Geely CK Series 2007 Workshop Manual

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Troubleshooting

Summary of Contents for Geely CK Series 2007

Page 2: Table Of Contents
Table of Contents Part I Engine ................1 Chapter 1 Engine Assembly (MR479Q, MR479QA, MR481QA) ....1 Section 1 Routine Inspection ..................1 Section 2 Drive Belt Replacement ................5 Section 3 Valve Clearance Adjustment ................6 Chapter 2 Engine Components Replacement (MR479Q, MR479QA, MR481QA) ..............10 Section 1 Engine Components ..................10 Section 2 Engine Components Replacement ............13 Section 3 Timing Belt Replacement...
Page 3 Chapter 6 Cooling System Inspection (MR7131A, MR7151A, MR7161A) ..............52 Section 1 System Check ....................52 Section 2 Water Pump, Thermostat and Radiator Replacement ........54 Chapter 7 Clutch (MR7131A, MR7151A, MR7161A) ........56 Section 1 Clutch Replacement ...................57 Chapter 8 Maunal Transaxle Assembly (MR7131A, MR7151A, MR7161A) ..............59 Section 1 Manual T ransaxle Replacement ..............60 Section 2 Vehicle Speed Sensor Replacement...
Page 4 Section 1 Propeller Shaft ....................97 Chapter 5 Front Suspension System ............... 103 Section 1 Front Suspension System ................103 Section 2 Front Suspension ....................105 Section 3 Front Wheel Alignment ..................106 Section 4 Front Strut Assembly ..................107 Section 5 Lower Swing Arm Assembly ................
Page 5 Section 8 Parking Brake System ..................155 Part III Electrical Equipment ............157 Chapter 1 Survey ....................157 Chapter 2 Starting and Charging System ............161 Section 1 Starting System (MR479Q MR479QA MR481QA) ..........161 Section 2 Charging System (MR479Q, MR479QA, MR481QA) ........164 Chapter 3 Combination Meter System ..............171 Section 1 Circuit Diagram of Combination Meter and Location of Multi-pin Plug-in Terminal ..........................
Page 6 Section 3 Removal & Installation ................... 262 Chapter 8 MK-20 ABS System................ 272 Section 1 ABS Diagnosis ....................272 Section 2 ABS System Check ..................276 Section 3 Removal and Installation ................. 292 Part IV Air Conditioner and Inside & Outside Trim ......297 Chapter 1 A/C System ..................
Page 7 (XIV) Rear trunk Inside Trim ................348 (XV) Engine Hood Inside Trim ................349 (XVI) Door ......................350 Part V Body................359 Chapter 1 General Information ..............359 Section 1 Body Structure ....................359 Chapter 2 Body Repair ..................369 Section 1 Body Damage Forms and Requirements for Repair ........369 Section 2 Typical Technology Of Body Panel Repair ..........372 Section 3 Repair after Body Damage ................372 Section 4 Features and Composition of Automobile Body ..........
Page 8: Part I Engine
Part I Engine Chapter 1 Engine Assembly (MR479Q, MR479QA, MR481QA) Section 1 Routine Inspection 1. Check coolant 2. Check engine oil 3. Check battery 4. Check air cleaner element assembly 5. Check spark plug 6. Check drive belt Belt deflection See (Table 1) Water pump Belt pressure: 98N generator...
Page 9 c) When fault diagnosis tester is not used (1) Shorting fault diagnosis interface socket 13 (TC) terminal and 4(CG) terminal. Notice: Ensure correct connection, otherwise the engine will be damaged. Switch off all electrical appliance system. Check when disconnecting cooling fan motor. (2) Using timing light to check ignition timing.
Page 10 The Min. compression pressure: 980 kPa The tolerance range of the cylinders pressure: 100 kPa Notice: Ensure sufficient battery power and the engine speed is no less than 250 RPM (revolutions per minute). Check the compression pressure of other cylinders in the same way. Complete the measure as quick as possible.
Page 11 Table 3 Problems Causes 1. Fault . Incorrect ignition timing . Fouled, shorted or improperly clearance of spark plug Normal High Rough idle 2. Incorrect valve clearance 3. Leaky intake & exhaust valves 4. Leaky cylinders 1. Air leaks . PCV hoses, intake manifold High Rough idle .
Page 12: Section 2 Drive Belt Replacement
Section 2 Drive Belt Replacement 1. Disconnect all engine pipe hose and wire joint. Remove engine assembly from the engine compartment, jack up the body, take out the engine assembly slowly (See Provision 20, Section Two, Chapter Two for detailed information) 2.
Page 13: Section 3 Valve Clearance Adjustment
Section 3 Valve Clearance Adjustment 1. Remove right camshaft timing gear 2. Remove ignition coil and high voltage cable 3. Remove cylinder head cover sub-assembly See (Figure 8) (a) Disconnect generator wire joint.. (b) Disconnect generator circuit. (c) Disconnect oil pressure switch connector. (d) Disconnect A/C compressor switch connector.
Page 14 Figure 11 6. Adjust intake valve clearance (a) Detach intake camshaft Notice: Because the camshaft end play is quite small, keep camshaft horizontal when removing it. If not, cylinder head may be partially damaged by the thrust force£¬it may stuck or damage camshaft when turning crankshaft. Take the following steps to avoid the damage: (1) Turn the pulley to access the hole on the camshaft drive gear where the counter gear is installed.
Page 15 Notice: Due to the small end play on camshaft, the cylinder head may be damaged by the thrust force when removing it, it may stuck or damage camshaft. Take the following steps to avoid damage: (1) Turn the crankshaft pulley to make exhaust camshaft dowel pin is a bit higher than the cylinder head. See (Figure 15).
Page 16 (4) Alternatively press valve tappet with the special tool (A) (B). Check valve clearance. See (Figure 19). 8. Install cylinder head sub-assembly (a) Remove all old gasket material. (b) Apply the seal glue to the cylinder head. (c) Connect wire harness and clip. (d) Install gasket under of cylinder head.
Page 17: Chapter 2 Engine Components Replacement (Mr479Q, Mr479Qa, Mr481Qa)
Chapter 2 Engine Components Replacement (MR479Q, MR479QA, MR481QA) Section 1 Engine Components Component 1 Air Filter Assembly W/ Hose Accelerator Control Cable Assembly Heater Inlet Hose Heater Outlet Hose Fuel Sub-Assembly Efi Fuel Pipe Clamp Transmission Control Cable Assembly Outlet Pipe Inlet Pipe Clutch Release Cylinder Assembly...
Page 18 Component 2 Fan & Generator V-Belt Vane-Type Pump V-Belt (V/ Power Steering) V-Belt No.1 Right Engine Glove Compartment Mounting Insulator Door Assembly Steering Column Assembly Steering Column Hole Cover Steering Column Hole Cover Left Engine Mounting Bracket Left Front Speed Sensor Front Shaft Hub Left Nut Front exhauxt pipe assembly Gasket...
Page 19 Component 3 Flywheel Clutch Disc Clutch Cover Clutch Release Bearing Clutch Release Fork Release Fork Support Release Fork Boot Figure 22...
Page 20: Section 2 Engine Components Replacement
Section 2 Engine Components Replacement 1. Avoid gasoline ejection when work. 2. Drain the coolant to empty. 3. Remove air filter assembly with hose. See (Figure 23) 4. Remove battery 5. Remove fuel delivery pipe sub-assembly 6. Disconnect water hoses, disconnect heater outlet hose from A/C hose.
Page 21 21. Remove radiator assembly 22. Remove engine V-belt 23. Remove No. 1 V- belt (A/C compressor to crankshaft pulley) 24. Remove generator assembly 25. Remove A/C compressor 26. Remove compressor installing No. 1 bracket. Remove 4 bolts and compressor installing No. 1 bracket.
Page 22 50. Install water outlet hose joint. See (Figure 29, 30) Figure 29 Figure 30 51. Install water inlet hose housing. See (Figure 31, 32) Figure 31 Figure 32 52. Install engine oil pressure switch 53. Install crankshaft position sensor Torque: 9, 3N. m 54.
Page 23 (c) Install and uniformly tighten connecting bolt in the sequence shown in the figure. Torque: 64N. m 62. Install manual transaxle assembly 63. Install starter assembly 64. Install power steering pump bracket 65. Install power steering pump adjusting bracket with 2 bolts. 66.
Page 24: Section 3 Timing Belt Replacement
Section 3 Timing Belt Replacement High Pressure Cable Air Filter Assembly W/ Hose Ventilation Pipe Seal Cylinder Head Right Engine Mounting Gasket Cylinder Head Gasket Vane-Type Pump V-Belt V/ Power Steering Fan & Generator V-Belt V-Belt No.1 Timing Chain Or Timing Belt Cover Assembly No. 2 Timing Belt Fan Pulley Crankshaft Or Pulley...
Page 25 1. Disconnect engine from all the wire harnesses and cables connected to body. 2. Remove air filter assembly with hose. See (Figure 38) 3. Disconnect oil pipe and water hoses 4. Loose positive and negative cables on battery 5. Detach propeller shaft 6.
Page 26 20. Remove timing belt guide wheel Hint: (a) Mark on pulley and belt (in engine turning direction) if re-using timing belt (See Figure 42). (b) Install bolt to the idler pulley. Move pulley to its far left and tighten it temperarily (See Figure 43). 21.
Page 27 (c) Check timing belt for deflection Check the belt distorn as shown in the figure. Belt deflection: 20N: 5~6mm Re-adjust the idler if the deflection does not comply with the regulation. 25. Install timing belt guide wheel. See (Figure 46) Install guide, place the cup side outward.
Page 28 39. Install oil pipe and water hose 40. Install left & right propeller shaft 41. Install left & right front wheel 42. Check engine oil for leakage 43. Install all connected wire harnesses and the cables on engine and vehicle body...
Page 29: Section 4 Camshaft Replacement
Section 4 Camshaft Replacement High Pressure Cable Vane-Type Pump V-Belt V/ Power Steering Fan & Generator V-Belt Ventilation Pipe Seal Air Filter Assembly W/ Hose V-Belt No.1 Cylinder Head Cylinder Head Gasket Crankshaft Bearing Cap Crankshaft Timing Belt Washer Crankshaft Counter Gear Wave Gasket Snap Ring Camshaft...
Page 30 1. Disconnect all connected wire harnesses and the cable on the engine and the vehicle body 2. Remove air filter assembly with hose 3. Disconnect oil pipe and water hose 4. Loose positive and negative cables of the battery 5. Detach propeller shaft 6.
Page 31 (c) Loose installing bolt of the idler. See (Figure 52). Move the pulley to its far left and tighten it temporarily. (d) Remove the belt from the camshaft timing pulley. Notice: Hold the timing belt, the engagement of the crankshaft timing pulley and timing belt will not move.
Page 32 (b) Remove the counter gear of the camshaft. (1) Clamp the camshaft's hexagon on the vise. (2) Turn the counter gear cloclwise, Remove the service bolt. (3) Remove the snap ring with a circlip pliers. See (Figure 57). (4) Remove waved gasket, camshaft counter gear and the camshaft gear spring. See (Figure 58) 24.
Page 33 (d) Install intake camshaft. (1) Make the exhaust camshaft dowel pin a bit higher than the top of the cylinder head. (2) Apply grease to camshaft's contact surface. Install Mark (3) Install intake camshaft gear to exhaust camshaft gear , Align the matchmarks on each gear.
Page 34 31. Install timing belt cover Torque: 9.3N. m 32. Install generator assembly 33. Install right engine mounting bracket. See (Figure 67) 34. Install cylinder head cover sub-assembly (a) Install 2 ventilation PCV hoses to the cylinder head cover. (b) Connect the generator wire. (c) Install the wire clip.
Page 35: Section 5 Cylinder Head Gasket Replacement
Section 5 Cylinder Head Gasket Replacement Component 1 Vane Pump Assembly V/ Power Steering Gasket Throttle Body Assembly Dipstick Fuel Delivery Pipe No.1 Inlet Pipe O-Ring Gasket Wire Harness Timing Chain Or Timing Belt Cover No. 2 Fan Pulley Crankshaft Or Pulley Cover Sub-Assembly Figure 68...
