & Electric Appliance Volume SRS - 18
 Vehicle Body & Electric Appliance Volume SRS - 19

Safety Belt Tensioner

Overview
The safety belt tensioner of seat, coupled with the double front airbags, can promote the
security. The safety belt tensioner of seat is integrated with the safety belt retractor of front
seats, which is fixed in the inner side of the B-pillar that is installed in the two sides of car.
And the retractor is hidden under the lower B-pillar trimming device.
The safety belt tensioner of seat mainly includes a sprocket wheel/pinion, a steel pipe, a
cast metal casing, many steel balls, a metal ball loop in punch forming, a twisting rod, a
little gas generator agitated by pyrotechnic and a short flexible circuit conductor. All the
components are positioned in one side of winding shaft that in the outside of the retractor
casing but except the twisting rod, which performs as mandrel with the retractor put on it.
The safety belt tensioner of seat is controlled by the controller in the protective equipment
for passenger and connected with the car’ s electric system by the body wire harness. The
safety belt tensioner of seat can not be repaired. If there is any trouble or damage, the
whole safety belt and retractor device of front seats shall be replaced. If the front airbag
has been inflated, the seat’ s safety belt tensioner shall have been inflated. After the
inflation of front airbag, the safety belt tensioner of seat can not be used again and shall
be replaced. While trying to operate the seat’ s safety belt retractor, if the noise of rumbling
or friction occurs, it illustrates that the safety belt tensioner of seat has been inflated and
needs to be replaced.

Working Principle
The controller of the protective equipment for passenger sends out the inflating signal to
the safety belt tensioner of seat by the circuit 1 of safety belt tensioner in the driver or
passenger and the sparking gear, so as to have the safety belt tensioner of seat inflated
with the front airbag in the same time. When the controller in the protective equipment for
passenger is sending out the correct signals to tensioner, the electric energy can produce
enough amount of heat to agitate the little pyrotechnic gas generator. The gas generator is
installed in one end of the steel pipe with many steel balls in it. When the gas inflates, the
inflation pushes the steel balls into the cast metal housing through the steel pipe. In the
metal housing, the director guides the steel balls to be engaged with the sprocket wheel,
which is connected with one end of the winding shaft of retractor. When the steel balls
pushes the sprocket wheel, it revolves and pushes the winding shaft of retractor in seat’ s
safety belt to revolve, so as to keep the seat’s safety belt away from loosing state. When
the steel ball leaves the sprocket wheel and is pushed out of the casing, the ball loop can
catch the steel ball. When the safety belt of front seat is not too loose, there are many
benefits, for example, while the collision happens to the front section of car and the airbag
has been inflated, the passengers can be constrained in the correct position; lessen the
injury for passenger’ s contact of steering wheel, steering column, console and or
windshield when the collision happens. The torsion strip in the safety belt tensioner of seat
provided with retractor winding shaft is designed as deformable in order to control the
force imposed by the seat safety belt for the front collision to lessen further the potential
injury to passengers. The controller in the protective equipment for passenger monitors
the situation of safety belt tensioner of seat by circuitous resistance and lightens the
indicating unit of airbag in the combined device. The detected trouble shall be stored with
 Vehicle Body & Electric Appliance Volume SRS - 20

a trouble code (DTC). If want to diagnose the safety belt tensioner of seat correctly, please
apply the diagnostic apparatus for trouble and the relevant diagnostic information of the
car body.
 Vehicle Body & Electric Appliance Volume SRS - 21

Diagnosis for Airbag System

Trouble Diagnosis
After the ignition switch is turned on and the indicator light extinguishes after flashing 6
times, the airbag is in normal working state. If the ignition switch has been turned on but
the indicator light does not extinguish or the
airbag’
s indicator light is still on, it illustrates that
there is trouble with the airbag system.

1. Ignition switch turned on.

2. Connect the diagnosis seat with the diagnosis

apparatus.
Choose the series of car

Special for the JAC vehicles

3. Choose the series of car.

Upside page Downside page

Backstep Help

Begin

Choice of systems
4. Choice of the car model. JAC Nice Wind
Nice Eagle

Upside page Downside page

First page in
Backstep Print Help
diagnosis

Begin
 Vehicle Body & Electric Appliance Volume SRS - 22

5. Choice of systems.
Choice of systems
Engine system
Anti-lock braking system
Safety airbag system
Delve anti-burglary system

Upside page Downside page

First page in Help

diagnosis Backstep Print

Begin

6. Enter the diagnosis function and read the Diagnosis function

trouble code. Read the trouble code
Clean out the trouble code
Read the data stream
Read the information of edition

Upside page Downside page

First page in Help

diagnosis Backstep Print

Begin
 Vehicle Body & Electric Appliance Volume SRS - 23

Clean out the Trouble Code

After the exclusion of trouble, clean out the trouble codes stored in the system with the
original apparatus in factory.
1. Turn on the ignition switch.
2. Connect the diagnosis bed with diagnosis apparatus.
3. Choose the series of car, car model, systems and the diagnosis function for the clean
out the trouble codes.
The trouble codes are listed as follows:
Diagnosis Diagnosis
Code Meaning Code Meaning
Code Code
Too strong resistance in driver’ s safety belt Too weak resistance in driver’ s safety
B1015 B1016
tensioner belt tensioner
Short-circuit to ground wire in driver’s safety belt Short-circuit to battery in driver’s safety
B1018 B1019
tensioner belt tensioner
Too weak resistance in driver’ s front
B1021 Too strong resistance in driver’
s front airbag B1022
airbag
Short-circuit to ground wire in driver’ s front Short-circuit to battery jar in driver’s
B1024 B1025
airbag front airbag
B1031 Too strong electric pressure in battery jar B1032 Too weak electric pressure in battery jar
Too strong resistance in passenger’ s front Too weak resistance in passenger’ s
B1041 B1042
airbag front airbag
Short-circuit to ground wire in passenger’ s front Short-circuit to battery in passenger’ s
B1043 B1044
airbag front airbag
Too strong resistance in passenger’ s safety belt Too weak resistance in passenger’ s
B1045 B1046
tensioner safety belt tensioner
Short-circuit to ground wire in passenger’ s Short-circuit to battery in passenger’ s
B1047 B1048
safety belt tensioner safety belt tensioner
B1051 Recorded collision in the front B1054 Beyond the largest number for reuse
B1056 Recorded collision in driver’ s side B1057 Recorded collision in passenger’ s side
B1058 Triggered safety belt tensioner B1061 Trouble in caution light
Short-circuit to ground wire in driver’ s
B1062 Trouble in airbag’
s indicator light B1063
side collision sensor
Short- or open circuit to power supply in driver’s Short-circuit to ground wire in
B1064 B1065
side collision sensor passenger’ s side collision sensor (SIS)
Short- circuit to power supply in passenger’ s Internal trouble (replace the self
B1066 B1071
side collision sensor (SIS) or circuit in damage diagnosis module for airbag)
Trouble of communication in driver’ s
B1072 Trouble in driver’
s side collision sensor (SIS) B1073
side collision sensor
Trouble in passenger’
s side collision sensor Trouble of communication in
B1074 B1075
(SIS) passenger’ s side collision sensor (SIS)
Wrong ID in passenger’ s side collision
B1076 Wrong ID in driver’
s side collision sensor (SIS) B1077
sensor (SIS)
Too weak resistance in driver’ s front
B1081 Too strong resistance in driver’
s front side airbag B1082
side airbag
Short-circuit to ground wire in driver’s front side Short-circuit to battery in driver’s front
B1083 B1084
airbag side airbag
Stronger resistance in passenger’ s front side Too weak resistance in passenger’ s
B1085 B1086
airbag front side airbag
Short-circuit to ground wire in passenger’ s front Short-circuit to battery in passenger’ s
B1087 B1088
side airbag front side airbag
Short-circuit to ground wire in cut-off switch of Short-circuit to power supply in cut-off
B10C1 B10C2
airbag switch of airbag
Trouble of stability in cut-off switch of
B10C3 Trouble in cut-off switch of airbag B10C4
airbag

● If the diagnosis apparatus for trouble displays that it can not communicate with SRS
system, there may be the following possible reasons:
● Trouble in diagnosis circuit wire and connector;
● Trouble in SDM.
 Vehicle Body & Electric Appliance Volume SRS - 24

Repair Steps for Airbag

When the airbag expands in collision:
1. The following parts shall be replaced:
 SRS-ECU
 Side airbag module for driver
 Side airbag module for passengers
 Clock spring
2. Check the following parts. Please replace them if there is any trouble.
 Steering wheel body, steering column and middle joint.
1) Check the wire of electric appliance and connector inside the steering wheel for its
damage, the terminal for its deforming.
2) Install the airbag module and check its matching with steering wheel to make sure
that they have been aligned.
3) Check the steering wheel for the noise and flexible operation and to see if the free
clearance is too large.
 Side airbag switch for passengers.
3. Check if the wire is locked, the connector for its damage or poor connection and the
terminal for its deforming.

While the car is in collision accident of low speed, side collision, side turn-over and
end collision with the airbag not expanded:
SRS-ECU
1. Check the SES-ECU casing and mounting support for its cave, crack or deforming.
2. Check the connector for its damage and the terminal for its deforming.
3. Check the mounting bolt and ground wire for its damage.
 Vehicle Body & Electric Appliance Volume SRS - 25

Maintenance and Check for the Airbag System

Airbag Module
1. Check the liner cover for its cave, crack and deforming.
2. Check the connector for its damage, the terminal for deforming and wire for lock.
3. Check the gas generator casing of airbag for its cave, crack or deforming.
4. Install the airbag subassembly to steering wheel and check their matching and
aligning.
Clock Spring
1. Check the connector of clock spring and protecting sleeve for their damage and the
terminal for deforming.
2. Check the casing with eyes for its damage.
Steering Wheel, Steering Column and Middle Joint
1. Check the wire of electric appliance (installed inside the steering wheel) and the
connector for their damage and the terminal for deforming.
2. Install the airbag subassembly and check its matching and aligning with the steering
wheel.
3. Check the steering wheel for the noise and operation and to see if the free clearance
is too large.
Attention: Align the clock spring in the bottom of steering wheel with the centre at
first and then install the steering wheel to the steering column.
Method for Clock Spring’ s Aligning with the Centre:
Revolve the protecting sleeve of clock spring to the stopping position and then revolve it
back by 2.5 circles to have the protective sleeve aligned with the mounting groove in the
lower cover of steering column.
Wire Connector (Electric Appliance Wire in Car Body)
Check the wire for its sticking, the connector for damage or in poor connection and the
terminal for deforming.
■ Repair of Separate Part
Replace the airbag components in trouble except the ECU, whose trouble can be
eliminated by the diagnosis apparatus and don’ t apply them by repairing.
For the cause of maintenance and trouble exclusion, if the parts of SRS need to be
dismantled or replaced, please abide by the relevant operation orders.
Warning/Attention Brand Mark
There are many caution/attention brand mark about SRS in the car.
 on the magnesium alloy framework of steering wheel;
 on the airbag subassembly of the driver;
 on the clock spring;
 airbag subassembly in second driver;
 on the SRS-ECU;
 on the sun visor over the front windshield.
Abide by the specifications on the index tags while repairing the SRS and replace them for
the dirt or damage.
Airbag Controller (SDM)
Attention:
◎ Replace the SDM in trouble. Don’ t repair them.
 Vehicle Body & Electric Appliance Volume SRS - 26

Treatment for the Obsolescence of Airbag Module

Apply the following treatments for the expansion of airbag before the obsolescence of it or
of the car installed with it.
Treatment for the Airbag Subassembly not in Expansion
1) Have the airbag expand inside or outside the car in consideration of the continuous
use of it, inside for its obsolescence and outside for airbag’ s obsolescence.
2) Be careful not to inhale the smoke for airbag’ s expansion, because it will stimulate the
throat and so lead to suffocation. Avoid the residence area as possible.
3) Avoid the residence area for the loud noise of airbag’ s expansion and warn the
approaching people of the coming noise.
4) Trigger only one airbag module each time.
5) Stand in the area away from the detonating component for at least 10m when
detonating the airbag module and airbag pre-tensioner.
6) Lay the airbag module aside for at least 30 minutes for the high heat after the
detonation.
7) The personnel for execution or onsite shall wear the suitable protective articles for ear
Treatment for the Internal Expansion (for Car’ s Obsolescence)
1) Remove the car to separated area.
2) Disengage the () electrode wire and () electrode wire from the storage battery
terminal and then dismount it from the car.
Attention:
◎ Wait at least three minutes for the next operation after the disconnection from
the storage battery wire.
3) Have the airbag module expand (aside the driver):
ａ. Dismount the steering lower cover.
ｂ. Disconnect the linking between the clock spring’ s feet leading connector and the
connector of airbag wire harness for car body.
Attention:
◎ The electrode of clock spring connector will be in short-circuit automatically after its
disconnection from the airbag wire harness of car body to avoid the accidental
expansion of airbag for electrostatic effect.
4) Connect two wires above 10m to the two conducting wires in the adapter wire of SRS
airbag and pack the connecting points with insulating cement. The other ends of the
two wires shall be linked together (in short-circuit) to avoid the accidental expansion of
airbag.
5) Connect the feet leading connector of airbag to its SRS adapter wire and extend the
wire for expansion to the outside of car.
6) Close all the doors and windows to control the expansion noise and apply cover on
the car.
Attention:
◎ The window glass will be broken during the expansion if there is any trace of damage in
the glass, so the car shall be applied with a cover.
7) Disconnect the two linked wires in the area away from the car as far as possible and
connect them to the two terminals of storage battery (dismounted from the car) to
have the airbag expanding.
Attention:
◎ Check if there is any person inside the car or in the nearby area before expanding the
airbag by this method and wear the safe-guard glasses.
◎ Wait at least 30 minutes after the expansion until the inflator has cooled down and
then remove it. The gas produced during the expansion of airbag is innoxious but can
not be inhaled in. As to the transportation rules after the expansion of airbag, please
refer to the method for the obsolescence of airbag subassembly in expansion.
◎ Don’ t approach the airbag subassembly if it fails in expansion while operating as the
above method. Contact the local dealer.
8) Discard the airbag subassembly in the relevant method for the well done expansion of
airbag subassembly after its expansion or operation.
Vehicle Body & Electric Appliance Volume SRS - 27
 Vehicle Body & Electric Appliance Volume SRS - 28

Treatment for the Expansion outside the Car

1. Operate the expansion on the spacious ground away from the obstacle and other
people for at least 10m.
2. Don’ t operate the expansion when it is winding severely outside. Even if it is breezing,
have the airbag expand under the lee of storage battery.
1) Disconnect the () electrode wire and () electrode wire from the storage battery
terminal and then dismount it from the car.
Attention:
◎ Wait at least three minutes for the next operation after the disconnection from
the storage battery wire.
2) Dismount the airbag from the car.
Attention:
◎ The airbag subassembly shall be laid aside on even surface with the liner cover
facing upward. No materials on its top surface.
3) When the airbag module aside the driver is in the need of expansion:
Connect two wires above 10m to the two conducting wires in the adapter wire of
airbag and pack the connecting points with insulating cement. The other ends of the
two wires shall be linked together (in short-circuit) to avoid the accidental expansion
of airbag.
4) Set up the airbag as follows:
Hold on the adapter wires of SRS airbag in the above mentioned wires and then
cross them over the upper side of the prepared old wheel tyre assembly to: a.
Connect them to the airbag module.
b. Cross the rough wire over the mounting hole in airbag and then fasten the relevant
subassembly to the old tyre with its liner facing upward.
Attention:
Leave some space for the adapter wire under the tyre. For the lack of such space, the
counteracting force due to the airbag’ s expansion will damage the adapter wire.
c. Pile up the three old tyres without wheel hub to the top of tyre in fixed airbag
subassembly.
d. Disconnect the linked two wires in the masking area away from the airbag module as
far as possible and connect them to the two terminals of storage battery (dismounted
from the car) to have the airbag expanding.
Attention
1) Check the nearby area to make sure there is nobody before the expansion.
2) Wait at least 30 minutes after the expansion until the gas generator has cooled down
and then remove it. The gas produced during the expansion of airbag is innoxious but
can not be inhaled in. As to the transportation rules after the expansion of airbag,
please refer to the method for the obsolescence of airbag subassembly in expansion.
3) Don’ t approach the airbag subassembly if it fails in expansion while operating as the
above mentioned method. Contact the local distribution store.
d. Obsolesce the airbag subassembly in the relevant method for the airbag
subassembly in expansion after the expansion or operation.
Obsolescence Method for the Airbag Subassembly in Expansion
Discard the airbag subassembly by the local laws and/or rules in compulsory execution
after its expansion just like the obsolescence of other parts. And pay attention to the
following points:
1) Wait at least 30 minutes after the expansion until the gas generator has cooled down
and then remove it.
2) Don’ t splash the water or oil on the airbag in expansion.
3) The materials making the stimulation to eyes and skin may stick to the airbag in
expansion. So please wear the protective gloves and safe-guard glasses while
removing the airbag subassembly in expansion.
Attention:
For the substance inside the eyes or attached on skin even if after the conformance
to these precautions, please wash these places and seek to medical treatment for
the inflammation in the skin.
 Vehicle Body & Electric Appliance Volume SRS - 29

4) Seal firmly the heave-duty polyvinyl chloride pocket filled with obsolesced airbag
subassembly.
5) Wash hands after these operations.
Dismantlement and Reassembly of Airbag System
SDM Precautions for SDM Installment
Install SDM onto the central passage behind the heat insulating mattress (i.e. the
front-lower of the gear lever).

The arrow on SDM label

indicates the advancing direction
of the car.

1. There are three installation holes.

2. Bolts of Φ6mm are used for fastening SDM.
3. The torque of SDM mounting bolts is 8N.m.
Dismantlement Steps:

1. Turn the key to “off” state, disconnect the

negative electrode of storage battery, wrap the SRS006
terminal, and wait for three minutes till the
energy-storage capacitor inside SDM
discharges.

2. Dismount the extended trimming plates at the

two sides of lower central control board.
SRS007
 Vehicle Body & Electric Appliance Volume SRS - 30

3. Unscrew and pull out the joints of SDM wire

harness, twist the three fastening bolts of SRS008
SDM, and take out SDM. (Attention: Keep
SDM from dropping or knocking.)

Installation Steps:
1. Plug and lock the wire harness of SDM, fasten SDM onto the central passage with
three bolts.
2. Install the extended trimming plates at the two sides of central control board and
screw down the related nuts.
3. Connect the power supply of storage battery, and test the state of SDM.
(Attention: Keep SDM from dropping or knocking.)
 Vehicle Body & Electric Appliance Volume SRS - 31

Dismantlement and Installation of Driver’

s Side Airbag
Structural Diagram of Driver’
s Side Airbag

1 2 3 4

6 7
5

No. Illustration No. Illustration

1 Driver 2 Air pocket assembly
3 Casing assembly 4 Nut
5 Cap 6 Retaining ring assembly
7 Generator assembly

Remarks: The side airbags and pre-tensioners of driver and passenger cannot be
dismantled.

Dismantlement Steps:

1. Disconnect the negative terminal of the storage battery for at least three minutes.

SRS009
 Vehicle Body & Electric Appliance Volume SRS - 32

2. Dismount the upper and lower protecting

SRS010
covers of steering column (just dismount the
fixed bolts to separate the upper and lower
parts).

SRS011
3. Turn by 90 degrees, and pry out the thimble
inside with an open knife.

SRS012

4. Take out the airbag module subassembly.

Installation:
Install in the reverse order to the dismantlement.
 Vehicle Body & Electric Appliance Volume SRS - 33

Spiral Cable

Dismantlement Steps:
1. Disconnect the negative terminal of the
SRS013
storage battery for at least three minutes.

2. Dismount the airbag module subassembly. SRS014

Turn by 90 degree, and pry out the thimble
inside with an open knife.

3. Dismount the fixed nuts in steering wheel. SRS015

4. Disconnect the wire harness joint of horn and

spiral cable.
SRS016
 Vehicle Body & Electric Appliance Volume SRS - 34

SRS017
5. Dismount the three fixed screws of spiral cable.

6. Take out the spiral cable. SRS018

Installation:
Install in the reverse order to the dismantlement.
Attention:
① Make sure the front wheels are in forward direction before installing spiral cable.
② Twist clockwise to end, and twist inversely by 2.5 circles at least and align it with the
triangle mark.
 Vehicle Body & Electric Appliance Volume SRS - 35

Passenger’s Side Airbag Assembly

Dismantlement Steps:
1. Disconnect the negative terminal of the SRS019
storage battery for three minutes.

2. Dismantle console assembly (refer to the

SRS020
dismantlement of inner and outer console for
its dismantlement steps).

3. Carry out the apparatus, and dismount the SRS021

fixed bolts in the airbag module subassembly.

4. Disconnect the wire harness joint, and take out the airbag module subassembly.

Installation:
Install in the reverse order to the dismantlement.
Fasten the airbag module subassembly.
Fastening torque: 9 ±2N.m
 Vehicle Body & Electric Appliance Volume SRS - 36

Disassembly Diagram of Safety Belt Pre-tensioner

 Vehicle Body & Electric Appliance Volume ATC-1

Precautions for Air Conditioning System

Precautions for Refrigerant:

1. Because of the low freezing point and strong

volatilization of refrigerant, do use gloves and
glasses to avoid chilblain and ablepsia
caused by the skin contact.

(Attention) If the refrigerant is sprayed into eyes

or onto skin,
☞ Rinse the contact parts with clean water, and
receive the ophthalmological and
dermatological diagnoses.
☞ Don’
t rub eyes with hands or handkerchief.

2. When handling the refrigerant, keep the

working site ventilated. Though refrigerant is
harmless, discharge with large quantity in a
closed space will induce anoxia.

☞ Permitted amount of discharge: 1,000ppm

(4,184mg/m2) Excessive discharge will
induce the disorder and irritability of the heart
and cardiovascular system and the immune
system, and the disorder of the respiratory
system, or induce skin diseases.
3. For handling refrigerant, keep such impurities
as moisture and dust away, for if they flow
into the air conditioning system, damage will
be caused to the system. So take care in
operation.
4. A gas leakage meter must be available. The
contact of R-134a refrigerant with sparkles
from the perceptron may generate harmful
gas. So take care in operation.
5. The type of refrigerant must be R-134a and other types of refrigerant will produce bad
effect on the components of the system.
6. The R-134a refrigerant can’
t be compatible with the R-12 refrigerant, so they can’
t be
 Vehicle Body & Electric Appliance Volume ATC-2

mixed even if a minute quantity is adopted.

7. For handling refrigerant, keep the pyrophorus
or ignitable objects away. Besides, the
refrigerant fluid exposed near heat reservoir
may easily lead to explosion. So take care in
operation.
As the R134a container is under the
high-pressure condition, it cannot be placed in
the environment with high temperature.
Besides, check if the environment temperature
for storage is under 52℃.
Precautions for Dismantling Air Conditioner:
1. Dust guard is used to prevent the dirty water,
dust, moisture from entering the air
conditioning components. Remove the dust
guard before operation, and seal it after Moisture
operation.
☞ PAG refrigeration oil for R-134a can absorb Dust
moisture more easily than that for R-12, and its
ratio of absorption is 10 times higher than that of
MINERAL refrigeration oil. Excessive moisture
Plug
will affect the compressor, lubrication and
durability.
☞Moisture has terribly bad effect on the air
conditioner, and hence it’ s better to avoid
operating in rainy days.
2. In reinstalling the air conditioning system after disassembly, always smear the
refrigeration oil on the O-ring; especially as to the screw-shaped connecting part,
connect it manually first, and then assemble it with 2 spanners. In assembling the
flange connecting parts, connect the nut and bolt while pushing slightly the pipeline.
3. During installation of the air conditioner, Bolt Locating Pin

assembling it with the torque above the

specifications or gripping with the O-ring above
the specifications may lead to the phenomenon Positive Connecting Negative
of refrigerant leakage, so always operate with Piece Nut Connecting Piece

specified torque.
Items kg·m
Installation bolt of compressor 2.04~3.06 Push
Installation bolt of expansion valve 0.8~1.2
Installation nut of expansion valve 1.0~1.5
Connecting nut of compressor and refrigerant
0.5~0.7
pipe
Connecting nut of induction pipe and hydraulic
0.5~0.7
pipe
4. Avoid twist of hoses.
5. Never separate the air conditioning system before reclaiming the refrigerant
completely.
☞ If separation is operated before reclamation, the refrigerant and refrigeration oil will be
 Vehicle Body & Electric Appliance Volume ATC-3

released under the effect of the system pressure, which will pollute the surroundings.
6.When replacing the air conditioning components, fill the refrigeration oil (Mode: FD46×G)
during filling refrigerant.
Filling refrigeration oil (no components to be replaced) 30 cc
Replacing compressor 170 cc
Replacing condenser 30 cc
Replacing drying bottle 30 cc
Replacing evaporator 50 cc
Replacing pipeline 30 cc
 Vehicle Body & Electric Appliance Volume ATC-4

Preparations
Special Tools

Table 1
Name of Tool Picture of Tool Name of Tool Picture of Tool
Digital universal High-intensity
meter invisible-light
lamp

R-134A manifold
Disconnection measuring
pliers device

Halogen leakage Tracing color

locator injector

R134A tracer Micro-

paint thermometer

Forward mobile Shaft seal

controlling valve protecting
device

50-pound- Pressure test

rechargeable adaptor
reclamation tank
 Vehicle Body & Electric Appliance Volume ATC-5

Table 2
Name of
Name of Tool Picture of Tool Picture of Tool
Tool
Lip-shaped Dismantling
seal tool of O
dismantling seal ring
tool of air
conditioning
system

Dismantling Installing
and installing tool of O
tool of valve seal ring
core

Spring tongs Spring

tongs

Reclaiming Passive
\reconditioning, test lamp
refilling system
of refrigerant
 Vehicle Body & Electric Appliance Volume ATC-6

Check of Air Conditioner and Filling of Refrigerant

Installation of Refrigerant Filling Device
1. Close the manual valves at the two ends of
Low
the refrigerant filling device. High
2. Fix the filling pipe of the refrigerant filling device
Close
at the connecting position. Screw down the nut
Close
after the low-pressure pipe is connected at the
low-pressure pipe orifice, and the
Vacuum pump or
high-pressure pipe at the high-pressure pipe refrigerant tank
orifice.
Refrigerant Discharge Operation
1. Connect the refrigerant filling device to the Low
High
system.
2. Place burlap on the open position of the central
hose. Close
Open
3. Open the high-pressure manual valve step
by step to discharge refrigerant.
Attention:
With a too fast discharge speed, the
refrigeration oil of the compressor will be
drained from the system. Low High
4. Check if there is any trace of the refrigeration
oil on the burlap; if there is, slightly close the
manual valve.
5. When the measuring meter of the filling Open Open
2
device lowers to 3.5kg/cm , slowly unlock the
low-pressure manual valve. Air

6. Unlock the high-pressure and low-pressure

Vacuum pump
manual valves slowly until the measuring
meter indicates 0kg/cm2 so as to lower the
Low High
system pressure.
Vacuum-Pumping of Refrigeration
System
Reference:
Close Close
Conduct vacuum pumping when the system
discharges refrigerant to remove the air and Air
moisture flowing into the system, and it will
Vacuum pump
last for 15 minutes after all components are
fixed. As to the open components in repair, it
needs 30 minutes.
1. Check if the engine is in the “OFF”position.
2. Connect the filling device to the adaptor part of the compressor, and then shut down the
two ends.
 Vehicle Body & Electric Appliance Volume ATC-7

3. Check if refrigerant is discharged from the system.

4. Connect the central pipeline to the suction part of the vacuum pump.
5. Open the high-pressure and low-pressure valves of the filling device after conducting
the vacuum pumping.
6. If the measuring scale of the low-pressure tester is above 0.96kg/cm2 vacuum after
10 minutes, and it is not caused by the leakage of the negative pressure system,
perform repair according to the following steps: Fill the system with the refrigerant
container; check phenomena with earth detector, and then repair; discharge
refrigerant and conduct vacuum pumping; continue the operation until the
phenomena are found.
7. Restart to conduct vacuum pumping.
8. Keep the filling device at both ends with the
vacuum of 0.96kg/cm2 as read from the Handle
Connecting
measuring scale. piece
9. Continue carrying out vacuum pumping until
the measuring scale indicates 0.96kg/cm2.
10. After conducting 15 minutes’ vacuum Disk

pumping, close the pressure valve of the

filling device, stop the vacuum pump, and
finally separate the pipelines from the
vacuum pump, through which the refrigerant
can be filled.
Usage of Refrigerant Controlling Valve
1. Before connecting the valve to the refrigerant container, fully rotate the handle
anticlockwise.
2. Place the disk to the highest position anticlockwise.
3. After installing the center pipeline on the valve device, rotate the disk clockwise.
4. Rotate the handle clockwise and bore a hole on the upper sealed part.
5. Unscrew the nut connecting the pipeline at the connecting point of the filling device
center.
6. Screw down the nut several seconds after discharge.
Filling of Refrigerant –Gaseous Condition
Low High
Reference:
This operation is to fill the gas refrigerant into
the system through the low-pressure side
device. Place the refrigerant container straight Open Close
for the gaseous refrigerant to flow into the
system.
Refrigeran

1. Install the refrigerant container to the adjusting

valve.
2. Open the low-pressure valve, and adjust the
valve to keep the low-pressure measuring scale
under 4.2kg/ cm2. Low High
3. Soak the refrigerant container in the warm water
(about 40℃) to make the pressure of the

Open Close
Refrigeran
 Vehicle Body & Electric Appliance Volume ATC-8

container higher than that of the system.

