Geely FC Workshop Manual
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Geely FC Workshop Manual

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Summary of Contents for Geely FC

  • Page 3 “make good cars that common people can afford, and let Geely cars go to the whole world” of Geely automobile. “FC” is combination of creativity and intelligence of quite a large number of...
  • Page 4 In addition, this manual is compiled with the following characteristics: in proper sequence, clear demarcations, easy to understand, excellent in picture and its accompanying essay, simple and clear, which is very applicable for a quite large number of “FC” automobile main- tenance technicians and service personnel to refer to.
  • Page 5 Note This manual is mainly for qualified vehicle technicians, but it does not in- clude all items on repair and maintenance. In order to avoid personnel injury and vehicle damage caused by dangerous operation, please observe the following regulations. Please read this manual carefully, and particularly fully master all con- tents in “Precautions”.

  • Page 6: Table Of Contents

    Contents Inspection ............26 Brief introduction on Geely model “FC” Basic parameters ........... 1 Drive belt .............. 29 Replacement ........... 29 Valve clearance ............ 30 Maintenance period Regular maintenance items ........4 Adjustment ............30 Engine assembly ..........36 Table on maintenance period at normal conditions5 Table on maintenance period at severe conditions ..
  • Page 7 Replacement ........... 72 Front stabilizer bar ..........96 Coolant ..............73 Overhaul ............96 Replacement ........... 73 Front left lower control arm ball joint assembly .. 99 Replacement ........... 99 Lubrication Lubricating system ..........74 Rear suspension On-vehicle inspection ........74 Rear suspension system ........
  • Page 8 Brake Transmission Brake system ............132 Disassemble assembly ........165 Notes .............. 132 Assemble the assembly ........191 Remove malfunction ........... 133 Malfunction phenomenon table ..... 133 Steering column Brake liquid ............135 Steering system ..........192 Discharge the air in brake system ....135 Note ...............
  • Page 9 Change ............234 Adjustments ..........287 Condenser Assembly ........... 236 Front fog light ............. 289 Inspection on the automobile ....... 236 Components ..........289 Overhaul ............236 Change ............290 Adjustment ............ 290 Side turning light ..........291 Supplemental restraint system Note ..............
  • Page 10 Replacement ..........308 Left front door loudhailer ........309 Panel / combination panel Change ............309 combination panel ..........334 Left front small loudhailer ........310 Trouble table ..........334 Change ............310 Vehicle inspection .......... 335 Rear loudhailer ..........311 Inspection ............
  • Page 11 Engine cover/automobile door Automobile control system Engine cover ............366 Ignition switch and anti-versa lock key warning switch . 394 Adjustment ............. 366 Malfunction phenomenon table ..... 394 Front automobile door ........367 Inspection ............394 Subassembly ..........367 Overhaul ............369 Electrical schematic diagram ......

  • Page 12: Brief Introduction On Geely Model "Fc" Basic Parameters

    Brief introduction on Geely model “FC” Basic parameters Brief introduction on Geely model “FC” Basic parameters Table 1 Complete vehicle basic parameters Number Unit Item name Parameters Length Overall Width dimension Height Front wheel ±15 Wheel track Rear wheel ±15 Wheel base ±20...
  • Page 13 Brief introduction on Geely model “FC” Basic parameters Table 2 Types and parameters of main assembly Types and parameters Item name Unit Number JL4G18 Model 4-cylinderin-line, four-stroke, water-cooling, double over-head Type camshaft, 16-valve, CVVT multipoint injection gasoline engine United Automotive Electronic Systems Co., Ltd. M7.9.7 electric injection system...
  • Page 14 Brief introduction on Geely model “FC” Basic parameters Table 3 Main performance parameters of complete vehicle Item name Unit Parameters Remarks Number Max. vehicle speed 0-100 km/h accelerating time Accelerating time from 30km/h to 100km/h at 4 gear Min. stable vehicle speed at 4 gear Max.

  • Page 15: Maintenance Period Regular Maintenance Items

    Maintenance period-Regular maintenance items Maintenance period Regular maintenance items Your precious automobile should be maintained according to maintenance period at normal conditions (see table on maintenance period at normal conditions) If your precious automobile is mainly driven under one or more of the following conditions, some maintenance items must be performed more frequently (see table on maintenance period at severe conditions).
  • Page 16 Maintenance period-Table on maintenance period at normal conditions Table on maintenance period at normal conditions Maintenance content: I: Inspection and correction or replacement if necessary R: Replacement Maintenance period mileage (Odometer readings or 7 . 5 1 5 22.5 30 37.5 45 53.5 60 67.5 7 5 82.5 90 months reading operating months subject to...
  • Page 17 Replace at initial 60000km, and replace every 30000km in future. Only “Geely genuine ultra-long engine coolant” or equivalent high-quality ethylene glycol engine coolant without silicate, amines, nitrite, borate and with long-life compound organic acid technology are allowed to use, and coolant should be repeated several times until it is filled up.
  • Page 18 Maintenance period-Table on maintenance period at severe conditions Table on maintenance period at severe conditions According to the driving conditions listed below, maintenance should be performed to the items that should be maintained more frequently (for other items not listed, please see Table on maintenance period at normal conditions) A-1: Driving on rugged, muddy or melting snow road Inspection of brake pad and brake disc...

  • Page 19: Engine Control System Efi System

    Engine control system·- EFI system Engine control system EFI system On-vehicle inspection 1. Inspection of the voltage of power steering oil pres- sure sensor Measure the voltage between PS terminal and E2 terminal with ohmmeter Conditions Voltage (V) Not turning steering wheel with engine at idle speed Turning steering wheel with 0-1.5...

  • Page 20: Inspection

    Engine control system·- EFI system Inspection 1. VVT control solenoid valve assembly (4G18-1006200) (a) Resistance inspection (1) Measure the resistance between terminals with ohmmeter Resistance: (b) Operation inspection Connect battery positive (+) wire to No.1 terminal and negative (-) wire to No. 2 terminal, and check valve operation.
  • Page 21 Engine control system·- EFI system 4. Knock sensor (4G18-3600020) Measuring method: (Removing the joint) place digital universal meter at ohm gear, 1 Vibration block and connect 2 terminals respectively to 1 # pin and 2 # pin, and 2 Housing the resistance under normal temperature should be more than 3 Piezoelectric ce- .
  • Page 22 Engine control system·- EFI system Use digital universal meter to measure: Resistance-temperature characteristics of temperature sensor Resistance at A and C Temperature range( Resistance at B 6. Intake air temperature sensor (4G18-3600090) Intake air temperature sensor is a resistor with negative tem- perature coefficient (NTC), resistance varies with intake air temperature, and this sensor sends a voltage indicating change of intake air temperature to controller.
  • Page 23 Engine control system·- EFI system Electrical wiring Pins: Pin A is connected to ECU No. 65 pin diagram Pin B is connected to ECU No. 66 pin on step- Pin C is connected to ECU No. 67 pin ping motor of idle Pin D is connected to ECU No.

  • Page 24: Throttle Body Assembly

    Engine control system·- Throttle body assembly Throttle body assembly Removing, installing and disassembling, assembling 1. Discharge coolant (see Page 73). 2. Remove air cleaner hose assembly. 3. Remove engine plastic hood components [4G18-1000310]. 4. Remove throttle pull cable assembly. 5. remove throttle body assembly [4G18-1008240]. (a) Uncouple throttle position sensor joint and stepping motor joint.

  • Page 25: Fuel

    Fuel-Fuel system Fuel Fuel system Precautions 1. Before repairing fuel system, uncouple battery negative (-) wire at first. 2. When operating on fuel system, do not smoke or repair near fire area. 3. Do not let gasoline come into contact with rubber or leather parts. 4.
  • Page 26 Fuel-Fuel system (1) It is not allowed to use o-ring repeatedly. o-ring Correct (2) When installing o-ring, always be careful to avoid dam- aging o-ring. (3) Before installing, coat o-ring with spindle oil or gasoline. injection nozzle oil feed pipe It is not allowed to coat with engine oil, gear oil or Wrong brake fluid.

  • Page 27: On-Vehicle Inspection

    Fuel-Fuel system On-vehicle inspection 1. Inspection of fuel pump function (a) Connect hand-held tester to diagnostic joint. (b) Turn ignition switch to ON and turn main switch of hand- held tester to ON. Note: do not start the engine. (c) Switch hand-held tester to function test state. (d) For further details, please see hand-held tester operating instruction.

  • Page 28: Inspection

    Fuel-Fuel system Inspection 1. Fuel injector components [4G18-1112120] (a) Check injection nozzle resistance. (1) Measure the resistance between terminals with ohmmeter. Resistance: Hint: if resistance is not within specification, replace in- jection nozzle. (b) Injection nozzle test. Warning: there should be no sparks during testing. (1) Purchase new fuel pipe and take out fuel hose joint.

  • Page 29: Injection Nozzle Assembly

    Fuel-Injection nozzle assembly Injection nozzle assembly Replacement 1. Take measures to prevent gasoline leaking. 2. Remove engine plastic hood components. 3. Uncouple engine wire harness [4G18-3724100]. (a) Remove injection nozzle joint. (b) Remove exhaust gas hose. 4. Remove fuel pipe assembly (a) Loosen oil feed hose clips.
  • Page 30 Fuel-Injection nozzle assembly 9. Install fuel rail component [4G18-1112110]. (a) Check injection nozzle o-ring and replace if there is damage. (b) Install isolator on cylinder head. (c) Install fuel rail component together with injection nozzle. Torque: (d) Install fuel pipe fixing clip. Torque: Check the function of electric fuel pump and check there is fuel leakage.

  • Page 31: Fuel Pump Assembly

    Fuel - Fuel pump assembly Fuel pump assembly Removing, installing and disassembling, assembling 1. Take measures to prevent gasoline leaking 2. Remove rear seat cushion assembly 3. Remove rear floor repairing hole cover 4. Remove No. 2 fuel evaporation assembly Notes: Check there is contaminant looked like dirt around the joint before operating and clean it off in the case of contaminant.

  • Page 32: Fuel Tank Assembly

    Fuel - Fuel tank assembly Fuel tank assembly Removing, installing and disassembling, assembling 1. Take measures to prevent gasoline leaking (see Page 14) 2. Remove rear seat cushion assembly 3. Remove rear floor repairing hole cover 4. Remove No. 2 fuel evaporation assembly 5.
  • Page 33 Fuel - Fuel tank assembly Be careful of the contaminant that looked like dirt, because fast-joint depends on o-ring to seal fuel pipe and joint. Do not perform this operation with tools. Do not bend or distort nylon hose. Cover the joint with plastic bag after removing the fuel hose. When the joint is stuck with fuel pipe, clip the hose with fingers and rotate carefully to release the hose, and then remove it.

  • Page 34: Exhaust Gas Control

    Exhaust gas control - Exhaust gas control system Exhaust gas control Exhaust gas control system On-vehicle inspection 1. Check oxygen sensor. (a) Let the engine run at idle speed for 3 minutes to ensure oxygen sensor reaches operating tempera- ture of 350 (b) Place digital universal meter at DC voltage gear, and connect 2 terminals respectively to (gray) pin and (black) pin of sensor, and voltage should fluctuate quickly between 0.1-0.9V at the moment.
  • Page 35 Exhaust gas control - Exhaust gas control system 5. Check heater resistance of heated oxygen sensor. (a) Uncouple oxygen sensor joint. (b) Place digital universal meter at ohm gear, and connect 2 terminals respectively to 1# (white) pin and 2# (black) pin, and the resistance under normal temperature is 1 6 Oxygen sensor Main relay 6.

  • Page 36: Inspection

    Exhaust gas control - Exhaust gas control system Inspection 1. Carbon canister assembly [4G18-1129020] Carbonl canister assembly. Check the function of carbon can- ister according to the following tables. Standard: Inspection Methods Standard Close B hole and C hole and then supply vacuum to A hole No leakage Close C hole and then supply vacuum...

  • Page 37: Engine Mechanism Engine Assembly

    Engine mechanism - Engine assembly Engine mechanism Engine assembly Inspection 1. Check coolant. 2. Check engine oil. 3. Check battery. 4. Check air filter assembly. 5. Check spark plug [4G18-3705113]. 6. Check drive belt [4G18-1307107]. Hint: do not check belt tension, because automatic tensioner is applied. 7.
  • Page 38 Engine mechanism - Engine assembly 9. Check compression pressure. (a) Warm up engine. (b) Remove ignition coil. (c) Remove spark plug. (d) Check cylinder compression pressure. (1) Install cylinder compression pressure gauge on spark plug hole. (2) Wide open throttle. (3) Measure the pressure during crankshaft rotating.
  • Page 39 Engine mechanism - Engine assembly Trouble occurrence Possible causes 1. Ignition system malfunction Ignition timing incorrect Spark plug too dirty, short circuit or clearance Normal High Unstable idle speed incorrect 2. Valve clearance incorrect 3. Air inlet and exhaust valve leaky 4.

  • Page 40: Drive Belt

    Engine mechanism - Drive belt Drive belt Replacement 1. Remove engine right bottom shield. 2. Remove drive belt Slowly turn drive belt tensioner clockwise to loosen it. Then remove drive belt and put back drive belt tensioner slowly and gently. 3.

  • Page 41: Valve Clearance

    Engine mechanism - Valve clearance Valve clearance Adjustment 1. Remove engine plastic hood components. Mark Mark 2. Remove ignition coil components [4G18-3705110]. 3. Remove cylinder head cover components [4G18- 1003130]. 4. Remove engine right bottom shield. 5. Turn crankshaft to cylinder 1 compression top dead center position.
  • Page 42 Engine mechanism - Valve clearance 8. Remove right engine mounting assembly (a) Remove PS oil pump reservoir and put it aside. (b) Place wooden block between jack and engine, properly place the jack, and then remove right engine mounting assembly. 9.
  • Page 43 Engine mechanism - Valve clearance (g) As sequences shown in the diagram, loosen camshaft bearing cover bolts on intake camshaft at several times and remove the bearing cover at the same time. (h) Hold timing chain with hands and then remove the camshaft.
  • Page 44 Engine mechanism - Valve clearance (n) Check intake side camshaft bearing cover forward re- mark and figure, and tighten the bolts as sequences shown in the diagram. Torque: Timing remark chain link (o) Align alignment mark on the chain with timing mark on camshaft timing sprocket, and place exhaust camshaft in cylinder head.
  • Page 45 Engine mechanism - Valve clearance (t) Check the matching marks on timing chain and cam- Mark Mark shaft timing sprocket, and then align the groove of crank- shaft pulley with the timing mark on timing chain hood as shown in the diagram. (u) Install chain tensioner.
  • Page 46 Engine mechanism - Valve clearance (4) Turn crankshaft clockwise, and check the sliding parts are blocked by plunger. Plunger Pushing Turning Hint: if the plunger does not eject, press the chain ten- sion rail toward chain tensioner with screwdriver or fingers to separate the hook from lock pin and make the plunger eject.

  • Page 47: Engine Assembly

    Engine mechanism - Engine assembly Engine assembly Replacement 1. Take measures to prevent gasoline leaking. 2. Remove engine right bottom shield. 3. Remove engine left bottom shield. 4. Discharge coolant. 5. Remove front wheels. 6. Remove engine plastic hood components. 7.
  • Page 48 Engine mechanism - Engine assembly Remove drive belt. Drive belt tensioner could turn belt tensioner clockwise to loosen it. Remove alternator mounting components [4G18- 3701100]. Remove compressor assembly. Remove front chassis bracket. Remove front exhaust pipe assembly. Remove steering middle shaft assembly. (a) Remove steering column seal hole cover.
  • Page 49 Engine mechanism - Engine assembly Disassemble left end front stabilizer link assembly. Fix bolts with hex socket wrench, and then remove nuts. Hint: perform the same steps at another side. Disassemble lower left control arm assembly. (a) As shown in the diagram, remove bolt and 2 nuts. (b) Disassemble drive shaft from shaft hub with plastic hammer.
  • Page 50 Engine mechanism - Engine assembly (f) As shown in the diagram, install front and rear hooks of Engine hook engine. Torque: Hint: install engine hooks to front and rear sides of engine. (g) Lift engine assembly with chain pulley block and en- gine lifting device.
  • Page 51 Engine mechanism - Engine assembly Remove speed sensor [4G18-3600010]. Remove knock sensor. Remove knock sensor with special tool. Remove water temperature sensor. Remove water temperature sensor with special tool. Replace engine assembly. Install water temperature sensor. (a) Install new gasket to water temperature sensor. (b) Install water temperature sensor with special tool.
  • Page 52 Engine mechanism - Engine assembly Install temperature regulator assembly. (a) Check temperature regulator assembly o-ring. (b) Install temperature regulator assembly as shown in the diagram. (c) Install engine water inlet pipe joint components. Torque: Install oil level gauge tube components. Install ignition coil mounting components.
  • Page 53 Engine mechanism - Engine assembly Install transmission assembly. (a) Install transmission assembly. Torque: bolt A: Bolt B: Bolt C: (b) Install 6 bolts. Torque: nstall starter mounting components. Torque: bolt: Nut: Install sub frame together with side member. Install front mounting assembly and rear mounting assembly.
  • Page 54 Engine mechanism - Engine assembly (k) Insert special tool into location hole on left side of sub frame and vehicle, and then tighten bolts up to speci- fied torque. Torque: bolt A: Bolt B: (l) As shown in the diagram, tighten 2 bolts. Torque: Note: after installing sub frame, check the sub frame is aligned with location hole on...
  • Page 55 Engine mechanism - Engine assembly Install alternator mounting components. Torque: 12mm bolt head A: 14mm bolt head B: Install drive belt. Install engine wire harness and all hoses not connected. (a) Check and connect all joints of engine wire harness. (b) Check and connect all hoses.