Page 36 Component 2 High Pressure Cable Ventilation Pipe Camshaft Bearing Cap Camshaft Seal Cylinder Head Cover Camshaft No.2 Oil Seal Cylinder Head Camshaft Timing Pulley Cover Gasket Cylinder Head Sub-Assembly Exhaust Manifold Insulator No. 1 Cylinder Head Gasket Gasket Exhaust Manifold Manifold Mounting Figure 69...
Page 37 Component 3 Engine Hood Air Filter Assembly W/ Hose Right Wiper Arm Left Wiper Arm Right Engine Mounting Bracket Right Scuttle Ventilation Grille Left Scuttle Ventilation Grille Wiper Arm Subassembly Accelerator Cable Assembly Generator EFI Fuel Hose Clamp Assembly Heater Inlet Hose Fuel Pipe Sub-Assembly Radiator Inlet Hose Heater Outlet Hose A...
Page 38 Replacement 1. Disconnect all the wire harnesses and the cables on the engine connected to the car body. 2. Detach air filter assembly with hose 3. Disconnect oil pipe and water hose 4. Loose positive and negative cables of the battery. 5.
Page 39 28. Install power steering adjusting pole 29. Install power steering pump assembly 30. Install wire harness. 31. Install No. 1 fuel delivery pipe 32. Set the new gasket on cylinder head with flange upward. Install water inlet hose. See (Figure 73) 33.
Page 40: Section 6 Oil Pump Oil Seal Replacement
Section 6 Oil Pump Oil Seal Replacement 1. Pry with 2 screwdrivers. Detach crankshaft timing pulley. See (Figure 74) 2. Remove oil pump oil seal. See (Figure 75) (a) Using a knife, cut off oil seal lip. (b) Using a screwdriver, pry out the oil seal. 3.
Page 41: Section 7 Engine Rear Oil Seal Replacement
Section 7 Engine Rear Oil Seal Replacement 1. Detach engine and manuel transaxle assembly on "Provision 20, Section 2, Chapter 2" 2. Detach clutch case assembly 3. Remove clutch plate assembly 4.Fix the front end of crankshaft. Detach flywheel. See (Figure 78) 5.
Page 42: Chapter 3 Lubrication System (Mr479Q, Mr479Qa, Mr481Qa)
Chapter 3 Lubrication System (MR479Q, MR479QA, MR481QA) Section 1 Oil Pressure Gage Sensor Replacement 1. Check oil level Warm up the engine. Check the dipstick to ensure oil level between "L" and "F" after engine stopped 5 minutes. Check for leakage if it is too low. Fill oil to "F. 2.
Page 43: Section 2 Oil Pump Assembly Replacement
Section 2 Oil Pump Assembly Replacement 1. Remove timing belt 2. Remove timing belt idler sub-assembly 3. Detach crankshaft timing pulley. See (Figure 74) 4. Remove the dipstick guide 5. Detach oil sump sub-assembly. See (Figure 83) 6. Detach oil strainer sub-assembly. See (Figure 84) 7.
Page 44 13. Install the dipstick guide. See (Figure 87) 14. Install crankshaft timing pulley. See (Figure 77) 15. Install timing belt idler sub-assembly No.1 16. Install timing belt 17. Fill in engine oil 18. Check oil for leakage Figure 87...
Page 45: Section 3 Oil Filter Replacement
Section 3 Oil Filter Replacement 1. Detach oil filter sub-assembly. See (Figure 88) 2. Install oil filter sub-assembly. See (Figure 89) Figure 88 Figure 89 3. Install drain plug Clean and use new washer to install drain plug. Torque: 54N. m 4.
Page 46: Section 4 Starter Replacement
Section 4 Starter Replacement 1. Detach starter assembly. See (Figure 90) 2. Install starter assembly Torque: Bolt 37N. m Figure 90...
Page 47: Section 5 Generator Replacement
Section 5 Generator Replacement 1. Detach V-belt of generator 2. Detach generator assembly (a) Disconnect wire joint of generator. (b) Remove wire of generator. (c) Disconnect oil pressure switch interface. (d) Disconnect A/C compressor switch connector. (e) Open wire clips. (f) Detach 2 bolts and generator.
Page 48: Chapter 4 Fuel System (Mr7131A, Mr7151A, Mr7161A)
Chapter 4 Fuel System (MR7131A, MR7151A, MR7161A) Section 1 Check Fuel System Pressure 1. Remove the fuel tank from the vehicle 2. Check the fuel pump running (a) Connect the positive and negative battery terminal to the concerned fuel pump connector. See (Figure 91). Notice: Do not start engine The sound of fuel flowing can be heard if there is pressure.
Page 49: Section 2 Fuel Pump Inspection
Section 2 Fuel Pump Inspection 1. Fuel pump Ω at 20°. Replace fuel pump if the resistance is not as specified. (a) Check fuel pump resistance, 0.2~3.0 See (Figure 93) (b) Fuel pump running: Check fuel pump by connecting with battery. Replace fuel pump or wire if the running is not as specified. See (Figure 94).
Page 50: Section 3 Fuel Injector Replacement
Section 3 Fuel Injector Replacement 1. Check fuel for ejection. 2. Remove PCV ventilation hoses. See (Figure 95). Remove fuel pipe clamp. 3. Detach fuel hose sub-assembly 4. Detach fuel delivery pipe sub-assembly. See (Figure 96) (a) Press the connector to lock the spring and pull the connector from the injector. (b) Remove 2 screws and detach fuel delivery pipe with injector.
Page 51 7. Install fuel delivery pipe sub-assembly (a) Install two washers in intake manifold. See (Figure 99). (b) Install 4 injectors and fuel delivery pipe assembly into intake manifold . (c) Temperarily install 2 bolts to attach the fuel delivery pipe to intake Washer manifold .
Page 52: Section 4 Fuel Pump Replacement
Section 4 Fuel Pump Replacement Figure 102...
Page 53 1. Avoid fuel ejection 2. Disconnect fuel tank hose 3. Disconnect fuel tank return hose 4. Disconnect fuel tank gas exhaust hose 5. Detach fuel pump assembly with filter screen. See (Figure 103) Figure 103 Using special tool, loose fuel tank cap. Be careful not to bend the fuel level sensor arm when pulling out fuel pump.
Page 54: Section 5 Fuel Emission Control System
Section 5 Fuel Emission Control System 1. Check the operation when the fuel is cut off. (a) Warm up the engine for at least 2500rpm. Using sound grade meter, check injector's noise when running. See (Figure 105). (b) The noise from the injector should stop immediately after loosing the throttle. Repeat for several times. 2.
Page 55: Section 6 Carbon Canister Replacement
Section 6 Carbon Canister Replacement 1. Check and replace carbon canister (a) Eye-inspect the carbon canister for crack or damage. See (Figure 109). (b) Check the carbon canister's operation. 1. Plug the exhaust hole. See (Figure 110). 2. Blow air in through (4.71kpa, 48kgf/cm ) fuel tank hole when the exhaust hole is closed.
Page 56 (3) Check VSV operation from hole E to F and that the air flow should be difficult. See (Figure 114). 3. PCV sub-assembly It should be easy for air to pass through the cylinder head. Notice: Do not suck air through valve. Never put any object into the valve.
Page 57: Chapter 5 Exhaust System (Mr7131A, Mr7151A, Mr7161A)
Chapter 5 Exhaust System (MR7131A, MR7151A, MR7161A) Component1 Figure 116...
Page 58 1. Detach tail exhaust pipe assembly Remove 2 bolts and the tail exhaust pipe assembly. 2. Remove intermediate exhaust pipe assembly Replace exhaust system Detach 2 bolts and intermediate exhaust pipe assembly. 3. Detach front exhaust pipe assembly Remove 2 bolts and front exhaust pipe assembly. 4.
Page 59: (Mr7131A, Mr7151A, Mr7161A)
Chapter 6 Cooling System Inspection (MR7131A, MR7151A, MR7161A) Section 1 System Check Radiator Cap Tester 1. Check the cooling system for leakage. See (Figure 118) (a) Fill coolant into radiator. Install the tester onto the radiator cap port. (b) Start engine. (c) The water pump pressure is 118Kpa.
Page 60 6. Fan (1) Check the cooling fan operation with low temperature (Lower than 83°C) (a) Turn the ignition switch to “ON” position. (b) Check that the cooling fan stops. Disconnest (c) Pull out the water temperature sensor connector. See (Figure 122) Figure 122 (d) Connect the water temperature sensor to car body with the...
Page 61: Section 2 Water Pump, Thermostat And Radiator Replacement
Section 2 Water Pump, Thermostat and Radiator Replacement Hoist the engine from the compartment. See "Provison 20, Section 2, Chapter 2". 1. Replace water pump. See (Figure 125) (1) Drain the coolant. (2) Detach timing belt. (3) Detach power steering pump assembly. (4) Remove the oil dipstick guide.
Page 62 (5) Disconnect auto-transmission oil cooler input pipe (Auto-transmission). (6) Disconnect auto-transmission oil cooler output pipe (Auto-transmission). (7) Remove 4 bolts from the radiator mounting bracket. See (Figure 129). (8) Detach radiator assembly, Remove 3 bolts. Detach the fan and fan shroud. See (Figure 130). Figure 127 Figure 128 (9) Install the cooling fan assembly...
Page 63: Chapter 7 Clutch (Mr7131A, Mr7151A, Mr7161A)
Chapter 7 Clutch (MR7131A, MR7151A, MR7161A) Component 1 (Hydraulic Manipulation) Figure 131...
Page 64: Section 1 Clutch Replacement
Section 1 Clutch Replacement Hoist the engine from the compartment. See "Provison 20, Section 2, Chapter 2". 1. Remove manual transaxle assembly 2. Remove the clutch release fork. See (Figure 132) 3. Detach clutch release fork boot. 4. Detach clutch release bearing 5.
Page 65 11. Using the dial gauge, check the flywheel runout. See (Figure 136). The maximum runout: 0.3mm 12. Check clutch release bearing The bearing is permanently lubricated. There is no need to lubricate or clean. 13. Check clutch plate 14. Install clutch cover. See (Figure 137) Figure 136 Align the Clutch cover to the mark on the flywheel.
Page 66: Chapter 8 Maunal Transaxle Assembly (Mr7131A, Mr7151A, Mr7161A)
Chapter 8 Maunal Transaxle Assembly (MR7131A, MR7151A, MR7161A) Component 1 Figure 139...
Page 67: Section 1 Manual Transaxle Replacement
Section 1 Manual Transaxle Replacement 1. Open the engine hood 2. Remove the battery 3. Remove clutch cylinder sub-assembly. See (Figure 140) 4. Detach transmission shift cable assembly. See (Figure 141) 5. Remove the connector and turn on the back-up lamp switch connector. 6.
Page 68: Section 2 Vehicle Speed Sensor Replacement
Section 2 Vehicle Speed Sensor Replacement 1. Disconnect vehicle speed sensor. See (Figure 142) 2. Remove bolt and vehicle speed sensor. 3. Install vehicle speed sensor. See (Figure 142) 4. Connect vehicle speed sensor connector. See (Figure 143) Figure 142 Figure 143...
Page 69: Section 3 Transmission Case Oil Seal
Section 3 Transmission Case Oil Seal 1. Remove transmission case oil seal. See (Figure 144) 2. Install transmission case oil seal. See (Figure 145) Notice: Be careful not to damage oil seal lip. Figure 144 Figure 145...
Page 70: Section 4 Transaxle Case Oil Seal Replacement
Section 4 Transaxle Case Oil Seal Replacement 1. Using special tool, remove transaxle case oil seal. See (Figure 146) 2. Install transaxle case oil seal. See (Figure 147) Figure 144 Figure 145...
Page 71: Chapter 9 General Engine Troubles And Their Troubleshooting
Chapter 9 General Engine Troubles and Their Troubleshooting Section 1 Overview The wide application of the electronic technologies to the vehicles brings innovation on diagnosis of the vehicle, many varieties of diagnosis instruments that are very effective and efficient for the vehicle diagnosis are innovated.
Page 72 g. Ignition system failure; h. Low engine compression pressure. (3) Diagnosis and Troubleshooting a. First, check the fuel tank for fuel level, turn on the ignition switch, if fuel gauge pointer does not move or fuel level warning lamp lights, then the fuel tank is empty, fuel shall be filled at this time. b.