4. Make the engine run at a high speed and open
the air conditioner.
Reference:
Place the container straight to avoid the gaseous refrigerant into the compressor
from the inlet port.
5. Close the low-pressure valve after filling the specified quantity.
The specified filling quantity … … … … … … 700±20g
6. If the speed of filling refrigerant is too slow, the container can be placed into the water
container of about 40℃.
 Vehicle Body & Electric Appliance Volume ATC-9

Attention:
1. Under no circumstances can water be
heated above 52℃.
2. Keep the furnace lamp away the
container.

Time for immersing it in

Refrigeran
Filling of Refrigerant –Liquid State the water and heating it to
be 40℃.
Reference:
This operation is employed in filling at
high-pressure side. Upend the refrigerant
container, and the refrigerant may flow into the
system.

1. After conducting vacuum pumping of the

system, close the two ends of the high and
High
low pressure valves fully. Low

2. Install the adjusting valve of the refrigerant

container.
Refrigeran
Open Close
3. After fully opening the high-pressure valve,
upend the container.
4. Overfilling of the system may increase the
discharging pressure, so fill the system with
the proper container and close the
high-pressure valve while measuring the
weight of the refrigerant.

Specified Filling Quantity… … … … … … 700±20g

5. After filling of the specified refrigerant, close

Refrigeran

the filling device valve.

6. Apply the earth detector to check if there is
any leakage.

Attention:
1. Don't start the engine when the filling at
high-pressure side is employed.
2. Never open the low-pressure valve when
the liquid refrigerant is filled.
Reference:
Always conduct the performance testing before separating the filling detector.
 Vehicle Body & Electric Appliance Volume ATC-10

Control of Air conditioning System

Refrigeration System
Introduction to Performance of Air conditioning System
By employing the steam compression refrigerating circulation (shown in Fig. 1), the air
conditioning system of the vehicle consists of four following elements as compressor,
condenser, expansion valve and evaporator, and the refrigerating effect is achieved
through refrigerant circulation between the gas phase and the liquid phase. As far as the
way to control temperatures is concerned, this vehicle is designed to be the air-mixed auto
temperature-controlling air conditioning system (as shown in fig. 2). The refrigerator is fully
integrated with the heater, and they share the same temperature-controlling system and
can work simultaneously. Through setting between the evaporator and the heater, the
mixed air duct door which can change angels continuously, and assisted with sensor,
electric control unit and performer, the system may allow the air exhausted from the
evaporator to pass fully or in part the heater as necessary, and hence achieve the
full-season air conditioning of heating, air changing, refrigerating, dehumidifying, as well
as the auto temperature-controlling function.
Principle of Control
High temperature/pressure Low temperature/pressure
gas liquid

High temperature/pressure Low temperature/pressure

liquid gas

Condenser Evaporator
It is installed on the When transferring the pulverized
front of vehicle. refrigerant to gaseous
Transfer the gaseous refrigerant, absorb heat from the
refrigerant to high air going through the evaporator
temperature with the blower. (Temperature of
/pressure liquid surrounds decreases.)
refrigerant.

Blower
Send air into the evaporator
and send cooling air into the
Stock solution tank Compressor
vehicle.
Absorb the moisture in Transfer the low
the refrigerant and store temperature/pressure gaseous
the refrigerant. refrigerant to the high
temperature/pressure gas and
Expansion valve
send it to the compressor by the
Expand the coolant rapidly
operation of wheel belt.
and transfer it to low
Achieve control with clutch.
temperature/pressure
liquid.
 Vehicle Body & Electric Appliance Volume ATC-11

1-Wind from outside 2-Inner circular wind

3-Blower 4-Evaporator core
5-Heat installation core 6-Front guard to defrost
7-Front guard to side defrost 8-Frontal wind outlet at front seat
9-Wind outlet at front seat of both sides 10-Rear seat blowing
11-Blowing from sole
Fig. 2 Air-Mixed Air Conditioning System

Composition of Air Conditioning System

 Vehicle Body & Electric Appliance Volume ATC-12

Code Illustration Code Illustration

1 Heater Assembly 2 Evaporator Fan Assembly
3 Compressor Assembly 4 Condenser Assembly
5 Controller Assembly 6, 7, 8 Filter (base, filter core, upper
cover)
9 Condenser Fan Assembly 10 Outlet Assembly
11 Inlet Assembly 12 Hydraulic Assembly
13 Condenser Bracket 14 Pipe Clamp
15 Outdoor (Environment) Temperature 16 Indoor Temperature Sensor
Sensor
17 Sunlight (Sunshine) Sensor
Form of Air conditioning Control Panel and Description of
Function
1) Overview of Man Machine Interface
The control panel of C-class vehicle consists of rotary knob and liquid crystal display
screen, and the indoor temperature sensor that is usually assembled on the panel is
removed to the other location, which is quite different from the key type or the rotary knob
type mostly used nowadays. This makes the control panel interface look simple but
distinctive, and easy to operate, while its function setting can achieve all functions
controlled by the auto air conditioning system. The effect picture is as follows:

Temperature
outside LCD indication
panel

Temperature
control knob

System close
switch Exterior/interior
Air condition air switch
switch Auto control
switch
Blast adjustment
knob Mode control
knob
 Vehicle Body & Electric Appliance Volume ATC-13

Schematic Diagram for Control Panel

Names of Function Keys:
Left Rotary Knob
The external circle is the controlling rotary knob for heating and refrigerating, and the blue
area indicates the mode of refrigerating, and the red one the mode of heating. Rotate the
external circle of the rotary knob to control temperatures. The middle area shows the
forms of the buttons, of which A/C gear is the manual control mode. And there is a lamp to
indicate whether it is at work.
Middle Rotary Knob
The external circle is the rotary knob controlling fan volume, and the middle knob has 2
keys, of which AUTO is the gear of auto controlling mode, and OFF switch of the air
conditioning system.
Right Rotary Knob
The right rotary knob is the switchover knob for exhausting modes.
The clockwise modes in the external circle are: 1 surface blowing mode 2 surface and &
foot blowing mode 3 foot blowing mode 4 defrosting and foot blowing mode 5 defrosting
mode. The middle key is the switchover knob of the fresh/circulating wind, and there is a
light to indicate the working state.
2) Description of Information Indicating Interface
The working condition and environmental condition of the air conditioner is shown
through the LC screen. Through the direct layout, the liquid screen can indicate the
changing conditions when such keys as temperature, wind volume, compressor,
defrosting, external and internal circulation, automation, front blowing, foot blowing,
and shutdown are pressed, which facilitate the driver to know easily the current
working condition of the air conditioner. The figure above is the indicating interface for
all functions of the whole display screen.
①Control of Wind Volume
The external circle of the middle rotary knob controls the fan volume. The left side of
the air blast controls the minimum volume, and the right the maximum. The change of
the wind volume is indicated through the change of the vertical condition bar on the
right of the LC screen.
②Control of Temperature
Temperature control is achieved through the right external circle rotary knob.
③Defrosting Controlling
Rotate the left-hand external rotary knob to the defrosting gear, and the LC screen
indicates the defrosting state/condition.
④Control Switch of Air conditioner
When the system switch is pressed, the air conditioning compressor doesn’ t work,
and the fan stops working. The closedown of the LC screen means the air conditioner
doesn’ t work.
⑤Control of External and Internal Air
Press the left middle key to achieve the mode transfer between the external and
internal air circulation.
⑥ Auto Control
If AUTO is on, it indicates the air conditioner automatically works according to the
internal and external condition signals.
 Vehicle Body & Electric Appliance Volume ATC-14

⑦Control of Connecting Rod

Mode 1 is for surface blowing, Mode 2 is for surface & foot blowing, Mode 3 is for foot
blowing, and Mode 4 is for defrosting.
3）Description of Function Keys

Key Function Description

1. If the internal air circulation is selected, the light above the key will be on,
Internal Switch between
or it will be off.
/external internal and
2. Press the internal/external circulation once, and the internal/external air
circulation external
actuator is transited once between the internal and external air working
key circulation
conditions.
For 1. In AUTO mode, adjust the set temperature value of the system; and in
temperature MANUAL mode, the set temperature value corresponds to the position of
controlling, the mixed air duct door.
Temperatur
rotate 2. The operation of the key doesn’ t affect the AUTO mode.
e adjustable
step-by-step 3. The set temperature scope is between 17-32℃. If the set temperature is
key
the left and below 17℃, it indicates LO, and if it is higher than 32℃, it indicates HI.
right rotary
knobs adjust
In AUTO mode:
1. According to the set temperature and the variation of outdoor and indoor
temperature signals, the system will automatically adjust the blowing
volume of the blower, the position of the mixed air duct door, A/C condition
and the internal/external switch working condition.
2. The initial state defaulted of the blowing mode is FD mode, i.e. surface &
Switch to AUTO foot blowing. The blowing mode can be controlled by the mode adjusting
AUTO key
mode rotary knob. This key is independent from the MODE adjusting rotary knob.
3. The working condition of the compressor is determined by the set
temperature.
4. When one of the following 3 conditions is satisfied: the air conditioning
system just starts to work (i.e. the motor just begins to run), the speed of
10km/h lasts for more than 10s, or the vehicle is parked, the system will
automatically shift to the internal circulation.
1. After the key is pressed, the system will be in the condition of OFF; the
screen is closed with all the actuators closed.
Shut down the
OFF key 2. When the system is in OFF, press AUTO or A/C key or defrosting mode,
system
and the system will automatically start to work in the way set by the user
previously.
1. The system contains 5 blowing modes, i.e. 3 basic modes of
Adjust blowing air-exchange (surface blowing) V, foot blowing F, defrosting D as well as
MODE key
mode foot blowing & air exchange V/F, and defrosting D mode.
2. This key is independent from the AUTO key.
1. When the air conditioning compressor begins to work, the light above
the key will be on, otherwise it will be off;
2. Switch the working conditions of the air conditioning compressor.
3. When the key is pressed, the initial state defaulted of the system is
Turn on/off air
surface & foot blowing V/F, input air of gear 4 and internal circulation.
A/C key conditioning
The system automatically will memorize the working conditions and
condenser
the interface set by the user previously and exit from the AUTO mode
to the MAUNAL mode.
4. In AUTO mode, press the key, and the working condition of the
compressor will exit from the AUTO mode to the MANUAL mode.
Defrosting Switch to 1. In Defrosting mode, the LC screen indicates the sign of the defrosting
key compulsory state;
defrosting 2. The initial state defaulted is: the defrosting state of the blowing mode,
external circulation, 4-gear wind volume (when the surrounding
temperature is below 12℃, the mode is full-warm defrosting; when it is
higher than 14℃, the mode is full-cold defrosting). It will automatically
memorize the working mode or the interface set by the user before.
Volume Decrease 1. Turn the wind volume adjusting knob leftwards, and the volume will
 Vehicle Body & Electric Appliance Volume ATC-15

decreasing volume decrease step by step to gear 1, with the lowest gear unchanged.
key 2. In AUTO mode, when the volume decreases to gear 1, the system will
exit from the AUTO mode.
Volume Increase 1. Turn the wind volume adjusting knob rightwards, the volume will
increasing volume increase step by step to gear 6, with the highest gear unchanged.
key 2. In AUTO mode, when the volume increases to gear 6, it will exit from the
AUTO mode.
 Vehicle Body & Electric Appliance Volume ATC-16

Illustration of Control Circuit Diagram and PIN

Key ON Power

Plus Plate of Storage

Battery

Blower Blower
High
Relay
Position
Relay

Positive Pole of Blower

Backlight Power Motor

Backlight Adjustable
Resistance Power
Transistor

Mode Air Door Executor

Compressor Relay

Compressor
Temperature Air Door
Executor

Water
Box Fan
Relay Engine
Control
Interior/Exterior Air
Unit Door Executor
Water Ternary Pressure
Box Switch
Fan
Motor

Evaporator
Temperature Sensor
Condenser Condenser
Fan Relay2 Fan Relay1

Condenser
Fan Motor Water Temperature Sensor

Outdoor temperature
Sensor

Sunshine Sensor

Interior
Temperature
Sensor
 Vehicle Body & Electric Appliance Volume ATC-17

Code Illustration Code Illustration

A1 Sensor of evaporator (5V) A2 Grounding of sensor of evaporator
A3 Actuator of internal and A4 Actuator of internal and external
external air duct door M+ air duct door M-
A5 Actuator of the A6 Actuator of the temperature air
temperature air duct door duct door M-
M+
A7 Actuator of mode air duct A8 Actuator of mode air duct door M-
door M+
A9 Actuator of mode air duct A10 Sensor of water temperature
door (5V)
A11 Actuator signals of the A12 Actuator signals of mode air duct
temperature air duct door door
B1 Rheostat B2 Anode of backlight power supply
B3 Anode of accumulator Low-speed control of power
B4
transistor
B5 High-speed control of Sensor of indoor temperature
B6
blower (M+)
B7 Ignition switch of ON-gear Ground
B8
power supply
B9 A/C SELECT (HI) B10 A/C THERMO (HI)
B11 High-speed relay Sensor of environment (outdoor)
B12
temperature (5V)
B13 Sunshine sensor (5V) B14 Sensor of indoor temperature (M-)
B15 Sunshine sensor of Sensor of indoor temperature (5V)
B16
(grounding)
Vehicle Body & Electric Appliance Volume ATC-18
 Vehicle Body & Electric Appliance Volume ATC-19

Diagnosis of Auto Air conditioning System

Self-diagnosis Method:

Shift the ignition switch from OFF to

IGN OFF → ON
ON

Press the interior/exterior

AUTO SW를 누 른상태에서 air switch with 2
seconds for 4 times under OFF condition.
OFF SW를 2sec 이내에 4회이상 누 름

The LCD screen gives a full display and

LCD winks for 5 5회
全 SYMBOL times.
점 멸

Operate OFF
Self-diagnosis
자가 진단항목 item
CHECK button
OFF SW 조작
(Continues operation)
(연속동작)

Operate
AUTO AUTO
SW 조작 Operate
AUTO SW 조작 AUTO
Button Button
Follow
A/C the
SWfollowing
조작시 Self-diagnosis
자가 진단항목 CHECK
procedures when (Single operation)
operating
다음 STEP A/C button
진행 (STEP 연속동작)

Operate
OFF SWOFF조작
Button
Back to the previous mode before
자자진단 이전 self-diagnosis
MODE로 복귀 제 어

※ The air conditioning system remains the closing condition during self-checking.

Trouble Inspection
① The data displayed is a 2-digit code for the position determined by the set
temperature, and the trouble code is displayed with light “on/off”, while the others are
displayed with light “off”.
② The trouble code is displayed with the light “on/off”every 0.5 second, but as to the
trouble types or the short-cycle interval, it is displayed with the light “on/off”every 1
second.
③ Continuously turn on/off the trouble code twice.
④ Value indication, i.e. Code11and Code 12.

Short cycle (once)

 Vehicle Body & Electric Appliance Volume ATC-20

Inquiry About Trouble Codes

Trouble Trouble Content Remarks
Code
00 Normal
11 Short circuit or open circuit of the internal sensor
12 Short circuit or open circuit of the environment
(outdoor) temperature sensor
13 Short circuit or open circuit of the temperature
sensor of the evaporator
14 Short circuit or open circuit of the water
temperature sensor
15 Short circuit or open circuit of the feedback end
of mode motor
16 Poor drive of the mode motor If the motor is blocked
against rotation
17 Short circuit or open circuit of the feedback end
of temperature control motor
18 Poor drive of temperature control motor If the motor is blocked
against rotation

Mode of Trouble Protective Function

Item Trouble Function
Indoor Short circuit, open Control at 25℃
temperature circuit
sensor
Outdoor short circuit, open Control at 20℃
(environment) circuit
temperature
sensor
Air duct sensor Short circuit, open Control at -2℃
circuit
When the set temperature is below or equal to
Short circuit, open 25℃, fix VENT
Mode motor
circuit When the set temperature is above 25℃, fix
DEF
When the set temperature is below or equal to
Temperature Short circuit, open 25℃, fix to the coldest position
control motor circuit When the set temperature is above 25℃, fix to
the hottest position
Vehicle Body & Electric Appliance Volume ATC-21
 Vehicle Body & Electric Appliance Volume ATC-22

Description of Functions of Air conditioning System Elements

Evaporator Fan Assembly
1. Function of Evaporator Fan
The blower consists of the motor and the fan, with the external and internal air mode
changed through the motor at the air entry door, and meanwhile inhales the indoor
and outdoor air.
The function of the motor at the air entry door is achieved by the control of the internal
and external air key of the controller.
In the mode of internal circulation, the air is inhaled through the 2 flank air intakes,
while in the mode of external circulation, the air is inhaled through the filter installed at
the front shelter of the vehicle.
The air is taken in through the blower, and heat is exchanged through the evaporator,
and last the air after being refrigerated enters the vehicle.
When the refrigerant in the evaporator passes the expansion valve, the
low-temperature and low-pressure liquid will be gasified through absorbing the heat of
the exterior air, thus lowering the temperature. In this way, the evaporator transfers
the heat energy to the refrigerant.
2. Names of Main Parts of Evaporator Fan Assembly

Code Name of Main Part Code Name of Main Part

1 Air duct sensor 5 Assembly of motor fan assembly
2 Air duct motor 6 Air inlet
3 Power amplifier 7 Assembly of evaporator core
4 Blower motor 8 Assembly of the evaporator fan
Vehicle Body & Electric Appliance Volume ATC-23

shell
 Vehicle Body & Electric Appliance Volume ATC-24

Air Duct Sensor

Function
It is used for sensing the temperature of the core of the evaporator to avoid the freezing of
the evaporator.

Assemble it at the evaporator core. There is a negative-characteristic heat-variable

resistor in the sensor, so when the temperature lowers, the resistance increases, and
vice versa.

Position of Installation
Illustration:
* The sensor is located at the place marked
with red on the core surface.

Table for Characteristics of Air Duct Sensor

Temperature Resistance Voltage Temperature Resistance Voltage
(℃) (㏀) (V) (℃) (㏀) (V)
30.00 1.98 0.99 2.00 7.23 2.37
25.00 2.45 1.17 1.00 7.60 2.44
20.00 3.06 1.38 0.00 8.00 2.50
15.00 3.85 1.62 -1.00 8.42 2.56
10.00 4.88 1.89 -2.00 8.87 2.63
5.00 6.22 2.19 -3.00 9.34 2.69
4.00 6.54 2.25 -4.00 9.48 2.71
3.00 6.87 2.31 -5.00 10.37 2.82
Vehicle Body & Electric Appliance Volume ATC-25
 Vehicle Body & Electric Appliance Volume ATC-26

Power Amplifier
Function:
It is used to adjust the rotate speed of the blower according to the variation of the
current provided to the power amplifier by the air conditioner controller.

Position of Installation:
Illustration:
Install it on the blower.

E B
Illustration of Internal Structure
①Range of Working Voltage: DC 9V∼ 16V
②Transistor
- Type: Silicon
- Maximum Permitted Electric Current: Ic=50A
- Maximum Permitted Load Power; Pc=300W
(at Tc=25℃)
③FUSE: 250V, 15A, 139℃
 Vehicle Body & Electric Appliance Volume ATC-27

Motor of Internal and External Air Door

Function:
It is attached to the internal and external air inlet duct of the evaporator blower and the
duct is driven by controlling the button for internal and external air selection.
Position of Installation
Illustration:
Attach it to the internal and external air inlet duct
of the evaporator blower.

Circuit and Operation

 Vehicle Body & Electric Appliance Volume ATC-28

Blower Motor

Function:
By using the power supply of the vehicle, it can rotate the fan to generate input air
needed by HVAC.

Motor Pattern
Rotary Direction: clockwise ( the fan part)
Fan Type: Φ147X76.2Ｈ Fan Type: Φ147X76.2Ｈ
Motor: Φ68, 234W, Motor: Φ68, 234W

Check Method
Apply any voltage to the “+”connector, and
check the “-”connector after grounding.

Anode Cathode

+
M
-
Illustration of Position:
Install it in the blower.
 Vehicle Body & Electric Appliance Volume ATC-29

Expansion Valve

Function:

By using the releasing function, the high-temperature and high-pressure liquid refrigerant
from the condenser is transformed into the vapor of moisture saturation with low
temperature and low pressure, which facilitates the fulfillment of the refrigerant
evaporation function of the evaporator.

Position of Installation
Illustration:
Install it at the entry hole of the evaporator.

Attention:
If the expanding valve falls off, the heat of the engine will be transmitted to the
temperature sensor, thus causing the pressure of the expanding valve to increase and
resulting in refrigerant excessiveness. If the evaporator can't perform the evaporation
function, the liquid refrigerant will flow into the compressor and damage it.
 Vehicle Body & Electric Appliance Volume ATC-30

Heater Assembly
Function
According to the different degrees of openness and closeness of the temperature control
duct, part of air passing through the evaporator is transmitted to the heater core, and the
left to the upper section of the heater case. In order to achieve the indoor temperature
adjustment and air mixture, mix the air flowing through the heater core and the air flowing
into the upper heater casing at the back part of the heater casing. Under the effect of the
mode air duct door motor, the mixed air will be transmitted to the required air outlet, thus
fulfilling the functions of indoor temperature adjustment, defrosting and demisting, i.e. the
heater unit adjusts the mixture of air, and controls the temperature and the air exhaust
direction.

Positions of Main Components of Heater

Motor of mode air duct

door

Temperature control
motor
Vehicle Body & Electric Appliance Volume ATC-31
 Vehicle Body & Electric Appliance Volume ATC-32

Motor of Mode Air Duct Door

Function
Installed at the left section of the heater casing, and it activates the small-sized motor
to adjust the position of the connecting rod under the signals of the FATC mode
switch. When the motor is activated, the varied motor voltage difference will be
reflected to the FATC, and the FATC will judge the reflected signals. When the air
duct door reaches the specified position, the motor will stop working.

Position of Installation
Illustration of Position:
Install it at the left side of the heater shell.

Working Field

Basic Diagram of Circuit

Color of Wire Harness
①R/W
②W
③R
④B/W
⑤R/B

Connector Figure

When ① is connected to +, and ② to -, VENT (CW)

When ②is connected to +, and ①to -, DEF (CCW)
 Vehicle Body & Electric Appliance Volume ATC-33

Motor of Air Duct Door of Temperature Control

Function
Installed at the bottom end of the heater casing, it activates the small-sized motor to
adjust the position of the temperature control under the signals of the FATC mode
switch. When the motor is activated, the varied motor voltage difference will be
reflected to the FATC, and the FATC will judge the reflected signals. When the air
duct door reaches the specified position, the motor will stop working.

Position of Installation
Illustration of position:
Install at the bottom of the heater casing.

Working Field

Working Principle Figure

Color of Connector Wire Harness
①G/W
②Lg/B
③L/W
④S/L
⑤R/B
Connector Figure

When ①is connected to +, and ② to -, VENT (CW)

When ②is connected to +, and ① to -, DEF (CCW)
 Vehicle Body & Electric Appliance Volume ATC-34

Compressor Assembly
Function
The compressor can enhance the pressure of refrigerant, thus facilitating condensation of
the gaseous refrigerant evaporated by the evaporator, i.e. the condensation of vapor.
Through the repetition of condensation and evaporation by the effect of the compressor,
the refrigerant device works circularly and the heat is transmitted from the place of low
temperature to that of high temperature.
① Induction function: it can decrease the pressure of the refrigerant inside the
evaporator, which may facilitate the evaporation of the liquid refrigerant under the low
temperature.
② Compression function: it can compress the pneumatolytic refrigerant, and transmit
the high-temperature and high-pressure refrigerant to the condenser, making it
liquefied under normal temperature.
③ Circulation function: the refrigerant is circulated in the above steps of induction and
compression, and hence making the system works continuously.
Position of Installation:
Illustration:
It is installed in the engine hatch.

Appearance and Specification of

Compressor
Appearance Graph

Specifications
Item Specifications
Type SE5V16
Cylinder number 5
Volume(cc/rev) 10~156
Refrigerant mechanic oil(cc) 160±15
Type Variable Discharge
Clutch gap 0.3 ~ 0.7mm
VELT TYPE 5PK -TYPE
Diameter of pulley Φ 120
 Vehicle Body & Electric Appliance Volume ATC-35

Volume of refrigerant 700±20g

 Vehicle Body & Electric Appliance Volume ATC-36

High-Pressure Safety Valve

The high-pressure safety valve may prevent such phenomena as the blocking of the air
conditioning system, overfilling, and malfunction of the condenser fan. In order to avoid the
above problems, apply the high-pressure safety valve to discharge the refrigerant and the
refrigeration oil, which may stabilize the air conditioning system. Hence when the
high-pressure safety valve is started owing to the high pressure, find the causes of the high
pressure first, and then refill the refrigerant and supplement the refrigerant oil ( about 50cc),
thus avoiding the abnormity of compressor.
Influencing Factors of Compressor
Poor Lubricating Effect Caused by Inadequate Refrigerant (Insufficient Filling
or Leakage of Refrigerant)
Both the refrigerant oil and the refrigerant circulate in the air conditioning system and are
sprayed onto the running position of the compressor in the form of fog, hence producing
lubricating effect. If the refrigerant is inadequate, the oil flowing into the compressor will
decrease, thus failing to produce proper lubricating effect. Meanwhile the high inspiration
temperature of the compressor may lead to the friction of the running position and
produce a large quantity of heat.
Attention：
☞ If the performance of A/CON declines, please check the volume of refrigerant and
make refilling.
☞ If the air conditioner is left unused in winter, start the air conditioner periodically (once
every 2 weeks) to check the leakage of refrigerant at an idle speed.
Hydraulic Compression Caused by Entrance of Liquid Refrigerant
The high pressure and unevaporated liquid gas caused by overfilling of refrigerant may
lead to the hydraulic compression if it flows into the compressor, which may increase the
running load of the compressor, and lead to the damage of the compressor and the
slipping of belts.
After installation, the A/CON flows into the compressor and rinses the lubricating oil
smeared at the moving position, so the compressor will be damaged if the compressor
runs without lubricating effect before the circulation of refrigerant oil.
Attention:
☞ After the operation of the refrigerant, keep the A/CON running for 5 minutes at an idle
speed and then restart it.
Poor Lubrication Caused by Jamming of Refrigerant Pipelines
Before filling refrigerant, because of the poor vacuum, the remaining moisture in the
system will lead to the icing of the expansion valve, thus blocking the system in a moment
and making the compressor operate without lubrication.
Attention:
☞ As to the vehicle into which the moisture flows, conduct full vacuum-pumping (above
30 minutes) after reclamation of refrigerant to remove the moisture of the system.
Separation and Movement of Refrigerant Oil of Compressor
Owing to the characteristics of R134a refrigerant, in the long-period delivery and deposit,
separation of refrigerant and refrigerant oil as well as movement of refrigerant oil may
occur under the effect of outdoor temperature differences. Thus, at the initial stage of
operating the air conditioning system, only the phenomenon of refrigerant’ s entering the
 Vehicle Body & Electric Appliance Volume ATC-37

compressor may lead to the inadequateness of lubricating oil.

Attention:
☞ In winter, keep the air conditioner running at an idle speed for 5 minutes before
starting it.
 Vehicle Body & Electric Appliance Volume ATC-38

Control Unit of Condenser Assembly

Function
Cool the high-pressure and high-temperature gaseous refrigerant under normal
temperature by the mono thermal condensation of compressor.
The cooling of condenser depends on the volume of traveling wind and forced wind of
fan.
The condenser of Benjoy car is in the parallel-flow mode and assembled with the
drying bottle.
The overcooling function can promote the cooling performance, reduce the quantity of
refrigerant needed and save the cost of main motor factory. Besides, the mode of
assembling with drying bottle can reduce the quantity of components. When pollution
arises, usually the drying bottle should be replaced first. But as for Benjoy car, you
could just replace the drying agent after separating the cover on the lower part of the
drying bottle. This variation improves the quality of after-sales service.
Positions of Primary Parts and Components of Condenser Unit

Condenser

Drying
Bottle

Position of Installation:
Behind the front fender-guard, and in the engine hatch.
 Vehicle Body & Electric Appliance Volume ATC-39

Sensor of Air conditioning System

Indoor Temperature Sensor
Function
It is used for sensing the signal about the inner
temperature of the vehicle and sending the
signal to the FATC to make the temperature and
volume of air blown out meet the driver’
s
selection. Benjoy car adopts the ACTIVE TYPE
sensor and the perception capability is improved
by inhaling some air by motor.

Position of Installation
Illustration: On the protecting plate above the
accelerator pedal.

Table for Working Performance of Sensor

Resistance Voltage Resistance Voltage
Temperature (℃) Temperature (℃)
(㏀) (V) (㏀) (V)
50.00 10.82 1.33 10.00 59.66 3.33
40.00 15.99 1.74 0.00 97.83 3.83
30.00 24.17 2.23 -10.00 165.60 4.23
20.00 37.47 2.78 -20.00 290.22 4.53
Motor Mode
①Working pressure: DC 9V ~ 16V
②Working temperature: -30 ~ +80℃
③Consumption current: Max. 100mA
④Rotation speed: Min 3,500RPM

Essentials for Measuring the Output Voltage of Indoor Temperature Sensor:

To obtain the output voltage of indoor temperature sensor, please measure the
temperature at the terminal B16 (SENSOR GROUND), B1 or B9 of the FATC. To confirm
the temperature of voltage value, please refer to the enclosed “SENSOR Electric
Resistance-Temperature Characteristics Table”.
 Vehicle Body & Electric Appliance Volume ATC-40

Outdoor Temperature Sensor (Ambient Temperature Sensor)

Function
It is used for sensing the signal about outdoor
temperature of the vehicle and sending the
signal to the FATC to make the temperature and
volume of air blown out meet the driver’
s
selection.