  • Page 56: Timing Chain Assembly

    Engine mechanism - Timing chain assembly Timing chain assembly Replacement 1. Remove engine left bottom shield. 2. Remove engine right bottom shield. 3. Discharge coolant. 4. Remove engine plastic hood components. 5. Remove drive belt. 6. Remove power steering pump assembly. 7.
  • Page 57 Engine mechanism - Timing chain assembly Remove drive belt tensioner device. Hint: operate the jack up and down to remove bolts. Remove water pump components [4G18-1307110]. (a) Remove 6 bolts and water pump components. Remove engine stabilizer bracket on engine cross member.
  • Page 58 Engine mechanism - Timing chain assembly (2) Use damping pulley bolts to turn crankshaft with its key Set key Toward port toward upward. (b) Install timing chain on crankshaft timing sprocket and Yellow align the chain link having yellow mark with timing mark mark of crankshaft timing sprocket.
  • Page 59 Engine mechanism - Timing chain assembly Install crankshaft front oil seal assembly. Special (a) Coat a little MP grease on oil seal lip. tool (b) Gently knock new oil seal in with special tool and ham- mer until the seal surface is parallel and level with the edge of timing chain cover.
  • Page 60 Engine mechanism - Timing chain assembly (b) Coat engine oil on the chain tensioner, and then install Torque: Note: when installing the chain temsioner, buckle on the hook again if plunger has ejected. Pushing into Install damping pulley. (a) Align the key groove on the damping pulley with the key on the crankshaft, and slide damping pulley in.
  • Page 61 Engine mechanism - Timing chain assembly Install speed sensor. Torque: Install engine fixing bracket Torque: Install water pump mounting components [4G18-1307100]. (a) Install new o-ring on water pump. (b) Install water pump with 6 bolts. Torque: bolt A: Install drive belt tensioner device. Torque: nut: Bolt: Install right engine mounting assembly.
  • Page 62 Engine mechanism - Timing chain assembly Install alternator mounting components. Torque: 12mm bolt head: 14mm bolt head: Refill coolant. Check there is coolant leakage. Check there is oil leakage.

  • Page 63: Camshaft

    Engine mechanism - Camshaft Camshaft Replacement 1. Remove engine hood. 2. Remove ignition coil assembly. 3. Remove cylinder head cover assembly. 4. Remove engine right bottom shield. 5. Turn crankshaft to cylinder 1 compression top dead center position. (a) Turn damping pulley to align its groove with “o” mark on Mark Mark timing chain hood.
  • Page 64 Engine mechanism - Camshaft 9. Remove camshaft. Note: do not turn crankshaft before installing timing chain tensioner. (a) Turn crankshaft to cylinder 1 top dead center position. (b) Make marks on timing chain and camshaft timing sprocket. Painting (c) Remove 2 bolts and chain tensioner. mark (d) Fix camshaft with variable wrench and then loosen the fixed Fixing...
  • Page 65 Engine mechanism - Camshaft (h) Hold timing chain with hands and then remove intake camshaft. (i) As shown in the diagram, tie up the chain with bandage. Note: be careful not to let anything fall into the timing chain hood. Check VVT driver assembly [4G18-1006300].
  • Page 66 Engine mechanism - Camshaft (4) Ensure whether the timing sprocket of VVT driver will turn toward timing advance direction in de- Advance Delay side creasing the pressure of timing delay oil duct. side oil oil duct duct (5) When camshaft timing sprocket turns at max. timing advance position, release the air pressure Dropping in timing delay side oil duct, and then release the...
  • Page 67 Engine mechanism - Camshaft Warning: if the air pressure in timing advance side oil duct is released earlier than that in timing delay side oil duct, VVT driver assembly will move suddenly toward delay side.This will cause the damage of lock pin. (g) Remove VVT drive fixed bolts.
  • Page 68 Engine mechanism - Camshaft (i) Temporarily tighten fixed bolts. (j) Check forward mark and figure, and tighten bolts as sequences shown in the diagram. Torque: ±0.78N.m (k) Install camshaft front bearing cover. Torque: 23 ±1.38N.m Fixing Tightening (l) Fix camshaft with variable wrench and then tighten the fixed bolts of exhaust camshaft timing sprocket.
  • Page 69 Engine mechanism - Camshaft (n) Install chain tensioner components. (1) Check o-ring is clean, and buckle on the hook as Lifting Pressing shown in the diagram. Hook (2) Coat engine oil on the chain tensioner, and then install it. Torque: 9 ±1.8N.m Pushing into Note: when installing the chain temsioner, buckle on the hook again if plunger has...
  • Page 70 Engine mechanism - Camshaft Adjust valve clearance. Install cylinder head cover components. (a) Install gasket to cylinder head cover. (b) Eliminate all old sealant (FIPG) materials. (c) Coat sealant on position shown in the diagram. Sealant: silicon rubber flange sealant 1596 (Kesaixin 1596).

  • Page 71: Crankshaft Front Oil Seal Assembly

    Engine mechanism - Crankshaft front oil seal assembly Crankshaft front oil seal assembly Replacement 1. Remove engine right bottom shield. 2. Remove drive belt. Slowly turn drive belt tensioner clockwise to loosen it. Then remove drive belt and put back drive belt tensioner slowly and gently.
  • Page 72 Engine mechanism - Crankshaft front oil seal assembly 5. Remove crankshaft front oil seal. (a) Cut oil seal lip with blade. position (b) Prize out oil seal with flat screwdriver whose sharp end is winded with tape. Note: check crankshaft is damaged after removing oil seal, and repair with abrasive paper (#400) if it is damaged.

  • Page 73: Crankshaft Rear Oil Seal Assembly

    Engine mechanism - Crankshaft rear oil seal assembly Crankshaft rear oil seal assembly Replacement 1. Remove transmission assembly. 2. Remove clutch assembly and flywheel components. Fix crankshaft with special tool, remove clutch assembly at first, and then remove flywheel components. 3.

  • Page 74: Cylinder Cover Gasket Components

    Engine mechanism - Cylinder cover gasket components Cylinder cover gasket components Replacement 1. Take measures to prevent gasoline leaking. 2. Remove timing chain assembly. 3. Remove camshaft. As sequences shown in the diagram, evenly loosen at several times, and remove 19 bearing cover bolts, and then remove 9 bearing covers of intake camshaft and exhaust camshaft.
  • Page 75 Engine mechanism - Cylinder cover gasket components (c) Tighten each cylinder head bolt in turn again. Torque: (d) Install heating air water outlet pipe components. Torque: 8. Install camshaft. (a) Coat engine oil on camshaft journal. (b) Put 2 camshafts on cylinder head and with cylinder 1 cam- shaft end toward the direction shown in the diagram.

  • Page 76: Exhaust

    Exhaust - Exhaust pipe assembly Exhaust Exhaust pipe assembly Removing, installing and disassembling, assembling 1. Remove oxygen sensor. (a) Uncouple oxygen sensor joint. (b) Remove oxygen sensor. 2. Remove exhaust pipe guard [64000051]. 3. Remove front exhaust pipe together with three-way catalytic converter assembly [64000042].

  • Page 77: Cooling Cooling System

    Cooling - Cooling syste Cooling Cooling system On-vehicle inspection 1. Check there is leakage with cooling system. Warning: when the temperature of engine and radiator is high, do not remove radiator cap to avoid be- ing scalded, because coolant and steam will spurt under high pressure.
  • Page 78 Cooling - Cooling syste (a) Immerse temperature regulator into water and heat gradually. (b) Check opening temperature of valve. Opening temperature of valve: 80 Hint: if opening temperature of valve is not within specified range, it is required to replace tempera- ture regulator.

  • Page 79: Cooling Fan System

    Cooling - Cooling fan system Cooling fan system On-vehicle inspection 1. Check cooling fan function at low temperature (below 95 ). (a) Turn ignition switch to ON. (b) Check cooling fan is stopped. Hint: if it is not stopped, check cooling fan relay and water temperature sensor, or check the joint or wire harness between them.

  • Page 80: Water Pump Assembly

    Cooling - Water pump assembly Water pump assembly Replacement 1. Remove engine right bottom shield. 2. Discharge engine coolant. 3. Remove drive belt. Slowly turn drive belt tensioner clockwise to loosen the belt; then remove drive belt and put back drive belt tensioner slowly to completely loosen the tensioner.
  • Page 81 Cooling - Water pump assembly 6. Install water pump assembly. (a) Install new o-ring on water pump. (b) Install water pump with 6 bolts. Torque: bolt A: Bolt B: 7. Install alternator mounting components. Torque: 12mm bolt head: 14mm bolt head: 8.

  • Page 82: Temperature Regulator Components

    Cooling - Temperature regulator components Temperature regulator components Replacement 1. Remove engine right bottom shield. 2. Discharge engine coolant. 3. Remove drive belt. Slowly turn drive belt tensioner clockwise to loosen the belt; then remove drive belt and put back the tensioner slowly to completely loosen it.

  • Page 83: Radiator With Electronic Fan Assembly

    Cooling - Radiator with electronic fan assembly Radiator with electronic fan assembly Replacement 1. Discharge coolant (see Page 73). 2. Disassemble radiator water inlet hose [64000062]. 3. Disassemble radiator water outlet hose [64000063]. 4. Disassemble No.1 oil cooler inlet pipe (auto gear). 5.

  • Page 84: Coolant

    Cooling - Coolant Coolant Replacement 1. Discharge engine coolant. Warning: when the temperature of engine and radiator is high, do not remove radiator cap to avoid being scalded, because coolant and steam will spurt under high pressure. (a) Remove radiator cap. (b) Open radiator drain valve and engine drain valve.

  • Page 85: Lubrication Lubricating System

    Lubrication - lubricating system Lubrication Lubricating system On-vehicle inspection 1. Check oil level. During engine warming up and after it flames out for 5 minutes, check oil level, and the level should be between two marks on oil dipstick at the moment.If oil level is too low, check there is leakage, and refill oil up to upper mark on oil dipstick.

  • Page 86: Oil Filter Assembly

    Lubrication - Oil filter assembly Oil filter assembly Replacement Warning: Long-term or repeat contacting mineral oil will cause decomposing of natural fat on skin, which will result in dry and sensitive skin and skin rankling. Used oil has potential harm and may cause carcinoma cutis.

  • Page 87: Oil Pump Assembly

    Lubrication - Oil pump assembly Oil pump assembly Replacement 1. Remove timing chain assembly (see Page 45). 2. Remove oil pump assembly [4G18-1011100]. Remove 5 bolts, oil pump and oil pump gasket. 3. Install oil pump assembly. (a) Install new gasket on cylinder body. (b) Align the guide groove of oil pump drive rotor with the key on crankshaft, and slide the oil pump in.

  • Page 88: Ignition Ignition System

    Ignition - Ignition system Ignition Ignition system Spark plug Inspection cleane 1. Spark plug (a) Clean spark plug. Air pressure: below 588kPa. Time: 20 s or less (b) Check the damage condition of spark plug and insulator. If there is something abnormal, please replace with new spark plug.
  • Page 89 Ignition - Ignition system 3. Inspection of ignition coil (including igniter) and spark test (a) Check DTC. Note: if there is display with DTC, perform trouble shooting according to DTC procedure. (b) Check there is spark. (1) Remove ignition coil (including igniter). (2) Remove spark plug with 16mm spark plug sleeve.

  • Page 90: Starting And Charging Starting System

    Starting and charging - Starting system Starting and charging Starting system Inspection 1. Starter installation components Note: this test must be finished within 3 to 5 seconds to avoid burning out coil. (a) Remove nut at C terminal to uncouple wire of field coil. (b) As shown in the diagram, connect battery wire to electro- magnetic switch, and check drive pinion is pushed outside, (pull-in coil and hold-in coil).
  • Page 91 Starting and charging - Starting system (f) Connect magnetic field coil wire to terminal C. (h) Torque: (i) Clamp starter with jaw vice. (j) As shown in the diagram, connect battery with ampere meter. (k) Read current value displayed on ampere meter. Ampere meter (l) Current value specification: 90 A or lower at 11.5 V.

  • Page 92: Charging System

    Starting and charging - Charging system Charging system Precautions 1. Check positive and negative wire of battery is con- nected correctly. 2. When performing quick charge to battery, please uncouple battery wire. 3. Do not test with high-pressure insulation resistance tester.

  • Page 93: On-Vehicle Inspection

    Starting and charging - Charging system On-vehicle inspection 1. Check battery voltage. (a) If extinguishing time of engine is not more than 20 minutes after driving, please turn on ignition switch and electric equipment (head lamp, blower motor and rear window defog line etc.) for about 60 seconds to eliminate surface charging during driving.
  • Page 94 Starting and charging - Charging system 7. Check charging system circuit at no load. (a) If there is battery/alternator tester, please connect tester Ampere meter to charging system circuit as manufacturer instruction. Uncoupling terminal B wire (b) If there is no battery/alternator tester, please connect volt- meter to charging system circuit as the following way.

  • Page 95: Alternator Components

    Starting and charging - Alternator components Alternator components Replacement 1. Remove engine right bottom shield. 2. Remove drive belt. Slowly turn drive belt tensioner clockwise to loosen the belt, then remove drive belt and put back the tensioner slowly to completely loosen it.

  • Page 96: Starter Components

    Starting and charging - Starter components Starter components Replacement 1. Remove engine lower left shield. 2. Remove starter components. (b) Uncouple starter joint. (b) Remove nuts, and uncouple starter wire. (c) Remove 2 bolts and starter. 3. Install Starter components. Torque: bolt: Wire harness:...

  • Page 97: Front Suspension

    Front suspension - front suspension system Front suspension Front suspension system Table on trouble occurrence This table could help you find out failure causes, and each figure in the table indicates the possible sequence of failure causes, please check every part as the sequence, and replace if necessary. Trouble occurrence Possible trouble part Pages to refer to...

  • Page 98: Front Wheel Alignment

    Front suspension - Front wheel alignment Front wheel alignment Adjustment 1. Inspection (a) Check tire is worn and inflation pressure is proper. Tire inflation pressure under normal temperature: Tire size Front and rear kPa *1 It is used under the condition of speed below 160 km/h. *2 It is used under the condition of speed above 160 km/h.
  • Page 99 Front suspension - Front wheel alignment (b) Loosen lock nuts at the end of transversal lever . (c) Evenly rotate end levers of left and right rack to adjust toe-in. Hint: try adjusting toe-in to medium value. (d) Ensure that the end lever length of left rack equals that of right rack.
  • Page 100 Front suspension - Front wheel alignment 7. Adjustment of camber Note: after adjusting the camber, please check toe-in. (a) Remove front wheels. (b) Remove 2 nuts under absorber. If it is necessary to repeat using bolts or nuts, please coat oil to thread of nuts.

  • Page 101: Front Absorber And Helical Spring

    Front suspension - Front shock absorber and helical spring Front absorber and helical spring Overhaul Hint: the following overhaul procedures only aim at left side (FL), and the overhaul procedures of another side (RL) are the same as FL. 1. Remove front wheels. 2.
  • Page 102 Front suspension - Front shock absorber and helical spring 4. Fix front absorber and helical spring. Install 2 nuts and 1 bolt to absorber bracket, and then fix it on jaw vice. 5. Remove front left absorber assembly [61001036]. (a) Compress helical spring with special tool. Note: do not use pneumatic wrench, or the special tool will be damaged.
  • Page 103 Front suspension - Front shock absorber and helical spring (e) As shown in the diagram, install upper insulator. Outside Outside (f) Install spring seat to absorber with mark toward outside of vehicle. (g) Install new dustproof seal ring and upper absorber bearing. (h) Fix upper shock absorber bearing with special tool, and install new nuts.