Page 73 f. The idle control valve is faulty; g. The water temperature sensor is damaged; h. The vacuum pressure sensor is damaged; i. The air filter is blocked; j. The injector leaks; k. The compression pressure in the cylinder is too low; l.
Page 74 Engine can not start Check the starting system Repair or replace the part if it is faulty Check the high voltage spark No high voltage spark or weak spark Check the ignition system Is there any sign of cranking No sign of cranking There is sign of cranking Check the electric fuel pump for operation Check the air cleaner filter...
Page 75 d. Fuel pressure system abnormal; e. Idle control valve fault; f. Vacuum pressure sensor fault; g. Ignition system fault; h. The compression pressure in the cylinder is a little lower; i. Injector leakage. 3. Diagnosis and Troubleshooting a. Perform self-diagnosis first, check whether there is any DTC, if there is, find the reason and cause by the DTC;...
Page 76 j. Poor intake and exhaust valve seal, failed piston ring, low compression pressure; h. Too many carbon deposit in spark plug and combustion chamber; k. Water temperature switch and thermostat fault; l. Aging of Oxygon sensor; Engine is difficult to start Clogged Check whether the air cleaner is clogged Troubleshooting...
Page 77 (3) Diagnosis procedure for insufficient engine power (Figure 150) Insufficient power Insufficient Unable to be fully open Check whether throttle valve can be fully open Adjust Clogged Check whether the air cleaner is clogged Clean or replace Abnormal Check the throttle valve position sensor for failure Repair or replace Check the water temperature switch and thermostat Replace...
Page 78 3. Poor acceleration (1) Symptom Engine speed can not be increased immediately after depressing the accelerator pedal, there is time lag,and the acceleration reaction is delayed or there is slight fluctuation during the acceleration. (2) Causes and Troubleshooting a. There is fault in throttle position sensor, repair or replace it; b.
Page 79 4. Big fuel consumption (1) Symptom: Engine power is ok, but the fuel consumption is big, exhaust pipe discharges black smoke. (2) Causes and Troubleshooting: a. When idling, idle speed is high and shall be adjusted; b. Water temperature sensor fault, service or replace it; c.
Page 80 7. Unstable idle or engine shut off at hot status (1) Symptom Idle speed is normal during the cold start and becomes unstable at hot status, idle speed is too low or engine is shut off. (2) Causes and Troubleshooting a.
Page 81 8. Idle speed too high at hot status (1) Symptom The engine runs at fast idle during cold start and remains fast idle at hot status, leading to excessively fast idle. (2) Causes and Troubleshooting a. The initial idle value is not properly adjusted, b.
Page 82 10. Engine overheat (Table 6) Table 6 Item Symptom Cause Troubleshooting Repair or replace Bad radiator cover Bad radiator hose Replace Supplement welding, otherwise Bad radiator tube strap replace it Insufficient Water coolant Bad cylinder gasket Replace leakage Remedy with infiltration technology Cracky cylinder block or replace it Poor water pump seal...
Page 83 11. General engine fault symptom and faulty area (Table 7) Table 7 Difficult to start Poor idling Engine off Poor driving Symptom Suspect Area Intake abosolute pressure sensor Water temperature sensor Control Revolution speed sensor system Throttle valve position sensor Vehicle speed sensor Fuel pump system Fuel...
Page 84: Section 3 Engine Noise Diagnosis And Troubleshooting
IV. Exhaust Pipe Discharges Gas with Abnormal Color (or odor) When there is failure in engine combustion system, the exhaust pipe discharges gas with abnormal color. 1. The discharged gas is thickly black This is caused by incomplete combustion. Since the mixed air is too thick, the combustion is not complete and part of the fuel is discharged without combustion, leading to decrease of engine power.
Page 85 (3) Valve free movement noise is caused by dropped valve keeper or broken valve head. It shall be replaced; (4) Noise between the intake & exhaust valve and valve bushing is caused by stagnation valve and bushing that can not be closed, repair the bushing or replace it; (5) Valve and valve seat can not be tightly closed and noise is generated, leading to abnormal engine operation.
Page 86 II. Crankshaft connecting rod noise diagnosis and troubleshooting 1. crankshaft connecting rod noise cause and troubleshooting Noise area Noise cause Troubleshooting Excessive connecting rod bearing radial Replace the bearing play Connecting rod cover bolt loosened Tighten Connecting rod bearing insert dimension Connecting rod not as specified result in rotation or Replace the insert...
Page 87 3. Piston knocking noise causes and troubleshooting Item Troubleshooting Main bearing oil channel depth and width Repair or adjust the oil pressure to misalined or insufficient oil pressure result Knock when specification in poor lubrication of the cylinder wall engine is cold Excessively big clearance between the Replace the piston to resume the normal clearance...
Page 88: Chapter 10 Engine Management Unit
Chapter 10 Engine Management Unit Section 1 System Description Engine Control System generally consists of sensor, controller and actuator. Sensor: convert the physical parameter of the device into electric signal (digital or analog) to monitor the operating condition of the device and send these signals to the controller. Controller: receive and process information sent from the sensor, and analyze the information to learn the conditions of the device: use predefined control strategy and procedure, determine how to control the device under current conditions;...
Page 89: Section 2 System Component And Working Principle
Starting condition ¡ª fixed ignition advance angle advance angle basic value - determined by MAP instantaneous correction Ignition advance angle control Running condition stable idle correction air fuel ratio feedback correction engine overheat correction advance angle correction knock control maximum advance/delayed angle control other correction Special control The control over the ignition advance angle is generally open loop control.
Page 90 ECU microcomputer consists of microprocessor, memory, clock generator, timer, I/O interface and input level A/D converter that are integrated in a large scale integrated circuit chip, that is SCM (Single Chip Microcomputer). 1. Input level The input signals from the sensor are pre-processed by the input level. The input signals are sent to protected circuit first, sometimes through the signal converter and amplifier, and then sent to microcomputer.
Page 91 3. Output Level ECU output level is designed to send control signal to the actuators of the electronic control system based on the orders of the microprocessor in the micro-controller. The microprocessor control the output level by controlling the occurrence position of the pulse, its length and duty ratio. (1) Injection output level The microprocessor controls the pulse length of the injection output level by making sure whether to trigger to circuit or not in the injection output level.
Page 92: Part Ii Chassis
Part II Chassis Chapter 1 Transmission Control Device Section 1 Transmission Control Device Description on Transmission Control Device This model is equipped with lever and cable transmission control devices, respectively used for 1.3L and 1.5L engine, both of their gears are: 5 forward gears + 1 reverse gear. PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem.
Page 93 Bottom Panel Assembly of Body Control Pull Rod Assembly Transmission Assembly Replacement 1. Remove shift lever assembly (1) Pull upwards to separate the shift lever assembly leather boot from the auxiliary console (2) Loosen the shift lever set screw with inner hex wrench. Remove the shift lever assembly counterclockwise 2.
Page 94: Section 3 Cable Type Transmission Control Module
(3) Dust cover retainer shall be assembled well, otherwise the dust seal effect will be af- fected (4) Dust cover fixing nut torque: 20~25N.m (5) Make sure the shift number words on the top of shift lever ball face towards the driving direction of the vehicle, properly tighten the set screw of the shift lever (6) Check whether the shift control is flexible and reliable;...
Page 95 Ball Seat Shift Lever Assembly E Shaped Bottom Bracket Clip Plate Support Shift Control Conjuction Plate Cables Frame Lever Ball Pin Spindle II E Shaped Clip Plate Spindle I Bush Torsion Spring Ball Pin Seat Wave Washer Spring Bush Bush Replacement 1.
Page 96 6. Separate the manual shift assembly from the transmission control cable assembly (1) Remove the E-shaped clip plate between the transmission control cable assembly and manual shift assembly (2) Remove the cotter pin and flat washer between the selector cable and shift assembly (3) Remove the locking nut connecting the cable and the shift assembly 7.
Page 97: Chapter 2 Accelerator Pedal
Chapter 2 Accelerator Pedal Section 1 Accelerator Pedal Components Hole Plug Cowl Baffle Accelerator Cable Adjusting Nut Accelerator Pedal Assembly Connect The Engine Replacement 1. Remove the accelerator cable Loosen the set nut attaching the accelerator cable to the accelerator cable bracket on the engine, remove the accelerator cable from the throttle valve rocker arm 2.
Page 98: Chapter 3 Clutch Control System
Chapter 3 Clutch Control System Section 1 Clutch Control System Clutch operating system description This model is equipped with hydraulic and cable clutch control system, respectively used for 1.3L engine 1.5L engine. Symptom Suspected Area 1. Clutch pedal position (Too low) Clutch slips 2.
Page 99 Clutch Pedal Adjusting Bolt Bracket Assembly Brake Pedal Assembly Bushing Bushing Connect The Sleeve Clutch Cable Pedal Mat Clutch Pedal Torsion Spring Retainer Clutch Pedal Assembly Adjustment 1. Check and adjust clutch pedal height The clutch pedal height should be 180~186 mm. Adjust the pedal by adjusting bolts. 2.
Page 100 Adjusting Bolt Adjusting Bolt Stroke Free Install Height Stroke Minimum Distance from the Cowl Panel Replacement 1. Remove the clutch cable (1) Loosen the clutch adjusting nut. Separate the clutch cable from the accelerator rocker arm (2) Remove the 2 set bolts from the clutch cable on the cowl panel (3) Separate the clutch cable from the clutch pedal Adjusting Nut 2.
Page 101: Section 3 Clutch Hydraulic Control Device
Section 3 Clutch hydraulic Control Device Components...
Page 102 Replacement 1. Remove the reservoir hose 1 and reservoir hose 2 Notice: Clutch hydraulic control system and hydraulic brake system share the reservoir. Prevent the brake fluid from overflowing when removing the reservoir hose. 2. Disconnect the connection with the pedal Remove the lock pin, flat washer, pin shaft to separate the clutch hydraulic control master cylinder from the clutch pedal 3.
Page 103 6. Remove clutch hydraulic control master cylinder Remove the 2 fixing bolts between the clutch hydraulic control master cylinder and the pedal bracket 7. Install and replace the parts in the reverse order of the above procedure Notice: (1) Be careful not to leak brake fluid onto other objects or paint surface. Clean it immedi- ately to avoid damage.
Page 104: Chapter 4 Propeller Shaft
Chapter 4 Propeller Shaft Section 1 Propeller Shaft Propeller shaft is constant velocity propeller shaft, consisting of tripod constant velocity universal joint and Rzeppa constant velocity univeral joint, where the tripod one is on the differential side and the Rzeppa one is on the wheel side.
Page 105 Components 1. Rzeppa Constant velocity universal joint 2. Snap ring 3. Clip Band 4. Rzeppa Type Constant velocity universal joint boot 5. Band 6. Shaft 7. Band 8. Tripod constant velocity universal joint boot 9. Band 10. Snap ring 11. Tripod constant velocity universal joint 12.
Page 106 Service 1. Remove the front wheel 2. Remove the ABS sensor signal wire 3. Remove the propeller shaft fixing nut (1) Remove the cotter pin of the propeller shaft fixing nut (2) loosen the propeller shaft fixing nut 4. Separate the steering tie rod (1) Remove the cotter pin and the nut (2) Separate the tie rod ball stud pin from the knuckle.
Page 107 (3) Check the Rzeppa Constant velocity universal joint for looseness (4) Check the boot for damage Notice: Check that the propeller shaft assembly is placed horizontal. 8. Disassemble the tripod constant velocity universal joint boot Use screwdriver to loose the tripod constant velocity universal joint boot band, remove the boot Notice: Replace the band if it is distorted 9.
Page 108 10. Remove the snap ring on the spline shaft end of the tripod constant velocity joint Notice: Do not damage the snap ring, or it shall be replaced 11.Disassemble the Rzeppa Constant velocity universal joint boot Use screwdriver to loosen the Rzeppa Constant velocity universal joint boot band, remove the boot Notice: Replace the band if it is distorted 12.
Page 109 Install front wheel, wheel nut torque: 95~115N.m Make sure that the propeller shafts for 1.3L engine and 1.5L engine are not interchanged at the time of replacement Check the ABS sensor signal, check and adjust the front wheel alignment if necessary.