Installation Illustration
Illustration: It is mounted in front of condenser in
the engine hatch.

Table of Working Temperature

Temperature Resistance Voltage Temperature Resistance Voltage
(℃) (㏀) (V) (℃) (㏀) (V)
50.00 10.83 1.33 10.00 59.60 3.33
40.00 16.00 1.74 0.00 97.50 3.82
30.00 24.18 2.23 -10.00 164.20 4.23
20.00 37.46 2.78 -20.00 284.50 4.52

Essentials for Measuring the Output Voltage of Outdoor Temperature Sensor

(Ambient Temperature Sensor):
To obtain the output voltage of outdoor
temperature sensor, please measure the pressure
at the terminal B16 and B3 of the FATC, or the two
ends of outdoor temperature sensor. To confirm
the temperature of voltage value, please refer to
the enclosed “SENSOR Electric
Resistance-Temperature Characteristics Table”.
Vehicle Body & Electric Appliance Volume ATC-41
 Vehicle Body & Electric Appliance Volume ATC-42

Sunlight (Sunshine) Sensor

Function
The sensor is used to produce current
according to the amount of sunlight. The current
produced will be sent to the FATC. The FATC
will judge and adjust the indoor temperature according to current value input.

Position of Installation
Illustration:
On the panel board of the passenger side (the
right side of the panel side).

Basic Diagram for Controlling

Image Connector Circuit

Characteristics of Output Voltage

 Vehicle Body & Electric Appliance Volume ATC-43

Cooling System of Engine

Concept of Control of Radiator Fan Assembly
– (Computer for engine control) compare the speed input, the load of air
conditioner and the temperature of cooling water, and then control the cooling fan
at 2 sections (high/low).
– When faults arise in the speed sensor and cooling water sensor, the driver
radiator and cooling fan would be at the high section and the on-off temperature
of the compressor of the air conditioner would be 115℃.

Relevant Circuit of Cooling Fan Control

Compressor relay

Compressor

Relay of
water box Engine
Medium pressure
fan controller unit High pressure Low pressure

Motor of Three-way
water tank pressure switch
fan

Condenser fan Condenser fan

relay 2 relay 1

Condenser fan
motor
 Vehicle Body & Electric Appliance Volume ATC-44

Three-Phase Pressure Switch

Function
Compared with the former double-end pressure switch, a medium switch is added into the
three-phase pressure switch, which would be started and send signal to the engine
computer when the system pressure increases. At this time, the drive radiator and cooling
fan are in the High mode to prevent the trouble of weak performance caused by increasing
pressure. The air conditioning system also could be protected when the pressure is
abnormal (high/low).
Precautions:
If the pressure switch is damaged and needs to be replaced, vacuate the air conditioning
system at first and make sure there is no refrigerant left in the system. After the
vacuum-pumping, loosen the switch clockwise with spanner and then replace the
damaged switch. At last, mount the new pressure switch and refill refrigerant into the
system.
Position of Installation

Illustration:
It is mounted in the engine hatch.

Basic Diagram for Switch Terminal and Circuit

Working Characteristics
Differentiation ON OFF Remarks
HIGH 26.0 32.0
LOW 2.3 2.0
 Vehicle Body & Electric Appliance Volume ATC-45

MEDIUM 18.0 14.0

 Vehicle Body & Electric Appliance Volume ATC-46

Dismantlement & Reassembly of Air Conditioning System

Evaporator Fan Assembly

No. Name of Spare Parts No. Name of Spare Parts

2 Core casing assembly of the

1 Evaporator fan casing assembly
evaporator
3 Motor fan assembly 4 Cooling air pipe
5 Blower wire harness and support 6 Evaporator wire harness
7 Air duct sensor 8 Screw
9 Air door motor 10 Expansion valve bolt
12 Expansion valve (connected
11 Power amplifier
with double end studs)
 Vehicle Body & Electric Appliance Volume ATC-47

Dismantlement & Reassembly of Evaporator Fan Assembly

Dismantlement Steps:
1. Reclaim the refrigerant in the system with
special device for refrigerant recovery. ATC001
Please refer to the part of refrigerant
reclamation.

2. Cut off the negative terminal of the storage

battery.

ATC002

3. Dismantle the instrument panel assembly. As

to the dismantlement steps, refer to the
dismantlement and reassembly of the
instrument panel.

4. Open the engine hatch, and dismantle the

fixed bolts of the expansion valve.

ATC003

5. Dismantle the fixed bolts of the evaporator

fan assembly (2 refers to the fixed bolt).

ATC004

6. Cut off the wire joint, and take out the

evaporator fan assembly.

Reassembly:
 Vehicle Body & Electric Appliance Volume ATC-48

Reassemble it according to the reverse order of dismantlement.

 Vehicle Body & Electric Appliance Volume ATC-49

Dismantlement of Heater Assembly

Dismantlement Steps:
1. Cut off the negative terminal of the storage ATC005
battery.

ATC006

2. Dismantle instrument desk assembly.

Please refer to the steps for dismantlement
and reassembly of instrument desk.
3. Open the engine hatch, and cut off the joint of
the warm-air water pipe.

4. Dismantle the fixed bolt of the heater.

ATC007

Tightening Torque: 23±4N·m

5. Disconnect the wire harness, and take out the

heater assembly. ATC008

Reassembly:
Reassemble it according to the reverse order of
dismantlement.
Fix the bolt.

Tightening Torque: 23±4N·m

 Vehicle Body & Electric Appliance Volume ATC-50

Dismantlement & Reassembly of Temperature Control Motor

Dismantlement Steps
1. Cut off the negative terminal of the storage ATC009
battery.

2. Dismantle the instrument desk.

(Please refer to the steps for dismantlement and reassembly of the instrument panel.)
3. Cut off the joint of wire harness, and
dismantle the fixed screws of the ATC010
temperature control motor.

ATC011

4. Dismount the temperature control motor.

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume ATC-51

Dismantlement & Reassembly of Mode Air Duct Door Motor

Dismantlement Steps
1. Cut off the negative terminal of the storage ATC012
battery.

2. Dismantle the instrument panel.

3. Cut off the joint and tie-point of wire
ATC013
harness, and dismantle the fixed screws of
the mode air motor.

4. Take out the motor of mode air duct door.

ATC014

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume ATC-52

Dismantlement & Reassembly of Power Amplifier

Dismantlement Steps:
1. Cut off the negative terminal of the storage ATC015
battery.

2. Dismantle the instrument panel.

(Please refer to the steps for dismantlement and reassembly of the instrument panel.)
3. Cut off the wire harness joint of the power
ATC016
amplifier and dismantle the two fixed
screws.

ATC017

4. Pull the power amplifier upwards to get it ATC018

out.

Reassembly:
 Vehicle Body & Electric Appliance Volume ATC-53

Reassemble it according to the reverse order of dismantlement.

 Vehicle Body & Electric Appliance Volume ATC-54

Dismantlement & Reassembly of Interior/Exterior Air Duct Door Motor

Dismantlement Steps:
ATC019
1. Cut off the negative terminal of the storage
battery.

2. Dismantle the instrument desk.

(Please refer to the steps for dismantlement and reassembly of instrument desk.)
3. Cut off the joint of wire harness and
dismantle the fixed screws of the motor of ATC020
interior/exterior air duct door.

ATC021

4. Take out the motor of the interior/exterior

air door. ATC022

Reassembly:
Reassemble it according to the reverse order of
dismantlement.
 Vehicle Body & Electric Appliance Volume ATC-55

Dismantlement & Reassembly of Compressor

Dismantlement Steps:
1. Reclaim the refrigerant in the system with special device for refrigerant recovery.
Please refer to the part of refrigerant reclamation.
2. Cut off the negative wire of the storage
ATC023
battery for more than 30 seconds, and then
cut off the joint of wire harness on the
electric magnetic clutch of the compressor.

ATC024

3. Unscrew the fixed bolts of pipeline and

ATC025
disconnect the high/low pressure pipeline
connected with the compressor.
Attention:
After dismantling the refrigerant hose, mount the
dust guard at once to prevent the exterior dust or
moisture from entering the hose and affecting the
normal operation of the air conditioning system.

4. Loosen the fixed nuts and adjusting bolts of ATC026

tension pulley, and then dismount the drive
belt of the compressor.
Locknut of Tension Pulley
28±7N·m

5. Lift the vehicle and dismount the mudguard.

(Please refer to the steps for dismantlement and reassembly of exterior trimmings)
 Vehicle Body & Electric Appliance Volume ATC-56

6. Dismount the four fixed bolts for mounting

ATC027
the compressor onto its support.

Tightening Torque: 45±5N·m

7. Take out the compressor from the bottom of

the vehicle.
ATC028

8. Unscrew the oil drain bolt of compressor to

discharge the compressor lubricating oil into
a container and record the quantity of the
ATC029
lubricant discharged.

Bolt of Lubricant Filling Hole

Tightening Torque: 15~20N·m

Attention:
Be careful not to spill the compressor lubricating
oil during operation.
Reassembly:
1. Refill the compressor oil into the compressor,
and screw down the bolt of the lubricating oil
filling port.
2. Install the compressor on the vehicle in the
reverse order of dismantlement.
3. Adjust the tension degree of the belt after
reassembly.
4. After refilling the refrigerant, check if the pipeline is leaking. The type of the
lubricating oil is: FD46×G, and the filling quantity is 170cc.
 Vehicle Body & Electric Appliance Volume ATC-57

Disassembly Drawing of Compressor Assembly

Screw of lead wire fixer
Fixed screw of dog plate

Components of Washer
sucking disk Dog plate of air
inlet
Fixed dog
plate of lead
Dog plate of air
wire
outlet

Rubber sealing
gasket of air inlet

Rubber sealing
gasket of air outlet

Circlip of belt
pulley

Components of Fixed screw

Components of coil ring
belt pulley

Oil plug Components of

pressure-relief valve
Components of
engine block

Components of
control valve

Disassembly of Compressor
1. Dismantle the sucking disc.
Dismount the sucking disc as shown in the figure.

2. Demount the clip.

 Vehicle Body & Electric Appliance Volume ATC-58

3. Dismantle the rotor and the coil. Apply the

tool with three claws to dismount the bearing
cap and the backing ring.
 Vehicle Body & Electric Appliance Volume ATC-59

Check of Safety Valve

① If the air conditioning system is running with the
high pressure exceeding 3,550kPa, the
high-pressure releasing valve will release part of Spring
the refrigerant in the system to the atmosphere,
thus protecting the system. Valve
② Once the pressure of the system decreases below
Compressor
2,400kPa, the high-pressure releasing valve will
close to keep the machine running.
③ If the leakage at A is detected, replace the
high-pressure releasing valve. If there is no
leakage at A, the valve will still be applicable.
④ If the leakage at B is detected, screw down the
valve. Replace the packing if there is still leakage
after screwing down the valve.

Reassembly:
Reassemble it according to the reverse order of
dismantlement.
Reassembly and Adjustment
Clearance Gauge
Check if the clutch gap is within the standard value.
Standard Value: 0.3~0.75mm

Remarks:
If the gap is deviant from the standard value, adjust the
number of gasket to adjust the gap.
 Vehicle Body & Electric Appliance Volume ATC-60

Condenser
Disassembly Drawing of Condenser Assembly

Code Name of Spare Parts Code Name of spare parts

1 Condenser 2 Drying bottle
Drying bottle
3 4 Upper buffer cushion
fastening assembly
5 Bearing bush 6 Bolt
7 Lower buffer cushion
 Vehicle Body & Electric Appliance Volume ATC-61

Dismantlement & Reassembly of Condenser

Dismantlement Steps:
1. Use the special refrigerant reclaiming equipment to reclaim the refrigerant of the system.
See the part of refrigerant reclamation.
2. Cut off the negative terminal of the storage
battery.
ATC030

3. Dismantle the front retainer.

ATC031
Dismantle the clip-type fixed screws from the
radiator trimming plate.

4. Dismantle the front bumper.

(Please refer to the steps for disassembly and ATC032
reassembly of exterior trimming).
As to the dismantling steps, see the part of body
exterior trimming.
5. Discharge the refrigerant and dismantle the
radiator assembly.

ATC033

ATC033
6. Cut off the pipeline connection.
 Vehicle Body & Electric Appliance Volume ATC-62

In Reassembly
ATC034
Tightening Torque: 9±2N·m

ATC035

7. Dismantle the fixed bolts of the condenser.

ATC036

In Reassembly

Tightening Torque: 23±4N·m

 Vehicle Body & Electric Appliance Volume ATC-63

8. Take out the condenser assembly in the direction of the engine.

Reassembly:
Reassemble it according to the reverse order of dismantlement.

Air conditioning Pipe of Drying Bottle

Tightening Torque: 9±2N·m

Fixed Bolt of Condenser

Tightening Torque: 23±4N·m

Outdoor (Ambient) Temperature Sensor

Dismantlement Steps:
1. Dismantle the front bumper assembly. (Please refer to the steps for disassembly and
reassembly of exterior trimming).
2. Dismantle the snapin of the outdoor (environment) temperature sensor.

ATC037

ATC038
3. Cut off the tie-point of the sensor, and take out the sensor.
 Vehicle Body & Electric Appliance Volume ATC-64

Reassembly:
Reassemble it according to the reverse order of dismantlement.
Sunlight (Sunshine) Sensor (Sunshine Temperature Sensor)
Dismantlement Steps:
1. Press the sensor, and pull it upwards to get it out. ATC039

2. Cut off the joint of the sensor, and take off the ATC040
sensor.

Reassembly:
Connect the joint of the wire harness and then press it down forcibly.
 Vehicle Body & Electric Appliance Volume ATC-65

Indoor Temperature Sensor

Dismantlement Steps:
ATC041
1. Cut off the negative terminal of the storage battery.

2. Dismantle the lower cover sheet, and cut off the wire harness joint of the small indoor
light (footwell light). (As to the dismantling steps, see the part of dismantlement and
reassembly of instrument panel).
3. Cut off the wire harness of the sensor.

ATC042

4. Dismantle the fixed screws of the sensor, and

take out the sensor. ATC043

Reassembly:
Reassemble it according to the reverse order of dismantlement.
 Vehicle Body & Electric Appliance Volume ATC-66

Ventilation System
Disassembly Drawing of Air Conditioner Ventilation Pipeline
 Vehicle Body & Electric Appliance Volume ATC-67

Dismantlement & Reassembly of

Operation Panel of Air conditioner Air
Outlet ATC044
Central Air Outlet of Instrument Desk
Dismantlement Steps:
1. Cut off the storage battery assembly.

2. Dismantle the control panel of air conditioner.

ATC045

3. Dismantle the two fixed screws of the central

air outlet panel.

ATC046

4. Dismantle the HIFI displaying system.

5. Dismantle the inner fixed screws of the central

control air outlet.

ATC047
ATC047

6. Pull the panel outwards, and cut off the

connecting wire harness of the central
alternation switch.
Vehicle Body & Electric Appliance Volume ATC-68
 Vehicle Body & Electric Appliance Volume ATC-69

7. Dismantle the fixed bolts of the panel and the ATC048

alternation switch.

8. Separate the panel and the switch. ATC049

Reassembly:
Reassemble it according to the reverse order of
dismantlement.
Air Outlet at Operation Panel Side
Dismantlement Steps:
1. Unclench the panel with tools.
ATC050
Attention:
When unclenching the panel, don’
t scrap the
instrument desk.
Reassembly:
Align the panel, and press it down.
Operation Panel of Back Air Outlet
Dismantlement Steps:
1. Press the air outlet, and for the left air outlet, push
leftwards, while for the right air outlet, push ATC051
rightwards, and finally pull upwards to get it out.

Reassembly:
Align the air outlet, and press it down.
 Vehicle Body & Electric Appliance Volume ATC-70

Filter
Dismantlement Steps:
ATC052

1. Open the engine hatch.

2. Dismantle the (right) wiper and the wiper trimming
plate in front of the passenger seat. As to the
dismantlement steps, see the part of wiper
system.
3. Dismantle the upper cover of the filter.

ATC053

Upper
Cover

ATC054
4. Take out the filter core.

Filter
Core

ATC055
5. Dismantle the fixed bolt of the powder filter base.

Tightening Torque: 9±2N·m

Bottom of Filter

element
Reassembly:
Reassemble it according to the reverse order of dismantlement.
Bolt of Filter Base
Tightening Torque: 9±2N·m
 Vehicle Body & Electric Appliance Volume Appendix - 1

Maintenance Data of Vehicle Body

Maintenance Data of Engine Hatch Cover

 Vehicle Body & Electric Appliance Volume Appendix - 2

Maintenance Data of Doorframe

 Vehicle Body & Electric Appliance Volume Appendix - 3

Maintenance Data of Boot

 Vehicle Body & Electric Appliance Volume Appendix - 4

Maintenance Data of Chassis

 Catalog ID-1

“Only for You”Maintenance Manual

Circuit Overhaul Volume

Preface Catalog
This “Only for You” Maintenance
Manual is prepared to help the
Catalog ID
technical service personnel exactly
understand and acquaint himself with
JAC cars, and thus to enable them to
How to Use Maintenance Manual GI
fast and reasonably maintain JAC cars.
This Maintenance Manual consists of
four volumes respectively for the
Circuit Diagram SD
engine, chassis, vehicle body &
electric appliance, and circuit overhaul.
The circuit overhaul volume explicates
Component Location CL
the overall circuit diagrams and wire
harness diagrams of “Only for You”car,
which are accompanied by the
Connector Shape CC
illustration and figure for the locations
of all electrical elements and sensors
on the vehicle, so as to assist the
Wire Harness Layout HL
overhaul personnel in fast finding out
the cause of trouble.

No part of this manual may be reproduced or used in any form or by any

means without prior written license; otherwise any infraction will be prosecuted
for.
 How To Use Maintenance Manual GI-1

How to Use This Maintenance Manual

Illustration… … … … … … … … … … … … … … … … … … … … … … ..... GI-2

Representation… … … … … … … … … … … … … … … … … … … … .... GI-7

Trouble Detection Guide … … … … … ......................................... GI-14

 How To Use Maintenance Manual GI-2

Illustration Circuit Diagram

This Manual contains five kinds of major Each system begins with its circuit diagram,
tools used for troubleshooting. which shows all the working routes of each
component, for example, the power supply
● Circuit Diagram of electrical load, minus grounding, the
● Component Position Index position of lead wire connector and the
● Component Position Diagram correlative fuse and switch in the circuit.
● Shape of Lead Wire Connector
● Wire Harness Layout For the diagnosis and troubleshooting, it
is required to well understand the circuit
diagram at first.
Engine ECM System - Fuel Injection Pagination Code of System
Nozzle and Ignition Coil
 How To Use Maintenance Manual GI-3

Component Position Index

For positioning the component shown in the The installation positions of all the
schematic diagram onto the vehicle, components, together with lead wire
refer to component position index following connectors, grounding and diode can be
the diagram. The index lists the major found in the position diagram.
components, lead wire connectors,
grounding, diode and their reference pages
of position diagram.

Component Component Name Reference

Page
E07 Fuse box of engine housing CL-8
M14 Ignition switch CL-2
FR04 Rear defrosting CL-21
M28 Instrument fuse box CL-3
Connector
ME01 (white) CL-4
ME02 CL-4
ME03 (black) CL-4
EE01 CL-11
MF03 CL-5
Grounding

Component Position Diagram

The installation positions of the fittings and
lead wire connectors listed in the component
position index can be easily found in the
component position diagram.

Cylinder head
cover

MA03 A10
C20 C21 C22 C23 Main wire Blower fan
Fuel injection nozzles motor
harness joint
How To Use Maintenance Manual GI-4
 How To Use Maintenance Manual GI-5

Shape of Lead Wire Connector when the lead wire connector is not
This section indicates the shape of each separated, take the wire harness of female
lead wire connector shown in the circuit lead wire connector harness towards the
diagram, and the specific position diagram male lead wire connector; while when the
which shows the position of each lead wire lead wire is separated, take the diagram as
on the connector according to wire color and the front plan of the component side or male
terminal. The shape diagram for lead wire lead wire connector. When the wiring of lead
connector can help you find out the position wire connector is shared with multi systems,
to be inspected. The interpretation method it means that the lead wire connector is
of the shape diagram is listed as below: communal.

ME03 ME03 MF03

MF03

1 2 3 4 5 6 6 5 4 3 2 1 1 2 3 4 4 3 2 1
7 8 9 10 111213 131211 10 9 8 7 5 6 7 8 9 10 10 9 8 7 6 5
1415 16 17 18 1920 2019 18 17 16 15 14
A-30 C-61

MF01 MF01

1 2 3 4 5 6 7 8 9 10111213 131211 10 9 8 7 6 5 4 3 2 1
1415161718 19 202122232425 2524 23 2221 20 19 181716 1514

C-02
 How To Use Maintenance Manual GI-6

Lead Wire Connector Shape Diagram and Terminal Number

Arrangement
1. Shape Diagram of Lead Wire Connector

Socket Plug Illustration

Locked point Locked point

Sockets and plugs are
Actual Illustration distinguished by terminal rather
than opening of protecting
sleeve.
Terminal Terminal
Protecting Protecting Please refer to the following
sleeve sleeve
table to number the connectors.
However, some connectors
Diagram in
cannot be numbered by this
This Manual method, please refer to
“Connector Configuration”
section.

2. Sequence of Terminal Number

Numbering Illustration
Sequence

Numbering from upper

Socket right to lower left

Numbering from upper left

to lower right
Plug
 How To Use Maintenance Manual GI-7

Wire Harness Layout

The wire harness layout illustrates the installation positions of the main wire harness and lead
wire connector as well as the route of main wire harness, and makes the circuit overhaul
easy.

FR04 R18 G10 R06 R08

R17 G11 FR01 R05 R07

 How To Use Maintenance Manual GI-8

Representation
The representations, electrical symbols and abbreviation are used in this manual as follows.

Representation in Circuit Diagram

Element
Diod
Diode indicates that the current
Real line indicates that the runs in the direction shown by
element is totally visible the arrow

Broken line indicates that the Fuse and Fusible

element is partly visible 请核实虚 Wire
Showing the current exists at
“ON”position
Fuse box

Stop
lamp There is its name on the top right Showing the short terminal
switch (it
is closed corner of element connected with other fuses
up when
the Fuse number
brake
pedal is
pressed Allowed current for protected
down) There is its function illustration loop
next to the name

Current always
Connector Relay box of engine
housing
Plug

Connector number Fusible piece

Socket

Inner terminal number of connector

Showing the direct connection

between connector and element

Circuit

Showing the connection with the

The circuit breaker is reusable,
element through the wire
and can open due to the heat
caused by overload current.
Some breakers can automatically
reset, but some ones cannot.

Showing the screw connection terminal

of spare parts
 How To Use Maintenance Manual GI-9

The wave line shows the circuit is Current exists at “ON”

interrupted, but it is closed
actually
Fuse box

The lead wire is a yellow wire with

a red line on it

See the power distribution on Page SD-15

The currents shown on two

separated pages are through. The
arrow shows the direction of
current, and you can find out “A”at For the branch circuit merely
the marked position indicates the connection point,
please refer to the identified circuit
for further information of additive
wire

One lead wire connects with Connection

another circuit pointed to by Point
arrow

Connection point
Circuit name number

The interrupted wire indicates that only

partial circuit is displayed; please refer to The connection point is represented
the circuit shown in element schematic by dots, while the accurate position
diagram of such point is different along with
the vehicle
See the grounding distribution on
Page SD-23

Grounding “G”

The various routes are shown by the This symbol indicates the terminal of
selection brackets as follows lead wire is connected with the metal
of vehicle body

Auto Manual
gear gear
This grounding mark (one dot and three
lines) indicates the element enclosure
connects with metal of vehicle body

Shielded Wire
Broken line indicates both the red
wire and the yellow and blue wire
are on the connector E35
For protecting it from radio interference,
the lead wire is enwrapped by the
shielding layer which is always earthed
grounded?
 How To Use Maintenance Manual GI-10

Switch Connector

Switches of this kind move together,

and the broken line indicates they Showing multi-power
are connected by machine device wires connected
together

Indicato
Relay r
Showing the warning light
of seat safety belt
connected with the other
This relay shows the indicator lights inside the
state without current in combined device
this coil, but if there is
current, the feeler will be
shifted Indicator
light
Warning light The indicator light is
Normally-open feeler of seat safety displayed with the symbol
belt
which is lighted
Normally-closed feeler
 How To Use Maintenance Manual GI-11

Electrical Symbols in Circuit Diagram

Electrical
电气符号 Symbol
符 号Illustration
说 明 Symbol
符 号 Illustration
说 明
Symbol
•通过化学作用产生电流
To produce current by chemical
+ - action • 通过电流产生热量
To produce heat by current
•向电路直接补充电流
To supplement current to circuit
directly

Storage battery Electric heating

电加热
蓄电池

•通过线束连接车身接地点，使电流接蓄电
Connected with the vehicle • 通过电流产生热量，也可做车载电源使用
To produce heat by current and
body grounding point via wire
池负极，形成回路 used as vehicle power supply too
harness to make the current
03 reach the negative pole of
battery to form a circuit
Grounding point Cigarette
点烟器 lighter
of 线束接地点
wire harness

• If current is larger than rated • 可给符合额定电压的外接用电器配电

To distribute power for the
current, the fusible wire is easy to
如果电流超过额定电流，易熔丝则熔断，电 external electric appliance
be burnt out, and the current is cut matchable with the rated voltage
流随即被切断
off
Slow-blow • 警惕：更换熔断器的时候不可超过额定电流
Caution: it is unallowable to
缓熔器
device exceed the rated current during
Vehicle
车载电源power
replacing fuse protector supply

• To make a sound by
通过电流发出声音
current

Slice片式保险片
safety lever Slice safety
片式保险片
Slow-blow
缓熔器 device lever Horn
喇叭
• Light and heat generated when
the current runs through the
当电流通过灯丝，产生光，并散发热量
filament

Light illumination
灯光照明
Loudspeaker
扬声器

• 主要用于串联电路，保护限定额定电压的电
Used in series circuit for • To allow or stop the current
通过打开或闭合回路，来允许或阻止当前电
protecting electrical elements of running by opening or closing the
器件 流通过。
limited rated voltage circuit.
Resistance
电阻
Switch
开关

• To convert electric energy into

通过电能转化成机械能 • 二极管，只允许电流在一个方向通过。
Diode allows the current to run in
mechanical energy
M one direction only.

Motor
电机 Diode
二极管

• To suck and release air or

liquid by the action of motor
通过电机的作用，吸放气体或液体 • 当电流通过时发光。
Light generated when the circuit is
P electrified.
• 二极管发光时不产生热量，与普通灯泡不同。
No heat generated when diode
emits light different from common
Pump
Light emitting bulbs.
泵 发光二极管
diode
 How To Use Maintenance Manual GI-12

Electrical Symbol in Circuit Diagram

Electrical
电气符号 Symbol
符 号Illustration
说 明 Electrical
电气符号 Symbol
符 号 Illustration
说 明
Symbol Symbol
•电阻值随温度变化而改变。
Resistance changes with
Sensor •用于给发动机散热。
For the radiating of engine.
传感器 temperature.