  • Page 104: Handling

    Front suspension - Front shock absorber and helical spring (c) Install 2 nuts to lower end of absorber. Torque: 153 10 N.m Hint: coat oil on thread of nuts. (d) Install brake hose and ABS speed sensor wire harness bracket with bolts. Torque: 19 9.

  • Page 105: Lower Left Control Arm Assembly

    Front suspension - Lower left control arm assembly Lower left control arm assembly Replacement Hint: the replacement procedures of right side are the same as that of left side. 1. Remove front wheels. 2. Separate front left stabilizer link assembly [64000097].
  • Page 106 Front suspension - Lower left control arm assembly Install front left brake wheel pump bracket as- sembly (see Page 141). Install fixed nuts of front left drive shaft (see Page 123). Install front left stabilizer link assembly [64000097]. Install stabilizer link with nuts. Torque: 74 5 N.m Hint: if ball joint rotates with nuts, please fix bolts with...

  • Page 107: Front Stabilizer Bar

    Front suspension - Front stabilizer bar Front stabilizer bar Overhaul 1. Remove dust cap inside steering column (see Page 194). 2. Separate steering sliding shaft assembly (see Page 205) 3. Remove front wheels. 4. Remove right engine bottom shield. 5. Remove left engine bottom shield. 6.
  • Page 108 Front suspension - Front stabilizer bar Remove front stabilizer bar. (a) Remove 4 bolts, bracket and bush. (b) Remove stabilizer bar. Install front stabilizer bar. (a) Install bracket and bush with 4 bolts. Hint: install bush to bush stop ring outside of Outside stabilizer bar.
  • Page 109 Front suspension - Front stabilizer bar Connect steering sliding shaft (see Page 205). Check front wheel center line. Install dust cover inside steering column. Refill power steering oil (see Page 200). Discharge air of power steering oil (see Page 200). Check there is oil leakage.

  • Page 110: Front Left Lower Control Arm Ball Joint Assembly

    Front suspension - Front left lower control arm ball joint assembly Front left lower control arm ball joint assembly Replacement Hint: the replacement procedures of right side are the same as that of left side. 1. Remove front wheels. 2. Remove front left shaft hub nuts (see Page 123). 3.

  • Page 111: Rear Suspension

    Rear suspension - rear suspension system Rear suspension Rear suspension system Table on trouble occurrence This table could help you find out failure causes, and each figure in the table indicates the possible sequence of failure causes, please check every part as the sequence, and replace if necessary. Trouble occurrence Possible trouble part Pages to refer to...

  • Page 112: Rear Wheel Alignment

    Rear suspension - Rear wheel alignment Rear wheel alignment Adjustment 1. Check tire (see Page 109). 2. Measure vehicle height (see Page 87). Note: adjust vehicle height to standard value before checking vehicle tire alignment. 3. Inspection of toe-in Toe-in: (General road) Toe-in Front...

  • Page 113: Rear Strut Assembly

    Rear suspension - Rear strut assembly Rear strut assembly Overhaul Hint: the following overhaul procedures only aim at left side (LH), and the overhaul procedures of another side (RH) are the same as LH. Remove rear wheels. 2. Remove rear left seat backrest assembly [68010078] (see Page 352). 3.
  • Page 114 Rear suspension - Rear strut assembly (b) Fix piston rod with a hexagonal wrench of 6mm, and remove nuts. (c) Remove bracket plate, washer, spring bracket, upper separator, suspension pedestal, spring absorber and heli- cal spring. [64000098] Press in and pull out absorber piston rod, and check there is abnormal resistance or abnormal sound.

  • Page 115: Handling

    Rear suspension - Rear strut assembly (j) Fix piston rod with a hexagonal wrench of 6mm, and tighten nuts. Torque: Temporarily lock up rear strut assembly. (a) Install rear strut, and temporarily lock up nuts and gasket. (b) Install 2 nuts and bolts. Torque: Install real left seat backrest assembly [68010078].

  • Page 116: Rear Stabilizer Bar

    Rear suspension - Rear stabilizer bar Rear stabilizer bar Overhaul 1. Remove rear stabilizer bar assembly. Remove 2 bolts, nuts and stabilizer bar. 2. Install rear stabilizer bar assembly. Install 2 bolts, nuts and stabilizer bar. Torque: Hint: install the tag on balance bar toward rear right side of vehicle.

  • Page 117: Rear Shaft Assembly

    Rear suspension - Rear shaft assembly Rear shaft assembly Overhaul 1. Remove rear wheels. 2. Disassemble rear left brake caliper assembly (see Page 144). 3. Disassemble rear right brake caliper assembly (see Page 144). 4. Disassemble rear wheel speed sensor wire harness (a) Uncouple sensor joint.
  • Page 118 Rear suspension - Rear shaft assembly 9. Remove left side rear shaft gum cover assembly. Installation remark (a) Inscribe 2 matching marks at the dent part of gum cover and axle beam. (b) Bend two parts of bush frame with chisel and hammer. Dent Hint: bend bush frame until it reaches the hook of spe- cial tool.
  • Page 119 Rear suspension - Rear shaft assembly Temporarily lock up rear left strut assembly. (a) Install rear left strut and gasket, and temporarily lock up nuts. (b) Perform to another side in the same way. Install rear stabilizer bar assembly (see Page 105). Install rear left/right brake assembly [64000137/64000139] (see Page 144).

  • Page 120: Tire And Wheel

    Tire and wheel- wheel and tire system Tire and wheel Wheel and tire system Inspection 1. Check tire. (a) Check tire is worn and inflation pressure is proper. Cold tire inflation pressure: Tire size Front and rear kPa *1 It is used under the condition of speed below 160 km/h. (b) Check tire run-out with dial indicator.
  • Page 121 Tire and wheel- wheel and tire system Check the function of absorber is normal. Check there is oil leakage. Check liner clamp is worn. Shake the front and rear of vehicle.

  • Page 122: Drive Shaft Drive Shaft

    Drive shaft--Driveshaft Drive shaft Drive shaft Notes Note: if happening any malfunction, it is necessary to change the exterior joint assembly of trans- mission shaft. 1. Check front drive shaft assembly. Exterior joint assembly Malfunction phenomenon table Malfunction phenomenon Possible malfunction part Reference page 1.

  • Page 123: Inspection On Automobile

    Drive shaft--Drive shaft Inspection on automobile 1. Check the bearing of front wheel hub (a) Disassemble the front wheels. (b) Disassemble front brake caliper assembly. (c) Disassemble front brake. (d) Check the axial clearance of bearing (referring to page 123) (e) Check the terminal run-out of shaft hub (referring to page 123).

  • Page 124: Front Drive Shaft

    Drive shaft--Front drive shaft Front drive shaft Overhaul Hint: overhaul procedure for right side is same as the left side. 1. Check the drive shaft (referring to page 111). 2. Discharge the oil in gearbox. (a) Disassemble oil plug and gasket to discharge the oil in gearbox.
  • Page 125 Drive shaft--Front drive shaft 6. Disassemble left transversal lever assembly. special tool (a) Disassemble cotter pin and screw cap. (b) Use special tool to disassemble terminal assembly from steering knuckle. 7. Disassemble left lower control arm assembly [64000091] Disassemble the bolt and two nuts, then disassemble lower control arm from lower ball joint.
  • Page 126 Drive shaft--Front drive shaft (b) Mesh clamp type: Liking that shown in figure, use pliers to disassemble No.2 fixing clamp of inner joint dust-proof cover of left front trans- Pliers clamp mission shaft. 12. Disassemble fixing clamp of inner joint dustproof cover of left front drive shaft.
  • Page 127 Drive shaft--Front drive shaft (e) Make mark on transmission shaft and triangle joint. Copper stick Align the mark Note: do not use the punch to make mark. (f) Use copper stick and hammer to disassemble triangle joint. Note: do not knock the stator position. (g) Disassemble No.2 fixing clamp of inner joint dustproof cover and fixing clamp of inner joint dustproof cover.
  • Page 128 Drive shaft--Front drive shaft 19. Disassemble clasp of inner joint of left front drive shaft. Use screw driver to disassemble the clasp. 20. Disassemble dustproof cover of left front drive shaft. Use special tool and press to disassemble dustproof cover . Special tool 21.
  • Page 129 Drive shaft--Front drive shaft (1) Put big fixing clamp on dustproof cover firmly. (2) Put special tool on big fixing clamp. (3) Lock special tool to tighten big fixing clamp. Note: do not tighten special tool too much. (4) Use special tool to adjust the clearance of big fixing Special clamp.
  • Page 130 Drive shaft--Front drive shaft (b) B type Liking that shown above, set up the distance of absorber: B type and C typ 470 ± 2mm Single-contact fixing 27. Assemble fixing clamp of dynamic absorber of drive clamp type shaft. (a) Single-contact fixing clamp type: Assemble new fixing absorber clamp on the absorber of drive shaft, then fix the fixing clamp with screw driver.
  • Page 131 Drive shaft--Front drive shaft (e) Use clasp spreading pliers to assemble the clasp. (f) Fill lubricating grease in inner joint assembly. Right trans- Left transmis- Capacity of lubricating grease mission shaft sion shaft A type A type 180-190 grams C type C type B type B type...
  • Page 132 Driveshaft--Front drive shaft (b) Mesh clamp type: Liking that shown in figure, use pliers to assemble No.2 fixing clamp of inner joint dust-proof cover. Pliers clamp 32. Check front drive shaft. (a) Check whether there is any obvious clearance on exterior joint.
  • Page 133 Drive shaft--Front drive shaft 35. Assemble left lower control arm assembly [64000091] (a) Assemble lower ball joint on lower suspension arm with the bolts and screw caps. Torque: 142 ± 10 N⋅ ⋅ ⋅ ⋅ ⋅ m 36. Assemble left transversal lever assembly. (a) Assemble transversal lever terminal to steering knuckle with screw cap.

  • Page 134: Left Front Shaft Hub Assembly

    Driveshaft--Left front shaft hub assembly Left front shaft hub assembly Change Hint: changing procedure for right side is same as the left side. 1. Disassemble front wheels 2. Disassemble fixing nuts of left front drive shaft [64000083] (a) Use special tool and hammer to unclench concave part of Special fixing nuts.
  • Page 135 Drive shaft--Left front shaft hub assembly 5. Disassemble left front brake assembly [64000134] Special tool 6. Disassemble left transversal lever assembly (a) Disassemble cotter pin and nuts. (b) Use special tool to disassemble transversal lever assembly from steering knuckle. 7. Disassemble left lower control arm assembly [64000091] Disassemble the bolt and two nuts, then disassemble lower control arm from lower ball joint.
  • Page 136 Drive shaft--Left front shaft hub assembly 11. Disassemble left front shaft hub assembly. (a) Use special tool to disassemble shaft hub. Special tool (b) Use special tool to disassemble inner ring (exterior) seat from shaft hub. Special 12. Disassemble left front brake bottom board. tool Disassemble three bolts, then take down the brake bottom board.
  • Page 137 Drive shaft--Left front shaft hub assembly 18. Assemble left front lower control arm ball head as- sembly [64000093] (a) Assemble lower ball head and locking nut. Torque: 103 ± ± ± ± ± 10 N⋅ ⋅ ⋅ ⋅ ⋅ m (b) Assemble new cotter pin.
  • Page 138 Drive shaft--Left front shaft hub assembly Use centimeter to check the axial clearance of shaft hub center. Maximal value: 0.05 mm If axial clearance exceeds the maximal value, it is necessary to change the bearing. 28. Check the terminal face run-out of shaft hub. Use centimeter to check the terminal run-out of exterior sur- face of shaft hub.

  • Page 139: Left Front Shaft Hub Bolt

    Drive shaft--Left front shaft hub bolt Left front shaft hub bolt Change Hint: changing procedure for right side is same as left side. 1. Disassemble front wheels 2. Disassemble left front brake branch pump assembly 3. Disassemble left front brake assembly [64000134] 4.

  • Page 140: Left Rear Shaft Hub And Bearing Assembly

    Drive shaft--Left rear shaft hub and bearing assembly Left rear shaft hub and bearing assembly Change Hint: changing procedure for right side is same as left side. 1. Disassemble rear wheels. 2. Disassemble rear brake caliper assemble Disassemble two bolts and take down brake caliper. 3.
  • Page 141 Drive shaft--Left rear shaft hub and bearing assembly 10. Check the axial clearance of bearing. Put the centimeter besides shaft hub center, and check the axial clearance of bearing. Maximal value: 0.05mm If axial clearance exceeds the maximal value, change the bearing assembly.

  • Page 142: Left Rear Shaft Hub Bolt

    Drive shaft--Left rear shaft hub bolt Left rear shaft hub bolt Change 1. Disassemble rear wheels 2. Disassemble left rear brake caliper assemble Disassemble two bolts and take down brake caliper. 3. Disassemble left rear brake assembly [64000137] 4. Disassemble left rear shaft hub bolt (a) Screw the shaft to the position in figure, then use special tool to disassemble shaft hub bolt.

  • Page 143: Brake System

    Brake--Brake system Brake Brake system Notes It is necessary to be very careful when changing any subassembly, for this will influence the perfor- mance of brake system and incur the running becomes unsafe. It is necessary to use those parts with same type or same grade when changing.

  • Page 144: Remove Malfunction

    Brake--Remove malfunction Remove malfunction Malfunction phenomenon table Use following table to help you find the reason of malfunction, the number in table indicates the preferred sequence of possible reasons of malfunction. Please check every part by sequence, if necessary, change this part.
  • Page 145 Brake--Remove malfunction Malfunction phenomenon Possible malfunction part Reference page 1. Brake block (damaged or distorted). 141, 144 2. Assembled nut (loose). 141, 144 3. Brake disk (scratched). 141, 144 4. Support sheet of brake block (loose). 141, 144 Brake noise 5.

  • Page 146: Brake Liquid

    Brake--Remove malfunction Brake liquid Discharge the air in brake system Hint: if any part of brake system has been damaged or you disbelieve whether there is any air in brake pipeline, it is necessary to discharge the air in brake system completely.

  • Page 147: Brake Pedal Assembly

    Brake--Remove malfunction Brake pedal assembly Adjustment Brake light switch 1. Check and adjust the height of brake pedal. (a) Check the height of brake pedal. Pedal distance from floor: 136.0-146.0mm (b) Adjust the height of brake pedal. (1) Disassemble lower trim board of panel. (2) Disassemble switch joint of brake light.

  • Page 148: Change

    Brake--Remove malfunction Change Hint: after assembling, check and adjust the height, free travel of brake pedal and the height from pedal to floor. Brake pedal bracket Brake pedal bushing Brake pedal shaft Locking shaft Brake main pump lever pin Brake pedal Rubber gasket Brake pedal N .

  • Page 149: Vacuum Booster Assembly

    Brake--Vacuum booster assembly Vacuum booster assembly Inspection on automobile 1. Check the vacuum booster (a) Check the gas sealed performance. Good (1) Start the engine, and extinguish after one or two minutes, then step and release brake pedal slowly several times. Hint: if the first step is lowest, second and third step rise gradually, and this shows the gas sealed per- Third...
  • Page 150 Brake--Vacuum booster assembly 5. Disconnect the U-shaped joint of brake main pump lever (a) Release fixing screw cap of lever U-shaped joint. (b) Disassemble locking pin of U-shaped joint and lever pin of brake main pump. 6. Disassemble left front wheel 7.
  • Page 151 Brake--Vacuum booster assembly 10. Connect brake main pump Assemble U-shaped joint pin in U-shaped joint and brake pedal, and assemble fixing clamp to U-shaped joint pin. 11. Assemble brake main pump 12. Assemble carbon canister assembly [4G18-1129020] 13. Assemble air filter assembly [64000033] 14.

  • Page 152: Front Brake Assembly

    Brake--Front brake assembly Front brake assembly Overhaul 1. Disassemble front wheels. 2. Discharge brake liquid. Note: do not spill the brake liquid on paint surface of automobile body, if having, wash it cleanly. 3. Disassemble brake branch pump assembly. (a) Disassemble the bolts and gaskets of brake hose joint on brake branch pump, then disassemble brake hose.
  • Page 153 Brake--Front brake assembly 13. Check the brake branch pump and piston Check whether there is rust or scratch in cylinder of branch pump and piston. 14. Check the thickness of brake block Use rule to measure the thickness of brake block. Standard thickness: 11.00mm Minimal thickness: 1.0mm 15.
  • Page 154 Brake--Front brake assembly 23.Assemble dustproof cover of branch pump.. (a) After spreading lithium soap base glycol lubricating grease on new dustproof cover of branch pump, assembling it in brake branch pump. Hint: dustproof cover should be assembled in branch pump firmly. (b) Use wrench to assemble fixing loop.