Page 110: Chapter 5 Front Suspension System
Chapter 5 Front Suspension System Section 1 Front Suspension System Description on front suspension structure This model uses strut swing arm independent suspension with stabilizer bar. The shock absorber upper end is flexibly connected to the body through the shock absorber mounting seat, the lower end is rigidly connected to the steering knuckle.
Page 111 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace parts. Symptom Suspected Area 1.
Page 112: Section 2 Front Suspension
Section 2 Front Suspension Components...
Page 113: Section 3 Front Wheel Alignment
Section 3 Front Wheel Alignment Adjustment 1. Inspect tire 2. Inspect toe-in Front Toe-in Tire Pressure 220KPa Toe-in C-D: 0±3mm If the toe-in is not as specified, adjust the tie rod (but the left and right tie rods must be adjusted symmetrically). 3.
Page 114: Section 4 Front Strut Assembly
Section 4 Front Strut Assembly Components: Washer Mount Cover Front Shock Absorber Shock Absorber Mount Support Protecting Sleeve Big Washer Thrust Ball Bearing Front Bumper Spring Upper Seat Front Coil Spring Front Coil Spring Lower Insulator Upper Insulator LF Shock Absorber Assembly Front Coil Spring Stabilizer Bar Left Link Rod Assembly...
Page 115 Replacement 1. Remove the front wheel. 2. Remove the ABS sensor from the steering knuckle. Separate the sensor and signal wire from the wire harness bracket on the front shock absorber. 3. Separate the front brake hose Remove 2 clips and separate the front brake hose from the front shock absorber bracket. 4.
Page 116 Disassemble the front strut assembly (1) Remove the nut on the shock absorber. Notice: the elasticity of the spring is recovered! (2) Remove the washer, collar, shock absorber mount seat and big washer. (3) Remove spring upper seat, front coil spring , front shock absorber boot, front dumper, front coil spring lower insulator.
Page 117: Section 5 Lower Swing Arm Assembly
Section 5 Lower Swing Arm Assembly Components...
Page 118 Replacement 1. Remove lower swing arm assembly (1) Remove the bolts and nuts between the lower swing arm assembly and front brake. (2) Remove the 4 bolts on lower swing arm rear spring joint cover. (3) Remove the bolts and nut between lower swing arm assembly and lower swing arm front bracket 2.
Page 119 3. Remove lower swing arm front support frame Remove the 4 bolts connecting the lower swing arm front support frame and vehicle body. 4. Disassemble lower swing arm assembly Disassembly of lower swing arm assembly is in the reverse order of the assembly. Notice: Do not tighten type 1 hexagon nut 5.
Page 120: Section 6 Front Stabilizer Bar And Link Rod Assembly
Section 6 Front Stabilizer Bar and Link Rod Assembly Components Stabilizer Bar Right Link Rod Assembly Front Stabilizer Bar Clamp Front Stabilizer Bar Rubber Bushing Right Bracket Welding Assembly RF Strut Assembly Front Stabilizer Bar Front Stabilizer Bar Clamp Front Stabilizer Bar Rubber Bushing Left Bracket Welding Assembly Stabilizer Bar Left Link Rod Assembly...
Page 121 Replacement Hint 1. Remove the stabilizer bar left link rod (1) Remove the nuts connecting the stabilizer bar left link rod and front shock absorber. (2) Remove the nut connecting the stabilizer bar left link rod and the left side of stabilizer bar. 2.
Page 122 5. Install the front stabilizer bar Install stabilizer bar, 2 rubber bushings, the front stabilizer bar clamp and 4 bolts. Torque: 50~60N.m Notice: (1) Align the inner rubber bushing with the mark on the stabilizer bar. (2) The 4 bolts connecting the stabilizer bar clamp and front stabilizer bar support frame welding assembly differ in length.
Page 123: Chapter 6 Rear Suspension System
Chapter 6 Rear Suspension System Section 1 Rear Suspension System Rear suspension structure description This model uses strut independent rear suspension with stabilizer bar. Rear suspension consists of the parallel front and rear double transverse arms, trailing rod, rear stabilizer bar and rear strut assembly.
Page 124: Section 2 Rear Suspension
Section 2 Rear Suspension Components...
Page 125: Section 3 Rear Wheel Alignment
No. 2 Transverse Arm Assembly Rear Wheel Toe-In Adjusting Plate No. 1 Transverse Arm Assembly Rear Wheel Toe-In Adjusting Cam Rear Wheel Toe-In Adjusting Panel Body Bottom Plate No. 2 Transverse Arm Assembly Rear Wheel Toe-In Adjusting Cam No. 1 Transverse Arm Assembly Section 3 Rear Wheel Alignment Inspection...
Page 126: Section 4 Left & Right Rear Strut Assembly
Section 4 Left & Right Rear Strut Assembly Components Upper Mount Cushion (Dumper) Cushion Dust Prevent Upper Mount Sleeve Rear Suspension Rear Suspension Spring Lower Spring Insulator Insulator Rear Left Shock Absorber Rear Suspension Conical Spring Replacement 1. Remove the rear wheel 2.
Page 127 4. Remove the left and right rear strut assembly (1) Remove the threaded connect of the rear strut assembly and rear brake assembly (2) Remove the 3 nuts attaching the rear suspension upper mount to the body Caution: reliable object shall be used to support the rear brake assembly! Make sure that the brake pipeline is not affected or damaged! 5.
Page 128: Section 5 Rear Stabilizer Bar Assembly, Strut Rod Components
Section 5 Rear stabilizer bar assembly, strut rod components Components Rear Stabilizer Bar Rubber Bushing Rear Stabilizer Bar Rear Stabilizer Bar Clamp Rear Stabilizer Bar Retainer Rear Stabilizer Bar Rubber Ring Rear Stabilizer Bar Retainer Strut Rod Welding Components Rubber Ring Bushing Strut Rod Mount Replacement...
Page 129 2. Remove the strut rod components Remove the thread connecting strut rod and No. 2 transverse arm assembly 3. Disassemble the strut rod components 4. Disassemble the rear stabilizer bar assembly (1) Remove the rear stabilizer bar clamp (2) Remove the rear stabilizer bar rubber bushing 5.
Page 130: Section 6 Left & Right Trailing Rod Assembly
Section 6 Left & Right Trailing Rod Assembly Components Trailing Rod Bushing Left Brake Manual Brake Cable LR Trailing Trailing Rod Replacement 1. Separate parking brake cable assembly Remove the parking brake cable set bolt on trailing rod Remove the trailing rod assembly (1) Remove the bolt connecting the trailing rod assembly and rear brake assembly.
Page 131: Section 7 No. 1 Transverse Arm Assembly
Section 7 No. 1 Transverse Arm Assembly Components Pivot bracket No. 1 Transverse arm welding components No. 1 Trailing arm bushing Replacement 1. Remove transverse arm assembly No. 1 (1) Remove the bolt connecting the No. 1 transverse arm assembly and rear brake assembly (2) Remove the bolt connecting the No.
Page 132: Section 8 No. 2 Transverse Arm Assembly
Section 8 No. 2 Transverse Arm Assembly Components Rear Stabilizer Bar Strut Rod Component Pivot Bracket Body Bottom Plate No. 2 Transverse Arm Rear Wheel Toe-in Welding Component Adjust Cam No. 2 Transverse Arm Bushing Rear Wheel Toe-in Adjust Plate Replacement 1.
Page 133: Chapter 7 Wheel
Chapter 7 Wheel Section 1 Tire Inspection Inspection 1. Check the tires for appearance and proper inflation pressure. Check for inflation pressure after the vehicle stops for over 15min. Tire module Tire inflation p ressure （ Kpa ） 175/65 R14 82H 2.
Page 134: Section 2 Wheel Replacement
Section 2 Wheel Replacement Replacement (1) Pry the edge of the wheel rim trim cover with screwdriver to remove the wheel rim trim cover (2) Loose every tire nut with tire nut wrench. (3) Four jacks support the vehicle body, two at each side as shown in the figure. The jack should be near to the to-be-replaced wheel with solid base.
Page 135: Chapter 8 Power Steering System
Chapter 8 Power Steering System Section 1 Power Steering System Power Steering System Description Power Steering System consists of the steering wheel, steering transmit device, power steering fixed device and steering pipelines. The steering gear is rack and pinion type. Major parameters for steering system: Item Parameter...
Page 136 Symptom Table The table below is helpful to find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. Repair or replace these parts or assemblies if necessary. Symptom Likely Cause 1 ．...
Page 137: Section 2 Steering Drive And Control Mechanism
Section 2 Steering Drive and Control Mechanism Components Air Bag Assembly Steering Wheel Assembly Upper Cover Combined Switch Bracket Lower Cover Head Light Dimmer Switch Wiper Switch Assembly Dust Cover Steering Column Assembly Intermediate Shaft Press Plate of Dustcover Universal Joint...
Page 138 Replacement 1. Cautions (refer to Steering System Cautions) 2. Make sure the wheels are placed straight ahead 3. disconnect the battery negative terminals 4. Remove the air bag assembly Remove two screws on both sides and pull out the wiring harness connector Notice: Do not pull air bag wire harness when removing the air bag assembly! Warning: Make sure the upper surface of the air bag assembly is kept upward when placing it!
Page 139 7. Remove the combination switch assembly (1) Remove 3 set screws. (2) Disconnect headlamp dimmer switch and wiper and washer switch wire harness (3) Remove the combination switch assembly 8. Disconnect the universal joint Remove the locking bolt between the joint yoke and the power steering gear 9.
Page 140: Section 3 Steering Pipeline Component
11. Complete the service or replace the steering column assembly, the installation procedure is in the reverse order of the removal Notice: (1) after the installation of the ignition lock core, check the steering lock operation: the steering mechanism lock when the ignition key is pulled out; the steering mechanism unlock when the key is inserted and turned to ACC position (2)The torque of the 2 bolts and 2 nuts securing the steer column assembly: 16~26N.m...
Page 141 On-vehicle inspection 1. check the drive belt Observe the drive belt for excessive wear and cordline wear. Replace the drive belt if necessary. Hint: Cracks on the rib side of a belt are considered acceptable. If missing chunks from the ribs are found on the drive belt, it should be replaced.
Page 142 Replacement 1. Drain the power steering system fluid 2. Remove the power steering high and low pressure pipe 3. Loosen the union screw of the high and low pressure pipe on the steering gear assembly, loosen the pipe clip. 4. Loosen the drive belt 5.
Page 143: Section 4 Power Steering Gear Retaining Device
Section 4 Power Steering Gear Retaining Device Components Front Cowl Panel Assembly Cotter Pin Cotter Pin...
Page 144 Tie Rod RH Ball Stud Pin Lock Nut No.1 Boot Wire Clip Pipe Band O-ring O-ring O-ring Joint Sub-assembly Joint Sub-assembly Band Wire Clip Tie Rod LH Ball Stud Pin No. 2 Boot Lock Nut Replacement 1. Drain the power steering system fluid 2.
Page 145 3. Loosen the union thread of the high and low pressure pipes on the steering gear assembly 4. Remove the boot band and No. 1, No. 2 boots 5. Disconnect the power steering gear assembly from the steering column Remove the steering gear pinion shaft spline lock bolt on the universal joint yoke 6.
Page 146: Chapter 9 Brake System
Chapter 9 Brake System Section 1 Brake System Precaution 1. It's very important to keep the parts and area clean when repairing the brake system. 2. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard.
Page 147: Section 2 Brake Fluid
Symptom Suspect area 1. Wheel cylinder piston (stuck) 2. Brake shoe lining (oily) 3. Disc (scratched) Brake Deviation 4. Brake shoes or lining (cracked or distorted) 5. Wheel hub bearing (worn or damaged) Tire pressure (not as specified) 1. Brake shoe lining (damaged) 2.
Page 148: Section 3 Brake Pedal
Section 3 Brake Pedal Components 1. Vacuum Booster Assembly 2. Liner 3. Spacer 4. Torsion Spring 5. Brake Pedal Arm 6. Cushion Gasket 7. Brake Pedal Mat Replacement: 1. Separate the vacuum booster with brake master cylinder assembly Remove the cotter pin, flat washer and pivot, separate the vacuum booster with brake master cylinder assembly from the brake pedal 2.