Heat-variable
resistance
（热敏电阻型） 请核实 Fan 风扇

Sensor
传感器 •电阻值随部件位置改变而改变。
Resistance changes with the D
position of parts. A B

• 上图式代表回路C-D内连于回路A-B。
The diagram above indicates
Sliding Loop
回路内连 loop C-D inside connects with
（滑动电阻型）
resistance intraconnection loop A-B.
•Magnetism is produced by coil to make feelers
通过线圈产生磁力，吸合继电器触点，使电流通过。
attract with each other to allow the current to
pass. Current passes through the
ON
线圈无电流通过时
No current passes through the coil 线圈有电流通过时
OFF
coil
No current
无电流 Current 有电流
exists
Constantly-open
常开继电器 ON
OFF
ed relay

•Magnetism is produced by coil to make feelers

通过线圈产生磁力，吸合继电器触点，使电流通过。
attract with each other to allow the current to pass.
Current passes through the
No current passes through the coil
线圈无电流通过时 coil 线圈有电流通过时
ON
OFF
Current exists No current
有电流 无电流
Constantly-close
常闭继电器 OFF
ON

d relay
 How To Use Maintenance Manual GI-13

Illustration of Lead Wire Color

Wire Color Code Wire Color Code

Black B Orange O
Blue L Pink P
Brown Br Red R
Green G Purple V
Gray Gr Yellow Y
Light Green Lg White W

Identification Mark of Wire Harness and Pagination Code of System

Function

The wire harness, according to the different All the circuits of vehicle are distinguished
positions of lead wires, can be divided into by the following pagination codes based on
the following categories: their system functions:

Connector Pagination
Wire Harness Name System Function
Code Code
Main wire harness M Distribution system A
ABS module wire harness Starter system B
and air conditioner wire A Charging system C
harness ECM system of engine D
Engine housing wire and Reversing radar E
E
power wire harness ACC system F
Controller wire harness C Lighting system G
Chassis wire harness F BCM system H
Left & right front door Electric back mirror I
D
harness Sunroof system J
Left & right back door Combined switch K
D
harness Airbag L
Tail door wire harness R Diagnosis system M
Ceiling wire harness R ABS braking system N
Air conditioning system O
Wire harness of radar sensor R
Instrument system P
Rear defrosting wire R Burglarproof system Q
 How To Use Maintenance Manual GI-14

Identification for Lead Wire Connector Code

The identification code of lead wire connector consists of the identification code of wire
harness position and the main number of lead wire connector. For the position of lead wire
connector, refer to the wire harness layout.
For example:

E 10

Showing the main number of lead wire connector (serial

number)

Showing the position code of wire harness (engine wire

harness)
Attention
Lead wire connectors between the wire harnesses are represented as the following
codes.
For example:

M R 01
Showing the main number of lead wire connector (serial
number)

Rear wire harness

Main wire harness

Relay Identification
The identification code of relay consists of its abbreviation and main number (serial number).
For example:

R/L 18

Showing the main number of relay (serial number)

Showing the abbreviation of relay

 How To Use Maintenance Manual GI-15

Trouble Inspection Guide

Trouble Inspection Procedure of inspection. The effective trouble
Inspection according to the following 5 diagnosis should be the logic and
phases: simple operation process, and the
1. Verification of Customer’s trouble causes should be affirmed by
Discontent trouble diagnosis program and trouble
For the correct maintenance, operate the diagnosis gauges; in addition, the
components of trouble circuit for inspection should be started from the
inspection, and record all the troubles; most possible cause and the position
don’
t disassemble any part before the most easily to be inspected.
causes are still uncertain. 4. Trouble Maintenance
2. Interpretation and Analysis of Circuit As for the trouble detected, conduct the
Diagram necessary maintenance.
According to the system circuit diagram, 5. Confirmation of Circuit Operation
analyze and judge the whole circuit of the It is indispensable to re-examine the
trouble component, from power supply to circuit to confirm the trouble has been
grounding, to decide the operating eliminated already after the
method. If the operating method cannot maintenance is finished. If the trouble
be decided, please see the circuit results from the broken fusible link, all
operating reference manual; further more, circuits shared with the fusible link
detect other circuits which are shared should be inspected.
with the trouble circuit, and refer to such Trouble Diagnosis Device
shared circuits as fusible link, grounding, Voltmeter and Testing Light
and breaker in the circuit diagram; then The existence of voltage can be detected by
detect the shared circuits left in the first the testing light, and the circuit state by the
phase of inspection; If the shared circuits testing light or voltmeter; the testing light
operate normally, the trouble should fall consists of a pair of lead wires and a bulb of
on its own circuit; and if the several 12V. During the inspection, set one lead
circuits are abnormal, it indicates that the wire grounded, and the other connected with
fusible link or grounding may be out of a measurement point. If the bulb is lit up, it
work. indicates the existence of power supply at
3. Inspection of Circuit and Component this point.
The tester is used for the second phase Attention
 How To Use Maintenance Manual GI-16

When inspecting the voltage of inspection.

electronic control module, such as the
engine control module (ECM) used by Attention
electronic control fuel injection engine, it When the testing light with power supply
is necessary to use the digital voltmeter is used to inspect the module circuit, the
of 10M or the higher resistance for testing light may damage the interior
inspection. If the testing light is used to circuit, so it is prohibited to test the
inspect the module circuit, the testing electronic circuit with testing lights with
lights may damage the interior circuit, so power supply.
it is prohibited to test the electronic The usage of ohmmeter and testing light
circuit with testing lights. with power supply is basically as same as
The usage of voltmeter and testing light is the testing light, whereas the difference
basically as same as the testing lights, but between them is that the ohmmeter can also
the differences between them are that the display the value of resistance, and the
testing light is used just to examine the lower resistance of circuit indicates a good
existence of current, whereas the voltmeter conductivity.
can also display the value of voltage. For the semiconductor element, it is
necessary to detect it with the digital
multimeter of 10M or higher resistance.
When the digital multimeter is used to
Testing Light inspect the resistance, the lead wire with
negative pole of battery should be opened,
or the wrong value of resistance will be
displayed. But when the resistance is
Testing Light and Ohmmeter with Power measured with ohmmeter, the measuring
Supply value will be influenced by the diode and
Testing light with power supply or ohmmeter semiconductor sub-assembly in the circuit.
is used to check the conductivity of circuit. For checking if the measuring value is
Testing light with power supply consists of influenced by the sub-assembly or not,
bulb, battery and two lead wires; when the measure one value firstly, then change the
pair lead wires are connected together, the polarity to measure another value; if the two
bulb will be lit up. The lead wire of negative values are unequal, it indicates that the
pole should be dismounted and the fusible measuring values are influenced by
link in the circuit should be drawn out before semiconductor sub-assembly.
 How To Use Maintenance Manual GI-17

Short-Circuit Detector
The short-circuit detector can be used to
find out the short-circuit position. The pulse
Testing Light with Power
Supply magnetism is produced by short-circuit
detector, and thus the short-circuit position
can be detected.
Trouble Detection
1. Voltage Detection

Jumper Line with Fusible Link Voltage detection is for a purpose of

For inspection the open loop circuit, the inspecting the existence of voltage at a

jumper line should be used. specific point. It can inspect one terminal of

The jumper line is an inspection tool used in connector of lead wire, without

series with tested lead wire. disassembling connection of lead wire, by

The jumper line can be used with most lead testing on the back of lead wire connector.

wire connectors, if it doesn’

t damage the ① When using the testing light or

lead wire connector. voltmeter to inspect the voltage, the

Caution both negative poles of measuring meter

For protecting the circuit to be tested, it and battery should be connected

is prohibited to use the jumper line with together first.

fusible link of a capacity greater than ② Then connect the other lead wire of the

rated capacity, and to use jumper line testing light or voltmeter with the

with fusible link as a substitute for detected position.

output or input signals under such the ③ For the inspection with the testing light,

control modules as ECM and TCM if the light is on, it indicates the circuit is

connected. electrified, while for the inspection with

the voltmeter, if the reading is less than
the specified value by 1V or over, it
indicates the circuit is in trouble.
How To Use Maintenance Manual GI-18
 How To Use Maintenance Manual GI-19

3. Short Circuit Testing

Current always exists ① Separate the negative poles of battery.
Instrument
Fuse box ② Connect a lead wire of testing light with
power supply or ohmmeter to a terminal
of fusible link.
③ Earth the other lead wire of testing light
with power supply or ohmmeter.
Switch

④ Inspect the wire harness from that

closed to fuse box in order. Repeat
such operation until it is about 15cm
Testing
light or away from the testing light with power
voltmeter Coil
supply or ohmmeter.
⑤ If the testing light with power supply
lights up or ohmmeter displays, it
means the short circuit occurs from this
section of lead wire to grounding.
2. Electrifying Testing Switch off battery
Fuse box
① Loosen off the negative pole of battery. (Take off fuse)
② Connect a lead wire of the testing light with
power supply or ohmmeter with the position to
Short circuit
be tested. Shorten the two lead wires of
ohmmeter and zero the ohmmeter before
using the ohmmeter. Switch
Testing light with
③ Connect the other lead wire of detector to power supply or
ohmmeter
the other terminal of load to be tested.
④ If the light with power supply is lit up, it
Cut-off of
means the lead wire is conductive; and if the load

ohmmeter displayed the resistance value is

Coil
low or close to 0, that means the lead wire is of
good conductivity.

Testing light Switch of

with power brake light
supply or
ohmmeter
 How To Use Maintenance Manual GI-20

4. Using Short-circuit Detector to Inspect

Switch off current
Short Circuit
Fuse box
(Take off fuse)
① Draw out the burnt fusible link and loosen
off the negative pole of battery. Short-circuit
indicator
② Connect short-circuit detector to the Pulse magnetic field

terminals of fusible link.

③ Switch on for inspecting the circuit.
④ Pulse magnetism will be produced Instrument
Switch
between fusible link and short-circuit
position, when the short-circuit detector
moves to the short-circuit position. Move the Pulse magnetic field
instrument
⑤ Move the short-circuit detector from the along the circuit

fuse box along the lead wire. As long as Short circuit

the short-circuit detector is between the
Coil
fusible link and shortened position, the
pointer will swing with the changes of
Pointer stops
swing
pulse magnetism. But once the
short-circuit detector goes away from the
shortened position, the pointer will stop
swinging.
How To Use Maintenance Manual GI-21
 Circuit Diagram SD-1

Circuit Diagram
Distribution System-A … … … … … … … … … … … … … … … … … … … … … … … … … ......... SD-2
Fuse Box of Engine Hatch… … … … … … … … … … … … .................................................... SD- 6
Indoor Fuse Box… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … SD-13
Starting System-B … … … … … … … … … … … … … … … … … … … … … … … … … ................ SD-15
Charging System-C … … … … … … … … … … … … … … … … … … … … … … … … … ............. SD-17
Engine ECM System-D … … … … … … … … … … … … … … … … … … … … … … … ............... SD-19
Reversing System-E … … … … … … … … … … … … … … … … … ........................................ SD-31
ACC System-F… … … … … … … … … … … … … … … … … … … … … … … … .......................... SD-34
Lighting System-G … … … … … … … … … … … … … … … … … … … … … … … ...................... SD-38
Headlight… … … … … … … … … … … … … … ........................................................................ SD- 38
Small Light… … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . SD- 39
Front Fog Lamp and Central Switch Group… … … … … … … … … … .................................. SD- 42
Turn Light and Hazard Alarm Light… … … … … … … … ...................................................... SD- 44
BCM System-H … … … … … … … … … … … … … … … … … … … … … … … … … … ................. SD-47
Power Supply and Grounding… … … … … … … … … … … … … … ........................................ SD- 47
Rear Fog Lamp… … … … … … … … … … … … … … … … … … … … … … … … .......................... SD- 48
Fuel Tank and Boot Actuator … … … … … … … … … … … … … … … … … … … ....................... SD- 49
Indoor Light… … … … … … … … … … … … … … … … … … … … … … … … ................................ SD- 50
Central Lock… … … … … … … … … … … … … … … … … … … … … … … … … … ........................ SD- 54
Electric Window… … … … … … … … … … … … … … … … ...................................................... SD- 55
Burglarproof… … … … … … … … … … … … … … … … … … … … … … … … … … … … … ............. SD- 59
Electric Back Mirror-I … … … … … … … … … … … … … … … … … … … … … … … … … … … ... SD-64
Sunroof System-J … … … … … … … … … … … … … … … … … … … … … … … … … … … … ..... SD-65
Horn and Windshield Wiper-K … … … … … … … … … … … … … … … … … … … ................. SD-67
Airbag-L … … … … … … … … … … … … … … … … … … … … .................................................. SD-70
Diagnosis System-M … … … … … … … … … … … … … … ................................................... SD-72
ABS Braking System-N … … … … … … … … … … … … … … … … … … ................................ SD-74
Air conditioning System-O … … … … … … … … … … … … … … … ..................................... SD-77
Blower … … … … … … … … … … … … … … … … … … … … … … … … … … ................................ SD- 77
Temperature Sensor … … … … … … … … … … … … … … … … … … … … … … … ..................... SD- 78
Three-way Pressure… … … … … … … … … … … … … … … … … … … ................................... SD- 79
Compressor … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … SD-
82
Instrument System-P … … … … … … … … … … … … … … … … … … … … … ......................... SD-84
Burglarproof Controller-Q… … … … … … … … … … … … … … … … … … … … … .................. SD-93
 Circuit Diagram SD-2

Distribution System-1
配电系统-1 A-1
Fuse box of engine hatch
E07 发动机仓保险盒

3.00W

3.00G

12.00B
F4 F2
50A 60A
蓄 电 池

F1
120A
Battery

20.00B/R

5.00B/W

5.00W
15.00B-R
20.00B/Y

2
ME02 5.00W

001
Starting system Charging system ABS system
起动系统 充电系统 ABS系统 A-6
C-1 N-1
B-1
 Circuit Diagram SD-3

Distribution system-2
配电系统-2 A-2

E07 发动机仓保险盒
Fuse box of engine hatch

3.00W

3.00G

F3 F7 F8 F9
50A 20A 20A 20A
5.00W/L

3.00W/G

3.00R/W
3.00R

3.00G
1 10
ME02 ME03
3.00W/G
3.00W/L
3.00B/W

002 003
易溶丝 F40
Fusible link F40 Electric电动窗
window
鼓风机
Blower
A-8 A-9 电动窗
Electric window 中控锁
Central lock
H-1H-1 Electric
电动座椅 seat Sunroof
天窗系统system
H-1H-1 H-1
H-1
 Circuit Diagram SD-4

Distribution system-3 A-3

配电系统-3
E07
Fuse box of engine hatch
发动机仓保险盒
3.00W

3.00G

F11 F5 F6 F10 F12

30A 30A 30A 15A 15A
3.00L/B

2.00W/R

3.00B/R

2.00B/Y

0.50B/Y
2.00Br

R/L2
1 4
Main relay of
engine
发动机主
继电器
ON
OFF
2 3

ME01 10
3.00L/B

0.50Gr/R
0.50L

1.25L
3.00L/B

0.50L/B

R/L14
1 4
Rear
defrosting
后除霜
relay
继电器
ON
OFF
Condensed
冷凝风扇 fan Radiator
散热器风扇 fan Cigarette
点烟器 lighter Rear oxygen Front
后氧传感器 oxygen Engine
前氧传感器 ECM
发动机ECM
2 3 Vehicle power sensor sensor
车载电源 碳罐
Carbon canister
0.50B/L

喷油嘴
Fuel injection
3.00B

nozzle

004 062

A-9 H-14
 Circuit Diagram SD-5

Distribution system-4
配电系统-4 A-4
Fuse box of engine hatch
发动机仓保险盒
E07

3.00W

3.00G F13 F14

20A 20A 005 A-10

2.00R/W
F16 F15
2.00W

2.00W
10A 15A
1.25B

2.00W/G

0.50W/G

Engine
发动机ECMECM Headlight
前灯 Headlight
前灯
Fuel
燃油泵
injection Fuel
燃油泵
injection
pump pump
 Circuit Diagram SD-6
☆ Engine hatch fuse box state I

Distribution system-5
配电系统-5 A-5
E07 Fuse box of engine hatch
E07 发动机仓保险盒

R/L8 F13 F14 F15 F16 F17 F18 F19

20A

20A

15A

10A
挂保险盒外面
Hanging outside the fuse box

F2 F3 F4 R/L5 R/L6 R/L7

60A

50A

50A

R/L1 R/L2 R/L3 R/L4

F5 F6 F7 F8 F9 F10 F11 F12

30A

30A

20A

15A

30A

15A
20A

20A

F2-IG Slow-blow device F13- Fuse of high beam light R/L5- Condensed fan relay
F2-IG缓容器 F13-远光灯保险 R/L5-冷凝风扇继电器
F3-30 Slow-blow device F14- Fuse of dipped headlight R/L6- Radiator fan relay 2
F3-30缓容器
F4- Starting slow-blow device
F14-近光灯保险
F15- Fuel injection pump fuse
R/L6-散热器风扇继电器2
R/L7- High beam relay
F4-启动缓容器
F5 -Electronic fan fuse 1 F15-燃油泵保险
F16- Electric injection constant-power fuse R/L8- Fan control relay
R/L7-远光继电器
F6- Electronic fan fuse 2 F17- Reservation Hanging outside the fuse box
F5-电子风扇保险1 F16-电喷常电保险 R/L8-风扇控制继电器
F7- Electric window fuse 1 F18- Reservation
挂保险盒外面
F6-电子风扇保险2
F8- Electric window fuse 2 F17-预留
F19- Reservation
F7-电动窗保险1
F9- Fuse of central lock R/L1- OilF18-预留
pump relay
F10- Cigarette lighter fuse R/L2- Main relay of engine
F8-电动窗保险2 F19-预留
F11- Rear defrosting / back mirror R/L3- Compressor relay
F9-中控锁保险
heating fuse R/L1-油泵继电器
R/L4- Low beam relay
F12-EFI Main relay fuse
F10-点烟器保险 R/L2-发动机主继电器

F11-后除霜/后视镜加热保险 R/L3-压缩机继电器
F12-EFI主继电器保险 R/L4-近光继电器
 Circuit Diagram SD-7
☆ Engine hatch fuse box state II

Distribution system-5

发动机仓线束（2）
E01 左侧转向灯 E07 Fuse box of engine hatch
E02 制动液位传感器
E04 左前轮速传感器
E05 左前制动蹄片磨损传感器
E06 蓄电池正极
Spare

E07 室外保险盒
E09 左前照灯
Spare

E10 高音电喇叭
E11 低音电喇叭
E12 冷凝风扇
Spare

E13 散热器风扇
E14120 左前雾灯
E15 室外温度传感器
Spare

E16 三元压力开关
E17 压缩机
E18 右前雾灯
E19 洗涤电机
E21 右前照灯
ME01 主线束接口1
ME02 主线束接口2
ME03 主线束接口3
EF01 车架线束接口1
EF02 车架线束接口2
CE01 控制线束接口1
CE02 控制线束接口2
F1- Master fuse F12- EFI main relay fuse R/L4- High beam relay
G03 前围接地
F2-IG Slow-blow device F13- Fuse of high beam light R/L5- Condensed fan relay
G04 前围接地
F3-30 Slow-blow device F14- Fuse of dipped headlight R/L6- Radiator fan relay 2
G06 前围接地
F4- starting slow-blow device F15- Fuel injection pump fuse R/L7- High beam relay
G07 前围接地
F5- Electronic fan fuse 1 F16-30 Slow-blow device 2 R/L8- Fan control relay
F6- Electronic fan fuse 2 F17-30 Slow-blow device 3 R/L9- Starting protective
relay
F7- Electric window fuse 1 F18- Blower fuse
F8- Electric window fuse 2 F19- EFI B + fuse
F9- Central lock fuse R/L1- Oil pump relay
F10- Cigarette lighter fuse R/L2- Main relay of engine
F11- Rear defrosting/back mirror heating fuse R/L3- Compressor relay

Note: The stateⅠcoexists with stateⅡ. Confirm the state of vehicle fuse box in maintenance, and then refer to
corresponding circuit for maintenance.
 Circuit Diagram SD-8

Distribution system-6
配电系统-6 A-6

Fusible
易熔丝 F2 link F2
A-1
001

3.00W
094 A-7

1.25W 启动保护Starting
095 protective
继电器 relay B-1
3.00W

B-1
5.00W

093 A-7

3.00R
M14
2

R ST LOCK ST R ON
ST
IG2
ACC 点火开关
Ignition switch
IG2 LOCK
3.00W

6 4
2.00L/B

3.00R/W
M28

B-31

F43 F44 F30

15A 7.5A 10A

Instrument fuse box

仪表保险盒
1.25R/W
0.85B/R
3.00R

起动系统
Starting 天窗 air
Sunroof
system 空调系统
conditioning
system

M14 Ignition switch

M14 点火开关

321
654
 Circuit Diagram SD-9

Distribution system-7
配电系统-7 A-7

3.00W
A-6 094

A-6 093

3.00R
M14
5

R ST R ON R ACC
LOCK Ignition switch LOCK LOCK
ST ST ST
IG1
ACC 点火开关 IG1 ACC IG1 IG2 ACC

1 3
3.00W/L

2.00L
M28
2.00W/L

3.00W/L

0.50W/L

3.00W

F28 F31 F26

10A 10A 10A

Instrument fuse box

4
R/L10
1
仪表保险盒
2.00L/R
1.25B/W
0.85W

2.00W

OFF
ON
3 2
0.50W/B

3.00W/R

05
Burglarproof BCM system
防盗控制器
controller BCM系统 ABS system
ABS系统 006 Electric
电动后视镜 back mirror
DVD
DVD
A-10 Antenna
天线放大器 amplifier
Cigarette
点烟器 lighter
Seat
座椅加热heating

R/L10 on Relay
R/L10 on继电器

1
2
4 3
 Circuit Diagram
SD-10

配电系统-8
Distribution system-8 A-8

Fusible link F3
易熔丝 F3
A-2
002
C-1
098
3.00W/L

M28
2.00W/L

2.00W/L

1.25W/L

1.25W/L

1.25W/L

3.00W/L

3.00B/W

F42 F47 F27 F48 F35 F41 F40

15A 15A 10A 10A 7.5A 20A 30A

主线保险盒
Fuse box of main
wire
1.25L/Y

1.25G/R

1.25B/Y
050R/Y

0.85Y

3.00L

Radio
收放机 Horn
喇叭 Instrume
仪表 Airbag
安全气囊 Trouble
故障诊断 Seat
座椅加热 Blower
鼓风机
recorder nt diagnosis heating
player
 Circuit Diagram
SD-11

Distribution system-9
配电系统-9 A-9

Fusible link F3 Relay R/L14

易熔丝 F3 继电器 R/L14
A-2 A-3
003 004

3.00B
3.0W/G

FR04 MF03
3.00B 8 3.00B 3.00B

后除霜
Rear
defrosting

008
Rear
后除霜
defrosting
指示灯
indicator
M28 G-6C-6
light
1.25W/G

2.00W/G

2.00W/G

1.25W/G

2.00W/G

2.00W/G

1.25B
F50 F25 F34 F46 F32 F24 F49
7.5A 20A 10A 7.5A 10A 15A 7.5A

仪表保险盒
Instrument of fuse
box
2.00B/L

1.25L/Y

1.25G/O

1.25G/B

0.85B/Y
1.25W/G

2.00G

1.25G

Position light
Back位置灯
lighting Indoor light Anti-theft Electric back
前雾灯fog
Front 室内灯 制动灯
Stop 危险报警
Hazard 防盗报警
Burglar 防盗控制器 电动后视镜加热
License light Foot lighting controller mirror heating
背光照明 lamp 照脚灯lamp lamp alarm alarm
牌照灯 Door
门控灯control
light

FR04
FR04 Rear defrosting
后除霜

1
 Circuit Diagram
SD-12

Distribution system-10
配电系统-10 A-10

Relay R/L10
继电器 R/L10
A-7
006

3.00W/R
ME03 9
2.00W/R 2.00W/R 2.00W/R
A-4 005
0.85W/R

3.00W/R
2
EE01
0.85W/R

007

M28
C-1
1.25W/R

2.00W/R

1.25W/R

F33 F29 F45

10A 10A 7.5A

Instrument fuse box

仪表保险盒
0.85R/B

1.25G/Y
1.25Br

Reversing
倒车灯 light Wiper
雨刮间歇 Turn
转向灯 light
intermission
 Circuit Diagram
SD-13

Distribution system-11
M28 Indoor fuse box A-11
配电系统-11 M28 室内保险盒

F20 F21 F22 F23 F24

20A
F25 F26 F27 F28 F29 F30 F31 F32 F33 F34 F35

20A

10A

10A

10A

20A

10A

10A

10A

10A

10A

10A
F36 F37 F38 F39 F40 F41 F42 F43 F44 F45 F46 F47 F48 F49 F50 F51

7.5A

7.5A

7.5A

7.5A

7.5A
30A

20A

10A

15A

15A

10A
R/L10 R/L11 R/L12 R/L13 R/L14 R/L15

R/L16 R/L17 R/L20 R/L18 R/L19

F20- Reservation
F20-预留 F36- Reservation
F36-预留 R/L10- on relay
R/L10-on继电器
F21- Reservation F37- Reservation R/L11- Starting
F21-预留 F37-预留 R/L11-启动保护继电器
protective relay
F22-预留
F22- Reservation F38-预留
F38- Reservation R/L12-鼓风机继电器1
R/L12- Blower relay 1
F23- Reservation F39- Reservation R/L13- Blower relay 2
F23-预留 F39-预留 R/L13-鼓风机继电器2
F24- Burglar alarm fuse F40- Blower fuse R/L14- Rear
F24-防盗告警保险
defrosting relay F40-鼓风机保险 R/L14-后除霜继电器
F25- Fuse of front fog lamp
F25-前雾灯保险 F41- Fuse of seat heating
F41-座椅加热保险 R/L15- Front fog
R/L15-前雾灯继电器 lamp
relay
F26-ACC保险 F42-收放机保险 R/L16-防盗继电器
F26- ACC fuse F42- Radio recorder player R/L16- Anti-theft relay
F27-仪表保险
F27- Instrument fuse F43-AM保险
F43- AM fuse R/L17-小灯继电器
R/L17- Small light relay
F28- BCM IG fuse F44- Coil fuse of starting relay R/L18- Horn relay
F28-BCM IG保险 F44-启动继电器线圈保险 R/L18-喇叭继电器
F29- Wiper motor fuse F45- Turn light fuse R/L19- Cigarette lighter relay
F29-雨刮电机保险
F30- IG2 fuse F45-转向灯保险
F46- Stop lamp fuse R/L19-点烟继电器
R/L20- Flasher relay
F30-IG2保险
F31- ABS IG fuse F46-制动灯保险
F47- Horn fuse R/L20-闪光器继电器
F32- Hazard alarm fuse F48- Airbag fuse
F31-ABS IG 保险 F47-喇叭保险
F33- Reversing light fuse F49- Electric back mirror heating fuse
F32-危险告警保险
F34- Indoor light fuse F48-安全气囊保险
F50- Small light fuse
F35- Diagnosis fuse
F33-倒车灯保险 F51- Reservation
F49-电动后视镜加热保险
F34-室内灯保险 F50-小灯保险
F35-诊断保险 F51-预留
 Circuit Diagram
SD-14

Distribution system-12
配电系统-12 A-12

Index of element location

元件位置索引

Element code Element Name

元件编码 元件名称
E07 发动机仓保险盒
Fuse box of engine hatch
M14 Ignition
点火开关 switch

FR04 Rear
后除霜defrosting
Instrument
仪表保险盒 fuse box
M28

Joint
接头
ME03 (Black)
ME03(黑)
ME01 (White)
ME01(白)
ME02
EE01
MF03

Grounding point
接地点
05
 Circuit Diagram
SD-15

Starting system
起动系统 B-1

Battery Fusible link F44

蓄电池 易熔丝 F44

A-6
095

H-13
013

0.85B/R

0.50P
R/L16 1 3

3 24
1 ON
OFF
1.25W

2 4

0.50B/W

0.50W/B
R/L11
1 4
20.00B/R

ON
OFF

2 3
1.25L/B

R/L11 1
0.50W/B

2
4 3
18 ME03
1.25L/B

EE01
6

1 2 3
1.25L/B

4 5 6

起动机
Starter
 Circuit Diagram
SD-16

Starting system-2
起动系统-2 B-2

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
E26 Starter
起动机B B

E25 Starter
起动机信号 signal

Joint
接头
ME03
EE01

Grounding
接地点 point
05
 Circuit Diagram
SD-17
Charging system
充电系统 C-1

Fusible link F2 Ignition switch (IG1) Fusible link F1

易熔丝 F2 点火开关（IG1） 易熔丝 F1

0.50W/L
5.00W
ME02 2
3.00W

R/L10

15.00B/R
1 4

ON
OFF
2 3
3.00W/R

0.50W/B

• Reserving
倒车灯
light 3.00W/R
• 雨刮间歇
Wiper
intermission
转向灯
2.00W/R

• Turn light

ME03 9
2.00W/R

2.00W/R
A-10 007
0.85W/R

EE01 2
0.85W/R

E28 3
E28 EE01 ME01
S B
0.50W 3 0.50W 3 0.30W
Generator
发电机 L 009 P-3
2

E28 Generator E&L

E28 发电机E&L

4 3 2 1
 Circuit Diagram
SD-18

Charging system-2
充电系统-2 C-2

Index of element location

元件位置索引

Element code Element code

元件编码 元件名称
E27 发电机B B
Generator
E28 发电机E&L
Generator E&L

Joint
接头
ME03
EE01
ME01

Grounding point
接地点
05
 Circuit Diagram
SD-19

Ignition system-1
点火系统-1 D-1

Ignition switch (IG1) Fusible link F12

点火开关（IG1） 易熔丝 F12
2.00W/R

2.00B/Y

0.50B/Y
ME03
9

发动机
Engine
R/L2
Main relayR/L2
R/L2
2.00W/R

主继电器 4 1

3
0.85W/R 12
4 ON
OFF
充电系统
Charging system
2.00W/R

3 2

0.50L
0.50Gr/R

F15 014 D-2

1.25L
15A
2.00W/G

11 2
CE02 CE02
2.00W/G

2.00W/G

1.25W/G

015 D-2
R/L1
1 3
12
CE02
ON
OFF
R/L1 1
2 4 2
4 3
2.00L/B

0.50G

CE02 J1-01 J1-58

FE01
3 6
J1-47 E C M
J1-23
2.00L/B

0.50Y/G 0.50Y/G 0.50Y/G

F07
8 4
2 4
0.50Y-G

FE02 CE01

M
Q 1 MF02
0.30Y/G

燃油泵 燃油传感器
1 Fuel injection 3 Fuel sensor
pump
2.00W/B

0.50W/B

010

燃油表
Fuel oil
P-8
meter
F07

4 3 2 1
 Circuit Diagram
SD-20

Engine ECM System –Oxygen Sensor and Carbon

发动机ECM系统-氧传感器、炭罐 D-2
Canister

D-1 D-1
014 015

1.25V/B
0.50L

FE01 9 1.25V/B 5 1.25V/B

016 D-3

0.85V/B
0.50L

CC01

0.50V/B
F06 C10

1.
25
1 1

L/
D D
2 2

R
1
C C

8 1.25L/R
096 D-3
0.50G/R

CC01
2
Carbo
碳罐
A B A B n C03
控制
4 3 4 3 Front caniste
阀
FE01 6 r
Rear
后氧传感器oxygen 前氧传感器
oxygen control
0.50G/O

0.50G/B

sensor sensor valve

0.85Br
0.50G/R

0.50G/R

FE01 FE01
1
0.50G/Y
0.50W/Y

2
0.50G/B
0.50G/O

1
CE01

4 CE02
8 0.50G/R
0.50P/B

CE02
0.50Br/O

0.50G/R

J1-64 J1-38 J1-61 J1-06 J1-62 J1-63

E C M

C01

R/L1 Oil pump relay R/L2发动机主继电器

Main relay of engine F07燃油传感器及燃油泵
Fuel sensor and fuel C03 Carbon canister control
R/L1 油泵继电器 R/L2 F07 C03 碳罐控制阀
injection pump valve
3 3
12 12 4 3 2 1 2 1
4 4
F06F06 Rear oxygen
后氧传感器 C10C10 Front oxygen
前氧传感器
sensor sensor