  • Page 155: Rear Brake Assembly

    Brake--Rear brake assembly Rear brake assembly Overhaul Hint: overhaul procedure for right side is same as the left side. 1. Disassemble rear wheels. 2. Discharge brake liquid. Note: do not spill the brake liquid on paint surface of automobile body, if having, wash it cleanly. 3.
  • Page 156 Brake--Rear brake assembly Use screw driver to disassemble oil seal of piston from brake branch pump. Note: do not damage cylinder wall and slot. 10. Disassemble exhaust bolt of branch pump. 11. Check whether there is any dust or scratch on branch pump and piston.
  • Page 157 Brake--Rear brake assembly 19. Assemble piston of Rear brake branch pump (a) Spread lithium soap base glycol lubricating grease on the piston. (b) Assemble piston on brake branch pump. Note: do not force piston to assemble in branch pump compulsively. 20.
  • Page 158 Brake--Rear brake assembly 24. Assemble rear brake block. Note: when changing brake block, the inside of muffle gasket should be changed together. (a) When assembling muffle gasket on every brake block, it is necessary to spread brake lubricating grease on the inside of muffle gasket. (b) When assembling inner brake block, abrasion indicator should face upside.

  • Page 159: Hydraulic Pressure Control Unit (Equipping With Abs)

    Brake--Hydraulic pressure control unit Hydraulic control unit (equipping with ABS) Inspection on automobile 1. Connect handle tester (a) Connect handle tester to DLC3. (b) Start the engine and make it run at idling speed. (c) Handle tester should choose “Active test” module. Hint: details could refer to operating instruction for handle tester.
  • Page 160 Brake--Hydraulic pressure control unit 3. Disassemble gasket of right wheel wing. 4. Disassemble hydraulic control unit and bracket. (a) Disassemble the joint and bolt. (b) Turn the locking bolt of joint of hydraulic control unit, and disassemble the joint. (c) Use special tool to disassemble the brake oil pipe on hy- draulic control unit.
  • Page 161 Brake--Hydraulic pressure control unit 7. Assemble hydraulic control unit and bracket. (a) Assemble hydraulic control unit and bracket with screw cap and two bolts. Torque: 19 N⋅ ⋅ ⋅ ⋅ ⋅ m (b) Liking that shown in figure, use special tool to assemble brake oil pipe on correct position of hydraulic control unit.

  • Page 162: Speed Sensor Of Front Wheel

    Brake--Speed sensor of front wheel Speed sensor of front wheel Change Hint: the process for changing right side is same as the left side. 1. Disassemble front wheels. 2. Disassemble gasket of left front wing. 3. Disassemble speed sensor of left front wheel. (a) Disassemble resinous clamp and speed sensor wiring har- ness from fixing clamp of automobile body.

  • Page 163: Speed Sensor Of Rear Wheels

    Brake--Speed sensor of rear wheels Speed sensor of rear wheels Change Hint: the process for changing right side is same as the left side. 1. Disassemble rear wheels. 2. Disassemble wiring harness of speed sensor of rear wheel. Disassemble the joint of speed sensor of rear wheel. 3.
  • Page 164 Brake--Speed sensor of rear wheels (c) Use special tool and press to assemble speed sensor of Special rear wheels to rear shaft hub. tool Note: Do not use hammer knock directly in speed sensor of rear wheels. Insure no sundries are attached on the supervising part of speed sensor of rear wheels Press speed sensor of rear wheels straightly and slowly.

  • Page 165: Parking Brake

    Parking brake--Parking brake system Parking brake Parking brake system Malfunction phenomenon table Use following table to find the reason of malfunction, the number in table indicates the preferred se- quence of possible reason. Please check each part by sequence, if necessary, change this part. Malfunction phenomenon Possible malfunction part Reference page...

  • Page 166: Parking Brake Handle Assembly

    Parking brake--Parking brake handle assembly Parking brake handle assembly Change 1. Disassemble trim board on central box. 2. Disassemble parking brake hole cover. 3. Disassemble central box. 4. Disassemble parking brake handle assembly. (a) Disassemble locking screw cap and adjusting screw cap. (b) Disassemble the joint of parking brake switch.

  • Page 167: Parking Front Bake Pull Cable Assembly

    Parking brake--Parking front bake pull cable assembly Parking front brake pull cable assembly Change 1. Disassemble upper trim board on box. 2. Disassemble parking brake hole cover. 3. Disassemble central box. 4. Disassemble parking brake handle assembly. 5. Disassemble front bottom board bracket. 6.
  • Page 168 Parking brake--Parking front bake pull cable assembly 12. Assemble front bottom board bracket. 13. Assemble parking brake handle assembly. 14. Check the travel of parking brake handle (referring to page 154). 15. Adjust the travel of parking brake handle (referring to page 154).

  • Page 169: Parking Rear Brake Pull Cable Assembly

    Parking brake--Parking rear brake pull cable assembly Parking rear brake pull cable assembly Change Hint: the changing procedure for left rear brake pull cable is same as parking right rear brake pull cable. 1. Disassemble rear wheels. 2. Disassemble rear brake disk brake branch pump bracket assembly(LH). 3.
  • Page 170 Parking brake--Parking rear brake pull cable assembly rear wheel to fixing clamp. 15. Assemble No.2 clapboard. 16. Assemble front part exhaust pipe assembly. 17. Assemble front bottom board bracket. 18. Connect parking left rear brake pull cable assembly. Assemble parking left rear brake pull cable assembly to brake back board with bolt.
  • Page 171 Parking brake--Parking rear brake pull cable assembly 23. Assemble parking brake shoe adjustor. 24. Assemble drag lever of parking brake shoe (LH). 25. Check the assembly of parking brake. 26. Assemble rear brake. 27. Adjust the clearance of parking brake shoe. 28.

  • Page 172: Parking Brake Assembly

    Parking brake--Parking brake assembly Parking brake assembly Overhaul Hint: overhaul process for right side is same as the left side. 1. Disassemble left rear wheel. 2. Disassemble left rear brake branch pump bracket assembly. 3. Disassemble left rear brake. Hint: Make mark on disk and shaft hub.
  • Page 173 Parking brake--Parking brake assembly 7. Disassemble parking brake shoe assembly (LH). Use special tool to disassemble parking brake shoe, localiz- ing spring, pin and brake exterior shoe. Special tool 8. Disassemble parking brake shoe assembly (LH). (a) Use special tool to disassemble parking brake shoe, localiz- ing spring, pin and brake inner shoe.
  • Page 174 Parking brake--Parking brake assembly 15. Assemble parking brake exterior shoe assembly (LH). Use special tool to assemble parking brake shoe with parking shoe, localizing spring and pin. Special tool 16. Assemble parking brake shoe adjustor. (a) Spread high temperature lubricating grease on adjusting bolt.
  • Page 175 Parking brake--Parking brake assembly 18. Check the assembly of parking brake system. Check every part after assembly. Note: do not attach oil dirt or lubricating grease on contacting surface between shoe friction sheet and brake drum. Left Right Front Front 19.

  • Page 176: Transmission Disassemble Assembly

    Transmission—Disassemble assembly Transmission Disassemble assembly Connecting bolt of cover Cover Stop disc spring of output shaft bearing Fastening bolt of shift cover Support cover of rear shaft of output shaft Connecting bolt Firstly, loosen the connecting bolt of cover, and take out cover and stop disc spring of output shaft bearing, secondly, put special wrench whose surface has four cylindrical column heaves in four holes of support cover of rear shaft of output shaft and screw it out;...
  • Page 177 Transmission—Disassemble assembly Take out interlocking pin with magnetic stick Take out clip spring of fork shaft, liking that shown in figure. Clamp the upside of fork shaft which is protected by some cloths and take it out, liking that shown in figure. Take out reverse gear and reverse gear shaft Disassemble two bolts and swing arm bracket of reverse gear, liking that shown in figure.
  • Page 178 Transmission—Disassemble assembly Disassemble interlocking pin with magnetic stick and take out fork shaft and fork. Disassemble bolt and fork shaft liking that shown in figure. Disassemble clip spring liking that shown in figure. Take out fork by disassembling clip spring.
  • Page 179 Transmission—Disassemble assembly Disassemble lubricating oil pipe. Take our bushing liking that shown in figure. Take our oil seal. Take our exterior ring of tapered shaft with special tool liking that shown in figure. Disassemble oil guide cover.
  • Page 180 Transmission—Disassemble assembly Check the axial clearance of third gear with clearance gauge, its standard value is: 0.1—0.35 mm. Third gear Check the axial clearance of fifth gear liking that shown in figure, its standard value is: 0.1—0.50 mm. Five gear Check the radial clearance of forth gear and fifth gear liking that shown in figure, its standard value is less than 0,058mm.
  • Page 181 Transmission—Disassemble assembly Put input shaft assembly into position with pressure machine liking that shown in figure, at the same time, hold the lower end of input shaft to disassemble gear cover, gear hub and five gear. Check the axial clearance of forth gear, its standard value is: 0.1—0.55mm.
  • Page 182 Transmission—Disassemble assembly Take down clip spring with clip spring wrench. Note: do not hurt its surface. Take down synchronizer assembly, synchronous loop and third gear with pressure machine liking that shown in figure. Note: hold lower end of shaft with hand to make it stand. Take down radial ball bearing with pressure machine, and hold lower end of shaft with hand to make it stand.
  • Page 183 Transmission—Disassemble assembly Take our elastic cylindrical pin from shift swing lever with pin taker and hand hammer liking that shown in figure. Note: do not hurt its surface. Take down clip spring liking that shown in figure. Disassemble interlocking bracket, shift swing lever, spring and A gasket liking that shown in figure.
  • Page 184 Transmission—Disassemble assembly Disassemble shift guide shaft and dust-proof cover from shift cover, and take down gasket liking that shown in figure. Take out the shift cover oil seal with wrench liking that shown in figure Take out the other oil seal on shift cover with same method.
  • Page 185 Transmission—Disassemble assembly Take down tapered bearing on differential shell liking that shown in figure. Note: put column end surface in bearing into position reliably. Take down cylindrical bearing of speedmeter driving wheel side liking that shown in figure. Take down driving gear of speedmeter Disassemble by sequence the fastening bolts of differential.
  • Page 186 Transmission—Disassemble assembly Check the radial run-out of input shaft liking that shown in figure, maximal diameter is 0.03mm. Check the distance from back surface of synchronous loop to gear end surface with clearance gauge, the minimal value should be 0.8mm, if the minimal distance could not reach this value, it is necessary to change synchronous loop.
  • Page 187 Transmission—Disassemble assembly 1 gear 2 gear Measure axial clearance of 1 gear and 2 gear with thickness gauge, 1 gear: 0.1—0.35mm 2 gear: 0.1—0.35mm Measureradial clearance of 1 gear and 2 gear liking that shown in figure, the maximal flop value is 0.056mm. Take down tapered bearing liking that shown in figure Note: 1.
  • Page 188 Transmission—Disassemble assembly Disassemble spring clamp loop on output shaft liking that shown in figure. Take down forth and fifth gear wheel with pressure machine. Note: hold the lower end of shaft to prevent it falling. Move first and second gear to first gear. Disassemble third gear with pressure machine, and hold the lower end of shaft to prevent it falling, at this time, disassemble roller bearing, synchronous loop and second gear.
  • Page 189 Transmission—Disassemble assembly Measure the round flop liking that shown in figure, its maxi- mal allowed flop value is 0.03, if exceeding this value, it is necessary to change the output shaft. Check the axial clearance between the back surface of syn- chronous loop and end surface of gear splines with clear- ance gauge, its minimal value is 0.8mm, if the clearance is less than this value, it is necessary to change the synchro-...
  • Page 190 Transmission—Disassemble assembly Press first and second gear synchronizer assembly in input shaft with pressure machine, its direction likes that shown in figure. Use new clip spring used for shaft to replace that one which has been stretched. Note: do not hurt the shaft surface. Assemble synchronous ring, roller bearing and second gear.
  • Page 191 Transmission—Disassemble assembly Press bearing in input shaft with pressure machine liking that shown in figure. Note: adjust to bearing inner ring and put it into position Assemble roller bearing, third gear and third gear synchro- nizer loop liking that shown in figure, and assemble synchro- nizer assembly by the direction in figure.
  • Page 192 Transmission—Disassemble assembly Assemble a new clip spring on input shaft. Assemble roller bearing, and assemble third and forth ssynchronizer assemble by the direction in figure, at this time, assemble forth gear on input shaft. Assemble fixting ball liking that shown in figure, and assemble fifth gear stop gasket in input shaft by this ball.
  • Page 193 Transmission—Disassemble assembly Assemble clip spring with same method. Assemble roller bearing, fifth gear, fifth gear synchronous loop with same method above. Assemble synchronizer assembly with pressure machine by the direction in figure. Press radial ball bearing in with pressure machine.
  • Page 194 Transmission—Disassemble assembly Press a new clip spring in input shaft by the direction in figure. Press front tapered bearing in output shaft with method in figure. Note: make sure the bearing inner ring has been put into position. Press rear tapered bearing in output shaft with method above. Note: make sure the bearing inner ring has been put into position.
  • Page 195 Transmission—Disassemble assembly Press shift cover oil seal in with the method in figure, and the distance from oil seal end surface to oil seal hole end surface is 2.0-2.5mm after pressing it in. Press in the other oil seal liking that shown in figure, and the distance from oil seal end surface to oil seal hole end surface is 0-0.5mm after pressing it in.
  • Page 196 Transmission—Disassemble assembly Assemble two new fork shaft clip spring, and assemble inter- locking pin in the position in figure. Assemble two new fork shaft clip springs liking that shown in figure. Assemble first and second gear fork on fork shaft, and put fork shaft in first and second gear cover, then assemble first and second guide block, at the same time, tighten the bolts, the torque is 16Nm.
  • Page 197 Transmission—Disassemble assembly Assemble lubricating oil pipe liking that shown in figure. Press a new fork shaft clip spring in third and forth gear fork shaft liking that in figure. Assemble reverse gear block and fork shaft clip spring liking that shown in figure. Assemble third and forth gear fork shaft in clutch shell body, and assemble third and forth shift fork in gear cover slot and tighten them.
  • Page 198 Transmission—Disassemble assembly Assemble interlocking pin in reverse gear block liking that shown in figure. Assemble two connecting bolts on reverse gear swing arm bracket liking that shown in figure, their torque is 17N•m, and put the head of reverse gear block in corresponding hole of reverse gear swing arm bracket.
  • Page 199 Transmission—Disassemble assembly Spread seal fastening glue on the bolts, and connect trans- position swing lever and transposition swing lever shaft with transposition cover with bolts, bolt torque is 16N•m Assemble A gasket, spring, interlocking bracket and shift swing lever on shift reverse shaft by the sequence in figure, then press elastic cylindrical pin in the hole of shift swing lever, at the same time, the distance from its end surface to hole should be 0-0.5mm after pressing it in.
  • Page 200 Transmission—Disassemble assembly Assemble two axle shaft gears and their gaskets in differen- tial shell by sequence, then screw two planetary gears and their gaskets in differential shell, and put planetary gear shaft, lastly, assemble a new elastic cylindrical pin liking that shown in figure.
  • Page 201 Transmission—Disassemble assembly Assemble chosen adjusting gasket in transmission shell. Spread seal glue on joint surface of shell body liking that shown in figure. Screw corresponding bolts liking that shown in figure, its torque is 29N•m. Spread anti-loose fastening glue on connecting bolts of re- verse shaft, and use a new gasket to cover on the bolt, then tighten reverse shaft on transmission shell, its torque is 29N•m Assemble shift fixing assemble on transmission shell, its torque...

  • Page 202: Assemble The Assembly

    Transmission—Assemble the assembly Transmission Assemble the assembly Connecting bolt of end cover Stop disc spring of output shaft bearing End cover Support cover of output rear shaft Screw support cover of output rear shaft in differential shell until reaching screwing torque that is 40N•m, then put stop disc spring of output shat bearing in support cover of output rear shaft by the direction in figure, lastly, press down end cover and tighten connecting bolts of end cover, their torque is 12N•m...

  • Page 203: Steering Column Steering System

    Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column Steering system Note 1. Notes that are necessary for steering system: (a) It is necessary to change parts correctly, for they will influence the performance of steering system to make running danger.