Page 149 (3) The 3 bolts connecting the brake pedal support bracket and cowl panel cross member Torque : 16-20N.m (4) The 4 bolts connecting the brake pedal support bracket and the vacuum booster with brake master cylinder assembly Torque: 16-20N.m Check the brake pedal Worn Or Damaged Worn Or Distorted Or Damaged...
Page 150: Section 4 Vacuum Booster With Brake Master Cylinder Assembly
Section 4 Vacuum Booster with Brake Master Cylinder Assembly Notice: The vacuum booster with brake master cylinder assembly must be repaired by manufacturer. Replace it if it is faulty. On-vehicle inspection 1. Check vacuum booster (a) Air tightness check (1) start the engine, run 1 or 2 minutes then shut off. Depress the brake pedal several times slightly. Hint: if the pedal rises gradually after depressing the pedal, the booster is airtight.
Page 151: Section 5 Front Brake Assembly
Section 5 Front Brake Assembly Components Inner Floating Clip Plate Inner Pad Backing Screw Plug Brake Caliper Plate Housing Inner Outer Pad Damper Backing Plate Outer Wheel Inner Pad Steel Wire Damper Cylinder Snap Ring Outer Pad Short Pin Piston Seal Set Bolt Wheel Outer Floating...
Page 152 Remove 2 boots from the brake cylinder support bracket. 7. Remove the brake cylinder guide boot Remove the clip and boot with screwdriver. 8. Remove the bleeder screw 9. Remove the front brake piston (1) Put a piece of soft cloth between the brake cylinder and piston. (2) Blow the piston out from the brake cylinder with the compressed air Notice: Be careful not to put your finger in front of the piston when blowing the compressed air.
Page 153 15. Remove the front disc floating 16. Installation is in the reverse order of the above-mentioned procedure Notice: (1) The maximum lateral runout of the disc surface should be no more than 0.05mm (Measured 10mm from the brake disc outside edge) (2) Be careful not to install the brake cylinder guide boot in the reverse direction (3) Make sure the cylinder and the piston oil seal are clean before installing the piston oil seal in the brake cylinder.
Page 154: Section 6 Rear Brake
Section 6 Rear Brake Components Repairing 1. Remove rear wheel 2. Drain the brake fluid 3. Remove the brake drum (1) loose the parking brake handle (2) Remove the cotter pin with a long nose pliers (3) loose the spindle slot nut...
Page 155 (4) remove the brake drum Push 4. Measure brake drum inside diameter Standard inside diameter: 180mm Maximum inside diameter: 181mm 5. Separate the parking brake left swing arm. Loose the parking brake cable end joint Separate the parking brake left swing arm. Remove the parking brake cable end joint with a screwdriver. 6.
Page 156 9. Remove the parking brake lever accessory 10. Inspect shoe lining thickness Standard thickness: 4.0mm Minimum thickness: 1.0mm Replace the shoe if the lining thickness is less than the minimum or seriously worn. 11.Inspect brake drum and brake shoe lining for proper contact If the contact between brake drum and shoe lining is improper, repair the lining with a brake shoe grinder or replace the brake shoe.
Page 157 19. Install rear brake clearance automatic adjustment lever Back Plate Adjust Bolt 20. Adjust the installing position of the brake shoe£¬install the brake drum 21. Fill the brake fluid 22. Bleed the air in the brake system 23. Check the fluid level in the reservoir 24.
Page 158: Section 7 Brake Line
Section 7 Brake Line Components 1. RF Brake Pipe Compo 2. Front Brake Hose Assembly 3. L-shaped spring Clip 4 U-shaped Clip 5. Hex Bolt Spring Washer and Flat Washer Compo 6. 5-pipe Clip 7. Brake Master Cylin- der to Controller No.1 Brake Pipe Compo. 8.
Page 159 Replacement 1. Drain the brake fluid in the brake pipeline 2. Separate rear left, right brake pipe compo. (1) Loose union thread. Separate the rear left brake pipe compo. and rear left No. 1 brake pipe compo. (2) Loose union thread. Separate the rear right brake pipe compo. and rear right No. 1 brake pipe compo.
Page 160 4. Remove the rear brake hose compo. Loose the union thread that connects the rear brake hose to LR and RR brake pipe compo., remove the E-shaped clip on the hose support bracket. Remove the rear brake hose compo. 5. Remove rear left, right brake pipe compo. (1) Remove a dual tube clip (2) Remove three 5-pipe clips (3) Remove rear left, right brake pipe compo.
Page 161 9. Remove rear left, right brake pipe No 1 compo. Loose the union thread that connects the brake pipe compo to HECU controller (ABS module) 10. Separate HECU controller assembly wire harness 11. Remove HECU controller bracket Remove the 3 hex bolts connecting the bracket and the body 12.
Page 162: Section 8 Parking Brake System
Section 8 Parking Brake System Problem symptoms table Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect area 1.
Page 163 (4) Install auxiliary console rear assembly (5) install the parking brake handle bushing Adjusting Nut Parking brake cable Components Equalizer Body Clip Pull Rod Adjusting Nut Parking M6 x 16 Brake Cable Rubber Ring M6 x 16 Bolt Compo. Replacement 1.
Page 164: Part Iii Electrical Equipment
Part III Electrical Equipment Chapter 1 Survey This part refers to the electrical repair of the Free Cruiser, and analyzes the faults from every system. Then some practicable diagnosis procedure and repair ways are given. I. HAND-HELD TESTER 1. Before the tester is used, a through reading of the Tester Operation Manual is commended. 2.
Page 165 III. CUSTOMER FAULT ANALYSIS NOTES: 1. When the troubleshooting analysis is underway, make sure to confirm the fault symptom correctly. Re- move kinds of suppositions in order to make an exact judgment. In order to find out what on earth the fault is, it is extremely important to ask customers about the fault symptoms and the conditions when faults occurred.
Page 166 Make a simulation test in a way of symptom simulation Inspect DTC Confirm symptom V. SYMPTOM SIMULATION NOTES: The most difficult conditions to handle in the fault troubleshooting are that the fault symptom dose not appear. Under the circumstances, make sure first to make a comprehensive analysis to the fault described by the customer, then to simulate an environment that is similar or the same with the conditions when the fault of the customer's vehicle occurred.
Page 167 3. Way of Heating: When getting warm in the suspected area may be the major cause of the fault. (a) Use a drier or other similar tool to heat the suspected area to check if the fault occurs. NOTES: The heating temperature must be less than 60¡æ £¨140¨H£©(The temperature shall not exceed the one that can damage the component.) Do not directly heat the ECU parts.
Page 168: Chapter 2 Starting And Charging System
Chapter 2 Starting and Charging System Section 1 Starting System (MR479Q MR479QA MR481QA) I. STARTER INSPECTION NOTICE: These tests must be done within 5 seconds to avoid burning out the coil. 1. INSPECT MAGNETIC SWITCH (a) Use wire to connect the starter as shown. (b) Connect the magnetic switch and the battery as shown.
Page 169 2. INSPECT STARTER NO-LOAD (a) Connect the magnet exciting coil and the terminal. (b) Connect the ammeter and the battery to the starter as shown. (c) Check that the starter rotates smoothly and steadily with the clutch pinion gear moving out. (d) Check that the ammeter shows the specified current.
Page 170 II. STARTER ASSEMBLY REPLACEMENT (MR479Q, MR479QA, MR481QA) 1. REMOVE STARTER ASSEMBLY (a) Disconnect the starter connector. (b) Remove the nut, and disconnect the starter cable. (c) Remove the 2 bolts and the starter assembly. 2. INSTALL STARTER ASSEMBLY Install according to the inverted order of removal. Torque: Bolt 37N.m (378kgf.cm, 27ft.lbf) Harness 9.8N.m(100kgf.cm, 7.0ft.lbf)
Page 171: Section 2 Charging System (Mr479Q, Mr479Qa, Mr481Qa)
Section 2 Charging System (MR479Q, MR479QA, MR481QA) I. BATTERY Maintenance-free battery is applied in this vehicle. Its termination voltage is 12V. It is connected inline by six 2V single cell in tandem with walls between every pole. 1. BATTERY WARNING SIGNS 1 -- Danger of corrosion The battery electrolyte is very corrosive.
Page 172 2. BATTERY REMOVAL AND INSTALLATION HINT: (1) The battery is not allowed to contact lubricating grease. (2) The battery terminal is only allowed to be softly pulled out, in order to void damaging the battery. REMOVAL (1) Remove the negative (-) ground cable (2) Remove the battery positive (+) cable (3) Loosen the fixing clamp on the battery.
Page 173 II. CHARGING SYSTEM INSPECTION 1. CHECK BATTERY WORKING VOLTAGE (a) After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor) for 60 seconds to remove the surface charge.
Page 174 3. INSPECT DRIVE BELT (a) Check the belt for excessive wear, frayed cords etc. HINT: If any defect has been found, replace the drive belt. Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.
Page 175 7. INSPECT CHARGING CIRCUIT WITHOUT LOAD (a) If a battery/starter tester is available, connect the tester to the Ammeter charging circuit as per instructions. Disconnect Wire from Terminal B (b) If a tester is not available, connect an ammeter and voltmeter to the Battery charging circuit as follows.
Page 176 III. ALTERNATOR INSPECTION 1. INSPECT ALTERNATOR Bearing Cover Rotor Bearing Retainer Bearing Ｓｔａｔｏｒ Bearing Pulley Brush IC Regulator Wire Clamp Rear Cover Brush Brush Holder Holder Cover Connecting Insulator Gasket Rectifier Frame Structure of Alternator (a) Inspect the rotor winding Inspect the resistance of the rotor winding Place the multimeter at R x 1, connect 2 pens and 2 slip rings of the rotor.
Page 177 (b) Inspect the stator winding Inspect the resistance of the stator winding Place the multimeter at R x 1, connect 2 pens of the meter to any of the 2 pens wires of the armature winding respectively. There must be continuity. Where the resistance reading is infinitely great shows an open circuit.
Page 178: Chapter 3 Combination Meter System
Chapter 3 Combination Meter System Section 1 Circuit Diagram of Combination Meter and Location of Multi-pin Plug-in Terminal I. CIRCUIT DIAGRAM OF CONBINATION METER Tachometer Speed Signal High Beam Lamp Rear Defrost Lamp Speedometer Ground The Sensor Rear Defog Lamp Revolution Signal Water Water Temperature Signa...
Page 179 II. LOCATION OF HARHESS MULTI-PIN PLUG-IN TERMINAL Color of connector A is white, and B is black (1) HINT: R -- RE Bl -- BLUE Y -- YELLOW B -- BLACK P -- G -- GREEN W -- WHITE O -- ORANGE Gr -- GRAY Br -- BROWN V --...
Page 180: Terminal
2. DEFINITION OF MULTIPIN PLUG-IN TERMINAL Terminal No. Definition of Terminal Color of Harness Empty Empty Empty Empty Empty Empty Combination switch (Position lamp Speed sensor groun Speed sensor power sourc Speed sensor signal outpu Fuel senso Alternator Brake fluid level switc Oil pressure switc Rear defrost Rear fog lamp...
Page 181: Section 2 Malfunction Symptom Table And Solution Procedure
Section 2 Malfunction Symptom Table and Solution Procedure I.MALFUNCTION SYMPTOM TABLE The table below lists the typical malfunction symptoms of the combination meter. These malfunctions can be solved by the procedure in the section of the Malfunction Diagnosis. Serial No. MALFUNCTION SYMPTOM The whole combination meter does not operate Speedometer malfunction...
Page 182 II. DETAILED SOLUTION PROCEDURE 1. THE WHOLE COMBINATION METER DOSE NOT OPERATE. (a) Inspect fuse Check fuse CLUSTER (10A) in the main fuse box for continuity. Check fuse AM (30A) in the main fuse box for continuity. Check fuse MAIN (80A) in the fuse box for continuity.
Page 183 (b) Inspect the combination meter connectors. Inspect continuity Disconnect the connector from the combination meter assembly Inspect continuity between terminals Standard: Tester connection Condition Standard condition B7 - ground Normal condition Continuity B8 - ground Normal condition Continuity Inspect voltage Disconnect the connector from the combination meter assembly Turn the ignition switch ON Inspect voltage between terminals...