4 3 2 1 4 3 2 1
 Circuit Diagram
SD-21

Engine ECM System –Fuel Injection Nozzle and Ignition

发动机ECM系统-喷油嘴、点火线圈 D-3
Coil 图片中间的四个小文本框中的没有翻译

C24
1 1 C25
D-2 D-2 B B
016 096

A A
2 2

1.25L/R

0.85L/R

0.85L/R
1.25V/B

1 C23
0.50R/Y

1 # 喷嘴
1# Fuel injection

1.00Y/R

1.00Y/L
nozzle

0.50V/B 2

1 C22
0.50R/B

2 # 喷嘴
2# Fuel injection

7 CC01
nozzle

CC01 6
0.50V/B 2

0.50R/L 1
C21
3 # 喷嘴
3# Fuel injection
nozzle

0.50V/B 2

0.85Y/B
0.50L/R
0.50R/W 1
C20
4 # 喷嘴
4# Fuel injection
nozzle

0.50V/B 2

CC01 4 3 2 1
0.50R/W

0.50R/L

0.50R/B

0.50R/Y

J1-71 J1-56 J1-70 J1-55 J1-32 J1-52

E C M

C01

C20喷油嘴
C20 Fuel 4injection nozzle 4 C21喷油嘴
C21 Fuel 3injection nozzle 3 C22喷油嘴
C22 Fuel injection
2 nozzle 2 C23喷油嘴
C23 Fuel injection
1 nozzle 1

2 1 2 1 2 1 2 1

C24
C24 Ignition
点火线圈 coil(2、3缸)
(2 and 3 cylinders) C25
C25 Ignition
点火线圈 coil(1、4缸)
(2 and 4 cylinders)

2 1 2 1
 Circuit Diagram
SD-22

Engine ECM System –ECM Power Supply and Stepper Motor

发动机ECM系统-ECM电源、步进电机 D-4

Fusible
易熔丝 linkF16
F16

Stepper
步进电机 C04
motor
1.25B

7 CE02
0.85R

0.50L/B

0.50W/G

0.50V/G

0.50G/B
0.85R

0.85R

J1-17 J1-18 J1-54 J1-33 J1-53 J1-34

E C M

C01

C04 Stepper motor

C04 步进电机

4 3 2 1
 Circuit Diagram
SD-23

Engine ECM System –Knock Sensor and Water Temperature

发动机ECM系统-爆震、水温传感器 D-5
Sensor

C06 Water
水温传感器 temperature C11
sensor

Knock
爆震
sensor
传感器

1 2 1 3 2

0.50B
0.50B/W

0.50G/W

091

P-8
0.50G/W

097 D-6
0.50G

J1-69 J1-43

E C M

C01

C06 Knock sensor

C06 爆震传感器 C11 Water temperature
C11 水温传感器
sensor

2 1 3 2 1
 Circuit Diagram
SD-24

Engine ECM System –Camshaft Position Sensor and

发动机ECM系统-凸轮轴位置传感器、节气门位置传感器 D-6
Air Throttle Position Motor

Camshaft
凸轮轴位置传感器position C12 Air throttle position
节气门位置传感器 C05
sensor sensor

2 1 3
2 3 1

0.50Y
0.50Y
0.50G/W

0.50G/W
0.50W/B

D-5 097
0.50Y/B
0.50Y
0.50G/W

J1-05 J1-10 J1-20 J1-24

E C M

C01

C12 Camshaft position

C12 凸轮轴位置传感器
C05 Air throttle position
C05 节气门位置传感器
sensor sensor

1
3 2 1
3 2
 Circuit Diagram
SD-25

Engine ECM System –Rotating Speed Sensor and Power D-7

发动机ECM系统-转速传感器、动力转向 Steering

C27

Rotating Speed

动力转向steering
转速传感器
Sensor

Power
C26
3 2 1

0.50L/W
3.00Br

0.50L

12
CC01

11
0.50Br 0.50Br 9 0.50Br
CC01
E-1 098

CC01
0.50L/W
0.50L
3.00Br

J1-73 J1-28 J1-12 J1-36

E C M

C01

C26C26 Power steering

动力转向 C27 Rotating Speed Sensor
C27 转速传感器

1
3 2 1
 Circuit Diagram
SD-26

Engine ECM System –Condensed Fan and Radiator Fan

发动机ECM系统-冷凝风扇、散热器风扇 D-8

Fusible
易熔丝link
F5 F5 Fusible
易熔丝 F6 link F6

2.00Br
2.00W/R

0.50Br

0.50Br

0.50Br
2.00Br
of radiator fan
散热器风扇继电器
Fan control Relay
R/L5 R/L8 R/L6
风扇控制继电器
1 4 1 4
Relay of condensed

5
冷凝风扇继电器

1
OFF OFF
ON ON

Relay
fan

ON
OFF
2 3 3 4 2 2 3
0.50Br/R
2.00B/R

2.00B/R
0.50Br/R

2.00B/W

0.50V
2.00B
2.00B/R

2.00W/B

3 CE02
0.50Br/R

1 2 E13
Condense
Radiator
E12 冷凝
d fan 散热器
fan
风扇 1 风扇
CE02

2 1
0.50V
0.50G/O
2.00W/B

03 03

J1-50 J1-67

E C M

C01

R/L5冷凝风扇继电器
R/L5 Relay of condensed fan R/L6
R/L6 Relay of radiator fan
散热器风扇继电器 R/L8R/L8 Fan control relay
风扇控制继电器

3 3 3
12 12 124
4 4 5
E12 Condensed fan
E12 冷凝风扇 E13 散热器风扇
E13 Radiator fan

2 1 2 1
 Circuit Diagram
SD-27

Engine ECM System –Condensed Fan and Radiator

发动机ECM系统-冷凝风扇、散热器风扇 Fan
D-9

Pressure and
temperature
压力温度传感器 sensor C02

O-5 4 3 1 2 O-3 O-3

034 078 079

0.50Gr/B
0.50B/Y

0.50B/R

0.50B/W
0.50B/O
0.50B

0.50L

5 CE02
3 CE01 2 CE01
0.50W/V

0.50Br
0.50Br/R

J1-46 J1-21 J1-27 J1-42 J1-04 J1-39 J1-09

E C M

C01

C02 Pressure and temperature sensor

C02 压力温度传感器

4 3 2 1
 Circuit Diagram
SD-28

Engine ECM System –Instrument Indication

发动机ECM系统-仪表指示 D-10

M-1 Q-1 P-7

Instrument
Diagnosis
诊断 Anti-theft 仪表
诊断 防盗控制
control
rotating speed
P-3 P-3 E-1 转速信号signal
070 072 084 085 089 090
0.85R/Y

0.50R/Y

0.50Gr/W
0.50B/Y
0.50Y
0.85R/Y

0.50B

CE01 9 CE01 11 CE01 7

ME01 7
0.85R/Y

0.50Br/B
0.50Gr/R

0.50R

CE01 10
0.50Br/W

J1-11 J1-31 J1-29 J1-03 J1-45

E C M

C01

C01
C01 ECU Module
ECU模块

53 54 5556 575859 60 61 62 6364 65 6667 6869 7071 72

33 34 3536 373839 40 41 42 4344 45 4647 4849 5051 52

17 18 1920 21222324 25 26 2728 29 3031 32

1 2 3 4 5 6 7 8 9 101112 13 141516 73
 Circuit Diagram
SD-29

Engine ECM System –11 D-11

发动机ECM系统-11

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
Fuel 燃油传感器及燃油泵
injection sensor and fuel injection pump
F07
Rear后氧传感器
oxygen sensor
F06
L-14 Front前氧传感器
oxygen sensor

L-04 Carbon
碳罐 canister

M-01 Fuel 喷油嘴4

injection nozzle 4

M-02 Fuel 喷油嘴3

injection nozzle 3

M-03 Fuel 喷油嘴2

injection nozzle 2

M-04 Fuel 喷油嘴1

injection nozzle 1

M-05 Ignition coil (2 and 3 cylinders)

点火线圈(2、3缸)
M-06 Ignition coil (1 and 4 cylinders)
点火线圈(1、4缸)
L-05 Stepper
步进电机motor

L-07 Knock sensor

爆震传感器
L-12 水温传感器
Water temperature sensor
L-06 节气门位置传感器
Air throttle position sensor
L-13 凸轮轴位置传感器
Camshaft position sensor
M-07 动力转向
Power steering
M-08 曲轴位置传感器
Crankshaft position sensor
E12 冷凝风扇
Condensed fan
E13 散热器风扇
Radiator fan
L-02 压力温度传感器
Pressure temperature sensor
L-01 发动机ECM
Engine ECM
 Circuit Diagram
SD-30

Engine ECM System –12

发动机ECM系统-12 D-12

Index of element location

元件位置索引

Joint
接头
ME03
ME01
ME02
MF02
FE01
L-19
L-91
M-09

Grounding point
接地点
03
05
 Circuit Diagram
SD-31

Reversing System
倒车系统 E-1

Fusible
易熔丝link F33
F33

R01
0.85R/B

Left
左探头 probe

ME03 3
089 D-4
0.85R/B

发动机ECU
Engine ECU 2 1 3

9 8
CE02 CE01

0.50G/R

0.50G/L

0.50G/B
0.50Gr

Speed
车速传感器 FR02 5 4 6
CE02 10 sensor

0.50G/R

0.50G/L

0.50G/B
0.85R/L

059 060
Speed
车速仪表 Speed
instrument 车速BCM
指示 BCM
indication
FE02 10 P-7
P-7 H-13
H-13
14 16 15
+ Signal
信号 -
0.85R/L

Reversing Eradar
倒车雷达 C UECU
0.50R/L 0.50R/L 1
+B

GND - +
0.85R/L

0.50R/L

10 11 2

4 4
0.50B

0.50R
0.50W/B

F14 F15

Left reversing
左倒车灯 Right
右倒车灯 reversing
light 3 3 light
MF01 4 17
0.50B

0.50R

1 2
07 08 07

Buzze
蜂鸣器 M23
r

F14 Left reversing light M23 Buzzer of

F14 左倒车灯 F15
F15 Right reversing light
右倒车灯 R01R01 Left probe of
倒车雷达左探头 M23 倒车雷达蜂鸣器
reversing radar reversing radar
2 1 2 1
6 5 4 3 6 5 4 3 3 2 1 2 1
 Circuit Diagram
SD-32

Reversing E-2
倒车系统
System

R02 R03 R04

Left middle probe
左中探头 Right middle probe
右中探头 Right
右探头 probe

2 1 3 2 1 3 2 1 3
0.50Br/R

0.50Br/L

0.50Br/B

0.50Gr/R

0.50Gr/L

0.50Gr/B

0.50Y/R

0.50Y/L

0.50Y/B
FR02 2 1 3 FR02 13 12 14 FR02 10 9 11
0.50Br/R

0.50Br/L

0.50Br/B

0.50Gr/R

0.50Gr/L

0.50Gr/B

0.50Y/R

0.50Y/L

0.50Y/B
F12
7 9 8 18 20 19 17 6 5
+ Signal
信号 - + 信号
Signal - + Signal
信号 -

Reversing radar
倒车雷达 E CECU
U

- Signal
信号 +
12 3 4
0.50Br
0.50L

0.50R

FR03 11 9 10
0.50Br
0.50L

0.50R

3 1 2

R11 GND DISPLAY VCC

Display
显示屏 screen

F12 Reversing radar ECU R02 Left middle probe of R03 Right middle probe of
F12 倒车雷达ECU R02 倒车雷达左中探头 R03 倒车雷达右中探头
reversing radar reversing radar
9 8 7 6 5 4 3 2 1
2019 18 1716 1514 13 1211 10 3 2 1 3 2 1

R04 Right probe of reversing

R04 倒车雷达右探头
R11 Display screen of
R11 倒车雷达显示屏
radar reversing radar

3 2 1 3 2 1
 Circuit Diagram
SD-33

Reversing System -3 E-3

倒车系统-3

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
F14 左后组合灯
Left rear combination light
F15 右后组合灯
Right rear combination light
L-09 车速传感器
Speed sensor
L-11 倒车开关
Reversing switch
F12 倒车雷达控制器
Reversing radar controller
R01 左后倒车雷达
Left rear reversing radar
R02 左中倒车雷达
Left middle reversing radar
R03 右中倒车雷达
Right middle reversing radar
R04 右后倒车雷达
Right rear reversing radar
R11 内后视镜
Interior back mirror
M23 倒车雷达蜂鸣器
Buzzer of reversing radar

Joint
接头
ME03
FE02
FR02
FR03
FE01
L-19
L-91

Grounding point
接地点
07
08
 Circuit Diagram
SD-34

ACC System- DVD F-1

ACC系统-DVD

Fusible
易熔丝link F42
F42

1.25L/Y
G-4

011
0.50L/Y

0.50L/Y

0.50R/G
M10

8 15 16
B/UP B/UP ILL+

D DVD
V DChanger
主 机

GND GND GND RL- RL+ RR- RR+

9 1 6 5 4 13 12
0.50Y

0.50B

0.50W

0.50R

16 3 22 10
0.50W/B

0.50W/B

MF01 MF02
0.50Y

0.50B

0.50W

0.50R
0.50W/B

10 5 10 5 FD04
FD04
0.50W

0.50R

0.50W

0.50R
Loudspeaker

左后门扬声器

右后门扬声器
on the left
rear door

Loudspeak

right rear
0.50W/B

er on the

door

2 1
- +

+ -
1 2
D22 D22
0.50W

0.50R
0.50R

0.50W

loudspeaker on
右后门高音扬声器
左后门高音扬声器
loudspeaker on

the right rear

05 05
High pitch
the left rear
High pitch

door
door

2 1
- +

+ -
1 2

D20 D20

D22 Loudspeaker on D22 Loudspeaker on D20

D20 High pitch
D22 左后门扬声器 D22 右后门扬声器 左后门高音扬声器 D20D20 High pitch
右后门高音扬声器
the left rear door 1 the right rear door 1 loudspeaker on the loudspeaker on the
2 1 2 1
2 2 left rear door right rear door
 Circuit Diagram
SD-35

ACC System- DVD

ACC系统-DVD F-2

Ignition switch (ACC)

点火开关（ACC）

2.00L
F-3 I-1
F-3
Sunroof
I-1
Electric back
遮阳板照明
illumination 电动后视镜
mirror

065 063 F26

10A

2.00L/R
0.50L/R

0.85L/R
天线
Antenna
amplifier
放大器
F17F17 1 2
+B 2.00L/R 2.00L/R 2.00L/R Cigarette
064 点烟器
lighter
1
MF03 F-3

0.50L/R
M10
7
天线
Antenna ACC

DDVD
V Changer
D 主 机

FL- FL+ FR- FR+

3 2 11 10
0.50Lg
0.50V

0.50P

0.50L

15 2 5 6
MF01 MF02
0.50V

0.50P

0.50L

0.50Lg

FD01 6 5 6 5 FD03
0.50Lg
0.50V

0.50P

0.50L
左前门扬声器
Loudspeaker on the

High pitch loudspeaker on Loudspeaker on the

右前门扬声器
left front door

right front door

2 1
- +
D09 D16
+ -
1 2
0.50Lg
0.50V

0.50P

0.50L
左前门高音扬声器

右前门高音扬声器
loudspeaker on the

the right front door

left front door
High pitch

2 1
- +
D02 D10
+ -
1 2

M10M10
DVD DVD
主机 Changer D09 Loudspeaker on
D09 左前门扬声器 D16 Loudspeaker on
D16 右前门扬声器
the left front door 1 the right front door 1
2 2
8 7 6 5 4 3 2 1
16 151413 1211 10 9 D02 High pitch
D02 左前门高音扬声器 D10
D10 High pitch
右前门高音扬声器
loudspeaker on the 2 1 loudspeaker on the 2 1
left front door right front door
 Circuit Diagram
SD-36

ACC System- Cigarette Lighter and Sunroof Illumination

ACC系统-点烟器、遮阳板照明 F-3

F-2 F-2 Fusible

易熔丝link
F10F10 G-3
065 064 024

3.00B/R
ME01 17

0.50L/R

3.00B/R
0.50L/R

R/L19
4 1
FR03 5
点烟继电器

Relay of
cigarette
3 4
2
lighter OFF 1

0.50G
0.50L/R

ON
3 2
0.85B/Y

0.85B/Y
0.50L/R

0.50L/R

MF03 7
R13 R14 M21
2 2 2 1
左遮阳板灯

右遮阳板灯
Left sunroof light

0.85B/Y
0.50W/B

Cigarette
Right sunroof

点烟器
lighter
light

1 1 3
0.50W/B

0.50W/B

F13
2

Vehicle
车载电源 power
1.25W/B

0.85W/B

FR03 1
0.85W/B
1.25W/B

08 05 07 06

B-24 Front
B-24 前点烟器
cigarette C-09 Vehicle power
C-09 车载电源 H-07左遮阳板照明
H-07 Left sunroof H-06 Right sunroof
H-06 右遮阳板照明
lighter F13 illumination illumination
R14
M21 F13 R13
M21 R13 R14
1
3 2 1 2 2 1 2 1
 Circuit Diagram
SD-37

ACC System- 4
ACC系统-4 F-4

Index of element location

元件位置索引

Element code Element code

元件编码 元件名称
D22 后低音扬声器
Rear bass loudspeaker

D20 后高音扬声器
Rear high pitch loudspeaker

M10 DVD
DVD
D09 左前低音扬声器
Left front bass loudspeaker

D02 左前高音扬声器
Left front high pitch loudspeaker

D16 Right front high pitch loudspeaker

右前高音扬声器

D10 Right front high pitch loudspeaker

右前高音扬声器
M21 Cigarette
点烟器 lighter
Rear
后车载电源vehicle power
F13
Left sunroof illumination,
左遮阳板照明 左遮阳板灯 left sunroof light
R13
Right
右遮阳板照明sunroof illumination,
右遮阳板灯 right sunroof light
R14

Joint
接头
ME01
MF01
MF02
FR03
MF03
FD01
FD03
FD04

Grounding point
接地点
05
06
07
08
 Circuit Diagram
SD-38

Illumination-
灯光照明-前照灯 Headlight G-1

Fusible
易熔丝link F28 Fusible
F28(IG1) 易熔丝link
F13F13 Fusible
易熔丝 linkF14
F14
(IG1)

2.00R-W
2.00R-W

0.50R-W

2.00R-Y

0.50R-W
R/L7 R/L4
1 4 1 4
High
远光beam 近光
Low
relay
继电器 beam
继电器
relay
ON ON
OFF OFF
0.50W

G-4

2.00R-B
2 3 2 3
High beam
0.50R-B
2.00R-L

048 instrument

0.50R-G
indication
远光仪表指示
0.50W-B
0.50G

012
1.25R-B

2.00R-B

2.00R-L
1.25R-L

P-5
0.85R

B-09 A-01 0.85R

6 1 2 11
+B
regulating switch of

2 7 3 2 7 3
Illumination for

A-01
前照灯调节

Regulating A-01
headlight
照明

switch of
Right Dipped headlight
前照灯 0.50L-R 0.50L-R 4
M M
左近光灯

左远光灯

右近光灯

右远光灯
headlight
调节开关

beam light
Left Dipped

Right high
beam light
开关

Left high
headlight

5 6 1 1
左前照灯
Left headlight
regulating motor 右前照灯
Right headlight
regulating motor

4 调节电机 调节电机
3
0.50R-B

5 4 5 4
0.50R-G

A-11 A-15
0.50R-G
0.50L-Y

1.25W-B

2.00W-B

1.25W-B

2.00W-B

047 A-01
Illumination
开关
regulating for 13 0.50L-Y
照明调节switch
G-4
G-4 03 03 04 04

0.50R-B

0.50R-B

B29-4 B29-1 B29-6

High
远光
0.50W-B B28-6 OFF Overtaking beam
超车 近光
Low
Headlight
前照灯开关 switch beam

B29-1

A-11 Left headlight B-29 Combined switch A B-09 Headlight

0.50W-B

A-11 左前照灯 B-29 组合开关 A B-09 前照灯调节开关

regulating motor

4 3 2 1 B-09
2 1 2 1
8 7 6 5 6 5 4 3 6 5 4 3
A-15 Right headlight B-28 Combined switch B
A-15 右前照灯 B-28 组合开关 B

4 3 2 1
4 3 2 1
8 7 6 5 10 9 8 7 6 5
 Circuit Diagram
SD-39

Illumination-
灯光照明-小灯 Small Light G-2

Fusible linkF50
F50
易熔丝

1.25W/G
1.25W/G

0.50W/G
0.50W/B

0.50W/B

R/L17 1 4
1 1 Small light
3 4 小灯
relay
继电器
2
Right license light

Left license light

1
右牌照灯

左牌照灯

RO6 RO5 ON
OFF

2 3
2 2 1.25G
G-3 017
0.50G

0.50G

FR01
0.50G 2
1.25W/B

1.25G
0.50G

0.50B/O

0.50G 0.50G 0.85G

4 1
G
50
0.50G

0.50G

0.85G

FE01 0. MF03
G
50

FR01 5
0.

7
8 8 9 13 1 M16
FD01 FD04
Left front position light

Left rear position light

右前位置灯

左前位置灯

左后位置灯
Right front position

0.50G

0.50G
1.25W/B

E21 E09 F14

light

5 5
018 019 7
1.25W/B

Switch Switch
左前门 左后门
0.50W/B
2.00W/B

illumination illumination
2.00W/B

电动窗
for electric 电动窗
for electric
开关照明
window on
the left front
开关照明
window on
the left rear
door door
H-11
H-11 H-10
H-10

07 04 03 07 05

E09E09 Left front R05 M16 组合开关

Combined
左前位置灯
position light
RO5 Left
左牌照灯 license M16 B
light light B

4 3 2 1
2 1 4 3 2 1
8 7 6 5 10 9 8 7 6 5
E21 Right front
E21 右前位置灯
R06 Right license
R06 右牌照灯
F14 Left rear
F14 左后位置灯
position light light position light

4 3 2 1 2 1
2 1 6 5 4 3
8 7 6 5
 Circuit Diagram
SD-40

Illumination- Small Light

灯光照明-小灯 G-3

Relay
继电器 R/L17
R/L17
G-2
017
1.25G

0.50G 0.50G
025 G-4
1.25G

0.50G

0.50G

0.50G
MF02 2
20
杂物盒照明开关
0.85G

miscellaneous articles
Illumination switch of

M25
compartment
0.50G

0.50G

1
0.85G

0.50G

023 024
Front fog Illumination
前雾灯 点烟器
0.50G/Y

9 13 lamp for cigarette

FD03 FD04 照明
1
G-5
G-5 lighter
F-3
F-3
0.50G

0.50G
Right rear position light
右后位置灯

2
F15
杂物盒照明灯
Lighting of miscellaneous
articles compartment

M26
1.25W/B

020 021 022

Switch Switch
右前门
illumination 右后门
illumination BCM 1
电动窗of electric 电动窗of electric
H-2
window on window on
0.50W/B

开关照明
the right front
开关照明
the right rear
door door
08
H-9
H-9
H-10H-10

06

F15
F15 Right
右后位置灯 rear position light M25 Illumination switch of
M25 杂物盒照明开关 M26 Lighting of miscellaneous
M26 杂物盒照明灯
miscellaneous articles articles compartment
compartment
2 1
6 5 4 3 2 1 2 1
 Circuit Diagram
SD-41

Illumination- Small Light

灯光照明-小灯 G-4

G-3
025
0.50G

0.50G

0.30G

0.50G

0.50G

0.50G

0.50G
0.50G

027 029 031 048 050 050

中央开关组
Central 仪表照明
Instrument 空调面板of
Illumination 前照灯调光
Regulating 行李箱
Switch 油箱盖
Switch
switch group illumination air switch illumination
照明 照明 开关照明
illumination of
开关照明 of illumination
开关照明 of
illumination P-8 conditioning headlight
boot the fuel tank
G-5
G-5 P-8 O-2
panel G-1
G-1 H-3
H-3 H-3
cover
O-2 H-3
M05 Illumination
中央开关组
6 regulating for
central switch
照明调节
group
Regulating switch G-5
G-5 P-8 O-2 G-1 H-3 H-3 F-1
照明调光开关
for illumination
028 011
030 032 047 049 049
3 4
0.50R/G

0.30R/G
0.50R/G

0.50R/G

0.50R/G
0.50R/G

0.50R/G

0.50R/G
0.50W/B

03

M05 Regulating switch of headlight

M05 前照灯调节开关

2 1
6 5 4 3
 Circuit Diagram
SD-42

Illumination –Front Fog Lamp and Central Switch

灯光照明-前雾灯、中央开关组 G-5
Group

G-3 Fusible
易熔丝 F25link F25 G-4 H-2
023 027 035
2.00B/L
0.50G

R/L15
4 1
Front fog
lamp 前雾灯
relay
继电器
OFF
ON
3 2
2.00L/W

ME03
2.00L/W 14 2.00L/W
Instrument indication of
前雾灯 P-6
front fog lamp
026 仪表指示 P-6

0.50L/B
0.50G
033 BCM H-2
0.50L

2.00L/W

1.25L-W

E14 E18
0.50L/W

1 1
左前雾灯

右前雾灯
Right front fog lamp
Left front fog lamp

2 2
1.25W/B

1.25W/B

03 04

8 16 6 15
Indicator light of

Front fog lamp

front fog lamp
Front fog lamp

illumination

Indicator light of
lamp switch

illumination
前雾灯指示灯

后雾灯指示灯
rear fog lamp
Rear fog

1K 1K 1K 1K
Rear fog
前雾灯开关

后雾灯开关
前雾灯照明

后雾灯照明
switch

lamp

4 1 Central switch
中央开关组合 9
0.50W/B

0.50R/G

combination
M12

034
06 028
BCM
H-2
G-4

M12
M12 Central switch combination
中央开关组合 E14
E14 Left
左前雾灯 front fog lamp E18右前雾灯
E18 Right front fog lamp

9 8 7 6 5 4 3 2 1 2 1 2 1
2019 18 1716 1514 13 1211 10
 Circuit Diagram
SD-43

Illumination –Front Fog Lamp and Central Switch Group

灯光照明-前雾灯、中央开关组 G-6

G-7 A-9 H-3

036 008 037
0.50G/O

0.50G/O
0.50B

3 18 19
alarm

Indicator light of
rear defrosting
Hazard alarm
危险报警照明

危险报警开关

后除霜指示灯

Rear defrosting

1K 3K
defrosting
illumination

1K 1K
illumination

后除霜开关
后除霜照明
switch

switch
Rear
Hazard

Central switch combination

中央开关组合
M12

M12
M12 Central switch group
中央开关组

9 8 7 6 5 4 3 2 1
2019 18 1716151413 1211 10
 Circuit Diagram
SD-44

Illumination –Turn Light and Hazard Alarm Light

灯光照明-转向灯、危险报警灯 G-7

Fusible
易熔丝 linkF45
F45 Fusible
易熔丝linkF32F32

1.25G/Y
8

1.25G/B
M16

Right
左 右
Left
3 9
0.85G/W

0.85G/L

4 3 8

15L 15R 30
9 0.50G/O
HWS 036 G-6
31 15R L Hazard alarm switch
危险报警开关
6
15L
0.85W/B

31 R
P-5 P-5
Instrument 右转向Instrument
左转向for 038
indication HWS 30 039 indication for
仪表指示
仪表指示
left turning right turning

Flasher relay
闪光继电器
0.30G/Y
0.30G/B

05

L R
2 5 16
0.50G/Y
0.85G/B

0.85G/Y 0.85G/Y

15 16 MA01
0.85G/B 0.50G/Y
0.85G/B
0.50G/B

ME03 ME03

MF03 11 MF02
0.50G/Y 0.85G/Y

10
0.50G/B 0.85G/B

0.50G/Y

0.50G/Y
0.50G/B

0.50G/B

BCM 040 041 BCM

H-13 H-13
E01 E09 F14 E21 A05
2 4 2 2 F15 4 2
左侧转向灯

左前转向灯

左后转向灯

右后转向灯

右前转向灯

右侧转向灯
Left rear turn light

Right front turn

Right turn light

Right rear turn
Left turn light

Left front turn

light

light

light

1 5 3 3 5 1
0.50W/B

2.00W/B

1.25W/B

1.25W/B

2.00W/B

0.50W/B

04 03 07 08 04 06

M16组合开关
M16 Combined
B switch E01
E01 Left turn light
左侧转向灯
E09 Left headlight
E09 左前照灯 F14左后位置灯
F14 Left rear position light
B
4 3 2 1 2 1 4 3 2 1 2 1
10 9 8 7 6 5 8 7 6 5 6 5 4 3
闪光继电器
Flasher relay A05右侧转向灯
Right turn E21 Right headlight F15 Right rear position light
A05 E21 右前照灯 F15 右后位置灯
3 2 1 light
6 5 4 2 1 4 3 2 1 2 1
9 8 7 8 7 6 5 6 5 4 3
 Circuit Diagram
SD-45

Illumination - 8
灯光照明-8 G-8

Index of element location

元件位置索引

Element Code Element Name

元件编码 元件名称
左前照灯
E09 Left headlight
E21 右前照灯
Right headlight
M15 组合开关A
Combined switch A
M16 组合开关B
Combined switch B
M04 前照灯调节开关
Regulating switch of headlight
R05 左牌照灯
Left license light
R06 右牌照灯
Right license light
F14 左后组合灯
Left rear combined light
F15 右后组合灯
Right rear combined light
M25 杂物盒照明开关
Illumination switch of miscellaneous articles compartment
M26 杂物盒照明灯
Lighting of miscellaneous articles compartment
M05 照明调光开关
Regulating switch for illumination
M12 中央开关组合
Central switch combination