  • Page 204: Inspection On Automobile

    Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system Inspection on automobile Maximal free clearance 1. Check the free clearance of steering wheel (a) Park the automobile, and the front wheels are towards the front.

  • Page 205: Steering Column System

    Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column system Overhaul 1. Put the front wheels towards the front. 2. Disassemble safety airbag assembly at the side of driver (equipping with SRS) [67000179] Note: if disconnecting airbag joint when ignition switch locates at ON position, checking number will record it.
  • Page 206 Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system 6. Disassemble right combination switch assembly [67000079] (referring to page 302) 7. Disassemble helix cable assembly (equipping with SRS) Note: do not disassemble helix cable or spread lubricat- ing grease.
  • Page 207 Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system 13. Disassemble ignition switch key tank assembly (a) Put ignition switch key tank on ACC position. (b) Pull down stop pin and pull out key tank assembly with right-angled screwdriver.
  • Page 208 Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system Steering column--Steering system (b) Align the mark on sliding yoke and middle shaft. (c) Assemble B bolt and tighten A bolt. Torque: 35 ± 3 N m Hint: When changing new sliding yoke, it is neces- sary to adjust the front wheel at the front, and Align the mark make the bolt hole surface of sliding yoke face...

  • Page 209: Power Steering

    Power steering--Poser steering system Power steering Power steering system Note 1. Notes for steering system: It is necessary to change parts correctly, for they will influence the performance of steering system to incur running danger. 2. Notes for SRS airbag system MR7180 equips with SRS (auxiliary protection system), such as safety airbag at the side of driver and safety airbag at the side of passenger, if repairment does not accord with correct sequence, it might incur SRS explodes suddenly in repairing term to make heavy accident.

  • Page 210: Malfunction Phenomenon Table

    Power steering--Poser steering system Malfunction phenomenon table Use following table to help you find the reason of malfunction, the number in table only show the possible preference sequence of malfunction, please check each part by sequence, if necessary, change this part. Malfunction phenomenon Possible malfunction part Reference page...

  • Page 211: Inspection On Automobile

    Power steering--Poser steering system Inspection on automobile 1. Check driving belt (a) Check whether the belt has been abraded too much with eyes, and rope is broken. If finding any defect, change the driving belt. Hint: Some light crack at the side of belt rib could be approved, but if belt has any crack from its rib, it is necessary to change.
  • Page 212 Power steering--Poser steering system (e) If there is any foam or emulsification phenomenon, it is necessary to exhaust air in power steering ¡Ü ¡Ü ¡Ü5mm ¡Ü ¡Ü system. (f) Keep the engine at idling speed, and measure the oil level of oil storage tank. (g) Engine extinguishes.
  • Page 213 Power steering--Power steering system exceed 10 seconds. Do not make oil temperature become too high. Oil tank (g) When engine is running at idling speed, open the valve Power completely. Open steer- (h) Measure the 1.000 rpm and 3.000 rpm oil pressure of engine.

  • Page 214: Power Steering Oil Pump Assembly

    Power steering--Power steering oil pump assembly Power steering oil pump assembly Overhaul 1. Disassemble front wheel 2. Disassemble right bottom defender board [68000004] 3. Disassemble driving belt. Special tool 4. Disassemble oil storage tank to the No. 1 oil pipe of power steering pump Disassemble fixed clamp, and take down the oil storage tank to the No.
  • Page 215 Power steering--Power steering oil pump assembly Special 10. Connect the in-out oil pipe assembly of power tool steering gear [64000131] (a) Assemble fixed clamp of in-out oil pipe with bolt. ¸Ü ¸Ü ¸Ë ¸Ë ³¤ ³¤ ¶È ¶È ¸Ü ¸Ë ³¤...

  • Page 216: Power Steering Gear Assembly

    Power steering--Power steering gear assembly Power steering gear assembly Overhaul 1. Make front wheel face the front 2. Disassemble safety airbag assembly at the side of driver (equipping with SRS) [6701011] 3. Disassemble steering wheel assembly [67010001]. 4. Disassemble dust-proof cover in steering column [64000123].
  • Page 217 Power steering--Power steering gear assembly (b) Disassemble the screw and disconnect the fixed clamp of in-out oil pipe assembly of power steering gear. 12. Disassemble linking lever assembly of front stabi- lizer bar [64000097]. (a) Use socket head wrench (5mm) to fix bolt, then disas- semble screw cap.
  • Page 218 Power steering--Power steering gear assembly 18. Disassemble steering middle shaft. (a) Make mark on middle shaft and steering small gear shaft. Align the mark (b) Disassemble bolt and steering middle shaft. 19. Disassemble power steering gear assembly [64000133]. (a) disassemble four bolts, and disassemble power steering gear from beam.
  • Page 219 Power steering--Power steering gear assembly 24. Check right transversal lever ball head. 25. Disassemble No.2 dust-proof cover of steering gear. (a) Use pliers to disassemble fixed clamp. (b) Use pliers to disassemble iron wire. Note: do not hurt dust-proof cover. Hint: make mark on RH and LH dust-proof cover.
  • Page 220 Power steering--Power steering gear assembly 29. Assemble steering No.2 dust-proof cover. (a) Insure steering gear hole is not plugged by lubricating grease. Hint: if hole is plugged, the pressure in dust-proof cover when steering wheel turns after combin- ing will change. (b) Assemble dust-proof cover, fixed clamp and new iron wire.
  • Page 221 Power steering--Power steering gear assembly 34. Assemble steering middle shaft. (a) Align the mark of steering middle shaft and steering small Align the mark gear shaft. (b) Assemble the bolt. Torque: 35 N m 35. Assemble exterior dustproof cover of steering column.
  • Page 222 Power steering--Power steering gear assembly 37. Connect the bolts and nuts of left/right control arm and control arm ball head. Torque: 142 ± 10 N m Hint: connect the other side with same method. Connect left lower control arm to steering knuckle with bolt and two nuts.
  • Page 223 Power steering--Power steering gear assembly 41. Connect the ball head at the right side of transver sal lever . 42. Assemble right bottom defending board of engine [68000004]. 43. Assemble left bottom defending board of engine [68000003]. 44. Assemble front wheel Torque: 103 ±...

  • Page 224: Air Conditioner

    Air conditioner--Air conditioning system Air conditioner Air conditioning system Note 1. Do not dispose Refrigerant in sealed space or near flame. 2. Wear glasses to protect your eyes. 3. Do not let liquid Refrigerant contact with your eyes or skin. If liquid Refrigerant contacts with your eyes or skin: (a) Wash the contacted part with much water.

  • Page 225: Inspection

    Air conditioner--Air conditioning system If the function does not accord with the regulation, it is necessary to change pressure switch. (b) Control for cooling fan: Check the function of pressure switch. (1) Connect the anode lead of OUM meter to No. 2 termi- nal and connect cathode lead to No.

  • Page 226: Refrigerant

    Air conditioner--Refrigerant Refrigerant Inspection on automobile 1. Inspection of refrigerant quantity Observe the visible window on high pressure liquid pipe. Testing condition: Engine runs at the speed of about 1500 rpm. ¡ñ ¡ñ ¡ñ ¡ñ ¡ñ Fan speed is controlled at “HI” position. ¡ñ...
  • Page 227 Air conditioner--Refrigerant (1) Refrigerant system with normal function. Meter reading Low pressure end: 0.15-0.25Mpa High pressure end: 1.37-1.57Mpa (2) Water in cooling system. Situation: too cold periodically, then lose cooling degree. Phenomenon Possible reason Diagnose Method W h e n c o o l i n g s y s t e m i s Water vapor enters refrigerant Dryer locates at full humidity (1)Change the condenser.
  • Page 228 Air conditioner--Refrigerant (4) Refrigerant cycle is poor State: cooling degree is not enough Phenomenon Possible reason Diagnose Method The pressure of high and low Refrigerant flow in adjuster Adjuster is obstructed. Change the condenser. pressure end is low. is obstructed by impurity. The pipeline from condenser to expansion valve frosts.
  • Page 229 Air conditioner--Refrigerant (6) Refrigerant is too much or the radiating fin of condenser is bad State: cooling degree is not enough. Phenomenon Possible reason Diagnose Method The pressure of high and Too much refrigerant in Filled refrigerant is too (1)Clean the condenser. low pressure end is high.
  • Page 230 Air conditioner--Refrigerant (8) Expansion valve is bad State: cooling degree is not enough Phenomenon Possible reason Diagnose Method The pressure of high and low E x p a n s i o n v a l v e h a s Refrigerant in low pressure Check the expansion valve.
  • Page 231 Air conditioner--Refrigerant Reading of filling meter (referred value) Pressure of low pressure side Fan “HI” phase Blower “LO” phase Pressure of high pressure side...

  • Page 232: Change

    Air conditioner--Refrigerant Change 1. Reclaim HFC-134a (R134a) (a) Turn A/C switch to ON. (b) Keep the engine speed at 1000 rpm, and rotate cooling compressor for 5 to 6 minutes to make refrigerant cycle, this could collect the Refrigerant oil in each part in cooling compressor as possible. (c) Extinguish the engine.

  • Page 233: Refrigerant Pipeline

    Air conditioner--Refrigerant pipeline Refrigerant pipeline Parts Refrigerant low pressure hose ¹Ü ¹Ü · · ÂÝ ÂÝ Ä¸ ĸ Pipeline nut ¹Ü · ÂÝ Ä¸ ¹Ü ¹Ü · · ÂÝ ÂÝ Ä¸ ĸ Refrigerant high pressure hose Refrigerant liquid pipe . : : : : Regulated torque...

  • Page 234: Control Assembly, Air Conditioner Control Panel (Auto A/C)

    Air conditioner--Control assembly, air conditioner control panel (AUTO A/C) Control assembly, air conditioner control panel (AUTO A/C) Overhaul 1. Disassemble central wind outlet trim board of panel. 2. Disassemble decoration panel assembly of shift organization. [68000076] 3. Disassemble central storage box. 4.

  • Page 235: Fan Assembly

    Air conditioner--Fan assembly Fan assembly Overhaul 1. Disassemble left/right front door pedal trim board. 2. Disassemble front lower inner trim board at the left/ right side. 3. Disassemble storage box assembly at the right side of panel. 4. Disassemble engine ECU. (a) Disassemble two fixed clamps and engine ECU cover.
  • Page 236 Air conditioner--Fan assembly Locking point Fixing claw (c) Disconnect joint and fixed clamp. Fixing clamp (d) Disassemble servo motor assembly joint of in-out air cycle flow choke. (e) Disassemble three screws and bolts. (f) Disconnect fixed claw and disassemble electric engine of fan.
  • Page 237 Air conditioner--Fan assembly 7. Disassemble servo motor assembly of indoor cycle flow choke. Disassemble two screws and servo electric engine assembly of indoor cycle flow choke. 8. Disassemble fan motor assembly. Disassemble three screws and fan electric engine assembly. 9. Disassemble fan motor control assembly (automatic air conditioner).

  • Page 238: Air Conditioner Central Heating Core Assembly

    Air conditioner--Air conditioner central heating core assembly Air conditioner central heating core assembly Overhaul 1. Disassemble radiator cover. 2. Reclaim HFC-134a(R134a) low pressure 3. Disconnect refrigerant No.1 low pressure hose. hose Note: after disassembling the pipeline, it is necessary to cover the joint to prevent humidity or dust from entering in system.
  • Page 239 Air conditioner--Air conditioner central heating core assembly 15. Disassemble central ventilation orifice assembly of panel [68010012]. 16. Disassemble right storage box assembly of lower panel [68010008]. 17. Disassemble inner trim board assembly of right front column [68010017]. 18. Disassemble inner trim board assembly of left front column [68010014]. 19.
  • Page 240 Air conditioner--Air conditioner central heating core assembly 39. Disassemble lower mounting bracket of panel frame- work [68000074]. (a) Disassemble the screw and disconnect wiring harness. (b) Disassemble the screw cap, bolt and lower assemble bracket of panel framework. 40. Disassemble panel framework body assembly [68000070].
  • Page 241 Air conditioner--Air conditioner central heating core assembly tioner group assembly. 45. Disassemble air conditioner central heating core assembly. (a) Disassemble the screw and pull out wind leading pipe. (b) Disassemble two screws. (c) Disconnect fixed claw and disassemble air conditioner central heating core assembly.
  • Page 242 Air conditioner--Air conditioner central heating core assembly 47. Disassemble servo motor of air mixing flow choke (automatic air conditioner). Disassemble two screws and servo motor of air mixing flow choke. 48. Disassemble air conditioner pipeline. (a) Disassemble two screws and extending cover. (b) Use planetary wrench (5.0mm) to disassemble two plan- etary bolts and air conditioner pipeline.
  • Page 243 Air conditioner--Air conditioner central heating core assembly 53. Assemble expansion valve. (a) Spread Refrigerant oil on two O-shape loops and assemble it on expansion valve. Refrigerant oil: ND-OIL No. 8 or other products with same grade. (b) Assemble expansion valve on evaporator. 54.
  • Page 244 Air conditioner--Air conditioner central heating core assembly 57. Assemble control cable of air mixing flow choke (manual air conditioner). (a) Connect control cable of air mixing flow choke to air condi- tioner control assembly. (b) Set up drag arm at “MAX>COOL” position. (c) Assemble inner pull cable terminal to control lever.

  • Page 245: Compressor Assembly

    Air conditioner--Compressor assembly Compressor assembly Change 1. Disassemble radiator cover. 2. Reclaim HFC-134a(R134a) 3. Disconnect refrigerant No.1 low pressure hose. (a) Disassemble the bolt from compressor and electromag- netic clutch assembly and disconnect refrigerant low pres- sure hose. (b) Disassemble O-shape loop from refrigerant low pressure hose.
  • Page 246 Air conditioner--Compressor assembly If Refrigerant oil quantity in the disassembled old com- pressor is too little, check whether the system leaks Re- frigerant oil. Only could use 100PG Refrigerant oil. 9. Assemble compressor and electromagnetic clutch. (a) Assemble compressor, electromagnetic clutch and three bolts.

  • Page 247: Condenser Assembly

    Air conditioner--Condenser Assembly Condenser Assembly Inspection on the automobile 1. Check the Condenser Assembly. (a) If the radiating fins of condenser assembly are dirty, wipe it with water and blow it to dry with com- pressed air. Notice: Do not damage the radiating fin. (b) If the radiating fin is curved, repair it with gad screw driver or pliers.
  • Page 248 Air conditioner--Condenser Assembly (b) Disassemble two bolts. (c) Pull the component on the top of water tank assembly back to disassemble the condenser assembly. 6. Disassemble the drier (a) Use 10mm hexagon wrench to disassemble the cover and filter core from regulator. Inner hexagon socket wrench Adjuster...
  • Page 249 Air conditioner--Condenser Assembly Assemble the Refrigerant liquid pipe A. (a) Disassemble the cover from the pipeline joint. (b) Assemble the O-shape ring to the Refrigerant liquid pipe (c) Spread enough Refrigerant oil to lubricate at the conencting part between the O-shape ring and the cover. Refrigerant oil: 100PG (d) Use the bolt to connect the Refrigerant liquid pipe A with condenser assembly.

  • Page 250: Supplemental Restraint System Note

    Supplemental restraint system--Note Supplemental restraint system Note Warning: This product is the SRS (supplemental restraint system) equipped by JILI “YUANJIN vision” type automobile, when the automobile frontal face is impacted heavily, this product could reduce the possible hurt for driver and passen- ger at the front seat, but this product could not replace the safety belt.
  • Page 251 Supplemental restraint system--Note Special tools and measurers which any safety airbag repairing position should have: Number Function Name and type of tool Disassemble airbag subassembly on steering wheel 5S hexagon wrench Assemble and disassemble big nut on steering column Socket wrench 18S Assemble and disassemble ECU and safety airbag assembly 14S socket wrench at the side of passenger on automobile body.
  • Page 252 Supplemental restraint system--Note (1) Terminal dual-locking organization: Locking block Each joint should be dual-locking organization and combines with joint body and locking block. This design is caused by Body the reason that dual-locking device (locking block and fixed sheet) could fix the terminal to prevent it from releasing. (2) Airbag anti-explosive organization Each joint has a short circuit sheet, when the joint is Mother...
  • Page 253 Supplemental restraint system--Note (4) Joint locking organization: Lock the locking clasp of joint to fasten the connection of joint. 2. When the automobile front face is impacted, and generated force is bigger than the standard pre-set, airbag will work automatically. The sensor in safety airbag controller will feel the impact, at the same time, it will judge the generation of impact by inner arithmetic to make ignition electric current.
  • Page 254 Supplemental restraint system--Note 2. Confirm inserting it until locking, after assemble, pull it to check whether it is locked (when locking, confirm exterior joint returns to former position, at the same time, assembling sound could hear). Hint: When moving the sliding block, do not contact it. Pay attention to do not distort the release board, if release board is distorted, it is neces- sary to change it with new helix cable.