Page 184 2. SPEEDOMETER MALFUNCTION CIRCUIT DIAGRAM Combined Meter Assembly Speedometer Sensor Ground the Speedometer Sensor Speedometer Sensor+8V Power Source Speed Signal INSPECTION (a) Inspect the combination meter assembly Remove the combination meter assembly and retain the connection of connectors. Inspect continuity Inspect continuity between terminals Standard: Tester connection...
Page 185 (b) Inspect the combination meter assembly speed input signal Inspect voltage Hold the front wheels up Push the shift lever to NEUTRAL Turn the ignition switch to ON Slowly turn the front wheel, measure the voltage between terminal A9 and A11 Standard voltage is as follows: Voltage changes alternately Below 0.5V...
Page 186 Inspect voltage between terminals Standard: Tester connection Condition Standard condition 3 - ground Turn the ignition switch to ON 7.5 – 9V Result and solution: Abnormal Repair or replace the harness or connector Normal Inspect the speed sensor output signal Inspect the speed sensor output signal Inspect voltage Hold the front wheels up...
Page 187 (c) Inspect the combination meter assembly Remove the combination meter assembly and disconnect connectors. Inspect continuity Inspect continuity between terminals Standard: Tester connection Condition Standard condition B7 - ground Normal condition Continuity B8 - ground Normal condition Continuity Inspect voltage between terminals Tester connection Condition Standard condition...
Page 188 3. TACHOMETER MALFUNCTION CIRCUIT DIAGRAM Combined Meter Assembly Engine ECU Engine Revolution Signal Inspection procedure (a) Inspect the combination meter assembly revolution input signal Remove the combination meter assembly and retain the connection of connectors. Connect the oscilloscope to the terminal B11 and ground.
Page 189 (b) Inspect the engine ECU revolution output signal Remove the engine ECU and retain the connection of connectors. Connect the oscilloscope to the terminal 54 and ground. Start the engine Inspect the signal wave form Standard: Show the correct wave form Result and solution: Normal Repair or replace the harness or connector...
Page 190 4. WATER TEMPERATURE GAUGE MALFUNCTION CIRCUIT DIAGRAM Combined Meter Assembly Water Temperature Sensor Water Temperature Signal (a) Get the value of water temperature with the diagnosis tester Connect the diagnosis tester to the diagnosis interface Turn the ignition switch to ON Read the value of engine water temperature displayed on the diagnosis tester Standard: The same with the actual engine coolant temperature.
Page 191 Standard: Tester connection Condition Standard condition C(60 ℃ ) 164.5±5Ω 1/2C(90 ℃ ) 56±3Ω B5 - ground H(115 ℃ ) 28.7±2Ω Result and solution: Normal Replace the combination meter assembly If abnormal inspect the water temperature sensor Inspect the water temperature sensor Remove the water temperature sensor and put it into the constant temperature cabinet.
Page 192 5. FUEL GAUGE MALFUNCTION CIRCUIT DIAGRAM Combined Meter Assembly Fuel Level Sensor Fuel Signal (a) Inspect the combination meter assembly Inspect resistance Remove the combination meter assembly and disconnect connectors Inspect continuity between terminals Standard: Tester connectio Conditio Standard conditio 110±6Ω...
Page 193 Standard: Condition Standard condition 110±6Ω 32.5±3Ω 3±2Ω Result and solution: Normal: Repair or replace the harness and connector If abnormal replace the fuel level sensor 6. THE OTHER INDICATORS Short the ports of the other indicators respectively to the ground or power source in accordance with the Circuit Diagram, the indicators will light correspondingly.
Page 194: Section 3 Combination Meter
Section 3 Combination Meter I. SYMPTOM AND SUSPECTED AREA HINT: The table below can help you find the causes of malfunction. The figures in the table show the most possible malfunctions in order of priority. Inspect each part in the order given. If necessary, repair or replace this parts.
Page 195 Symptom Suspected Area 1. Harness or connector. ABS warning light does not light up 2. ABS controller or ABS warning light driver module 3. Combination meter assembly 1. Harness or connector. SRS warning light does not light up 2. SRS controller 3.
Page 196 II. SPEEDOMETER INSPECTION 1. INSPECT THE INDICATING ERROR ALLOWED BY SPEEDOMETER USING A SPEEDOM- ETER TESTER, AND INSPECT THE OPERATION OF THE ODOMETER. Analog Meter (Km/h) Meter indication Value displayed on the tester 17—23 35—40 55—60 75—80 95—100 114—120 133—140 152—160 171—180 NOTICE:...
Page 197 Analog Meter Tachometer (r/min) handy tachometer (r/min) 740—860 1000 900—1100 2000 1850—2150 3000 2800—3200 4000 3800—4200 5000 4800—5200 6000 5750—6250 4. INSPECT FUEL LEVEL GAUGE (1) Inspect resistance When the fuel level gauge indicates no fuel, inspect the resistance between terminal A-12 and B-7 on the combination meter connector.
Page 198 Standard Standard indication Resistance (Ω) 159.5—169.5 Ｃ 1/2 Ｈ 53—59 Warning point 26.7—30.7 20—24 NOTICE: Connector should be disconnected when measured. 6. INSPECT WATER TEMPERATURE WARNINGLIGHT (a) Disconnect the water temperature sensor connector. (b) Turn the ignition ON, the water temperature warning light should go out. (c) Ground the terminal B5 of the meter connector, the water temperature warning light should light up.
Page 199 10. INSPECT PARK BRAKE SWITCH (1) Disconnect the connector from the park brake switch. (2) Pull up the hand brake, inspect continuity between its terminal and ground. Hand brake is pulled up: Continuity Hand brake is released: No continuity 11. INSPECT BRAKE FLUID LEVEL WARING LIGHT (1) Disconnect the connector from the brake fluid level sensor.
Page 200: Chapter 4 Wiper And Washer System
Chapter 4 Wiper and Washer System Section 1 Wiper and Washer System Inspection I.WIPER AND WASHER SYSTEM SYMPTOM ANALYSIS NOTES: The table below can help you find the causes of malfunction. These figures show the most possible malfunc- tions in order of priority. Inspect each part in the order given. If necessary, repair or replace these parts. Symptom Suspected Area 1.
Page 201 II. MALFUNCTION INSPECTION 1. WASHER PUMP INSPECTION (1) Mount washer pump on the can system. Pour washer fluid into the can. (2) Disconnect the connector of washer pump. (3) Connect the terminal 1 of washer pump to the battery positive (+) and the terminal 2 to the negative (-), as shown below.
Page 202 Front washer switch Switch position Tested terminal Specified condition No continuity Continuity 8（+）—7（-） If no continuity, replace the switch. (b) Operation inspection (washer switch) Turn the washer switch on the position OFF. Connect the connector terminal 8 to the battery positive (+) and the terminal 2 of wiper connector to the negative (-).
Page 203: Section 2 Replacement And Adjustment
Section 2 Replacement and Adjustment I WIPER MOTOR ASSEMBLY REPLACEMENT 1. REMOVE WIPER MOTOR (a) Disconnect the connector. (b) Remove the 4 mounting bolts. (c) Separate the shaft of the motor crankshaft arm and the wiper link with special tools. 4 Mounting Bolts 2.
Page 204 III. WIPER SWITCH ASSEMBLY REPLACEMENT 1. DETACH STEERING WHEEL ASSEMBLY (a) Disconnect the main power source of the vehicle. (b) Remove the passenger SRS module assembly, and cautiously put it in a safe place. (c) Loosen steering wheel lock-bolts and remove the assembly. 2.
Page 205: Chapter 5 Light System
Chapter 5 Light System Section 1 Survey of Light System I. COMPOSITION 1. Front combination lamp assembly: turn signal lamp, high beam, low beam, head lamp, front position lamp. 2. Rear combination lamp: turn signal lamp, back-up lamp, rear fog lamp, tail lamp, brake lamp, retro reflector. 3.
Page 206 III. BULB SPECIFICATIONS Name Specifications Headlamp (High beam and Low beam) H1 12V 55W Turn signal lamp P21W 12V 21W Position lamp W5W 12V 5W Front fog lamp H3 12V 55W Rear combination lamp (Turn signal lamp) PY21W 12V 21W Rear combination lamp (Brake / Position lamp) P21/5W 12V 21/5W Rear combination lamp (Rear fog lamp)
Page 207 IV. LOCATION OF LIGHT SYSTEM Rear Row Reading Lamp Interior Lamp Fuse Box Door Courtesy Lamp Switch LH/Front, Rear Door Courtesy Lamp Assembly LH Turn Lamp Assembly LH Front Combined LH Front Fog Assembly Lamp Assembly Headlamp Switch Lamp Front Headlamp Height Control Switch, Haedlamp Adjusting Switch Hazard Warning...
Page 208 High Mounted Stop Lamp RH-rear Combined Lamp Rear Trunk Lamp Switch License Plate LH Rear Lamp Combined Lamp...
Page 209: Section 2 Light System Symptom Inspection
Section 2 Light System Symptom Inspection I. LIGHT SYSTEM PROBLEM SYMPTOMS TABLE NOTES: The table below can help you find the causes of malfunction. These figures show the most possible malfunc- tions in order of priority. Inspect each part in the order given. If necessary, repair or replace these parts. 1.
Page 210 2. FRONT FOG LAMP SYSTEM Symptom Suspected Area 1. Fog lamp fuse 2. Front fog lamp relay Front fog lamp dose not light up with light control switch HEADLAMP (Head lamp is normal). 3. Light switch assembly 4. Harness 1. Bulb Only one side front fog lamp dose not light 2.
Page 211 4. TURN SIGNAL AND HAZARD WARNING SYSTEM Symptom Suspected Area 1. HAZARD Fuse “Hazard" and “Turn” does not operate 2. Central controller 3. Harness 1. Hazard warning switch Hazard warning lamp does not operate (Turn is normal) 2. Harness 1. Turn signal switch Hazard warning lamp is abnormal (Hazard is abnormal) 2.
Page 212 6. BACK-UP LAMP SYSTEM Symptom Suspected Area 1. Back-up lamp fuse Back-up lamps on both sides do not light up 2. Back-up lamp switch assembly 3. Harness 1. Back-up lamp switch assembly Back-up lamps on both sides remains always ON 2.
Page 213 9. LICENSE PLATE LAMP Symptom Suspected Area 1. Bulb License plate lamp does not light (Tail lamp is normal) 2. Harness 10. REAR TRUNK LAMP Symptom Suspected Area ． Bulb Rear trunk lamp does not light (Room lamp is ． Rear trunk lamp switch normal) ．...
Page 214 Headlamp combinated terminal position diagram 9NB1 9NA1 9NB2 5BA1 9NA2 5BB1 5BB2 9NB3 5BB3 5BA3 9NB4 9NA3 9NB5 9NA4 (a) Inspect light control switch continuity Inspect each terminal for continuity when the switch is on every position according to the table. Switch position Tested terminal Condition...
Page 215 (d) Inspect front and rear fog switch continuity Inspect each terminal for continuity when the switch is on every position according to the table. Switch position Tested terminal Condition 5BB3-9NB4-9NB1 No continuity Front fog lamp 5BB3-9NB4 Continuity Rear fog lamp 5BB3-9NB1 Continuity If it is not as specified, replace the switch.
Page 216 5. DOOE COURTESY LAMP SWITCH ( ON DOOR LOCK ACTUATOR) Inspect door courtesy lamp switch for continuity. Inspect continuity between the terminal and the ground when the switch operates. Switch position Tested terminal Condition ON (The door is well closed) 1 –...
Page 217 8. REAR ROW READING LAMP ASSEMBLY Inspect rear row reading lamp switch assembly continuity Inspect continuity between the 2 terminals when the switch operates Switch position Tested terminal Condition Continuity No continuity If it is not as specified, replace the switch. 9.
Page 218: Section 3 Headlamp Replacement
Section 3 Headlamp Replacement I. REMOVAL 1. Remove front bumper (See bumper replacement). 2. Remove the 3 mounting bolts (A, B, C as shown in the illustration) on the headlamp. 3. Remove the electrical connector. Electrical Connector 4. Move the assembly forwards and upwards then remove it.