E14 左前雾灯
Left front fog lamp

E18 右前雾灯
Right front fog lamp

E01 左侧转向灯
Left turn light

A05 右侧转向灯
Right turn light
 Circuit Diagram
SD-46

Illumination - 9
灯光照明-9 G-9

Index of element location

元件位置索引

Joint
接头
ME03
FR01
MF02
FE01
MF03
FD01
FD03
FD04

Grounding point
接地点
03
04
05
06
07
08
 Circuit Diagram
SD-47

BCM System –Power Supply and

BCM系统-电源、接地 H-1
Grounding

B C M
KL.30 KL.30 KL.30 KL.30 blinker KL.31 KL.31 KL.31
F01 F03 F03 F02 F01 F01 F03
1 1 4 1 2 17 2

2.00G
3.00R/W
3.00G

3.00R

3 MF03

3.00W/B

3.00W/B
3.00W/B
2.00G
3.00R/W
3.00G

1.25G

1.25G

EF01 EF01 EF01

4 2 3

042 043 044 09 09 09

Sunroof
天窗 电动座椅 Anti-theft
防盗
J-1
Electric seat
controller
控制器
3.00G

3.00R

3.00R

2.00G

J-1 Q-1
Q-1

Fusible
易熔丝link
F09F09 Fusible
易熔丝link
F07F07 易熔丝
Fusible
F08link 易熔丝link
Fusible F24F24
F08

F01 BCM A F02 BCM B F03 BCM C

191613 10 7 4 1 161310 7 4 1 13 10 7 4 1
20 17 14 11 8 5 2 17 14 11 8 5 2 14 11 8 5 2
21 1815 12 9 6 3 1815 12 9 6 3 1512 9 6 3
 Circuit Diagram
SD-48

BCM System –Rear Fog Lamp

BCM系统-后雾灯 H-2

Position Front
B Rear
C M Rear
Ignition Light Fog Light Fog Light Switch Fog Lamps
F01 F01 F01 F02 F01
9 8 15 5 18

0.50L/Y

0.85L/W
0.50L/W
2.00W

MF03 MF01 MF01 0.50L/W

4 21 20

MF01
0.50G
2.00W

0.85L/W

0.85L/W
11

0.30L/W
F14 F15
6 6
0.50L/Y

0.85L/Y

左后雾灯

右后雾灯
Right rear fog
Left rear fog
0.50L/W

0.50L/Y

lamp

lamp

0.30L/W

0.30L/W

045 092
1.25W/B
1.25W/B

046 035
IG仪表
power 防盗控制
IG power
of
IG电源 of
IG电源 后雾灯
Instrument 后雾灯
Operating
2.00W

indication of indication of
instrume anti-theft 仪表指示
rear fog
工作指示
rear fog
nt
P-8 control
Q-1 lamp lamp
P-8 Q-1 P-5
P-5 G-5
Q-5

07 08
Fusible
易熔丝 F28 link F28
022 033 034

G-3 G-5 G-5

F14左后雾灯
F14 Left rear fog lamp F15
F15 Right rear fog lamp
右后雾灯

2 1 2 1
6 5 4 3 6 5 4 3
 Circuit Diagram
SD-49

BCM System –Fuel Tank and Boot Actuator

BCM系统-油箱、行李箱执行器 H-3

B C M
Rear Trunk Trunk Fuel Fuel
Defogger Lid open Lid Open Lid open Lid open

F01 F01 F01 F02 F01

6 3 7 15 4
0.50Br/W

0.50Br/G
G-4 G-4
0.50P/G

1.25Br

1.25B
050 051

MF01 FR01 MF01

8 3 7
1.25Br

1 MF01
0.50G

0.50G
0.50Br/W

0.50Br/G

F16
1 RO7 1

M M
M02 M03
9 8 9 8
行李箱开关照明

油箱盖开关照明

2 2
Fuel tank cover
Illumination for

Illumination for
fuel tank cover
switch
0.50P/G

boot switch
行李箱开关

油箱盖开关
switch

switch
Boot

1.25W/B

6 3 6 3
1.25W/B
0.50R/G

0.50R/G
0.50W/B

0.50W/B

7 FR01
1.25W/B

037 049 051

Rear
后除霜 开关Switch 开关 Switch
defrosting illumination illumination
开关 照明调节
regulation 照明调节
regulation
switch
G-4 G-4
G-6
G-6 G-4 G-4
03 07 03 08

M02 Boot switch R07 Boot actuator M03 Boot actuator F16 Fuel tank cover actuator
M02 行李箱开关 R07 行李箱执行器 M03 油箱盖开关 F16 油箱盖执行器

4 3 2 1 2 1 4 3 2 1 2 1
10 9 8 7 6 5 10 9 8 7 6 5
 Circuit Diagram
SD-50

BCM System –Indoor Light

BCM系统-室内灯 H-4

B C M Interior
Light

F01

Fusible 20
易熔丝link
F34F34
1.25L/Y

MF02
1.25L/Y 4 1.25L/Y 1.25L/Y
053 H-5
0.85L/Y
1.25L/Y

FR03
4
0.85L/Y
0.50L/Y

0.50L/Y

0.85L/Y

0.50L/Y

0.85B/R

M13 M24
2 2 R15 R10
1 1
左照脚灯

右照脚灯 lamp
lamp

dome lamp
Front dome lamp
Right foot
Left foot

前顶灯

后顶灯
lighting
lighting

Rear

1 1

2 3 2 3
0.50B/R

0.50B/R

0.85B/R

0.50B/R
0.85B/R
0.85W/B

0.50W/B

FR03
0.50B/R

3
0.85B/R

MF01
6 0.50B/R 0.85B/R

1.25W/B 1.25W/B
08
1
FR03

M13 Left foot lighting lamp M24 Right foot lighting lamp
M13 左照脚灯 M24 右照脚灯 R15 R15
前顶灯 Front dome lamp R10R10
后顶灯Rear dome lamp

2 1 2 1 3 2 1 3 2 1
 Circuit Diagram
SD-51

BCM System –Indoor

BCM系统-室内灯 H-5
Light

B C M
FL Door Contact FR Door Contact

F02 F02

8 7

1.25L/Y 1.25L/Y 1.25L/Y

H-4 053 054 H-6
0.50L/Y

0.50L/Y
FD01 FD03
0.50B/G

0.50B/O
14 14
0.50L/Y

0.50L/Y

2 2
FD01 FD03
左前门灯

左前门灯
Left front door

Left front door

D07 10 D14 10
light

light

1 1
0.50B/G

0.50B/O

0.50B/G 0.50B/O
0.50B/G

0.50B/O

4 4
左前门灯开关

右前门灯开关
Left front door light

Right front door

light switch
switch

D06 D13

1 1
0.50W/B

0.50W/B

FD01 FD03
31 31
0.85W/B

0.85W/B

07 08

D07 左前门灯
Left front door light D06 左前门灯开关
Left front door light switch D14 Right front door light D13 Right front door light
D07 D06 D14 右前门灯 D13 右前门灯开关
switch

2 1 3 2 1 2 1 3 2 1
6 5 4 6 5 4
 Circuit Diagram
SD-52

BCM System –Indoor

BCM系统-室内灯
Light H-6

B C M
RL Door Contact RR Door Contact

F02 F02

12 11

1.25L/Y 1.25L/Y 1.25L/Y

H-5 054 055 H-7
0.50L/Y

0.50L/Y
FD04 FD04
0.50B/Y

0.50B/W
6 6
0.50L/Y

0.50L/Y

2 2
FD04 FD04
左后门灯

右后门灯
Left rear door

Right rear
door light

D17 11 D17 11
light

1 1
0.50B/Y

0.50B/Y

0.50B/Y 0.50B/Y
0.50B/Y

0.50B/Y

4 4
左后门灯开关

右后门灯开关
Left rear door light

Right rear door

light switch
switch

D19 D19

1 1
0.50W/B

0.50W/B

FD04 FD04
9 9
0.50W/B

0.50W/B

07 08

D17 左后门灯
Left rear door light D19 Left rear door light switch D17
D17 Right rear door light
D17 D19 左后门灯开关 右后门灯 D19D19 Right rear door light
右后门灯开关
switch

2 1 3 2 1 2 1 3 2 1
6 5 4 6 5 4
 Circuit Diagram
SD-53

BCM System –Indoor Light

BCM系统-室内灯 H-7

B C M
HDF Door Open
F02 F02

10 9

1.25L/Y
H-6 055

0.50L
1.25L/Y

1
0.50B/V
行李箱灯
Boot light

F10
5
MF01
2
0.50B/V

0.50L

0.50B/V 0.50Br/W
0.50B/V

FR01 15
MF02
9
0.30Br/W
0.50B/V

2
行李箱灯开关
Boot light switch

056 057
R08

P-3 P-2
1
0.50W/B

FR01
7
1.25W/B

07

F10 Boot
行李箱灯 light R08
R08 Boot light switch
行李箱灯开关
F10

2 1 2 1
 Circuit Diagram
SD-54

BCM System –Central lock H-8

BCM系统-中控锁

Key Cylinder Key Cylinder

B C M
Driver Door Passenger Door CL Lock CL Unlock
F02 13 F02 14 F02 17 F02 16
0.50L/R

0.50L/B

3.00L/R

3.00L/B
D06

1.25L/R
2
1.25L/R
2
M 5
1.25L/B
1
1.25L/B

FD01 Locking motor of FD01

左前门锁电机
left front door
3.00L/R
0.50L/R

0.50L/B
0.50L/B
0.50L/R

3.00L/B
D13

FD01
3
FD01
4
FD03
3
FD03
4
1.25L/R
2
1.25L/R
2
M 5
1.25L/B
1
1.25L/B

FD03 Locking motor of FD03

右前门锁电机
3.00L/R

right front door

0.50L/R
0.50L/R
0.50L/R

3.00L/B
0.50L/R

D19

2 D23 1 2 D24 1
1.25L/R
4
1.25L/R
2
M 5
1.25L/B
1
1.25L/B

FD04 Left rear door lock FD04

lock Unlock lock Unlock 左后门锁电机 motor

3 3
D19

M
0.50W/B

0.50W/B

1.25L/R 1.25L/R 1.25L/B 1.25L/B

4 2 5 1
FD04 Right rear door FD04
右后门锁电机
lock motor
FD01 FD03
31 31
0.85W/B

0.85W/B

07 08

D23
D23 Lock core of left front
左前门锁芯 D24
D24 Lock
右前门锁芯core of right front
door door

2 1 2 1
3 3

D06 Left front door D13 D19 Left rear door

D06 左前门灯开关 D13 Right
右前门灯开关front door D19 左后门锁电机 D19 右后门锁电机
D19
Right rear door
light switch light switch lock motor lock motor

3 2 1 3 2 1 3 2 1 3 2 1
6 5 4 6 5 4 6 5 4 6 5 4
 Circuit Diagram
SD-55

BCM System
BCM系统-电动窗 – Electric H-9
Window

B C M
PW SW FL up PW SW FL down PW SW FR up PW SW FR down
F03 3 F03 5 6 F03 8
F03

0.50Lg/R

0.50Lg/B
0.50Lg/R 0.50Lg/B
0.50Gr/R

0.50Gr

15 18 FD03
FD03

0.50Lg/R
0.50Lg/R

G-3

0.50Lg/R
0.50Lg/R
15 18 020
FD01 FD01
24 26
FD01 FD01

D12 1 5 4
0.50Lg/R

0.50Lg/R
0.50Gr/R

Electric
右前门
Window
0.50Gr

电动窗
switch of
right front
开关
door

3 2
0.50W/B
0.50Br

FD03 11 31 FD03
0.85W/B
0.50Br

FD01
0.50Br 11
058 H-10

D04 08
7 9 8 13 12
Protective lock

Driver-side electric window

children

司机侧电动窗开关
儿童锁

switch
for

10
0.50W/B

FD01
0.85W/B
07
31

D04D04 Electric Window

左前门电动窗开关 D12D12 Electric Window
右前门电动窗开关
switch of left front door switch of right front door

6 5 4 3 2 1 2 1
1312 11 10 9 8 7 5 4 3
 Circuit Diagram
SD-56

BCM System - Electric Window

BCM系统-电动窗 H-10

B C M
PW SW RL up PW SW RL down PW SW RR up PW SW RR down

F03 9 F03 11 12 F03 F03

15
0.50R/L

0.50R/G

0.50G/L

0.50G/W
0.50R/L 0.50R/G 0.50G/L 0.50G/W

FD04
7 12 FD04 FD04
7 12 FD04
0.50R/L

0.50R/G

0.50G/L

0.50G/W
G-2 G-3
0.50R/L

0.50R/G

0.50R/L

0.50R/G
019 021

25 29 27 28
FD01 FD01 FD01 FD01
D18 1 5 4 D18 1 5 4
0.50R/L

0.50R/G

0.50G/W
Electric Electric
左后门
Window 右后门
Window
电动窗
switch of
left rear
电动窗
switch of
right rear
开关 开关
0.50G/L

door door

3 2 3 2
0.50W/B

0.50W/B
0.50Br

0.50Br

FD04 2 9 FD04 FD04 2 9 FD04

0.85W/B

0.85W/B
0.50Br
0.50Br

H-9 058

08 08
2 1 5 6

Driver-side electric window

司机侧电动窗开关
switch

D04

D18 Electric Window switch of left rear

D18 左后门电动窗开关 D18 Electric Window switch of right
D18 右后门电动窗开关
door rear door

2 1 2 1
5 4 3 5 4 3
 Circuit Diagram
SD-57

BCM System - Electric Window

BCM系统-电动窗 H-11

B C M
Unlock/Lock
Button PW FL up PW FL down PW FR up PW FR down

5 F02 F01 10 F01 13 F03 13 14

F03
0.50Br/L

1.25Gr/R

1.25Gr/L

1.25Lg/R

1.25Lg/B
G-2
23 13 17 13 17
FD01 FD01 FD01 FD03 FD03
018

1.25Lg/B
1.25Lg/R
1.25Gr/L
0.50Br/L

1.25Gr/R

D08 D15

11 3
2
M 1 2
M 1
门锁控制器

Electric
左前门 window Electric
右前门 window
Door lock
controller

motor of left front motor of right

电动窗电机 door 电动窗电机
front door

D04

D08 Electric window motor

D08 左前门电动窗电机 D15 Electric window motor
D15 右前门电动窗电机
of left front door of right front door

2 1 2 1
 Circuit Diagram
SD-58

BCM System - Electric Window

BCM系统-电动窗 H-12

B C M
PW RL up PW RL down PW RR up PW RR down

F03 7 10 F03 F01 16 F01 19

1.25G/W
1.25R/G
1.25R

1.25G
3 8 3 8
FD04 FD04 FD04 FD04
1.25R/G

1.25R/G
1.25R

1.25R

D21 D21

2
M 1 2
M 1
Electric window
左后门
Electric window 右后门
motor of right
motor of left front
电动窗电机 door
电动窗电机
front door

D21 Electric window motor

D21 左后门电动窗电机 D21 Electric window motor
D21 右后门电动窗电机
of left front door of right front door

2 1 2 1
 Circuit Diagram
SD-59

BCM System
BCM系统 H-13

Left Right
B C M
Blinker Blinker Horn Safe LED Speed

F02 2 F02 3 21 F01 14 F01 12 F01

0.50Y/G
0.50P
0.85G/B

0.85G/Y

0.50Gr
MF01 MF01
23 18
0.50P

0.50Y/G
FE01
5

2
0.50P

Burglarproof

040 041 M06

防盗LED
LED

G-7 G-7
0.50P

8 0.50Gr
MA01

1
0.50P
alarm

1
防盗警铃

A06
Burglar

013
0.50W/B

2 Starting protective
启动保护继电器
0.50W/B

relay

B-1 060

E-1
MA01
10
1.25W/B

06 05

A06A06 Burglar
防盗警铃 M06
M06 Burglarproof LED
防盗LED
alarm

2 1 2 1
 Circuit Diagram
SD-60

BCM System
BCM系统 H-14

B C M
Antenna Crash Sensor K-line Rear Defoger

F02 18 F01 11 F02 6 F02 4

0.85B/R

0.50B/L
2.00B

0.50Y

FR03 MF01 MF03 MF01

7 22 9 19
0.50B/L
0.85B/R
2.00B

0.50Y

069 062
061
Diagnosi
诊断 s
L-1 A-3
M-1
 Circuit Diagram
SD-61

BCM System - 15
BCM系统-15 H-15

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
F01 BCM A
F02 BCM B
F03 BCM C
F14 左后组合灯
Left rear combined light
F15 右后组合灯
Right rear combined light
M02 行李箱盖开关
Boot cover switch
R07 行李箱执行器
Boot actuator
M03 油箱口盖开关
Fuel tank cover switch
F16 油箱盖执行器
Fuel tank cover actuator
M13 左照脚灯
Left foot lighting lamp
M24 右照脚灯
Right foot lighting lamp
R15 前室内灯
Front indoor light
R10 后顶灯
Rear dome light
D07 左前门门灯
Left front door light
D06 左前门门锁控制器
Lock controller of left front door
D14 右前门门灯
Right front door light
D13 右前门门锁控制器
Lock controller of right front door
D17 后门门灯
Rear door light
D19 后门门锁控制器
Lock controller of rear door
F10 行李箱照明灯
Boot lighting
R08 行李箱照明开关
Boot illumination switch
D04 左前门电动窗开关A
Electric window switch of left front door A
D12 右前门电动窗开关A
Electric window switch of right front door A
D18 后门电动窗开关
Electric window switch of rear door

D08 左前门玻璃升降器电机
Glass frame riser motor of the left front

D15 door
右前门玻璃升降器电机
D21 Glass frame riser motor of the right front
后门玻璃升降器电机
A06 door
防盗警铃
M06 Glass
防盗LED frame riser motor of the rear door

F27 Burglar
电动座椅 alarm
Burglarproof LED
 Circuit Diagram
SD-62

BCM System- 16
BCM系统-16 H-16

Index of element location

元件位置索引

Joint
接头
EF01
MF01
FR01
MF02
FR03
FE01
MF03
FD01
FD03
FD04
MA01

Grounding point
接地点
03
05
06
07
08
09
 Circuit Diagram
SD-63

Electric Back Mirror

电动后视镜 I-1

FD01
22
0.85L/R 0.85L/R
F-2 063
D05
Electric back mirror switch
Fusible
易熔丝 link
F49 F49
电动后视镜开关 7

Left Lower Upper

上

下
L
左

Left Lower Upper Right

右
0.85B/Y

下
R
左

Right
右

8 1 3 6 4 5
MF06
6
0.50Br/Y
0.50B/W

0.50Br/B
0.50Br/Y
FD01
12
FD01 FD01 7 16
0.85B/Y

0.50Br/B
0.50Br/Y
0.50B/W

0.85W/B
0.50Br/Y
0.50Y/B

0.50P/B

FD03 FD03 FD03

12 7 16
0.50Br/B
0.50B/W

0.50Br/Y

D01
3 1 6 3 1
D11

6
0.85B/Y

左
Left Lower
下 Left
左 下
Lower

M M M M
右
Right 上
Upper 右 上
0.85B/Y

Right Upper
FD01
Left electric back mirror
左电动后视镜 Right electric back
8 右电动后视镜
mirror
0.85B/Y

4 8 4 8
FD03
8
0.85W/B

0.85B/Y

0.85W/B
0.85W/B

FD03
31
0.85W/B

FD01
31
0.85W/B

D05 Electric back mirror D01 左电动后视镜

Left electric back mirror D11 Right electric back mirror
D05 电动后视镜开关 D01 D11右电动后视镜
switch
08 07

3 2 1 3 2 1 3 2 1
8 7 6 5 4 8 7 6 5 4 8 7 6 5 4
 Circuit Diagram
SD-64

Electric Back Mirror -2

电动后视镜-2 I-2

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
D05 Electric
电动后视镜开关back mirror switch

D01 Left electric back mirror

左电动后视镜
D11 Right electric back mirror
右电动后视镜

Joint
接头
FD01
FD03

Grounding point
接地点
07
08
 Circuit Diagram
SD-65

Sunroof System
天窗系统 J-1

H-1 Fusible
易熔丝 linkF30(IG2)
F30 (IG2)
042

1.25R/W
066 Blower relay
鼓风继电器
O-1O-1
Air conditioning
067 空调控制面板
control panel
O-2 O-2

1.25R/W
1.25G

MF02 18
0.85R/W

FR03 6

FR03 2
0.85R/W
1.25G

Sunroof control
天窗控制模块
R12 module
6
0.85R/W

0.50R/W

VBU
REG Sunroof switch
3
R16
天窗开关
4
M CPU 5 0.50G/B 1
10 0.50R/Y 3

4 0.50G/W 2

Uppe Close Lowe Ope

上 关 下 开
r r n
2
1.25W/B

FR03
1
1.25W/B

08

R12 Sunroof control module

R16R16 Sunroof switch
天窗开关 R12 天窗控制模块

5 4 3 2 1
4 3 2 1 10 9 8 7 6
 Circuit Diagram
SD-66

Sunroof System -2
天窗系统-2 J-2

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
R16 天窗开关
Sunroof switch
R12 天窗控制模块
Sunroof control
module

Joint
接头
MF02
FR03

Grounding point
接地点
08
 Circuit Diagram
SD-67

Combined Switch –Horn and Windshield Wiper

组合开关-喇叭、刮水器 K-1

T ADD
M19 P VL

INT

T HI LO AS INT3 INT4 ACC WA

P
Washing switch of front
前刮水洗涤开关

MIST
wiper

OFF
INT
LO
HI

1.25Gr
11
ME03
19

1.25Gr
AS INT3 INT4 ACC WA VL E1
Intermission control
间歇控制电路 circuit
E19
1
Washing motor
洗涤电机

9 8 7 10
1.25W/B

M
Fusible link
F29F29
1.25Br

易熔丝
1.25Br/W

1.25Br/Y

1.25Br/R

2
1.25Br
1.25W/B
1.25Br

MA01 2 1 7 14
1.25W/B
06 05 04
1.25Br/R
1.25Br/Y
1.25Br/W

1.25Br

10 MA01
4 2 3
雨刮电机
Wiper
motor

A02 M 5

1
1.25W/B
 Circuit Diagram
SD-68

Combined Switch –Horn and Windshield

组合开关-喇叭、刮水器 K-2
Wiper

Fusible link F47

易熔丝 F47

1.25G/R
0.50G/R

1.25G/R
R/L18
4 1
Horn relay
喇叭继电器

3 4
2
ON 1
OFF
3 2
1.25G/W
0.50L/W

20 ME03
1.25G/W

1
低音喇叭
Bass horn

+ E11

1 2
0.85G/W

0.85W/B
switch

M30
喇叭开关

High
Horn

1
高音喇叭

-
E10
pitch horn

+
2
0.85W-B

03

M19 Combined
M19 组合开关 C switch C M30 Horn switch
M30 喇叭开关 E10
E10 High
高音喇叭 pitch horn

5 4 3 2 1 1 2 1
1211 10 9 8 7 6
A02 Wiper motor
A02 刮水电机 E19 Wishing motor
E19 洗涤电机 E11低音喇叭
E11 Bass horn

1 2 1
5 4 3 2 1
2
 Circuit Diagram
SD-69

Combined
组合开关-3 Switch K-3
–3

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
M19 组合开关C
Combined switch C
M30 喇叭开关
Horn switch
E10 高音电喇叭
High pitch electric
E11 低音电喇叭
horn
E19 洗涤电机
Bass electric horn
A02 刮水电机
Washing motor
Wiper motor

Joint
接头
ME03
MA01

Grounding point
接地点
03
04
05
06
 Circuit Diagram
SD-70

Airbag
安全气囊 L-1

Fusible
易熔丝 linkF48
F48

M31 M32

Clock Side airbag for the

副驾驶员侧气囊
时钟弹簧 second driver’
s
spring seat
1 2 1 2
Diagnosi
068 诊断s
0.85Y

0.50L/Y M-1

0.50B/Y

0.50Y/R

0.50Y/L

0.50Lg
M33
5 10 11 18 19 9

Safety Airbag Module

安全气囊模块
6 15 7 13 14 17 16
0.50G

0.50W

0.50R

0.50L
0.30Y/W
0.50Y
0.50W/B

2 1 2 1
Pretension of Pretension of
驾驶员侧 副驾驶员侧
second-driver
driver-side safety
安全带预紧 belt
安全带预紧
safety belt

069 082 M34 M35

10 BCM P-2
H-14

M33安全气囊
M33 Airbag ECU
ECU

25 24 2322 21 20 191817 161514 13 12 1110 9 8 7 6 5 4 3 2 1

M31 Clock spring

M31 时钟弹簧 M32 Airbag of passenger
M32 乘客气囊 M34
M34 Pre-tension of driver
司机安全带预紧 M35 Pre-tension of
M35 乘客安全带预紧
safety belt passenger safety belt

1 1 2 1 2 1
2 2
 Circuit Diagram
SD-71

Airbag- 2
安全气囊-2 L-2

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
M33 Airbag ECU ECU
安全气囊
M31 时钟弹簧
Clock spring
M32 副安全气囊
Secondary airbag
M34 司机安全带预紧
Pre-tension of driver safety belt
M35 乘客安全带预紧
Pre-tension of passenger safety belt

Joint
接头

Grounding point
接地点
10
 Circuit Diagram
SD-72

Diagnosis
诊断系统 System M-1

Fusible link F35

易熔丝 F35

H-14
1.25B/Y 068 061

0.85B/R
0.50Lg
M18
16 12 11

7 4 2
1.25W/B
0.85R/Y
0.85Y

0.50B

05

076 070 071

N-1 D-4 P-7

M18 M18
诊断接口Diagnosis
interface

1615 1413 1211 10 9

8 7 6 5 4 3 2 1
 Circuit Diagram
SD-73

Diagnosis - 2
诊断系统-2 M-2

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
M18 诊断接口
Diagnosis
interface

Joint
接头

Grounding point
接地点
05
 Circuit Diagram
SD-74

ABS and Braking System

ABS、制动系统 N-1

Fusible
易熔丝 linkF4F4 Fusible
易熔丝 link
F31
F31
M-1
ABS
P-1 P-1
ABS
ABS诊断
diagnosis ABS
instrument
073
5.00B/W

仪表指示
indication

1.25B/W 076 074

ME02 3

0.30Br
0.30B/R
5.00B/W

0.85Y
MA01 9 0.50G/W
075 N-2
MA01 4 MA01 18 MA01 3 11 MA01
2
1.25B/W

MA02

0.50B/R

0.50G/W
5.00B/W

050P/W
0.85Y

46 16 8 38 25 41

ABS ECU
42 43 12 13 24 39 27 28 1 31
0.50G/Y

0.50G/R

0.50L/Y

0.50L/B

0.50B/W

0.50B/O

2.00W/B

3.00W/B
MA01 19 20 MA01 12 13 MA01 5 6
0.50B/W

0.50B/O
0.50L/Y

0.50L/B
0.50G/Y

0.50G/R

MA02 1
0.50R/Y

0.50R/B

MF02 3 2 MF02 9 8 ME03 7 8

5.00W/B
0.50G/Y

0.50G/R

0.50L/Y

0.50L/B

0.50B/W

0.50B/O

06

2 1 2 1
1 2 1 2

RR LR RF LF

F08 F09 A03 E04

A01 ABS ECU

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
30 29 28 27 26 25 24 23 22 21 20 19 18 17
46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

F09 Speed sensor of left

F09 左后轮速传感器 F08右后轮速传感器
F08 Speed sensor E04左前轮速传感器
E04 Speed sensor A03右前轮速传感器
A03 Speed sensor of
rear wheel of right rear wheel of left front wheel right front wheel

2 1 2 1 1 2 1 2
 Circuit Diagram
SD-75

ABS and Braking System

ABS、制动系统 N-2

Fusible
易熔丝 linkF46
F46

1.25G/O
1
制动灯开关
Stop lamp switch

M17

3
1.25G/W
1.25G/W

0.50G/W

MF03 5 075

ABS
0.85G/W
0.85G/W

0.50G/W

0.50G/W

5 5 2
左后制动灯

右后制动灯

高位制动灯
Right rear stop
Left rear stop

High position
stop lamp

F15 F11
lamp

lamp

F14

3 3 1
0.50W/B
1.25W/B
1.25W/B

07 08 08

M17 Stop lamp switch F14 Left rear stop light F15 Right rear stop F11 High position stop light
M17 制动灯开关 F14 左后制动灯 F15 右后制动灯 F11 高位制动灯
light
2 1 2 1
3 2 1 6 5 4 3 6 5 4 3 2 1
 Circuit Diagram
SD-76

ABS and Braking System -3 N-3

ABS、制动系统-3

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
A01 ABSABS模块
module
F09 左后轮速传感器
Speed sensor of left rear wheel
F08 右后轮速传感器
Speed sensor of right rear wheel
E04 左前轮速传感器
Speed sensor of left front wheel
A03 右前轮速传感器
Speed sensor of right front wheel
F14 Left 左后组合灯
rear combined light
F15 Right右后组合灯
rear combined light
F11 High高位制动灯
position stop lamp

Joint
接头
MF02
MF02
MF03
MA01
MA02

Grounding
接地点 point
06
07
08
 Circuit Diagram
SD-77

Air conditioning system

空调系统 O-1

J-1 Fusible
易熔丝 link
F40F40
066
0.85L
077 Compressor
压缩机继电器
relay
O-5
3.00L
0.50R/W