  • Page 255: Malfunction Treatment

    Supplemental restraint system--Malfunction treatment Malfunction treatment 1. Basic procedure of malfunction diagnosis After assembling new electronic control unit of safety airbag system, indicating light of safety airbag system will extinguish forever after flashing for 5 seconds when ignition switch is at state of ON, this shows airbag system works normally.
  • Page 256 Supplemental restraint system--Malfunction treatment Malfunction display of SRS could confirm originally by the flash of indicating light, detailed information could be gained by malfunction diagnostic tool. a. Safety airbag indicating light is driven by ECU, all malfunction displays are finished by ECU. After working voltage is supplied for safety airbag controller (KD4.1) by battery, safety airbag controller (KD4.1) illuminates indicating light to check SRS.
  • Page 257 Supplemental restraint system--Malfunction treatment Inner malfunction information could see following table 2. Table 2: ECU inner malfunction information indicating table Number Malfunction type Fast flash type Remark 0001 Electronic acceleration offset malfunction Short, short, short and long 0010 Electronic acceleration self-checking malfunction Short, short, long and short 0011 SCM inner RAM is wrong...

  • Page 258: Repair

    Supplemental restraint system--Repair Repair a. In using process, if happening any malfunction of power supply, it shows the voltage of power supply is less than 9V or higher than 18V, or the battery is damaged, at this time, it only needs to charge or change the battery.
  • Page 259 Supplemental restraint system--Repair there are some malfunctions, indicating light will indicate them. If exterior malfunctions are historical, after they are removed, indicate will disappear. one displayed or historical malfunction is only set up again by server. Inner malfunction or “impact record”...

  • Page 260: Inspection

    Supplemental restraint system--Inspection Inspection I. The inspection for airbag module at the side of driver could be divided into three situations: Automobile is not impacted, automobile is impacted but airbag does not explode, and automobile is impacted and airbag explodes. 1.
  • Page 261 Supplemental restraint system--Inspection 1. Automobile is not impacted: a. Make malfunction diagnostic inspection, b. Check the safety airbag assembled on panel framework with your eyes, including following items mainly: Check whether the airbag has any cut and small crack, the surface and concave slot of airbag has obvious changed color, and connecting bolts are loosened.

  • Page 262: Remove Malfunction

    Supplemental restraint system--Remove malfunction Remove malfunction Malfunction table Number Malfunction removing item Specification Indicating light of safety airbag system does not illuminate Warning circuit of safety airbag system happens malfunction Indicating light of safety airbag system illuminates usually Warning circuit of safety airbag system happens malfunction or there is exterior malfunction Malfunction Test state...
  • Page 263 Supplemental restraint system--Remove malfunction 2. Indicating light of safety airbag system illuminates usually Malfunction Test state Possible reason Power supply of battery is lack ECU has inner malfunction Indicating light of combination meter safety airbag has malfunction Indicating light of Indicating light of safety Plug connection of ECU has malfunction airbag system illumi-...
  • Page 264 Supplemental restraint system--Remove malfunction (3) Confirm the malfunction will not happen again after repairing, a. Set ignition switch at LOCK position, b. Cut off cathode of battery, and keep this state for one minutes at least, c. Connect all ECU plugs, d.
  • Page 265 Supplemental restraint system--Remove malfunction Diagnostic procedure (1) Check the battery Is the voltage higher than 9V? Yes: make next operation, No: The voltage of battery is too low, check the charging/discharging system. Refer to chapter 1, Inspection of battery, charging system (2) Check the wiring harness between battery and safety boox.
  • Page 266 Supplemental restraint system--Remove malfunction 5. Malfunction at the side of driver Malfunction of safety airbag at the side of driver (resistance is too big or too small, short circuit, grounding and so on) Warning If the treatment is wrong, safety airbag assembly might be triggered to unfold to make heavy human hurt, so, before the treatment, it is necessary to read repairing warnings Test condition carefully.
  • Page 267 Supplemental restraint system--Remove malfunction (4) Check the wiring harness between helix cable and electronic control unit of safety airbag system a. Set ignition switch at LOCK position, b. Loosen the cathode cable of battery and keep this state for one minute at least, c.
  • Page 268 Supplemental restraint system--Remove malfunction a. Set ignition switch at LOCK position, b. Loosen the cathode cable of battery and keep this state for one minute at least, c. Disassemble glove box, d. Loosen the connector of safety airbag assembly at the side of passenger, e.
  • Page 269 Supplemental restraint system--Remove malfunction 7. Malfunction of pre-tension safety belt Malfunction of pre-tension safety belt (resistance is too big or too small, short circuit, grounding and so on) Warning If the treatment is wrong, safety airbag assembly and pre-tension safety belt might be Test condition triggered to unfold to make heavy human hurt, so, before the treatment, it is necessary to read repairing warnings carefully.
  • Page 270 Supplemental restraint system--Remove malfunction d. Loosen the connectors of all safety airbag system units, e. Check whether the connector between electronic control unit of safety airbag system and the circuit between connector of safety belt pre-tension have following situations: Earth Short connection with power supply Open circuit f.

  • Page 271: Diagnosis Of Impacted Automobile

    Supplemental restraint system--Remove malfunction Diagnosis of impacted automobile No matter whether the safety airbag has been unfolded, the inspection and maintenance for impacted auto- mobile should be made by following sequence. 1. Check the ECU diagnostic signal. (1) Connect the diagnostic joint of diagnostic tool, (2) Use diagnostic tool to read the diagnostic result.

  • Page 272: Disassemble And Assemble

    Supplemental restraint system--Disassemble and assemble Disassemble and assemble Electronic control unit of safety airbag (ECU) 1. Note (referring to chapter 1) 2. Disassembling sequence: (1) Disassemble the cover board at the side of central channel (or disassemble auxiliary panel). (2) Disassemble the connector connecting with safety airbag ECU. (3) Disassemble the ECU.
  • Page 273 Supplemental restraint system--Disassemble and assemble (4) Disassemble the joint of loudspeaker and airbag wiring harness. (5) Take down safety airbag module at the side of driver. Note: Disassembled safety airbag assembly at the side of driver should make its bottom surface face the upwards, and it should be stored in clean and dry environment.

  • Page 274: Safety Airbag Assemble At The Side Of Passenger

    Supplemental restraint system--Disassemble and assemble (3) Make three fixed claws mesh steering column. When changing with new helix cable, it is necessary to disassemble yellow clamp before assembling. (4) Insert the plug of airbag wiring harness in the plug of helix cable and make this connection firm. (5) Connect the lower cover of combination switch.

  • Page 275: Scrap Treatment For Safety Airbag

    Supplemental restraint system--Scrap treatment for safety airbag Scrap treatment for safety airbag Hint: When scraping a automobile with SRS or disposing safety airbag module, it is necessary to explode the airbag by following steps at first. If there is any abnormal phenomenon when exploding airbag, please contact with our service store or automobile factory in time.
  • Page 276 Supplemental restraint system--Scrap treatment for safety airbag (7) Safety airbag assembly at the side of driver after explosion should be scraped by the scrap main points. Note: Firstly, confirm whether there are people on automobile and near the automobile, do not operate until confirming none there.
  • Page 277 Supplemental restraint system--Scrap treatment for safety airbag (3) Fix the module on wheel. a. Assemble two bolts with gasket on two assembling holes of safety airbag module at the side of driver. Size of bolt: L 35.0 mm M 6.0 mm Note: tighten the bolts with hand until they could not be turned in.
  • Page 278 Supplemental restraint system--Scrap treatment for safety airbag (5) Fix three scraped old tyres without wheel hub on the fixed tyre of safety airbag assembly at the side of driver. The Old tire terminal end of unfolding wiring harness is 10m apart from without hud wheel of fixed airbag at least.
  • Page 279 Supplemental restraint system--Scrap treatment for safety airbag b. Use maintenance electric wire used for automobile to fix safety airbag module at the side of driver on wheel. Section area of nude wire part of wiring harness is more than 2 mm .
  • Page 280 Supplemental restraint system--Scrap treatment for safety airbag (5) Put two tyres at least under the tyre fixed with airbag assembly, and put two tyres at least on the tyre fixed with airbag assembly, at the same time, top tyre should have wheel hub.

  • Page 281: Safety Belt

    (equipping with safety belt pre-tension crimper), firstly, it is necessary to make by following steps. If happening any abnormal phenomenon, please consult with GEELY automobile company. When disposing a impacted automobile, and its safety belt pre-tension crimper did not explode, its treatment step is same as the “Treatment step 1-(e)”.
  • Page 282 Safety belt--Front safety belt (1) Connect special tool with battery, Connect the red clamp of special tool with the anode of battery (+), and black clamp with the cathode of battery Battery (-). Hint: Do not connect the yellow joint with safety Special belt pre-tension crimper.
  • Page 283 Safety belt--Front safety belt (d) Explode safety belt pre-tension crimper. (1) Confirm there is no one in automobile and in 10m scope apart from automobile. (2) Press down working switch of special tool and explode safety belt pre-tension crimper. Hint: when LED of working switch of special tool illuminates, safety belt pre-tension crimper will explode charged gas at the same time.

  • Page 284: Subassembly

    Safety belt--Front safety belt (e) Treatment for safety belt pre-tension crimper. (1) Disassemble the tyre and special tool. (2) Put safety belt pre-tension crimper in plastic bag, then bind the bag for treatment with other parts. Subassembly Q184C1020 Trim cover of safety belt upper fixed bolt Lower inner defending board of middle column...

  • Page 285: Change

    Safety belt--Front safety belt Change Hint: When assembling, please work by the sequence that is reverse with disassembling sequence, if necessary, assembling instruction could be got. Changing procedure for left side and right side is same. Refer to subassembly drawing of front safety belt on page 273. 1.

  • Page 286: Rear Safety Belt

    Safety belt--Rear safety belt Rear safety belt Subassembly 1. Inner trim board assembly of left rear column 6. Rear platform with sun blind assembly [68010026] [68010032] 2. Inner trim board assembly of right rear column 7. Plastic clamp of column trim board [68000089] [68010027] 8.
  • Page 287 Safety belt--Rear safety belt 1. Inner trim board assembly of left rear column 7. Step bolt of hexagon flange face [68000203] [68010026] 8. Combination part of hexagon bolt with flat big 2. Inner trim board assembly of right rear column washer M10*1.25*22 [Q1401022] [68010027] 9.

  • Page 288: Change

    Safety belt--Rear safety belt Change Hint: When assembling, please work by the sequence that is reverse with disassembling sequence, if necessary, assembling instruction could be got. Changing procedure for left side and right side is same. Refer to subassembly drawing of front safety belt on page 275. 1.
  • Page 289 Safety belt--Rear safety belt 12. Assemble middle waistband of rear row safety belt Protuberant with locker assembly [68010043] part (a) Use the bolts to assemble middle waistband of rear row safety belt with locker assembly. Torque: 41 N⋅m Note: insure the clamp part does not press the protu- berant part of floor.

  • Page 290: Light

    Light--Light System Light Light System Notes 1. Notes for changing the front combination bulb (a) When the surface of halogen bulbs (the bulb of front assembled headlamp and front fog light) touches oil, their working life will be shorten. When it lights, it becomes hot. (b) Because of pressured gas in halogen bulbs (the bulb of front assembled headlamp and front fog light), the bulb may explode and pieces of broken glass disperse around.
  • Page 291 Light--Light System 2. Fog light System phenomena Possible part Reference pages 1.(front fog light)fuse The light control switch switches on, 2.fog light relay the front fog lights do not light (front 3.fog light switch combination lights are normal) 4.wiring harness Lamp switch turn to “HEAD”.

  • Page 292: Inspect The Car

    Light--Light System 4. Room lights system phenomena Reference pages Possible parts All lights do not light 1. (room light) fuse When driver cap side door opens, 1. driver cap side door control switch the light does not light 2. wiring harness 3.
  • Page 293 Light--Light System Avometer terminals condition regular situations 7-earth normal conduct 1-earth turn light switch ON battery voltage 1-earth turn light switch ON no voltage 4-earth normal battery voltage (b) Connect joint to directional switch and inspect from wiring harness’s side joint as following table: Avometer terminals condition egular situation...

  • Page 294: Inspect

    Light--Light System (a) Turn the ignition switch to OFF and open all doors, then lock driver cap side door. (b) Unlock the drive’s side door and open any door, then inspect whether room light lights. Close the door and inspect whether room light lights off in 15 seconds. (c) Turn ignition switch to ON, then open any door to inspect whether room light lights off immediately.
  • Page 295 Light--Light System (d) Inspect conduction of front fog light switch (1) Inspect switch on every positions, the conduction among terminals as following table. Switch positions Avometer terminals regular situation not conduction conduction 2. Interior rear top light assembly [67010006] (a) Inspect the conduction of interior rear top light (1) Inspect switch on every position, the conduction among terminals as following table.
  • Page 296 Light--Light System (a) Inspect the conduction of B pillar control switch assembly (1) Inspect the conduction between terminal 1 and bodywork earth, when switch works. Standard: ON (when press the switch): conduction OFF (when un-press the switch): not conduction 7. Inspect the C door pillar control switch assembly [67000076] (a) Inspect the conduction of C pillar control switch assembly (1) Inspect the conduction between terminal 1 and bodywork earth,when switch works.

  • Page 297: Front Combination Light (Lh)

    Light--Front fog light joint Front combination light (LH) Subassembly Radiator cover assembly Front fog light Left front combination joint light units Front combination light bulb Light seat cap Bulb joint Bulb Bulb Ultrasonic sensor joint Front combination light bulb Front combination light bulb joint Front fog light joint Front bumper...

  • Page 298: Change

    Light--Front fog light joint Change Notes: Assemble according to the opposite of disassemble. Instructions comes when necessary. The replace procedure are the same on the left and right side. Referring to the drawing of front combination light on page 286. 1.
  • Page 299 Light--Front fog light joint (10) Inspect front combination light whether it irradiates on the area as drawing. (11) If not, adjust light on vertical line or level line. Distant beam light light wire wire wire wire wire wire H RH and H LH wire 1 2 0 9 .

  • Page 300: Front Fog Light

    Light--Front fog light joint Front fog light Components Front fog light joint Left front fog light unit Bulb...

  • Page 301: Change

    Light--Front fog light joint Change Notes: Assemble according to the opposite of disassemble. Instructions comes when necessary. The replace procedure are the same, left and right side. Referring to the drawing of front combination light on page 286 1. Replace front fog light bulb (a) Disassemble front fog light seal cap (b) Press front fog light bulb spring (c) Disassemble the bulb...

  • Page 302: Side Turning Light

    Light--Side turning light Side turning light Components Side turning light...

  • Page 303: Rear Combination Light (Lh)

    Light--Rear combination light Rear combination light (LH) Components Bulb Left rear combination light...

  • Page 304: Change

    Light--Rear combination light Change Notes: Assemble according to the opposite of disassemble. Instructions comes when necessary. The replace procedure are the same on the left and right side. Referring to the drawing of front combination light on page 286 1. Disassemble left rear combination light assembly [67000108] (a) Disassemble three bolts and rear combination light.

  • Page 305: Rear Fog Light

    Light--Rear fog light Rear fog light Components Left rear fog light Rear fog light joint Bulb...

  • Page 306: Change

    Light--Rear fog light Change Notes: Assemble according to the opposite of disassemble. Instructions comes when necessary. The replace procedure is the same on the left and right side. Referring to the drawing of front combination light on page 286 1. Disassemble rear fog light. (a) Disassemble two bolts.

  • Page 307: Number Plate Light

    Light--Number plate light Number plate light Change 1. Disassemble key aperture of trunk cover and bracket 2. Disassemble number plate light of trunk cover 3. Disassemble number plate light assemble [68000097] (a) Disassemble the joints. (b) Disassemble number plate light using vice screw driver. Fixing Clues on: Before using vice screw driver, its cusp claw...

  • Page 308: High Brake Light Assembly

    Light--High brake light assembly High brake light assembly Change 1. Disassemble high brake light assembly [67010008] (a) Loosen two fixed jaw just as drawing. (b) Loosen two fixed jaw and disassemble high brake light assembly as the drawing, then take the joint apart. Fixing claw...