Page 219 II.INSTALLATION 1. Install the electrical connector of the headlamp assembly. 2. Install the headlamp assembly and the 3 mounting bolts. 3. Install the front bumper. 4. Adjust the condition of the vehicle. 5. Adjust the headlamp beam. III.HEADLAMP BULB REPLACEMENT 1 - LOW BEAM DUST COVER 2 - HIGH BEAM DUST COVER 3 - TURN SIGNAL LAMP DUST COVER 4 - HEADLAMP HOLDER 1.
Page 220 IV. HEADLAMP BEAM ADJUSTMENT LOW BEAM 1. Adjust the condition of the vehicle. Make sure the body around the headlamp is not deformed Tire inflation pressure is the specified value Park the no-load vehicle on a level spot Sit on the driver's seat and be ready for driving (with a full fuel tank) Put the vehicle in front of a wall, and let it be perpendicular to the wall Ensure the distance from the headlamps to the wall is 10 m Low Beam Lay...
Page 221 V-line V LH V RH Central of the Headlamp Central of the Headlamp Corner Point of Dim and Bright the "Cut-off" Line Cut Line Angle NOTICE: The screw must be tightened when adjusting the headlamps. If it needs loosening for adjusting, you should completely loosen it and then begin to tighten it.
Page 222: Section 4 Front Fog Lamp Replacement
Section 4 Front Fog Lamp Replacement I. REMOVAL 1. Remove the front bumper.(See bumper replacement) 2. Remove the electrical connector. 3. Remove the mounting bolts (A, B as shown in the illustration). Electrical Connection 4. Remove the front fog lamp assembly. II.
Page 223 IV. FRONT FOG LAMP BEAM ADJUSTMENT 1. Adjust the tire inflation pressure with the standard value 2. Start the engine 3. Turn the fog lamp switch ON 4. Adjust the fog lamp beam. Turn the bolt A for adjusting fog lamp beam in vertical direction. NOTES: Turn the screwdriver counter-clockwise to make the light beam up, clockwise make the light beam down.
Page 224: Section 5 Rear Combination Lamp Replacement
Section 5 Rear Combination Lamp Replacement I. REMOVAL 1. Remove rear trunk seal strip and interior trimming. Seal Strip Interior Trimming Buckle and Plug 2. Remove the 3 mounting bolts (A, B, C as shown in the illustration). Electrical Connecto 3.
Page 225: Section 6 High Mounted Stop Lamp Replacement
II. INSTALLATION 1. Install the rear combination lamp and then the 3 mounting bolts. 2. Install the electrical connector. 3. Install the rear trunk interior trim. 4. Install the seal strip. III. REAR COMBINATION LAMP BULB REPLACEMENT 1. Remove the O-ring seal. 2.
Page 226: Section 7 Interior Dome Lamp Replacement
Section 7 Interior Dome Lamp Replacement 1. Gently Pry the lamp shield off at the point a with a screwdriver. Roof Panel Interior Tri m Lamp Body Lamp Shield 2. Remove the 2 mounting bolts with a screwdriver (take care not to touch the bulb). 3.
Page 227: Section 8 Rear Row Reading Lamp Replacement
Section 8 Rear Row Reading Lamp Replacement Roof Panel Interior Trim Rear Reading Lamp (original status) 1. Gently pry the rear row reading lamp off at the point a with a screwdriver (Position 1 as shown in the illustration). 2. Pull out the rear reading lamp downwards with an angle (Position 2 as shown in the illustration) 3.
Page 228: Chapter 6 Audio System
Chapter 6 Audio System Section 1 Audio System Description Description: 1. Radio Wave Band The radio wave bands used in radio broadcasting are as following: Frequency 30KHZ 300KHZ 3MHZ 30MHZ 300MHZ Band Radio wave Amplitude modulation Frequency modulation Modulation LF: Low frequency MF: Medium frequency HF: High frequency VHF: Very High frequency...
Page 229 (2) Multipath transfer Noise caused by bouncing of radio waves off Multipath obstructions is called "multipath transfer". Transfer Multipath transfer occurs when a signal from the broadcast transmitter antenna reflects off buildings and mountains and interferes with the signal that is received directly. (3) Fade out Because FM radio waves are of higher frequen- Fade out...
Page 230 tion Problems". 5. COMPACT DISC PLAYER Compact Disc Players (hereinafter referred as CD) use a laser beam pick--up to read the digital signals recorded on the CD and reproduce analog signals of the music, etc. HINT: Never attempt to disassemble or oil any part of the player unit. Do not insert any object other than a disc into the disc box.
Page 231: Section 2 Audio System Connector Terminal Layout
Section 2 Audio System Connector Terminal Layout 1. Connector terminal layout on wire harness 2. Connect terminal definition Terminal Function Wire color Condition Standard Voltage Wave form is synchronized with The audio system is on the output sound Wave form is synchronized with The audio system is on the output sound Ignition switch turned to ACC 10 ～...
Page 232: Section 3 Audio System Inspection
Section 3 Audio System Inspection I Troubleshooting Symptom Suspected Area Radio not operating when power switch 1. Radio assembly circuit faulty turned to “ON”. 2. Radio assembly The radio backlight does not light up with 1. Radio assembly backlight terminal the illumination switch ON 2.
Page 233 II. Inspection 1. Power switch system doesn't work Wiring Diagram Radio and CD Main Fuse Box Ignition Switch Fusible Link Box Battery (1) Check radio assembly (+B, ¬ACC, ¬GND) Check the continuity between terminals under each operating condition as shown in the table below Standard: Tester connection Condition...
Page 234 2. The radio backlight does not light up with the illumination switch ON Wiring Diagram Light Control Switch Radio and CD Main Fuse Box Fusible Link Box Battery Battery (1) Check radio assembly (TAIL) Check the voltage between terminals under each operating condition as shown in the table below. Standard: Tester Connection Condition...
Page 235 3. Speaker soundless in all modes Wiring Diagram Main Fuse Box Radio and CD Ignition switch Left Rear Speaker Fusible Link Box Battery Right Rear Speaker Left tweeter Speaker Left Front Speaker Right Front Speaker Right tweeter Speaker (1) Check LCD (Liquid Crystal Display) illumination Turn ignition switch to ACC Connect radio assembly continuity Switch on position lamp...
Page 236 (3) Tweeter speaker assembly inspection Disconnect speaker connector Check resistance Notice: Do not remove the speaker during inspection. Ω Standard Value: 4 ¸ Abnormal Replace tweeter speaker assembly NORMAL Check wire harness and connector (4) Check front speaker assembly Disconnect speaker connector Check resistance Standard Value: 4Ω...
Page 237 4. Unable to receive radio broadcast (poor reception) (1) Check if the radio auto-research function works Perform the radio auto-research function to see if it works Normal: Check and replace radio assembly Abnormal: Check the antenna for noise (2) Check the antenna for noise Turn on radio to AM with the ignition switch ACC.
Page 238 (4) Check if the radio auto-research function works Perform the radio auto-research function to see if it works Standard: The operation works. Normal: Check and replace radio assembly Abnormal: Check radio assembly (+B, ACC, GND) (5) Check the radio assembly (+B, ACC, GND) Check the continuity between terminals under each operating condition as shown in the table below.
Page 239 7. Poor sound quality only when playing tape (1) Replace it with another tape and re-check Replace the faulty tape with working tape to see if the same fault will re-occur. Standard: The fault is cleared Normal: There is something wrong with the tape Abnormal: Check for foreign object (2) Check for foreign object Check the radio assembly and the cassette player for foreign objects or defects.
Page 240 9.CD can not eject after inserted (1) Check if the CD box power supply is NORMAL Turn the ignition switch to ACC Check the continuity between the CD box terminals under each operating condition as shown in the table below Standard: Tester connection Condition...
Page 241 Check the voltage between terminals under each operating condition as shown in the table below. Tester Connection Condition Standard Status +B - GND Constant Status 10 ～ 14V ACC - GND Ignition switch ACC or ON 10 ～ 14V Abnormal: Repair or replace wire harness and connector Normal: Check and replace radio assembly 10.
Page 242 (4) Replace it with another CD and re-check. Replace the faulty CD with working CD to see if the same fault re-occurs. Standard: The fault is cleared Abnormal: There is something wrong with CD Normal: Check if the radio auto-research function works (5) Check if the radio auto-research function works Perform the radio auto-research function Standard: The fault is cleared.
Page 243 Abnormal: Repair or replace wire harness and connector Normal: Check and replace radio assembly 11. Sound quality poor only when playing CD (Volume faint) (1) Replace it with another CD and re-check Normal: CD failure Abnormal: Replace the disc box (2) Replace the disc box Normal: Box damaged Abnormal: Check and replace radio assembly...
Page 244 Standard: Installation correct Abnormal: Install CD box correctly Normal: Has suddent emperature change occurs inside the disk cabin? (6) Has sudden temperature change occurs inside the disk cabin? Check if sudden temperature change occurs inside the disk cabin? Standard: Sudden temperature change occurs inside the disk cabin. Description: Formulation of dew condensation inside the CD player is due to temperature changes.
Page 245: Section 4 Audio And Video System Replacement
Section 4 Audio and Video System Replacement I. Notice on operation Please explain to the customer that the AM/FM broadcast channel information will be cleared when remov- ing the battery negative terminal cable. Record the channel information before removing the negative termi- nal cable if necessary.
Page 246 Antenna Assembly Antenna Cable Tweeter Rear Speaker Assembly Front Speaker Assembly...
Page 247 II. Radio assembly 1. Remove the intermediate instrument panel (See interior trim) 2. Remove the radio assembly Remove 4 bolts Disconnect connector III. Front speaker assembly 1. Remove front outside rear view mirror cover 2. Remove door handle 3. Remove the front door power window switch assembly 4.
Page 248 VII. Overhead antenna assembly 1. Remove the roof interior trim 2. Disconnect connector 3. Remove antenna nut 4. Remove the overhead antenna assembly VIII. CD, DVD 1. Remove the left side rear trunk interior trim 2. Disconnect connector 3. Remove 4 bolts and disc box...
Page 249: Chapter 7 Srs (Supplemental Restraint System)
Chapter 7 SRS (Supplemental Restraint System) Section 1 SRS-General Information I. PRECAUTION For safe reasons, read the following precautions before starting any operation. 1. When servicing the SRS, correct sequence and items are described in the following chapter. 2. Instruments and special tools recommended in this chapter shall be used for operation. 3.
Page 250 DAB Lo Driver airbag, low position 13 (Option) PAB Hi Passenger airbag, high position 14 (Option) PAB Lo Passenger airbag, low position Passenger Airbag Deactivation Passenger airbag deactivation indicator light Indicator PPD/ Passenger Airbag Passenger airbag deactivation switch, high position Deactivation Switch, High Crash Output Crash output...
Page 251 II. TEST INSTRUMENTS Instrument Designation Usage Diagnostic detector Check system troubles of the SRS, and (Hi-DS T Scan meter) clear the DTC of ECU Special diagnostic meter III. TROUBLESHOOTING 1. Basic process of trouble diagnosis DTC of the present fault may coexist with that of the history fault. NOTICE: After the new SRS ECU is installed, the warning light of the SRS, with the ignition switch ON, will be on for 6s and then go out permanently, indicating SRS works normal.
Page 252 4. Trouble Identification (1) Trouble Record (DTC storage) When the circular diagnostic tests are involved in identification of a trouble, the SRS ECU (HAE2.5) will store relevant codes, first/last diagnosis time and frequency of the trouble in EEPROM. SRS ECU (HAE2.5) can store up to 6 troubles, low voltage trouble as well as two crash records (front and side).
Page 253 C ommunication trouble Y e s Internal trouble (se e the follow ing ta ble) N o (replace SR S EC U (H A E2.5)) P A D S （ pa ssenger airbag de activation sw itch ） , connected to pow er sourc e or ope n Y e s circuit P A D S （...
Page 254 Ignition circuit 4 (passenger seat belt pretensioner), low resistance B1 368 or short circuit Ignition circuit 4 (passenger seat belt pretensioner), ground B1 369 Ignition circuit 4 (passenger seat belt pretensioner), connect to B1 370 power source High voltage of power source B1 111 Low voltage of power source B1 112...