3.00R/L
0.50G
3.00L

R/L12 R/L13
3 1 3 1
3.00G
鼓风机继电器1

鼓风机继电器2
Blower relay 1

relay 2
3 3
12 12
0.50L
4 ON 5 ON 4

Blower
MA03
OFF OFF
4 2 4 2
3.00R/W
3.00G
0.50W/B

2
A10

M
0.50Lg/B

3.00W/B
1
3.00B/W

3.00B/W

A11 1
3.00B/W
功率放大器

3
amplifier
Power

2 6 MA03
3.00B

0.50Br

3.00R/L

MA03
4
0.50R/L

MA03 1
3.00W/B

0.50V

05 06 05

4 3 11 5
P/TR(B) BATT+ HSR P/TR(C)

Air Conditioning Panel

空 调 面 板

M22

M22空调面板
M22 Air conditioning panel A10
A10Blower
鼓风机电机motor A11功率放大器
A11 Power amplifier

8 7 6 5 4 3 2 1 1 1
16 1514 13 1211 10 9 2 3 2
 Circuit Diagram
SD-78

Air Conditioning System

空调系统 O-2

Outdoor temperature Indoor temperature sensor

sensor Sunlight sensor
M01 室内温度传感器
室外温度传感器 日照传感器
M27
E15

2 1 1 2
0.50P/B

1 2 3 4
0.50Lg/R

ME01 5
0.50Gr/W

0.50Gr/R
0.50P/B

0.50P/B

0.50Gr
0.50P
0.50P/B

4 ME01
0.50Lg/R

0.50P/B

M22
12 13 15 16 14 6
AMB(5V) SUN(5V) SUN INCAR MOTOR(-) MOTOR(+)
GND (5V)

Air Conditioning
空 调 面 板Panel

E15 Outdoor temperature M27

E15 室外温度传感器 M27 Sunlight
日照传感器 sensor M01 Indoor temperature sensor
M01 室内温度传感器
sensor

2 1 2 1 4 3 2 1
 Circuit Diagram
SD-79

Air Conditioning System

空调系统 O-3

04 06

078 079

0.50W/B

0.50B/O
0.50B/W
E16

J-1 G-4 G-4

G-4
4 中压开关
Middle pressure
switch
Illumination 1
067 030
空调面板
regulation of air
照明调节
conditioning panel 2 高低压开关
High-low pressure
switch

031
三元压力开关
Three-way
pressure switch
0.50Lg/W

0.50W/B
6 ME01
0.50R/W

0.50R/G
0.50G

0.50Lg/W

7 2 3 10 8
IGN TAIL+ TAIL- A/C THERMD(HI) GND

Air Conditioning
空 调 面Panel 板 M22

E16
E16 Three-way
三元压力开关pressure switch

2 1
4 3
 Circuit Diagram
SD-80

Air Conditioning system –Mode Motor and

空调系统-模式电机、温控电机
Temperature Control Motor O-4

A16 Mode
模式电机 motor A14 Temperature
温控电机 control motor

M M

6 3 5 1 2 6 3 5 1 2
0.50R/W
0.50R

0.50B

0.50R

0.50B
0.50Lg/B

0.50G/W
0.50R/B
0.50B/W
0.50R
0.50W

0.50B 0.50B
043 O-5
0.50B

A17
7 9 12 2 8 5 11 6
M+ CCW REF PBR Sensor GND M- (DEF) M+ CCW PBR(Warm) M-(Warm)
(DEF) (5V) (Warm)

Air Conditioning Panel 2

空 调 面 板2

A17 Air
A17 conditioning panel 2
空调面板2 A16
A16 Module
模式电机-白色motor - white A14温控电机(黑色)
A14 Temperature control motor (black)

6 5 4 3 2 1 2 1 2 1
121110 9 8 7 7 65 4 3 7 65 4 3
 Circuit Diagram
SD-81

Air Conditioning System –Water Temperature

空调系统-水温传感器、风门传感器、风门电机 O-5
Sensor, Air Door Sensor and Air Door Motor

Air door motor

A13 风门电机
7 3
M
Water temperature Airduct sensor
A15 水温传感器 A12 风道传感器
sensor

1 2 1 2

0.50Br/W
0.50L/W

0.50Gr
0.50B

0.50B

0.50L

AA01 1 AA01 3 AA01 4

AA01
0.50B
O-4 043
2
0.50Br/W
0.50Gr
0.50L

10 1 3 4

Water Duct M+ CCW M-(REC)

(5V) (5V) (REC)

Air Conditioning
空 调 面 Panel 板

A15
A15 Water temperature sensor
水温传感器 A12
A12 Airduct
风道传感器 sensor A13A13 Air door motor (white)
风门电机（白色）

2 1 2 1 2 1
7 65 4 3
 Circuit Diagram
SD-82

Air Conditioning System

空调系统 O-6

O-1
077

0.85L
18 ME01

0.85L
0.50L

0.85L

R/L3
4 1
Compressor relay
压缩机继电器

ON
OFF
3 2
0.85G/W
0.50B

080

Compressor
压缩机
1

E17

E17 Compressor
E17 压缩机 R/L3压缩机继电器
R/L3 Compressor relay

3
1 1 2
4
 Circuit Diagram
SD-83

Air Conditioning System - 7

空调系统-7 O-7

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
M22 空调面板 panel
Air conditioning
E15 室外温度传感器
Outdoor temperature
M27 日照传感器
sensor
M01 室内温度传感器
Sunlight sensor
E16 三元压力开关
Indoor temperature sensor
E17 压缩机 pressure switch
Three-way

Joint
接头
ME01

Grounding point
接地点
04
05
06
 Circuit Diagram
SD-84

Instrument
仪表系统 system P-1
Fusible
易熔丝 linkF27
F27

0.50R/Y

G-32
KL.30

5V

081 P-2
IGN
Parking and EBD
驻车及EBD
indicator light
指示灯
Reservation
预留
ABS

G-04 G-08 G-07

0.30P/W
0.30B/R

0.30Br

0.30P/W

0.30P/W

10 9
MF01 ME01
0.50P/W

0.50P/W

1 2
brake switch

074
F04 E02
073
手刹开关

N-1 ABS
N-1
Manual

1
0.50W/B

04

E02 Braking fluid level sensor F04

E02 制动液位传感器 F04手刹开关
Manual brake switch

1
2 1
 Circuit Diagram
SD-85

Instrument System
仪表系统 P-2

P-1 081 083 P-3

蹄片磨损告警灯
Wear alarm llight of
brake shoe

Door unclosed
Airbag
安全气囊

门未关
L-32 G-05 G-06
0.30Gr/L
0.30Gr/L

0.30Gr/L

0.30Y/W

0.50L

15 2
MA01 ME03
0.30Gr/L

0.30Gr/L

A04 E05
2 2
Wear sensor Wear sensor
右前制动
of right front 左前制动
of left front
蹄片磨损
brake shoe 蹄片磨损
brake shoe
传感器 传感器 082 057
Airbag
气囊SDM BCM
SDM
1 1 L-1
L-1 H-7
0.50W/B

0.50W/B

06 04

E05 Wear sensor of left A04 Wear sensor of right

E05 左前制动蹄片磨损传感器
front brake shoe A04 右前制动蹄片磨损传感器
front brake shoe

2 1 2 1
 Circuit Diagram
SD-86

Instrument
仪表系统 System P-3

P-2 083 086 P-4

charging/disch
Indication of
inspection
发动机检查

充放电指示

行李箱开启
Engine

arging

opening
Boot

EOBD
G-03 L-18 L-21 L-31
0.30B/Y
0.30Y

ME01 25 ME01 1
0.30Br/W
0.30W

0.50B/Y
0.50Y

CE01 9 CE01 11

084 009 056 085

Engine ECU
发动机ECU 发电机
Generator BCM Engine ECU
发动机ECU
D-4 D-4
D-4 C-1
C-1 H-7 D-4

M07 Instrument interface -

M07 仪表接口-绿
green
161514 13 121110 9 8 7 6 5 4 3 2 1
32 3130 29 2827 26 2524 23 2221 2019 18 17
 Circuit Diagram
SD-87

Instrument System
仪表系统 P-4

P-3 086
Reservatio

Reservatio

传感器地
groundin

groundin
Sensor

Vehicle

车身地
body
n

g
n

g
预留

预留

G-27 G-28
0.50W/B
0.50W/B

05 05

M08 Instrument
仪表接口-蓝 interface- blue
M08

16 1514 13121110 9 8 7 6 5 4 3 2 1
32 3130 292827 26 25 24 232221 2019 1817
 SD-88

仪表系统

Left turn light

左转向灯

G-18
0.30G/B

038

G-7
Right turn
light
右转向灯

L-15
Instrument System

0.30G/Y

039

G-7
Reservatio
预留n
Circuit

High

ME03
beam
远光

G-19
0.30R/L 0.30R/L

012

G-1
12
Rear fog
lamp
后雾灯
L-16
0.30L/W

046

H-2
087
P-6
P-5
Diagram
 Circuit Diagram
SD-89

Instrument System
仪表系统 P-6

P-5 087
防盗告警alarm

Front fog
Anti-theft

lamp
前雾灯

G-17 G-02
0.30L/Y

0.30L/B

088 026

Q-1 G-5
 F05
SD-90

F05 Safety

2
1
lock switch
仪表系统

安全带接插锁开关
Diagnosis
诊断

G-23
0.50B

071

M-1

belt connector
M-1
diagnosis
Instrument
仪表诊断
ME01
Speed signal
Instrument System

8
车速信号

G-14
0.50Gr 0.30Gr

059

E-1
M
Engine oil pressure
机油压力传感器

CE01
sensor
Engine oil pressure

ME01 20

6
机油压力报警

G-15
0.50Y/B 0.30Y/B alarm
op
Circuit

F05
C

MF01
Patch lock switch of
安全带插锁开关
safety belt

9
Safety belt

2
1
G-16
0.50W/B 0.50V/W 0.30V/W 安全带

07
U

CE01
Rotating speed signal

7
ME01 15
转速信号
G-13
0.50Gr/W 0.30Gr/W

090

D-4
P-7
Diagram
 Circuit Diagram
SD-91

Instrument System
仪表系统 P-8

M C U
temperature

Illumination

Small light
regulation
Water

signal
燃油信号

水温信号

照明调节
Fuel oil
signal

KL.15
小灯

G-09 G-10 G-11 G-31 G-30

0.30Y/R

ME01 12
0.30R/G

0.50L/Y
0.30Y/G

0.30G
0.50Y/R

CE01 5

010 091 030 029 045

D-1 Water
水温传感器
temperature
Illumination regulation
照明调节 G-4
Small light
小灯照明
illumination G-4
H-2
sensor
G-4 G-4
 Circuit Diagram
SD-92

Instrument
仪表系统-9System P-9
-9
Index of element location
元件位置索引

Element code Element name

元件编码 元件名称
E02 制动液位传感器
Braking fluid level sensor
F04 手制动开关
Manual braking switch
E05 左前制动蹄片磨损传感器
Wear sensor of left front brake shoe
A04 右前制动蹄片磨损传感器
Wear sensor of right front brake shoe
M07 组合仪表（绿）
Combined device (green)
M08 组合仪表（兰）
Combined device (blue)

F05 左安全带接插锁开关
Connector lock switch of left safety belt

L-10 机油压力传感器
Engine oil pressure sensor

Joint
接头
ME03
ME01
MF01
MA01
L-19

Grounding point
接地点
04
05
06
07
 Circuit Diagram
SD-93

Burglarproof Controller
防盗控制器 Q-1

H-1 H-2
044 092

1.25G

0.85W

M20
8 1
KL.30 KL.15

Burglarproof Control Box

防 盗 控 制 盒
LED K-Line GND
3 5 2
0.30L/Y

0.50R/Y

0.85W/B

05
088 072

仪表指示
Instrument
indication
D-4
P-6
P-6

M20 Burglarproof control box

M20 防盗控制盒

3 2 1
8 7 6 5 4
 Circuit Diagram
SD-94

Burglarproof Controller -2
防盗控制器-2 Q-2

Index of element location

元件位置索引

Element code Element name

元件编码 元件名称
M20 Burglarproof
防盗控制盒 control box

Joint
接头

Grounding point
接地点
05
 Component Position CL-1

Component Position

Main Wire Harness… … … … … … … … … … … … … … … … … … … … … … ..............CL-2

ABS Wire Harness … … … … … … … … … … … … … … … … … ................................CL-7
Air Conditioning Wire Harness… … … … … … … … … … … … … … … … … .............CL-8
Wire Harness of Engine Hatch … … … … … … … … … … … … ..............................CL-9
Power Supply Wire Harness..............................................................................CL-12
Controller Wire Harness … … … … … … … … … … … … … … … … … … … … ............CL-13
Chassis Wire Harness ....................................................................................CL-15
Car Door Wire Harness ....................................................................................CL-19
Rear Door Wire Harness ..................................................................................CL-21
Tail Door Wire Harness＆Sensor Wire Harness ............................................CL-22
Ceiling Wire Harness ........................................................................................CL-23
Grounding Wire Harness ...................................................................................CL-24
 Component Position CL-2

Main wire harness

Main wire harness (1)

Back of
Instrument
M13 Left foot lighting desk
lamp

M08 Combined M07 Combined

device device
（blue） （green）

Disassemble the lower left

M01 Indoor
anti-collision trimming plate
temperature
sensor

M01 M07 M08

M03 Switch of M02 Switch of

the fuel tank the boot cover
cover

M10 M11
DVD DVD antenna

M05 Regulating M04

switch of Illumination
headlight regulating
switch

M02 M03 M04 M05 M10 M11

Instrument
desk

M06 M12 Mid

Burglarproof switch
LED group

M06 M12
 Component Position CL-3

Main wire harness (2)

M13 Left
foot lighting
lamp
M17 Stop
lamp M18
switch Diagnosis
interface

M01 Indoor
Disassemble the lower left
temperature
anti-collision trimming plate
sensor

M13 M17 M18

M09
Induction coil

M20
Burglarproof
ECU

M14 Ignition switch

M14 M09 M20

M15 M22 Air

Combined conditioning
switch A panel

M21
Cigarette
lighter
M16 M19
Combined Combined
switch B switch C

M15 M16 M19 M21 M22

 Component Position CL-4

Main wire harness (3)

M27 Sunlight sensor

Back of Console

Instrument
desk
M23 Buzzer of
reversing radar

M23 M27

M28
Indoor
fuse box
M24 Right
foot lighting
lamp

M24 M28

M29 Shielded
wire of
antenna

M25 Contact M26 Lighting of

switch of
miscellaneous
miscellaneous
articles articles
compartment compartment

M25 M26 M29

 Component Position CL-5

Main wire harness (4)

M30 Horn switch

Left front door

M34 Driver safety

belt pre-tension

M31 Clock spring

M30 M31 M34

M32 Secondary Right front door

airbag

Rear side of
console
M35 Passenger
safety belt
pre-tension

M32 M35

Disassemble trimming ME02

plate of central control
desk

ME01 (white)

ME03 (black)

EF02
M33 Airbag
ECU
EF01

M33 ME01 ME02 ME03

 Component Position CL-6

Main wire harness (5)

MA01
EF01

MA02

EF02

MF01 MF03 MF02

FR03

MF01 MF03 MF02 MA01 MA02

Blower

MA03

MA03
 Component Position CL-7

ABS wire harness

Right front Fender

door

A01 ABS
module
A05 Right
turn light

A03 Speed
sensor of
right front

A01 A03 A05

ECM
A06
A02 Burglar
Wiper alarm
motor

A02 A06

A04 Wear
sensor of
right front
brake shoe

A04
 Component Position CL-8

Air conditioning wire harness

A15 Water
temperatur
e sensor

A14
Temperature
MA03 A10
controlling motor
Main wire harness Blower motor
interface

A10 A14 A15

A16
A11 Power Mode
amplifier motor

A17
To FATC
A13 Air door motor control

A11 A13 A16 A17

AA01 Air
conditioning
wire harness
interface

A12
Airduct
sensor

A12 AA01
 Component Position CL-9

Wire harness of engine hatch

Wire harness of engine hatch (1)

EO5 Wear
Fender sensor of left
front brake
shoe

E01 Left
turn light

E01 E05

E02 Braking
liquid level
sensor

E06 Positive
pole of battery

E02 E06

E07
E04 Speed Outdoor
sensor wire fuse box
harness of
left front
wheel
R/L8 Fan
controlling
relay

E04 E07 R/L8

 Component Position CL-10

Wire harness of engine hatch (2)

E09 Left headlight

E14 Left front fog
lamp

E09 E14

E10 High pitch E11 Bass

electric horn electric horn
temperature sensor
E15 Outdoor

E10 E11 E15

Three-way
pressure
E16

E13
E12 Radiator
Condensed fan
fan

E12 E13 E16

 Component Position CL-11

Wire harness of engine hatch (3)

E17
Compressor

E21 Right headlight

E17 E21

ME02

ME01

ME03

ME01 EF02
ME02
E18 ME03
Right front fog 仪表线束接口
lamp
EF01

E18 EF01 EF02

E19
Washing
motor

E19
 Component Position CL-12

Power supply wire harness

E26 Starter B
EE01

E25 Starter signal G08 Master grounding

point
E24 Battery B_ E22 Battery B+

EE01 E22 E24 E25 E26

E22 E24

E27
Generator B

E28
Generator
E&L
E23
To master fuse

E23 E27 E28

 Component Position CL-13

Controller wire harness

Controller wire harness (1)

C05 Air throttle

position sensor

ABS
assembly

Air intake hose

C01
ECM

C01 C05

G20 Engine C12 Cam shaft

C02 Absolute grounding position sensor
pressure sensor

C11 Water
temperature
sensor
C03 Carbon
canister solenoid
valve

C10 Front
oxygen sensor

C02 C03 C10 C11 C12

C04 Stepper
motor Cylinder head
cover

CC01

C06 Knock
sensor
C20 C21 C22 C23
Fuel injection nozzle

C04 C06 C20 C21 C22 C23

 Component Position CL-14

Controller wire harness（2）

Intake G08 Master

manifold side grounding point

C24 (2, 3 cylinders), C25 (1, 4

Gearbox
cylinders) C32 Reverse gear
ignition coil switch

C24 C25 C32

C04 Stepper
motor

C26 Power
steering pump
CC01

C06 Knock
sensor
C27 Crankshaft
position sensor

C26 C27 CC01

C31 Speed sensor

C30 Engine oil

pressure switch
CE01 CE02

C30 C31 CE01 CE02

 Component Position CL-15

Chassis wire harness

Chassis wire harness (1)

Lower part of driver

seat

G05

F19 To the F06 Rear

antenna of oxygen sensor
F03 F01 F02
instrument wire
BCM C BCM A BCM B
harness

F01 F02 F03 F06 F19

Disassemble
F04 Manual
the rear seat
brake switch

F07 Fuel injection

sensor and fuel
injection pump

F04 F07

F09 Speed sensor F08 Speed sensor

of right rear wheel of left rear wheel
(black) (green)

F05 Left safety

belt lock switch

Rear subframe

F05 F08 F09

 Component Position CL-16

Chassis wire harness (2)

F15 Right
rear
combined
light

F10 Lighting of F12 Reversing

boot radar controller

F10 F12 F15

F11 High
position stop
lamp

F12

F16 Fuel tank

actuator

F11 F16

FR01

F14 Left rear F17 Power

combined supply of
antenna
light
amplifier

F13 Rear F18 Antenna

vehicle power interface
supply

FR02

F13 F14 F17 F18

 Component Position CL-17

Chassis wire harness (3)

F06 Rear
oxygen sensor
FD01 Left front
door

F19 To
antenna of
instrument wire
harness

F19 FD01

Disk bag wire

and disk Bag
box
Right front
door

FD03

DVD terminal of
disk bag

FD03

F27 Electric seat

(un-mounted)

Left
front
door

Disassemble
the seat
FD04

F27 FD04
 Component Position CL-18

Chassis wire harness (4)

Disassemble the
upper trimming
Right plate of C pillar
front Right
door rear
door

FR04

FD05

FD05 FR04
FR01

F14 Left rear

combined light

F13 Rear
vehicle power
supply

FR02

FR01 FR02

MA01

MA02

MF02

FR03

FR03
 Component Position CL-19

Car door wire harness

Wire harness of left front door

D04 Electric
window switch of D05 Electric
left front door back mirror
switch

D01 Left
electric back
mirror
D02 Left front high
pitch loudspeaker

D01 D02 D04 D05

D06 Lock D08 Glass frame

controller of left riser motor of the
front door left front door

D07 Left front

door light D09 Left front
bass
loudspeaker

D06 D07 D08 D09

 Component Position CL-20

Right front wire harness

D12 Electric window
switch of right front
door
D11 Right
electric back
mirror

D10 Right front

high pitch
loudspeaker

D10 D11 D12

D13 Lock
controller of right
front door D16 Right front
D15 Glass frame
bass loudspeaker
riser motor of
the right front
door

D14 Right front

door light

D13 D14 D15 D16

 Component Position CL-21

Rear door wire harness

D21-1 Glass frame riser motor of left rear door
window
D21-2 Glass frame riser motor of right rear door
window

D19-1 Lock controller of left rear

door
D19-2 Lock controller of right rear
door

D18-1 Electric window switch of left rear

D17-1 Left rear door door
light D18-2 Electric window switch of right
D17-2 Right rear door rear door
light
D17-1 D17-2 D19-1 D19-2 D18-1 D18-2

D21-1 D21-2

D20-1 High pitch loudspeaker of left rear D22-1 Bass loudspeaker of left rear door
door D22-2 Bass loudspeaker of right rear door

D20-1 D20-2 D22-1 D22-2

 Component Position CL-22

Tail door wire harness＆sensor wire harness

R18 Rear
R05 Left license light R06 Right license defrosting wire
light （＋）

G10 Trap filter

grounding

R07 Boot FR04

actuator

R08 Boot illumination switch

R05 R06 R07 R08 R18

R17 Rear
FR02 defrosting wire
（I）

G11 Rear
defrosting wire
R01 Left rear R02 Left middle R03 Right rear R04 Right
grounding
reversing radar reversing radar middle
sensor sensor reversing radar reversing radar
sensor sensor

R01 R02 R03 R04 R17

 Component Position CL-23

Ceiling wire harness

R14 Right
sunroof
R13 Left
sunroof

R10
Rear ceiling
light

R10 R13 R14

R15 Front
ceiling light
R11 Interior
back mirror

R12 Sunroof
R16 Sunroof controller
switch

R11 R12 R15 R16

 Component Position CL-24

Grounding wire harness

Grounding wire harness (1)

Left rear door

G05
Floor
grounding 5
G01
Floor grounding 1

G01 G05

Right rear G06 G07

door Front wall
grounding
G02
Floor grounding
2

G02 G06 G07

G08 Master
grounding point

G03 G04
Front wall
Gearbox
grounding C32 Reverse gear
switch

G03 G04 G08

 Component Position CL-25

Grounding wire harness (2)

G15 Instrument grounding

2A
G16 Instrument grounding
G10 Trap filter 2B
G17 Instrument grounding
grounding 3

Disassemble
trimming
plate of right
C pillar

G10 G15 G16 G17

C02 Absolute G20 Engine

pressure sensor grounding
G11 Rear
defrosting
grounding

C03 Carbon
Disassemble canister
the upper
trimming plate
of left C pillar

G11 G20

Disassemble the trimming

plate of central control
desk

G12 Instrument grounding

1A
G13 Instrument grounding G30
1B Air bag
G14 Instrument grounding grounding
4

G12 G13 G14 G30

 Connector Shape CC-1

Connector Shape
Main Wire Harness … … … … … … … … … … … … … … … … … ...................................... CC-2
ABS & Air Conditioning Wire Harness… … … … … … … … … … … ............................. CC-6
Wire Harness of Engine Hatch ................................................................................. CC-7
Controller Wire Harness … … … … … … … … … … … … … … … ................................ CC-9
Frame Wire Harness.................................................................................................. CC-11
Wire Harness of Left and Right Doors..................................................................... CC-13
Sensor Wire Harness & Tail Door Wire Harness … ................................................ CC-15
Ceiling Wire Harness & Rear Defrosting Wire… … ................................................. CL-15
 Connector Shape CC-2

Main Wire Harness

主线束
Main Wire Harness (1)
主线束（1）
M03 Switch of fuel tank M04 Lighting adjusting
M01 室内温度传感器
M01 Indoor temperature M02 Boot cover switch cover switch
M04 照明灯调节开关
sensor M02 行李箱盖开关 M03 油箱口盖开关

4 3 2 1 4 3 2 1 2 1
4 3 2 1 10 9 8 7 6 5 10 9 8 7 6 5 6 5 4 3

M05 Adjusting switch of headlight M07 Combined device-green

M05 前照灯调节开关 M06 M06 防盗LED
Burglarproof LED M07 组合仪表-绿

2 1 2 1
6 5 4 3 161514 13 121110 9 8 7 6 5 4 3 2 1
32 3130 29 2827 26 25 24 23 2221 2019 18 17

M08 Combined device-blue

M08 组合仪表-蓝

M09M09
Induction
感应线圈 coil
16 1514 13 121110 9 8 7 6 5 4 3 2 1
32 3130 29 2827 26 25 24 23 2221 2019 18 17
BLANK 321

M10 DVD M12 Mid

M12 switch group assembly
中间开关组总成

8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
16 151413 121110 9 BLANK 2019 18 1716 1514 13 1211 10

M13
M13Left
左照脚灯foot lighting lamp M14 Ignition switch M15 Combined switch A M16 Combined switch B
M14 点火开关 M15 组合开关 A M16 组合开关 B

2 1 321 2 1 4 3 2 1
654 6 5 4 3 10 9 8 7 6 5

M19 Combined switch C M20 Anti-theft controlling

M17 Stop
M17 制动灯开关lamp switch M18
M18 Diagnosis
诊断接口 interface M19 组合开关 C M20 防盗控制盒
box

5 4 3 2 1 3 2 1
8 7 6 5 4 3 2 1
3 2 1 12 11 10 9 8 7 6 8 7 6 5 4
16 1514 13 12 11 10 9
 Connector Shape CC-3
Main Wire Harness
主线束（2） (2)

M21 Cigarette lighter M22 Air conditioning panel M23 Buzzer of reversing radar M24 Right foot lighting
M21 点烟器 M22 空调面板 M23 倒车雷达蜂鸣器 M24lamp
右照脚灯

3 2 1 8 7 6 5 4 3 2 1 2 1 2 1
16 1514 13 1211 10 9

M25 Contact switch of

miscellaneous articles M26 Lighting of M27 Sunlight sensor
M25 杂物盒接触开关
compartment M26 杂物盒照明灯
miscellaneous articles M27 日照传感器
compartment

2 1 2 1 2 1 BLANK

M30 Horn switch M31 Clock spring M32 Secondary airbag

M30 喇叭开关 M31 时钟弹簧 M32 副安全气囊

1 1 1
BLANK 2 2

M33 Airbag ECU

M33 安全气囊 ECU

1 2 3 4 5 6 7 8 9 10 111213 1415 16 17 18192021 22232425

M34 Driver safety belt M35 Passenger safety belt

司机安全带预紧
M34 pre-tension M35 pre-tension
乘客安全带预紧

2 1 2 1 BLANK BLANK

ME01 (White) ME01 (White)

ME01（白） ME01（白） ME02 ME02

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 111213 131211 10 9 8 7 123 321
14 15 16 17 18 1920 2019 18 17 16 15 14
 Connector Shape CC-4

Main Wire Harness (3)

主线束（3）

ME03
ME03 (Black)
（黑） ME03ME03
(Black)
（黑） MF03
MF03

1 2 3 4 5 6 6 5 4 3 2 1 1 2 3 4 4 3 2 1
7 8 9 10 1112 13 131211 10 9 8 7 5 6 7 8 9 10 10 9 8 7 6 5
14 15 16 17 18 1920 2019 18 17 16 15 14
A-30 C-61

MF01 MF01

1 2 3 4 5 6 7 8 9 10111213 13 1211 10 9 8 7 6 5 4 3 2 1
1415161718 19 202122232425 2524 23 2221 20 19 181716 1514

MF02 MF02

1 2 3 4 5 6 7 8 9 10111213 13 1211 10 9 8 7 6 5 4 3 2 1
1415161718 19 202122232425 25 24 23 2221 20 19 18 1716 1514

MA01 MA01 MA02 MA02

1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 111213 13 1211 10 9 8 7 1 2 2 1
14 15 16 17 18 1920 2019 18 17 16 1514

MA03 MA03

1 2 3 3 2 1 BLANK BLANK
4 5 6 6 5 4
 Connector Shape CC-5

Main Wire Harness (4)

主线束（4）

M28 Indoor fuse box

M28 室内保险盒

R/L16
Burglarproof R/L10
R/L16 R/L10
relay On relay
防盗继电器 3 4 on继电器

1 2 2 1
4 3
R/L17 R/L11
Small
R/L17 light Startup
R/L11protection
relay
小灯继电器 3 4 relay
启动保护继电器

1 2 2 1
4 3

R/L12
R/L12
4 Blower relay
R/L20
R/L20 鼓风机继电器1
1
Flasher
闪光继电器 relay
2 1
3 2 1
3
4 9 8 R/L13
Blower relay
R/L13
2
5 6 7 4 鼓风机继电器2

2 1
3
R/L14
R/L18
R/L18 Rear defrosting
R/L14
Horn
喇叭继电器 relay 3 4 relay
后除霜继电器

1 2 2 1
4 3
R/L19 R/L15
Cigarette
R/L19 Front fog
R/L15
4 lamp relay
lighting relay
点烟继电器 3 前雾灯继电器

1 2 2 1
4 3
 Connector Shape CC-6

ABS & Air Conditioning Wire

ABS、安全气囊线束
harness

A01 ABS module A02 Wiper motor A03 Speed sensor of right
front wheel
A01 ABS模块
A0