  • Page 309: Left Combination Switch

    combination Light--Left switch Left combination switch Change 1. Disassemble decorative board under steering column [67000129] 2. Disassemble left combination switch assembly [67000078] (a) Take the joint apart. (b) Loosen fixed jaw and pull left combination switch assembly. Fixing claw...

  • Page 310: Wiper And Cleaner

    Wiper and cleaner--Wiper and cleaner system Wiper and cleaner Wiper and cleaner system Malfunction phenomena table The underside table can help you to eliminating malfunction in wiring. It sorts as possibilities of malfunction’s reasons. Malfunction Component names Reference pages 1. ignition switch 2.

  • Page 311: Inspect

    Wiper and cleaner--Wiper and cleaner system Inspect 1. Inspect the conduction of right combination switch [67000079] (a) Inspect the conduction of every terminal of joints. Right combination switch Switch positions terminals connect with avometer regular situations MIST SWL-WIG Conduction AS-SWL Conduction AS-SWL/SWL-WIG Conduction...
  • Page 312 Wiper and cleaner--Wiper and cleaner system 2. Inspect the function of generator (a) low speed: Connect battery positive wire with joint terminal SWL, connect negative to terminal ES. Inspect whether generator work at low speed. If its function does not in conformity with regulations, replace wiper. (b) high speed Connect battery positive wire with joint terminal SWH, connect negative to terminal WS.

  • Page 313: Right Combination Switch

    combination Wiper and cleaner--Right switch Right combination switch Change 1. Disassemble the lower trim board of the steering gear 2. Disassemble right combination switch assembly Fixing [67000079] claw (a) Disassemble the joints. (b) Press fixed jaw to separate meshing then disassemble right combination switch assembly.

  • Page 314: Wiper Motor

    Wiper and cleaner--Wiper generator Wiper generator Change 1. Disassemble wiper arm cap. 2. Disassemble auxiliary wiper arm assembly [68000059] Disassemble screw cap and auxiliary wiper arm assembly. 3. Disassemble main wiper arm assembly [68000057] Disassemble screw cap and main wiper arm assembly. 4.
  • Page 315 Wiper and cleaner--Wiper generator 8. Disassemble wiper generator (a) Separate two connecting rod caps of shaft pins. (b) Separate two star- bolts so as to disassemble wiper generator. 9. Assemble wiper generator (a) Daub MP grease to connecting rod caps of wiper generator. (b) Use two Star-bolts to assemble wiper generator to wiper connecting rod.

  • Page 316: Wiper

    Wiper and cleaner--Wiper Wiper Change 1. Disassemble left wiper shelf. Disassemble left wiper shelf from left wiper arm. Note: Do not bend wiper arm adown when disassemble wiper shelf. 2. Disassemble wiper blade Disassemble wiper blade from wiper shelf. 3. Disassemble wiper blade fixed branch vane. 4.

  • Page 317: Cleaner Nozzle

    Wiper and cleaner--Cleaner nozzle Cleaner nozzle Adjustments 1. Inspect cleaner nozzle When engine works, inspect whether wiper water blast spurt in the area of wind shield bias as the drawing. Adhesives strip...

  • Page 318: Audio System Audio System

    Audio system--Audio system Audio system Audio system Notes 1. Observe notes for disposal and operation (a) Please explain to customers: when take battery’s negative terminal off, the memory broadcasting station on the audio AM/FM set on the radio will be deleted. So, before taking battery s negative terminal off ,note the station’s information according to your need.

  • Page 319: Radio Assembly

    Audio system--Radio assembly Radio assembly Change 1. Disassemble the CD machine assembly (referring to page 342) 2. Disassemble radio assembly (a) Disassemble four bolts as the drawing. (b) Take the joint apart, then disassemble radio assembly.

  • Page 320: Left Front Door Loudhailer

    Audio system--Left front door loudhailer Left front door loudhailer Change 1. Disassemble left front door control panel assembly [68000142] 2. Disassemble left front door inner guard board as- sembly [68010049] 3. Disassemble left front door water screen assembly [68000140] 4. Disassemble left front door loudhailer assembly [67000127] (a) Disassemble three rivets.

  • Page 321: Left Front Small Loudhailer

    Audio system--Left front small loudhailer Left front small loudhailer Change 1. Disassemble left front door control panel assembly [68000142] 2. Disassemble left front door inner guard board as- sembly [68010049] 3. Disassemble left front door water screen assembly [68000140] 4. Disassemble left front door small loudhail cover assembly [67000131] 5.

  • Page 322: Rear Loudhailer

    Audio system--Rear loudhailer Rear loudhailer Change 1. Disassemble rear platform sun blind assembly [68010032] (referring to page 277) 2. Disassemble rear loudhailer assembly [67000133] Disassemble eight tapping screws and two loudhailers.

  • Page 323: Outdoor Antenna

    Audio system--Outdoor antenna Outdoor antenna Change 1. Disassemble battery negative wire 2. Put the front tyre forward 3. Disassemble safety airbag assembly at the side of the driver 4. Disassemble steering wheel 5. Disassemble integration instrument cap 6. Disassemble integration instrument 7.

  • Page 324: Circuitry Power Supply

    Circuitry--Power supply Circuitry Power supply Components (For reference only) engine room assistant fuse box Engine room main fuse box Center power distribution...
  • Page 325 Circuitry--Power supply 1. ST startup system 20. left distance headlight 2. HEAD MAIN light system 21. right distantce headlight 3. spare 22. left low beams 4. ECU instrument travel 23. right low beams computer (Aldine) 5. horn 6. turn light, alarm light 7.
  • Page 326 Circuitry--Power supply 24. spare light 25. OBD discharge test system 39. brake light 26. rear fog light 40. electric sunroof 27. Anti-burglary 41. instrument system, air condition 28. DOOR center control, light con- system, defrost system, Re- trol system verse Radar, rear light, turn light. 29.

  • Page 327: Horn System

    Horn--system Horn system Horn system Position Horn (alt) Horn (undertone) Inspect 1. Inspect the relay (a) Inspect Whether horn relay (mark: HORN)is conduct Condition regular situations avometer connection terminal Normal conduction Supply battery voltage conduction to Terminal 1 and 2 If the conduction situation does not accord with regulations, re- place the relay.

  • Page 328: Windshield/Window Glass/Wing Mirror Electric Window Control System

    Windshield/bodywork glass/wing mirror--Electric window control system Windshield/window glass/wing mirror Electric window control system Position drawing (For reference only) Right front door electric window generator Electric window Electric window switch switch Electric window main switch Right front door electric window lift Left front door electric window lift Right rear door electric...
  • Page 329 Windshield/bodywork glass/wing mirror--Electric window control system (4) Inspect other windows whether they can not actuate except window of driver seat room, when the electric window switch locked. 2. Inspect automation function (a) inspect basic function (1) Turn the ignition switch to ON (2) Inspect whether driver seat window automatic descends completely, when you press electric win- dow main switch.

  • Page 330: Malfunction Phenomena Table

    Windshield/bodywork glass/wing mirror--Electric window control system Malfunction phenomena table Phenomena impossible positions wiring harness Electric window does not Work(all)(electric 1. POWER fuse(center power distribution box) door lock does Not work) 2. window shift main relay (center Distribution box) 3. wiring harness 1.
  • Page 331 Windshield/bodywork glass/wing mirror--Electric window control system 2. Inspect electric window switch assembly Active switch, inspect the conduction among the joint terminals. Switch position avometer terminals situations 4-5, 2-3 conduction 4-5, 1-3 conduction DOWN 2-5, 1-3 conduction If the conduction does not limit to regulations, replace electric window main switch.

  • Page 332: Front Windscreen

    Windshield/bodywork glass/wing mirror--Front windscreen Front windscreen Change Clues on: Please assemble as the disassembly opposite sequence. Assemble directions could be got when necessary. 1. Disassemble right front pillar trim board assembly [68010017] (referring to page 390) 2. Disassemble left front pillar trim board assembly [68010014] (referring to page 390) 3.
  • Page 333 Windshield/bodywork glass/wing mirror--Front windscreen Assemble two orientation block on the windscreen as the drawing. A: 40mm B: 8mm 16. Assemble front windscreen in board sealed tape [68000063] Stick sealed tape with double faced adhesive tape on both sides. a: 7mm b: 22.5mm c: 45mm d: 5mm...
  • Page 334 Windshield/bodywork glass/wing mirror--Front windscreen time. (h) Use brush or sponge to daub G priming paint on the front windscreen brim and contacting interface. (i) When daub other areas beside regulations, use clean duster cloth to clean before priming paint gets dry. Notes: Use G priming paint over three minutes.

  • Page 335: Rear Ventilation Window

    Windshield/bodywork glass/wing mirror--Rear ventilation window Rear ventilation window Change Clues on: Please assemble by the sequence opposite with disassembling sequence. Assemble directions could be got when necessary. 1. Disassemble the step trim board of left rear door [68010022] (referring to page 390) 2.
  • Page 336 Windshield/bodywork glass/wing mirror--Rear ventilation window figure. A: 40mm B: 8mm 17. Assemble rear ventilation window inboard sealed tape [68000105] Stick sealed tape with double faced adhesive tape on both sides. 18. Assemble rear ventilation window assembly [68000103] (a) Put rear ventilation window at the right position. (b) Inspect the contacting part of rear ventilation window brim whether it is flat.
  • Page 337 Windshield/bodywork glass/wing mirror--Rear ventilation window cloth to clean before priming paint gets dry. Clues on: Use G priming paint over three minutes. Opened G priming paint can not use for the next time. (j) Cut a hole on glue canister sharp nose. (k) Put the glue canister in the sealed glue jet gun.

  • Page 338: Fog Defrost System

    Windshield/bodywork glass/wing mirror--Fogbroom system Fog defrost system Position drawing Demist wire Demist (Defrost)switch Malfunction phenomena table Malfunction components name reference pages 1. DEF main relay 2. DEF-IP fuse All demists (defrosts) do not work 3. DEF-m fuse 4. demist switch 5.

  • Page 339: Inspect

    Windshield/bodywork glass/wing mirror--Fogbroom system Inspect 1. Inspect the relay Inspect the conduction of rear window demist(defrost) relay (mark: DEF) If the conduction does not accord with the regulations, replace relay. Conditions avometer terminals regular situations Always conduction Supply battery voltage between terminal1 and conduction Terminal2...

  • Page 340: Electric Rearview Mirror Control System(Option)

    Windshield/bodywork glass/wing mirror--Electric rearview mirror control system Electric rearview mirror control system(option) Inspect the vehicle 1. Inspect Electric retractable rearview mirror function (a) Turn the ignition switch to ACC (b) Inspect operating electric retractable rearview mirror function, when it at different positions. (1) When retractable switch at steering position and left/right rearview mirror at steering position either, press retractable switch, inspect left and right rearview mirrors whether they remove from steering position to retraction position and stop at it.
  • Page 341 Windshield/bodywork glass/wing mirror--Electric rearview mirror control system (c) When operating left and right rearview mirrors, inspect whether ignition switch works when turn it to OFF. (1) When operating left and right rearview mirrors, turn ignition switch to OFF and inspect rearview mirrors function whether they stop.

  • Page 342: Position Drawing

    Windshield/bodywork glass/wing mirror--Electric rearview mirror control system Positions Electric rear view mirrors switch Left rear view mirrors Right rearview mirrors Trouble table Trouble Components name Reference page 1. (accessory) fuse 2. rearview mirror switch rearview mirrors do not work 3. wiring harness 1.

  • Page 343: Inspect

    Windshield/bodywork glass/wing mirror--Electric rearview mirror control system Left and right INSPECT Folding switch adjusting switch (optional) 1. Inspect rear view mirrors switch Inspect conduction of rearview mirror. (1) Adjust left or right for side of the switch. Rearview Inspect conduction of rearview mirror on left side mirror switch Switch positions...
  • Page 344 Windshield/bodywork glass/wing mirror--Electric rearview mirror control system Notes: When repeat the same inspection, cut off the voltage of battery, then inspect again with same steps. When supply battery voltage, the rearview mirror will not retract even if trying to move the crust of rearview mirror.

  • Page 345: Panel / Combination Panel Combination Panel

    Panel/combination instrument--combination instrument Panel / combination instrument combination instrument Trouble table Lightening: Phenomenon Possible parts of trouble Reference pages 1. combination instrument assembly All lights fail 2. joint or harness Only one light fails 1. combination instrument assembly Indicator light: Phenomenon Possible parts of trouble Reference pages...

  • Page 346: Vehicle Inspection

    Panel/combination instrument--combination instrument Indicator light: Phenomenon Possible parts of trouble Reference pages 1. harness or joint Turning light fails 2. turn light and safety warning light system 3. combination instrument assembly 1. harness or joint Distant light fails 2. left combination switch 3.
  • Page 347 Panel/combination instrument--combination instrument 2. Inspect output signal of vehicle speed. (1) When vehicle run at 10km/h, inspect voltage between ter- minal10 and terminal A1 of combination instrument assembly. Standards: the voltage pulsates repeatedly between 0V to 5V for thirteen times. Notes: Inspect the ignition switch “on”...
  • Page 348 Panel/combination instrument--combination instrument (1) Disassemble fuel meter joints or break wire, when indictor is at E, fuel indictor does not light. (2) Jumper a 300-330 resistor from the corner of terminal1 and termianl2, turn ignition switch to ON, indictor is at E line, the indictor light lights. 6.
  • Page 349 Panel/combination instrument--combination instrument (b) Inspect light warning buzzer function (1) Disassemble combination instrument. (2) Connect battery positive wire to terminal A5 and nega- tive to terminal A1 and A2. (3) Connect battery positive wire to terminal A18 and nega- tive to terminalA17,inspect buzzer. Audio buzzer: long buzzes (4) When buzzer works, connect battery positive wire to ter- minal A4,inspect whether buzzer stop working.

  • Page 350: Inspection

    Panel/combination instrument-combination instrument 13. Check the switch of indicating light of brake liquid level. (1) Disassemble the cover and filter screen of liquid storage tank of brake main pump. (2) Disassemble the joint. (3) Check the conduction between switch side joints. Float (switch is OFF): not conduction (4) Use siphon and other tools to absorb brake liquid in storage tank.

  • Page 351: Panel

    Panel/combination instrument-- panel Panel Preparation 1. Automobile prepares to equip with SRS airbag and safety belt pre-tension crimper. Parking disassembling and assembling works in this chapter might influence SRS airbag. Before imple- menting these works, it is necessary to read the notes in SRS chapter. Change 1.
  • Page 352 Panel/combination instrument-- panel 5. Disassemble safety airbag assembly at the side of driver [67010011] (Referring to page 261) 6. Disassemble steering wheel assembly [67010001] (referring to page 194) 7. Disassemble Combination instrument cover [68000077] (a) Disassemble fixing clamp. (b) Use screw driver to unclench three fixing clamps and four 3 Fixing clamp fixing clasps, then disassemble Combination instrument.
  • Page 353 Panel/combination instrument-- panel 13. Disassemble air conditioner control panel assem- bly [67000148] (a) Use screw driver to unclench four fixing clamps and four fixing clasps, then disassemble air conditioner control panel assembly. Hint: before using screw driver, it is necessary to wrap its needled top with adhesive tape.
  • Page 354 Panel/combination instrument-- panel 19. Disassemble upper panel assembly [68010004] (a) Disassemble D bolt and two A screws. (b) Use disassembling tool for trim tape to unclench six fixing clamps. (c) Disassemble upper panel assembly. 6 Fixing clamp 5 Fixing clasp 20.
  • Page 355 Panel/combination instrument-- panel 25. Disassemble parking brake hole cover. Use screw driver to unclench four fixing clamps, then disas- semble parking brake hole cover. Hint: before using screw driver, it is necessary to wrap its needled top with adhesive tape. 4 Fixing clasp 26.
  • Page 356 Panel/combination instrument--panel 32. Disassemble lower panel assembly [68010005] (a) Disassemble the joint of indoor temperature sensor. (b) Disassemble machine cover locking pull cable with handle assembly. (c) Disassemble six D bolts. (d) Disassemble six fixing clamps and panel lower board. <D>...
  • Page 357 Panel/combination instrument--panel (b) Assemble CD machine assembly and panel central ventila- tion hole assembly. 4 Fixing clamp 36. Assemble helix cable assembly (referring to page 261) Fixing 37. Assemble steering wheel assembly [67010001] clamp (referring to page 194) 38. Check the central position of steering wheel. 39.

  • Page 358: Combination Instrument Assembly

    Panel/combination instrument--Combination instrument assembly Combination instrument assembly Disassembly and assembly 1. Disassemble Combination instrument cover [68000077] (a) Disassemble fixing clamp. (b) Use screw driver to unclench three fixing clamps and four fixing clasps, then disassemble combination penal cover. 2. Disassemble Combination instrument assembly [68000081] (a) Disassemble the screw.