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 5
30 29 28 27 26 25 24 23 22 21 20 19 18 17
46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31

A04 Wear sensor of right front A05 Right turn light A06 Burglar alarm
brake shoe
A04 右前制动蹄片磨损传感器 A05 右侧转向灯

2 1
2 1

A10 Blower motor A11 Power amplifier A12 Airduct sensor A13 Air door motor (White)
A10 鼓风机电机 A11 功率放大器 A1

1 1
2 3 2

A14 Temperature control A15 Water temperature A16 Mode motor - white A17 To FATC controller
motor (Black) sensor
A14 温控电机(黑色) A15 水温传感器 A1

2 1 2 1
7 6 5 4 3

AA01 AA01

1 2 3 4 4 3 2 1
 Connector Shape CC-7

发动机仓线束
Wire Harness of Engine Hatch
Wire Harness of Engine Hatch (1)
发动机仓线束（1）
E02 Braking liquid level E04 Speed sensor of left E05 Wear sensor of left front
E01
E01 Left
左侧转向灯turn light sensor
E02 制动液位传感器 E04 front
左前轮速传感器
wheel E05 左前制动蹄片磨损传感器
brake shoe

1 2 2 1
2 1 2 1

E09 Left headlight E10 High pitch electric

E09 左前照灯 E10 horn
高音电喇叭

BLANK BLANK 4 3 2 1
2 1
8 7 6 5

E11 Bass electric horn E12 Condensed fan E13 Radiator fan E14 Left front fog lamp
E11 低音电喇叭 E12 冷凝风扇 E13 散热器风扇 E14 左前雾灯

2 1 2 1 2 1
2 1

E15 Outdoor temperature E16 Three-way pressure E17 Compressor E18 Right front fog lamp
E15 室外温度传感器
sensor E16 switch
三元压力开关 E17 压缩机 E18 右前雾灯

2 1 1 2 1
2 1
4 3

E19 Washing motor E21 Right headlight

E19 洗涤电机 E21 右前照灯

1 4 3 2 1 BLANK BLANK
2 8 7 6 5

E25 Starter signal E28 Engine E&L

E25 起动机信号
E28 发电机E&L

1 BLANK BLANK
4 3 2 1
 Connector Shape CC-8

Wire Harness of Engine Hatch (2)

发动机仓线束（2）

EF01 EF01 EF02 EF02

1 2 3 4 4 3 2 1 1 2 2 1
5 6 7 8 9 10 10 9 8 7 6 5 3 4 4 3

EE01 EE01 R/L8 Fan

R/L8 control relay
风扇控制继电器

5
1 2 3 3 2 1 BLANK 4 2 1
4 5 6 6 5 4
3

发动机仓保险盒
E07 E07 Engine hatch fuse box

R/L8
R/L8
Hanging
挂保险盒外
outside the
fuse box

Condensed fan Radiator fan relay High beam relay

冷凝风扇继电器 散热器风扇继电器 远光继电器
relay
R/L5 R/L6 R/L7
3 3 3
1 2 1 2 1 2
4 4 4
Oil pump Master
发动机
relay relay
主继电器 of
油泵继电器 3 engine 3 3 3
1 2 1 2 1 2 1 2
R/L1 4 R/L2 4 R/L3 4 R/L4 4
Compressor
压缩机继电器 relay Dipped light relay
近光继电器
 Connector Shape CC-9

Controller Wire Harness

控制线束
Controller Wire Harness (1)
控制线束（1）

C01 ECM

53 54 5556 5758 596061 62 6364 65 6667 6869 7071 72

33 34 3536 3738394041 42 4344 45 4647 4849 5051 52

17 18 1920 2122232425 26 2728 29 3031 32

1 2 3 4 5 6 7 8 9 101112 13 141516 73

C05 Air throttle position

C02 Absolute pressure sensor C03 Carbon canister solenoid C04 C04
Stepper motor C05 节气门位置传感器
sensor
C02 绝对压力传感器 C03 碳罐电磁阀 步进电机
valve

4 3 2 1 2 1 4 3 2 1 1
3 2

C11 Water temperature C12 Camshaft position

C06 Knock sensor C10 Front oxygen sensor sensor
C11 水温传感器 C12 凸轮轴位置传感器
sensor
C06 爆震传感器 C10 前氧传感器

2 1 3 2 1
4 3 2 1
3 2 1

C20 Fuel injection nozzle C22 Fuel injection nozzle 2

C20 喷油嘴 4 4 C21 Fuel injection nozzle C22 喷油嘴 2 C23 Fuel
C23injection
喷油嘴 1
nozzle
C21 喷油嘴3 3 1

2 1 2 1 2 1 2 1

C25 Ignition coil (1, 4 C26 Power steering pump

C24 Ignition coil (2, 3 cylinders) C27 Crankshaft position sensor
C24 点火线圈 (2、3缸) C25 点火线圈 (1、4缸) C26 动力转向泵 C27 曲轴位置传感器
cylinders)

2 1 2 1 1 3 2 1
 Connector Shape CC-10

Controller Wire Harness (2)

控制线束（2）

C30 Engine oil pressure C31 Speed sensor C32 Reverse gear switch
C30 机油压力开关
switch C31车速传感器 C32 倒档开关

1
3 2 1 2 1 BLANK

CE02 CE02
CE01 CE01

1 2 3 4 4 3 2 1
1 2 3 4 4 3 2 1 5 6 7 8 8 7 6 5
5 6 7 8 8 7 6 5 9 10 11 12 12 11 10 9
9 10 11 12 12 11 10 9 13 14 15 16 16 15 14 13

CC01 CC01

1 2 3 4 5 6 6 5 4 3 2 1 BLANK BLANK
7 8 9 10 11 12 12 11 10 9 8 7
 Connector Shape CC-11

Frame Wire Harness

车架线束
Frame Wire Harness (1)
车架线束（1）

F01 BCM A F02 BCM B F03 BCM C F04 Manual brake switch
F04 手制动开关

1916 1310 7 4 1 161310 7 4 1 13 10 7 4 1

14 11 8 5 2 1
2017 1411 8 5 2 17 14 11 8 5 2
2118 15 12 9 6 3 18 15 12 9 6 3 15 12 9 6 3

F05 Left safety belt connector F07 Fuel sensor and fuel
lock switch F06 Rear oxygen pump
F07 燃油传感器及燃油泵 F08 Speed sensor of left rear
F05 左安全带接插锁开关 F06 后氧传感器 F08wheel
左后轮速传感器-绿
sensor - green

1
2 4 3 2 1 4 3 2 1 2 1

F09 Speed sensor of right F10 Boot lighting F11 High position stop lamp
F09 右后轮速传感器-黑 F10 行李箱照明灯 F11 高位制动灯
rear wheel - black

2 1 2 1 BLA N K
2 1

F12 Reversing radar F13 Rear vehicle

F12 倒车雷达控制器
controller F13 power
后车载电源 F14 LeftF14
rear左后组合灯
combined light

9 8 7 6 5 4 3 2 1 1 2 1
2019 18 1716 1514 13 1211 10 2 6 5 4 3

F15 Right rear combined light F16 Fuel tank actuator

F15 右后组合灯 F16 油箱执行器 F17 Power supply of antenna F17 Electric seat
F17 天线放大器电源 F17 电动座椅
amplifier

2 1 1
6 5 4 3 2 1 1 2

FD01 FD01

1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
101112131415161718 192021 21 2019 18 1716 1514 13 1211 10
2223 2425 2627 28 2930 31 32 3231 3029282726 25 24 23 22
 Connector Shape CC-12

车架线束（2）
Frame Wire Harness (2)

FD03 FD03

1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
101112131415161718 1920 21 21 2019 18 17 1615 13 1211 10
14
2223 2425 26 27 28 29 30 31 32 32 31 302928 2726 25 24 23 22

FD04 FD04 FD05 FD05

1 2 3 3 2 1 1 2 3 3 2 1
4 5 6 7 8 8 7 6 5 4 4 5 6 7 8 8 7 6 5 4
9 101112 13 13 1211 10 9 9 101112 13 13 1211 10 9

FR01 FR01 FR02 FR02

1 2 3 4 4 3 2 1 1 2 3 4 5 6 6 5 4 3 2 1
5 6 7 8 9 10 10 9 8 7 6 5 7 8 9 10 11121314 1413 1211 10 9 8 7

FR03 FR03 FR04 FR04

1 2 3 4 4 3 2 1
5 6 7 8 9 1011 1110 9 8 7 6 5 1 1
 Connector Shape CC-13

Wire Harness of Left and Right Doors (1)

左右门线束（1）

D01 Left electric back mirror D02 Left front high pitch D04 Electric window switch of D05 Electric back mirror switch
D01 左电动后视镜 D02 左前高音扬声器
loudspeaker D04 左前门电动窗开关
left front door
D05 电动后视镜开关

3 2 1 6 5 4 3 2 1 3 2 1
8 7 6 5 4 2 1 131211 10 9 8 7 8 7 6 5 4

D06 Lock controller of left front D08 Glass frame riser motor of D09 Left front bass loudspeaker
D06 左前门门锁控制器
door D07 Light
D07of左前门门灯
left front door D08 左前门玻璃升降器电机
left front door D09 左前低音扬声器

1
3 2 1
2 1 2 1 2
6 5 4

D12 Electric window switch of D13 Lock controller of right front

D10 Right front high pitch D11 Right electric back mirror
D10 右前高音扬声器 D11 右电动后视镜 right front door
D12 右前门电动窗开关 door
D13 右前门门锁控制器
loudspeaker

3 2 1 2 1
2 1 3 2 1
8 7 6 5 4 5 4 3 6 5 4

D15 Glass frame riser motor of D16 Right front bass

D14 Light of right front door D15right front door
右前门玻璃升降器 电机 D16loudspeaker
右前低音扬声器
D14 右前门灯

1 BLANK
2 1 2 1 2

D17-1 Light of left rear door D18-1 Electric window switch of D19-1 Lock controller of rear D20-1 High左后门高音扬声器
pitch loudspeaker
左后门电动窗开关
D18-1 left D19-1 后门门锁控制器 D20-1
D17-1 左后门门灯 rear door door of left rear door

2 1 3 2 1
2 1 2 1
5 4 3
6 5 4

D21-1 Glass frame riser motor D22-1 Left rear bass

D21-1 of左后门玻璃升降器电机
left rear door D22-1loudspeaker
左后低音扬声器

BLA N K BLA N K
2 1 1
2
 Connector Shape CC-14
Wire Harness of Left and Right Doors
左右门线束（2） (2)

D17-2 Light of right rear door D18-2 Electric window switch D19-2 Lock controller of rear
D17-2 右后门门灯 D18-2 of右后门电动窗开关 D20-2 High pitch loudspeaker
right rear door D19-2 后门门锁控制器
door D20-2of 右后门高音扬声器
right rear door

2 1 2 1 3 2 1
5 4 3 2 1
6 5 4

D21-2 Glass frame riser motor D22-2 Right rear bass

D21-2 of
右后门玻璃升降器电机
right rear door loudspeaker
D22-2 右后低音扬声器

BLA N K BLA N K
2 1 1
2
 Connector Shape CC-15
Sensor Wire Harness, Tail Door Wire Harness,
传感器线束、尾门线束、
Ceiling Wire Harness and Rear Defrosting Wire
顶棚线束及后除霜线

R01 Left rear reversing radar R02 Left middle reversing R03 Right middle reversing R04 Right rear reversing radar
R01 左后倒车雷达传感器
sensor R02radar sensor
左中倒车雷达传感器 R03 radar sensor
右中倒车雷达传感器 sensor
R04 右后倒车雷达传感器

3 2 1 3 2 1 3 2 1 3 2 1

R05 Left license light R06 Right license light R07 Boot actuator R08 Boot illumination switch
R05 左牌照灯 R06 右牌照灯 R07 行李箱执行器 R08 行李箱照明开关

2 1 2 1 2 1 2 1

R10 Rear dome lamp R11 Interior back mirror R12 Sunroof control module
R10 后顶灯 R11 内后视镜 R12 天窗控制模块

BLA N K 3 2 1 3 2 1 5 4 3 2 1
10 9 8 7 6

R13 Left sunroof R14 Right sunroof R15 Front indoor light R16 Sunroof switch
R13 左遮阳板 R14 右遮阳板 R15 前室内灯 R16 天窗开关

2 1 2 1 3 2 1 4 3 2 1

R17 Rear defrosting wire (-) R18 Rear defrosting wire (+)
R17 后除霜线（-） R18 后除霜线（+）

BLA N K BLA N K
1 1
 Wire Harness Layout HL-1

Wire Harness Layout

Main Wire Harness… … … … … … … … … … … … … … … … … … .............................. HL-2

Air Conditioning Wire Harness… … … … … … … … … … … … … … … … … … .......... HL-4
Wire Harness of Engine Hatch… … … … … … … … … … … … … … … … … ............... HL-5
Controller Wire Harness… … … … … … … … … … … … … … … … … … … … .............. HL-7
Chassis Wire Harness … … … … … … … … … … … … … … … … ............................... HL-9
Wire Harness of Left Front door … … … … … … … … … … … … … … … … ............... HL-11
Wire Harness of Right Front door… … … … … … … … … … … … … ........................ HL-12
Rear Door Wire Harness … … … … … … … … … … … … … … … … … … .................... HL-13
Tail Door Wire Harness… … … … … … … … … … … … … … … … … … … … ................ HL-14
Ceiling Wire Harness… … … … … … … … … … … … … … … … … … … … … … … ......... HL-15
Sensor Wire Harness… … … … … … … … … … … … … … … … … … … … ................... HL-16
 M28 ME01 ME02 M15 ME03 M07 M06 M19 M08 M31 M12 M10 M11 A06 M32 A02 M27 M23 A01 MA01 A03 MA02
主线束
M02
M03
M04
主线束（1）

M05
Main Wire Harness
Main Wire Harness (1)

G12、G13、
G14

MF01

MF03

M16
A05
M14
M30
A04
M13
M34
Wire Harness Layout

M33 G30 M25 M26 M24 MA03 M29 G15、G16 MF02

M17 M18 M20 G17
M01 M22

M21 M35
HL-2
 Wire Harness Layout HL-3
Main Wire Harness (2)
主线束（2）

M01M01 室内温度传感器
Indoor temperature sensor M32
M32 副安全气囊
Secondary airbag
M02M02 Boot cover switch
行李箱盖开关 M33
M33 Airbag ECU
安全气囊ECU
M03 Fuel tank cover switch M34 Driver safety belt pre-tension
M03 邮箱口盖开关 M34 司机安全带预紧
M04 Illumination regulating switch M35 Passenger safety belt pre-tension
M04 照明调节开关 M35 乘客安全带预紧
M05 Regulating switch of distance headlight ME01 To front wall wire harness
M06M05 前照灯调节开关
Burglarproof LED ME01
ME02 接前围线束
To engine wire harness
M07M06 防盗LED
Combined device (green) ME02
ME03 接发动机线束
To front wall wire harness
M08M07 Combined
组合仪表（绿）device (blue) MF01
ME03 To chassis wire harness
接前围线束
M10 DVD MF03 To chassis wire harness
M08 组合仪表（蓝） MF01 接车架线束
M11 DVD antenna MA01 Wire harness interface A of ABS module
M10 DVD MF03 接车架线束
M12 Middle switch group assembly MA02 Wire harness interface B of ABS module
M13M11 LeftDVD天线
foot lighting lamp MA01
MA03 ABS模块线束接口A
Air conditioning wire harness interface
M14M12 中间开关组总成
Ignition switch MA02
MF02 ABS模块线束接口B
To chassis wire harness
M15M13 Combined
左照脚灯 switch A G12
MA03 Main wire harness grounding 1A
空调线束接口
M16 Combined switch B G13 Main wire harness grounding 1B
M14 点火开关 MF02 接车架线束
M17 Stop lamp switch G14 Main wire harness grounding 4
M15 组合开关A G12 主线束接地1A
M18 Diagnosis interface G15 Main wire harness grounding 2A
M19M16 组合开关B
Combined switch C
G13
G16
主线束接地1B
Main wire harness grounding 2B
M20M17 制动灯开关
Anti-theft control box G14
G17 主线束接地4
Main wire harness grounding 3
M21M18 Cigarette
诊断接口 lighter G15
G30 主线束接地2A
Airbag grounding
M22 Air conditioning panel G16 主线束接地2B
M19 组合开关C
M23 Reversing radar buzzer ABS Wire Harness
M20 防盗控制盒 G17 主线束接地3
M24 Right foot lighting lamp MA01 Instrument wire harness interface
M21
M25
点烟器
Illumination switch of miscellaneous articles
G30
MA02
气囊地
Instrument wire harness interface
M22
compartment 空调面板 A01 ABS module
M26M23 倒车雷达蜂鸣器
Lighting of miscellaneous articles compartment ABS线束
A02 Wiper motor
M27M24 Sunlight
右照脚灯 sensor A03
MA01 Speed sensor of right front wheel
仪表线束接口
M28 Indoor fuse box A04 Wear sensor of right front brake shoe
M25 杂物盒照明开关 MA02 仪表线束接口
M29 Shield wire of antenna A05 Right turn light
M26 杂物盒照明灯 A01 ABS模块
M30 Horn switch A06 Burglar alarm
M31M27 日照传感器
Clock spring
A02 刮水电机
M28 室内保险盒 A03 右前轮速传感器
M29 天线屏蔽线 A04 右前制动蹄片磨损传感器
M30 喇叭开关 A05 右侧转向灯
A06 防盗警铃
M31 时钟弹簧
 Wire Harness Layout HL-4

空调线束
Air Conditioning Wire Harness

A16 A17 AA01 A13 A11

A15 A14 A12 MA03 A10

A10 Blower motor

A10
A11 鼓风机电机
Power amplifier
A11
A12 功率放大器
Airduct sensor
A12
A13
风道传感器
Air door motor
A13 风门电机
A14 Temperature controller motor
A14 温控电机
A15 Water temperature sensor
A15 水温传感器
A16 Mode motor
A16 模式电机
A17 To FATC control
A17 接FATC控制
AA01 Air conditioning wire interface
AA01 空调线接口
MA03 Main wire harness interface
MA03 主线束接口
 E21 E16 G6,G7 E17 E13 G09 E28 E27 E24 E22 E23 CE01 E02 CE02 E04 ME03 ME02 ME01 E01

R/L8
发动机仓线束
发动机仓线束（1）
Wire Harness of Engine Hatch
Wire Harness of Engine Hatch (1)
Wire Harness Layout

E18 E19 E15 E25 E26 E12 E11 G08 E14 E10 E09 EE01 E06 G03,G04 E05 E07 EF02 EF01
HL-5
 Wire Harness Layout HL-6

发动机仓线束（2）
Wire Harness of Engine Hatch (2)

E01
E01 Left turn light
左侧转向灯
E02
E02 Braking liquid level sensor
制动液位传感器 R/L8R/L8Fan风扇控制继电器
control relay
E04 Speed sensor of left front wheel Power Supply Wire Harness
E04
E05
左前轮速传感器
Wear sensor of left front brake shoe
电源线束
EE01 To power supply wire harness
E05 左前制动蹄片磨损传感器 +
E06 Positive pole of battery E22EE01
Battery B接电源线束
E06
E07 蓄电池正极
Outdoor fuse box E23 E22
Master fuse
蓄电池B+
E07
E09 室外保险盒
Left headlight E24 Battery B-
E23 总保险
E10
E09 High pitch electric horn
左前照灯 E25 Starter signal
E11 Bass electric horn
E24
E26 Starter B
蓄电池B-
E10 高音电喇叭
E12 Condensed fan E27 E25
Generator起动机信号
B
E11 低音电喇叭
E13 Radiator fan E28 E26
Generator起动机B
E&L
E12 冷凝风扇
E14 Left fog lamp G08E27
Master grounding
发电机B
E13
E15 散热器风扇
Outdoor temperature sensor G09E28
Engine grounding point
发电机E&L
E14
E16 左前雾灯
Three-way pressure switch
G08 总搭铁点
E17
E15 Compressor
室外温度传感器
G09 发动机搭铁点
E18
E16 Right fog lamp
三元压力开关
E19 Washing motor
E17 压缩机
E21 Right headlight
E18 右前雾灯
ME01 Main wire harness interface 1
E19
ME02 洗涤电机
Main wire harness interface 2
E21
ME03 右前照灯
Main wire harness interface 3
ME01
EF01 主线束接口1
Chassis wire harness interface 1
EF02
ME02 Chassis wire harness interface 2
主线束接口2
CE01 Controller wire harness interface 1
ME03 主线束接口3
CE02 Controller wire harness interface 2
EF01 车架线束接口1
G03 Front wall grounding
EF02
G04 车架线束接口2
Front wall grounding
CE01
G06 控制线束接口1
Front wall grounding
G07
CE02 Front wall grounding
控制线束接口2
G03 前围接地
G04 前围接地
G06 前围接地
G07 前围接地
 Wire Harness Layout HL-7

控制线束
Controller Wire Harness
Controller Wire Harness (1)
控制线束（1）
C06

C11
C32
CE01

CE02
CC01

C12
C04

C10
C05
C31

C20

C25
C30

C21

C24
C02

C22
C23
G20
C01

C03

C27

C26
 Wire Harness Layout HL-8

Controller Wire Harness (2)

控制线束（2）

C01 ECM C30 Engine oil pressure switch

C01 ECM C31 Car
C02 Absolute pressure sensor C30speed机油压力开关
sensor
C02
C03 绝对压力传感器
Carbon canister solenoid valve C32 Reverse gear
C31 车速传感器switch
C04
C03 炭罐电磁阀
Stepper motor CC01 Wire harness interface of ignition and fuel
C32 倒档开关
C05 Air throttle position sensor injection
C04 步进电机 点火喷油线束接口
CC01harness interface of engine hatch 1
C06 Knock sensor CE01 Wire
C05 节气门位置传感器
C10 Front oxygen sensor CE02 Wire 发动机仓线束接口1
CE01harness interface of engine hatch 2
C06 爆震传感器 G20 发动机仓线束接口2
Grounding
C11 Water temperature sensor CE02
C10
C12
前氧传感器
Camshaft position sensor G20 搭铁
C11
C20 水温传感器
Fuel injection nozzle 4
C21
C12 Fuel injection nozzle 3
凸轮轴位置传感器
C22 Fuel injection nozzle 2
C20 喷油嘴4
C23 Fuel injection nozzle 1
C21 喷油嘴3
C24 Ignition coil 2, 3
C22
C25 喷油嘴2
Ignition coil 1, 4
C23
C26 喷油嘴1
Power steering pump
C27
C24 点火线圈2.3
Crankshaft position sensor
C25 点火线圈1.4
C26 动力转向泵
C27 曲轴位置传感器
 FD05 G02 F07 F08 F18 F17 FR04 F16 F12 F15 F11 F10
车架线束
车架线束（1）

FR01
Chassis Wire Harness
Chassis Wire Harness (1)

F14

FR02
FD03
FR03
F19 F13
MF02

F06
F04
Wire Harness Layout

F05

EF02

EF01 MF03 MF01 FD01 G05 F03 F27 F01 F02 FD04 G01 F09
HL-9
 Wire Harness Layout HL-10

Chassis Wire Harness (2)

车架线束（2）

F01
F01
BCM A
BCM A
EF02
EF02
接发动机线束
To wire harness of engine
F02
F02 BCM BB
BCM FD03
FD03 接右前门线束
To wire harness of right front door
F03
F03 BCM
BCM CC FR03
FR03 接顶棚线束
To ceiling wire harness
F04
F04 Manual
手制动开关 brake switch FR01
FR01 To tail door wire harness
接尾门线束
F05 Connector lock switch of left safety FR02 To sensor wire harness
F05 左安全带插锁开关 FR02 接传感器线束
belt FR04 Rear defrosting power supply
F06
F06 后氧传感器
Rear oxygen sensor
FR04
G01
后除霜电源
Floor grounding 1
F07
F07 燃油传感器及燃油泵
Fuel sensor and fuel injection pump G01
G02 地板接地1
Floor grounding 2
F08
F08 Speed sensor of left rear wheel
左后轮速传感器（绿） G05
G02 Floor
地板接地2 grounding 5
(green)
F09 右后轮速传感器（黑） G05 地板接地5
F09 Speed sensor of right rear wheel
F10 行李箱照明灯
(black)
F11
F10 高位制动灯
Boot lighting
F12
F11 倒车雷达控制器
High position stop lamp
F12
F13 Reversing
后车载电源 radar controller
F13
F14 Rear
左后组合灯 vehicle power supply
F14 Left rear combined light
F15 右后组合灯
F15 Right rear combined light
F16
F16 油箱执行器
Fuel tank actuator
F17
F17 天线放大器电源
Power supply of antenna amplifier
F18
F18 Antenna
天线接口 interface
F19
F19 To transition antenna
接过渡天线
F27 Electric seat
F27 电动座椅
MF01 To main wire harness
MF01
MF02 To接主线束
main wire harness
MF02
MF03 To接主线束
main wire harness
FD05
MF03 To接主线束
wire harness of right rear door
FD04
FD05 To接右后门线束
wire harness of left rear door
FD01 To wire harness of left front door
FD04 接左后门线束
EF01 To wire harness of engine
FD01 接左前门线束
EF01 接发动机线束
 Wire Harness Layout HL-11

Wire Harness of Left Front Door

左前门线束

D06 D04 D05 D02 D01

D07 D08 D09 FD01

D01
D01 左电动后视镜
Left electric back mirror
D02 Left front high pitch loudspeaker
D02 左前高音扬声器
D04 Electric window switch of left front door
D04
D05 左前门电动窗开关
Electric back mirror switch
D06
D05 Lock controller of left front door
电动后视镜开关
D07 Light of left front door
D06
D08 左前门门锁控制器
Glass frame riser motor of left front door
D09
D07 Left front bass loudspeaker
左前门门灯
FD01 To chassis wire harness
D08 左前门玻璃升降器电机
D09 左前低音扬声器
FD01 接车架线束
 Wire Harness Layout HL-12

右前门线束
Wire Harness of Right Front Door

D11 D10 D12 D13

FD03 D16 D15 D14

D10
D10 Right front high pitch loudspeaker
右前高音扬声器
D11 Right electric back mirror
D11 右电动后视镜
D12 Electric window switch of right front door
D12
D13 右前门电动窗开关
Lock controller of right front door
D14 Light of right front door
D13 右前门门锁控制器
D15 Glass frame riser motor of right front door
D14
D16 右前门门灯
Right front bass loudspeaker
FD03 To chassis wire harness
D15 右前门玻璃升降器电机
D16 右前低音扬声器
FD03 接车架线束
 Wire Harness Layout HL-13

Rear Door Wire Harness

后门线束

D19-1 D18-1 D20-1

D19-2 D18-2 D20-2

D17-1 D21-1 D22-1 FD04

D17-2 D21-2 D22-2 FD05

D17-1 Light of left rear door D17-2 Light of right rear door
D18-1 Electric window switch of left rear door D18-2 Electric window switch of right rear
D17-1 左后门门灯 D17-2 右后门门灯
D19-1 Lock controller of left rear door door
D20-1D18-1 左后门电动窗开关
Left rear high pitch loudspeaker D18-2
D19-2 Lock右后门电动窗开关
controller of right rear door
D21-1D19-1 左后门门锁控制器
Glass frame riser motor of left rear D20-2 Right
D19-2 rear high pitch loudspeaker
右后门门锁控制器
door D21-2 Glass frame riser motor of right rear
D20-1 左后高音扬声器 D20-2 右后高音扬声器
D22-1 Left rear bass loudspeaker door
FD04D21-1 左后门玻璃升降器电机
To chassis wire harness-left rear door D21-2
D22-2 右后门玻璃升降器电机
Right rear bass loudspeaker
D22-1 左后低音扬声器 FD05 To 右后低音扬声器
D22-2 chassis wire harness-right rear
door
FD04 接车架线束-左后门 FD05 接车架线束-右后门
 Wire Harness Layout HL-14

Tail Door Wire Harness

尾门线束

FR04 R18 G10 R06 R08

R17 G11 FR01 R05 R07

R05 Left license light

R06
R05 Right license light
左牌照灯
R07 Boot actuator
R06 右牌照灯
R08 Boot illumination switch
R07
FR01 行李箱执行器
To chassis wire harness
R08 行李箱照明开关
Rear Defrosting Grounding Wire
FR01 接车架线束
R17 Rear defrosting wire (-)
后除霜接地线
G11 Rear defrosting grounding
R17 后除霜线（-）
Rear Defrosting Power Supply
G11 后除霜接地
R18 Rear defrosting wire (+)
后除霜电源线
G10 Trap filter grounding
R18
FR04 后除霜线（+）
To chassis wire harness
G10 陷波器接地
FR04 接车架线束
 Wire Harness Layout HL-15

Ceiling Light Wire Harness

顶棚线束
R14 R11 R13 R15 R16 R12

R10

FR03

R10
R10 后顶灯
Rear ceiling light
R11 Inner back mirror
R11 内后视镜
R12 Sunroof control module
R12
R13 天窗控制模块
Left sunroof
R14 Right sunroof
R13 左遮阳板
R15 Front indoor light
R14
R16 右遮阳板
Sunroof switch
FR03
R15 To chassis wire harness
前室内灯
R16 天窗开关
FR03 接车架线束
 Wire Harness Layout HL-16

Sensor wire harness

传感器线束

R01 FR02 R02 R03 R04

R01
R01 Left rear reversing radar sensor
左后倒车雷达传感器
R02 Left middle reversing radar sensor
R02 左中倒车雷达传感器
R03 Right middle reversing radar sensor
R03
R04 右中倒车雷达传感器
Right rear reversing radar sensor
FR02
R04 To chassis wire harness
右后倒车雷达传感器
FR02 接车架线束