  • Page 359: Chair

    Chair--Front chair Chair Front chair Subassembly Head pillow assembly Head pillow bracket Chair backrest gasket Chair backrest bracket Exterior cover of chair backrest With waist support: Waist support adjustment assembly Exterior cover of Clamp chair gasket With waist support: Inner trim cover of Adjusting lever of front chair gasket waist support lever...

  • Page 360: Overhaul

    Chair--Front chair Overhaul Hint: When assembling, please work by the sequence opposite with disassembling sequence, but when it has items that need to pay special attention, it will add special specification. This overhaul procedure is the disassembling procedure for left side, and the procedure for right side is same.
  • Page 361 Chair--Front chair 5. Disassemble lower trim cover of front chair gasket. 6. Disassemble inner trim cover of front chair gasket. Disassemble the screw and inner trim cover of front chair gasket. 7. Disassemble left front safety belt locker assembly [68010040] (a) Cut off fixing clasp.
  • Page 362 Chair--Front chair (b) Use new clamp to assemble chair gasket on chair gasket Locking loop pliers bracket. Hint: Do not damage or dirty exterior cover of chair gasket. When assembling clamp, it is necessary to prevent exterior cover of chair gasket from crinkling. 15.

  • Page 363: Rear Chair (Separating Type)

    Chair--Rear chair (separating type) Rear chair (separating type) Overhaul Hint: When assembling, please work by the sequence opposite with disassembling sequence, but when it has items that need to pay special attention, it will add special specification. 1. Disassemble rear row chair cushion assembly. Pull rear row chair cushion assembly upwards, then disas- semble it.
  • Page 364 Chair--Rear chair (separating type) (f) Disassemble the clamp, then disconnect exterior cover of Locking loop pliers rear row backrest with gasket. 10. Disassemble exterior cover of rear row chair cushion. Disassemble the clamp, then disconnect exterior cover of cush- ion with gasket. 11.

  • Page 365: Rear Chair (Fixing Type)

    Chair--Rear chair (fixing type) Rear chair (fixing type) Overhaul Hint: When assembling, please work by the sequence opposite with disassembling sequence, but when it has items that need to pay special attention, it will add special specification. 1. Disassemble rear row chair cushion assembly. Pull rear row chair cushion assembly upwards, then disas- semble it.

  • Page 366: Anti-Stealing And Door Lock Electric Door Lock Control System

    Anti-stealing and door lock--Electric door lock control system Anti-stealing and door lock Electric door lock control system Position of parts (only for reference) Door control switch of electric window main switch assembly (Used for handle operation) Door control switch of left front door locker assembly (Used for key operation) Door control light switch...
  • Page 367 Anti-stealing and door lock--Electric door lock control system (d) Check security function: (1) When closing all doors, open the driver window to operate door control switch out of automobile. (2) Take down the key, open driver door, then close the door and lock (not use key). In this situation above, check that door could not open locker even if door control switch (handle operation) is pressed to locker opening side out of automobile.
  • Page 368 Anti-stealing and door lock--Electric door lock control system Grounding wire Power supply (+) Power supply (+) Sunroof Power supply Power supply Power supply (-) 1G2 in 1G2 out Power supply (+) Power supply (+) Power supply (+) Power supply (+) Brake light Anti-steal Rain wiper...

  • Page 369: Malfunction Phenomenon Table

    Anti-stealing and door lock--Electric door lock control system Malfunction phenomenon table Malfunction phenomenon Possible malfunction part Referred page “Door locker control system” does not work 1. DOOR fuse (panel J/B) (all). 2. Wiring harness Door locking/unlocking malfunction (use 1. Electric window main switch (door control switch) handle operation and key operation) 2.

  • Page 370: Inspection

    Anti-stealing and door lock--Electric door lock control system Inspection 1. Check driver sear door locker assembly. (a) Liking that shown in figure, check the conduction of every terminal of door key switch. Position of switch Terminal connected by avometer Regulated situation LOCK Conduction Close...
  • Page 371 Anti-stealing and door lock--Electric door lock control system 2. Check front passenger seat door locker assembly Liking that shown in figure, supply battery voltage to terminal, Close and check the function of door locker. Open Condition Function Supply battery anode to No. 6 terminal, cathode to No.5 terminal Open Supply battery anode to No.

  • Page 372: Electronic Anti-Stealing System

    Anti-stealing and door lock--Electronic anti-stealing system Electronic anti-stealing system Electronic anti-stealing system consists of anti-stealing controller, anti-stealing loop and transmitter. One end of loop covers ignition locker core, the other end connects with anti-stealing controller, and the other end of controller connects with engine ECU, at the same time, transmitter is assembled in key. Memory of transmitter stores only mark (code) showing the legal identity of automobile owner, transmitter, anti-stealing controller and electric injection ECU constitutes a multi-layer effective electronic anti-stealing system verified by password.

  • Page 373: Electric Sunroof

    Electric sunroof (optional)--Sunroof Electric sunroof (optional) Sunroof Overhaul Hint: when assembling, please work by the sequence which is opposite with disassembling sequence; but when it has items that need to pay special attention, it will add special specification. 1. Disassemble inner trim board of top (referring to page 390). 2.
  • Page 374 Electric sunroof (optional)--Sunroof 7. Use screw driver (twisted by adhesive tape) to align the sunroof driving pull cable with right mark. Assembly mark 8. Assemble sunroof shell body assembly. (a) Bolt. Torque: 5.5 N⋅ ⋅ ⋅ ⋅ ⋅ m (b) Screw cap. Torque: 5.0 N⋅...

  • Page 375: Specification For Sunroof Function

    Electric sunroof (optional)--Sunroof system Sunroof system Specification for sunroof function 1. Operation category Spot contact: press the keystroke one time, then release immediately (the time is less than 0.3 seconds). Long press: press the key stroke for long time (the time is more than 0.3). 2.

  • Page 376: Inspection For Sunroof Switch

    Electric sunroof (optional)--Sunroof system Inspection for sunroof switch (a) Check the function of switch. Disassemble front top light, and disassemble the joint of front top light, then check the joint at the side of switch liking that shown in figure. Condition Regulated situa- Terminal connected by avometer...

  • Page 377: Engine Cover/Automobile Door Engine Cover

    Engine cover/automobile door--Engine cover Engine cover/automobile door Engine cover Adjustment 1. Check engine cover assembly. Check whether the clearance of engine cover is in regulated value shown in table. 2. Adjust engine cover assembly. (a) Adjust engine cover assembly by loosening the hinge bolt at the side of engine cover.

  • Page 378: Front Automobile Door

    Engine cover/automobile door--Front automobile door Front automobile door Subassembly : Regulated torque...
  • Page 379 Engine cover/automobile door--Front automobile door Marked Number of parts Name of parts Specification Amount number 6 8 0 0 0 1 4 7 Right front glass assembly 6 8 0 0 0 1 6 2 Seal tape of right front glass leading slot 6 8 0 0 0 1 4 9 Right front glass leading slot assembly M6 ×...

  • Page 380: Overhaul

    Engine cover/automobile door--Front automobile door Overhaul Hint: When assembling, please work by the sequence which is opposite with disassembling sequence; but when it has items that need to pay special attention, it will add special specification. Overhaul procedure for right side is same as the left side. Please refer to subassembly figure of front door on page 360.
  • Page 381 Engine cover/automobile door--Front automobile door 8. Disassemble left front glass assembly [68000146] Hint: insert the cloth in door steel board to prevent it from scratching the glass. (a) Turn the door glass until the bolts happens in repairing hole. (b) Disassemble two bolts and door glass. Note: do not damage the door glass.
  • Page 382 Engine cover/automobile door--Front automobile door 17. Assemble left front door glass lift assembly [67000122] (a) Use six bolts to assemble left front door glass lift. Torque: 8.0 N⋅ ⋅ ⋅ ⋅ ⋅ m (b) Assemble electric window lift and door glass. (c) Connect electric window switch to wiring harness and turn ignition switch to ON.

  • Page 383: Adjustment

    Engine cover/automobile door--Front automobile door Adjustment Hint: the working procedure for right side is same as left side. 1. Check the clearance of left front door (a) Check whether following data is in standard value. At the side of At the side of 2.

  • Page 384: Rear Automobile Door

    Engine cover/automobile door--Rear automobile door Rear automobile door Overhaul Hint: When assembling, please work by the sequence which is opposite with disassembling sequence; if necessary, it will have assembling instruction.. Overhaul procedure for right side is same as the left side. 1.
  • Page 385 Engine cover/automobile door--Rear automobile door 11. Spread lubricating grease on automobile body. Spread MP lubricating grease on sliding and turning parts of door locker. 12. Disassemble left rear door exterior handle pedestal. (a) Use planetary socket wrench to disassemble the screw and left rear door exterior handle cover.

  • Page 386: Adjustment

    Engine cover/automobile door--Rear automobile door Adjustment Hint: working procedure for right side is same as the left side. 1. Check the clearance of left rear door. (a) Check whether following data is in standard value.
  • Page 387 Engine cover/automobile door--Rear automobile door At the side of 2. Adjust the clearance of left rear door. At the side of automobile body automobile door (a) Loosen hinge screw cap at the side of automobile body to adjust the door. Torque: 26 N⋅...

  • Page 388: Trunk Cover

    Engine cover/automobile door--Trunk cover Trunk cover Adjustment 1. Check the clearance of trunk cover. (a) Check whether following data is in standard value. 2. Adjust the clearance of trunk cover. (a) If you want to make front and rear, left and right adjustment, please loosen the bolt at first.

  • Page 389: Torsion Spring Of Trunk Cover

    Engine cover/automobile door--Torsion spring of trunk cover Torsion spring of trunk cover Change Hint: When assembling, please work by the sequence which is opposite with disassembling sequence; if necessary, it will have assembling instruction. Changing procedure for right side is same as the left side. For torsion spring is disassembled, trunk cover does not have any tension, at this time, when opening and closing trunk cover, it is necessary to support it with hand to prevent trunk cover from closing for other resistances.

  • Page 390: Subassembly

    Exterior/inner trim board--Front bumper Exterior/inner trim board Front bumper Subassembly Inner gasket of right front wheel Fixing pedestal of radar probe Inner gasket of left front wheel Radiator cover assembly Radar probe head Radar probe head Fixing pedestal of radar probe head Front bumper Equipping with fog light Front fog light assembly...

  • Page 391: Exterior/Inner Trim Board Front Bumper

    Exterior/inner trim board--Front bumper Change Hint: When assembling, please work by the sequence which is opposite with disassembling sequence; if necessary, it will have assembling instruction. Please refer to subassembly figure of front bumper on page 379. 1. Disassemble radiator cover assembly [68000094] (a) Disassemble the bolt and radiator cover assembly.

  • Page 392: Rear Bumper

    Exterior/inner trim board--Rear bumper Rear bumper Subassembly Left decoration of luggage cas Right decoration of trunk Rear trim board of trunk Trim board of right rear wheel Equipping with radar: fixing pedestal of radar probe head Trim board of left Equipping with rear wheel reversing radar:...

  • Page 393: Change

    Exterior/inner trim board--Rear bumper Change Hint: When assembling, please work by the sequence which is opposite with disassembling sequence; if necessary, it will have assembling instruction. Please refer to subassembly figure of rear bumper on page 381. 1. Disassemble trunk carpet assembly [68000114] 2.

  • Page 394: Nameplate

    Exterior/inner trim board--Rear bumper Nameplate Change 1. No.2 nameplate of trunk cover 2. No.3 nameplate of trunk cover 3. No.6 nameplate of trunk cover C h i n a - Geely 4. Nameplate of front wing board...

  • Page 395: Exterior Seal Tape Of Left Front Door Glass (Lh)

    Exterior/inner trim board--Exterior seal tape of left front door glass Exterior seal tape of left front door glass (LH) Change Hint: When assembling, please work by the sequence which is opposite with disassembling sequence; if necessary, it will have assembling instruction. Changing procedure for right side is same as left side.

  • Page 396: Exterior Seal Tape Of Left Rear Door Glass

    Exterior/inner trim board--Exterior seal tape of left rear door glass Exterior seal tape of left rear door glass Change Hint: When assembling, please work by the sequence which is opposite with disassembling sequence; if necessary, it will have assembling instruction. Changing procedure for right side is same as left side.

  • Page 397: Light Fender

    Exterior/inner trim board--Light fender Light fender Change 1. Disassemble locker core and pedestal of trunk. 2. Disassemble number plate light defender [68000107] Disassemble four screw caps, then disassemble the defender. 2 Fixing clamp 3. Assemble rear logo assembly [61000019] (a) Use white gasoline to clean the assembling surface of logo. (b) Use heating light to heat defender and logo.

  • Page 398: Top Left Trim Tape

    Exterior/inner trim board--Top left trim tape Top left trim tape Change Hint: When assembling, please work by the sequence which is opposite with disassembling sequence; if necessary, it will have assembling instruction. Changing procedure for right side is same as left side. 1.

  • Page 399: Left Lower Fender Of Automobile Body (Lh)

    Exterior/inner trim board--Left lower fender of automobile body Left lower fender of automobile body (LH) Subassembly Lower fender Mudguard of left front wheel Fixing clasp...

  • Page 400: Change

    Exterior/inner trim board--Left lower fender of automobile body Change Hint: When assembling, please work by the sequence which is opposite with disassembling sequence; if necessary, it will have assembling instruction.. Changing procedure for right side is same as the left side. Please refer to the subassembly figure of body left lower fender on page 388.

  • Page 401: Inner Trim Board Of Top

    Exterior/inner trim board--Inner trim board of top Inner trim board of top Change Hint: When assembling, please work by the sequence which is opposite with disassembling sequence; if necessary, it will have assembling instruction. Changing procedure for right side is same as the left side. 1.
  • Page 402 Exterior/inner trim board--Inner trim board of top left pillar [68010018] 13. Disassemble upper inner trim board assembly of right pillar [68010025] (a) Disassemble the bolt and upper fixing bolt trim cover of front Fixing safety belt. clamp (b) Use screw driver to disassemble upper inner trim board of right stand pole.
  • Page 403 Exterior/inner trim board--Inner trim board of top 24. Disassemble right sun shade assembly [68010085] (a) Liking that shown in figure, use screw driver to unclench the trim cover of fixing pedestal, then pull down the trim cover. Hint: before using screw driver, its needled top should be twisted by adhesive tape.
  • Page 404 Exterior/inner trim board--Inner trim board of top 29. Disassemble the pothook of sun shade [68010086] Turn the pothook of sun shade to left for 90°, then disassemble 30. Disassemble fixing pedestal of rear window sun blind. Use screw driver to turn the fixing pedestal of sun blind for 90°, then disassemble it.

  • Page 405: Automobile Control System

    Automobile control system--Ignition switch and anti-versa lock key warning switch Automobile control system Ignition switch and anti-versa lock key warning switch Malfunction phenomenon table Phenomenon Possible malfunction part Reference page Ignition switch could not insert on any 1. Ignition switch position 2.

  • Page 406: Electrical Schematic Diagram

    Electrical schematic diagram--Ignition switch/starting/charging Ignition switch/starting/charging...
  • Page 407 Electrical schematic diagram--Electric injection control of engine...
  • Page 408 Electrical schematic diagram--Anti-locking brake system ABS Brake distribution EBD Anti-locking brake system ABS Brake distribution EBD...
  • Page 409 Electrical schematic diagram--Electric glass lifter Electric glass lifter...
  • Page 410 Electrical schematic diagram--Electric sunroof Electric chair Electric sunroof Electric chair...

  • Page 411: Brake Light

    Electrical schematic diagram--Wiper and water injection Brake light Wiper and water injection Brake light...
  • Page 412 Electrical schematic diagram--Electric rearview mirror Electric rearview mirror...
  • Page 413 Electrical schematic diagram--Reversing radar system Reversing radar system...
  • Page 414 Electrical schematic diagram--Safety airbag system Safety airbag system...
  • Page 415 Electrical schematic diagram--Air conditioning system Defrosting system Air conditioning system Defrosting system...
  • Page 416 Electrical schematic diagram--Door control system Anti-stealing system Central control system Light system...
  • Page 417 Electrical schematic diagram--Adjustment for headlight height Speaker cigar lighter Sound system Adjustment for headlight height Speaker cigar lighter Audio system...
  • Page 418 Electrical schematic diagram--Combination instrument...
  • Page 419 Electrical schematic diagram--Self-diagnosis Chip anti-stealing system Self-diagnosis Chip anti-stealing system...

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