Page 255 An external watchdog can check the operation situation of the microcontroller. The failure of the microcontroller can trigger the watchdog, which in turn can reset the microcontroller and turn on the warning light. [Table] Internal troubles predicted by SRS ECU (HAE2.5) List of Troubles Trouble Description Microcontroller...
Page 256 (3) Clear DTCs When ECU diagnostic tester (Hi-DSTM) receives the "Clear DTCs" command from the serial interface, the DTCs stored in ECU will be cleared off. But if an internal DTC is recorded or there is one crash record, the command will not be executed. 5.
Page 257 (2) Trouble indication In case of a trouble, the warning light will indicate. If the external trouble is a history trouble, the indication will be cancelled. When the history trouble happens for no less than 5 times, the indicator light will remain on even if there is no more trouble.
Page 258: Section 2 Troubleshooting
Section 2 Troubleshooting I. LIST OF TROUBLES Troubleshooting Items Description SRS warning light is OFF SRS warning circuit trouble. SRS warning light remains on SRS warning circuit trouble or external trouble. 1. SRS warning light OFF Trouble Checking Status Possible Cause ·Loss of voltage (fuse circuit break) ·Instrument cluster trouble SRS warning light OFF SRS warning circuit trouble...
Page 259 (3)Check the connection between ECU and instrument cluster Turn the ignition switch to LOCK. Disconnect the negative (-) terminal cable from the battery. Disconnect the connector of instrument cluster. Check if the related circuits of the warning light are connected or not. Yes: continue with next step.
Page 260 Yes: continue with next step. No: check the circuit, repair it and continue with step (5). Turn the ignition switch to LOCK. Check the continuity of the terminal of instrument connector and that of diagnostic interface (check the two ends of K line). Yes: continue with next step.
Page 261 3.Internal trouble DTC B1620 Internal trouble of SRS uni Checking Conditions CAUTION ● Condition for running the DTC is to inspect the diagnostic trouble code that may not appear prior to this test. Performing this test may results in body injury or damaged system due to misoperations.
Page 262 (3) Check the wire harness between the fuse box and the connector of the SRS unit CAUTION If it is not handled properly, the airbag assembly may be triggered and deployed, leading to serious injury to a person. Therefore, prior to handling, read the service cautions carefully. See service cautions for SRS. Turn the ignition switch to LOCK.
Page 263 DIAGNOSTIC PROCEDURES (1) Check clock spring CAUTION If it is not handled properly, the airbag assembly may be triggered and deployed, leading to serious injury to a person. Therefore, prior to handling, read the service cautions carefully. See service cautions for SRS. Do the related parts of the clock spring work normal? (Are the pins correctly correlated? There should be no unnecessary short or open circuit, etc).
Page 264 Remove left trim plate. Loosen all the SRS unit connectors. Check the wire harness between the connector terminals of SRS unit and that of clock spring for the following: Ground. Short circuit with power supply. Open circuit. Is the above-mentioned wire harness normal? Normal: completion of trouble diagnosis, and install all the parts.
Page 265 Turn the ignition switch to LOCK. Loosen the negative terminal cable from the battery and wait for over 1 minute. Remove the glove box. Loosen the passenger airbag assembly connectors. Is the connector of the passenger airbag assembly normal? Normal: [DTC of present trouble] Continue with next step.
Page 266 III. DIAGNOSIS OF CRASHED VEHICLEs Whether the SRS is deployed or not, the checking and maintenance of the crashed vehicle shall be carried out according to the following procedures. 1. Check the diagnostic signal of ECU (1) Connect the check connector of the Hi-DS T Scan Meter. (2) Read out the diagnostic results from Hi-DS T Scan Meter.
Page 267 (4) Check the installation status of the airbag assembly. NOTICE 1. Work must be started 60s after the negative (-) terminal cable is disconnected from battery. The disconnected negative (-) terminal cable shall be protected with insulating tape for insulation. 2.
Page 268 IV. WARNING MARKS When using or maintaining an airbag, the warnings shall be indicated. When maintaining, proceed in accor- dance with the description of mark. In addition, if the mark is damaged or stained, it shall be replaced. 1. Driver airbag assembly, see Fig. 1. 2.
Page 269: Section 3 Removal & Installation
Section 3 Removal & Installation I. SRS ELECTRONICAL CONTROL UNIT (ECU) 1. Operations prior to Removal (1) Turn the ignition switch OFF. (2) Remove negative (-) terminal cable of the battery. Put it in a proper position or wrap it up with insulating tape.
Page 270 5. Check: ECU case for pitting, crack and distortion. The joint for damage and distortion. For other ECU checkings, see Troubleshooting. NOTICE If pitting, crack or distortion is found on an ECU, replace it with a new one. II. AIRBAG ASSEMBLY & CLOCK SPRING 1.
Page 271 5. Installation procedures of clock spring: (1) Pre-Check Thread the line at the upper end of the clock spring through hole on the body part of the steering wheel Connection and fixation of the clock spring and steering wheel (2) Install the upper hood of the combination switch (3) Install the steering wheel (4) Install the airbag assembly components (5) Connect the negative (-) terminal cable of the battery...
Page 272 III. KEY POINTS FOR INSTALLATION 1. Pre-Check (1) The new airbag or clock spring shall be checked before being installed. (2) Connect negative (-) terminal cable of the battery. (3) Connect Hi-DS T to the diagnostic interface (16 connector). NOTICE In case of scrapping an airbag, it shall be noted that the airbag shall be deployed according to the specified procedures before being scrapped.
Page 273 4. Check after installation (1) Slightly rotate the steering wheel left and right, make sure that there is no abnormality or noise. (Driver airbag module, clock spring) (2) Turn the ignition switch ON. (3) The warning light goes on within 6s, and then goes out. (4) The trouble shall be eliminated if the warning light remains on when the ignition switch is turned on or after it goes out after 6s.
Page 274 (5) With reference to the figure below, insert thin probes into the current tester to check the conduction of the terminals. NOTICE Never insert probe directly from the lower end of the connector. V. KEY POINTS FOR SCRAPPING THE AIRBAG ASSEMBLY The airbag shall be deployed according to the following procedures before scrapping the airbag assembly or a vehicle installed with an airbag.
Page 275 Disconnect the positive (+) and negative (-) terminal cables from the battery and remove the battery from the vehicle. The airbag assembly shall be deployed according to the following procedures. NOTICE Work must be started 60s after the positive (+) and negative (-) terminal cables are detached from battery. (2) Driver airbag assembly Remove the knee bolster.
Page 276 After the driver airbag is deployed, the gas generator is of high temperature. Keep it for 30 minutes until it gets cool for use. If the driver airbag assembly cannot be deployed, discuss the problem with the local Geely service station. The deployed driver airbag assembly shall be scrapped according to the scrapping procedures.
Page 277 Prepare two 6m plus wire harnesses for deployment, connect the other two ends to avoid unexpected deployment in case of static electricity (see the figure below). Wire Harness for Deployment Short Circuit Locatio n 6m plus Touch the body of the vehicle with hands for static electricity elimination. NOTICE: The above-mentioned procedures can prevent the unexpected deployment due to static electricity and shall therefore be performed strictly.
Page 278 Put three old tires without hubs onto the tire used to fix the driver airbag assembly (see the figure below). Old Wheels without Hub Wire Harness for Deployment Try to disconnect at a location far away from the vehicle the connector of the wire harness for deployment of the driver airbag assembly, connect with the two terminals of the battery removed from the vehicle and deploy the airbag (see the figure below).
Page 279: Chapter 8 Mk-20 Abs System
Chapter 8 MK-20 ABS System Section 1 ABS Diagnosis I. Check the ABS Warning Light 1. Check the ABS Warning Light goes on as the following: Turn the ignition switch to ON, the ABS Warning Light goes on for about 1.7 seconds and then goes off. If the above condition is not satisfied, it indicates that there is a fault, please check the DTC.
Page 280 IV. DTC Display Method System Problem Code Displayed Never happened before No DTC There is no problem current ABS Warning Light does not light up ） Happened before Occasional DTC Never happened before Non-occasional DTC The problem still exists （ ABS Occasional DTC and Non- Warning Light goes on ）...
Page 281 VI. Troubleshooting Quick Index Inspection Reference Fault Description Diagnosis Result Table No. Page 65535 Damaged 1276 ABS hydraulic pump Motor can not operate LF Wheel Sensor RF Wheel Sensor Electrical or mechanical 2,3,4 fault LR Wheel Sensor RR Wheel Sensor 1044 ABS programming error Power supply terminal 30...
Page 282 VIII. ABS ECU Connector Pin Layout ABS ECU Connector (End Views) Electrical Wiring Diagram Combination Meter ABS Warning Light Drive Module ABS ECU...
Page 283: Section 2 Abs System Check
Section 2 ABS System Check I. DTC Problem Inspection Table DTC 01276 Like ly Caus e s Power supply is disconnected or grounded [De s cription] When the vehicle speed exceeds Motor wire harness is disconnected 20km/h, ABS ECU detects that the motor can not Motor is damaged operate normally and record this DTC.
Page 284 DTC 00283,00285,00283,00285, Like ly Caus e s 00287,00290 The sensor is not installed inadvertently [De s cription] When no open in the circuit can Short circuit in the sensor coil or wire harness be detected and there is no signal output when Excessive big clearance between the sensor and the vehicle speed exceeds 20km/h, this DTC is the ring gear...
Page 285 DTC 00283, 00285, 00287, 00290 Likely Causes The intermittent poor connection or short circuit of [Description] When the vehicle speed exceeds the sensor coil or wire harness 20km/h, if the sensor signal goes beyond the Excessively big or small clearance between the tolerance range, this DTC is set.
Page 286 DTC 00283, 00285,00287, 00290 Likely Causes [Description] When there is recognized open Open circuit in the sensor connector or coil or short circuit in the sensor, this DTC is set. Short circuit in the sensor coil [Hint] The likely cause may be the poor The sensor connector or wire harness is short to connection of the sensor, short circuit in the coil ground or power supply...
Page 287 DTC 01044 Likely Causes ABS wire harness pin connection error [Description] When the ECU programming is ABS ECU programming error not consistent with the ABS wire harness pin connection, this DTC is set Use the scan meter to check whether the ABS ECU programming is correct Reprogram Correct: 01901...
Page 288 DTC 00668 Likely Causes ABS system fuse is broken [Description] When power supply terminal 30 Battery Voltage too low or high does not supply the voltage or the voltage is too ABS wire harness connector is damaged high, this DTC is set. ABS ECU is damage Abn.
Page 289 DTC 01130 Likely Causes [Description] High frequency electromagnetic wave interference When ABS is affected by high Damaged sensor or its wire harness frequency electromagnetic wave or the micro- Damaged ABS ECU processor determines that the input vehicle speed is suspect, this DTC is set Abn.
Page 290 II. Non-DTC Problem Inspection Table 1 With ignition switch ON (Engine Off), Likely Causes the ABS warning light does not go on Burned fuse [Description] ABS Warning Light does not go ABS Warning Light Bulb burned on, the likely cause may be the open in the Power supply circuit open warning light power supply circuit, burned bulb ABS Warning Light Drive Module damaged...
Page 291 2 After the engine is started, ABS Likely Causes Warning Light is normally on [Description] One of the Likely Causes is that The warning light drive module is damaged ABS warning light drive module is damaged or ABS warning light drive module circuit open there is an open in the ABS warning light ABS ECU is damaged circuit.
Page 292 3 Abnormal ABS operation Likely Causes [Description] Improperly installed sensor It is in close connection with the Sensor wire harness faulty driver status and the road conditions and is Damaged sensor difficult to diagnose. However, if there is no Damaged ring gear DTC memory, the following inspections can be Foreign objects in the sensor performed.
Page 293 Excessively long brake pedal stroke Likely Causes Brake fluid leakage [Description] Visually inspect whether there Air in the system is leakage or mechanical fault. Use bleeding Brake disc severely worn method to check whether there is air in the Brake fluid level switch faulty system.
Page 294 5 The Pedal must be depressed heavily Likely Causes Boost faulty [Description] Use traditional method to check Normally-close valve faulty the booster and the brake pedal stroke. Scan meter HCU function can be used to check the fault of the normally-open valve Abn.
Page 295 6 No DTC output （ can not Likely Causes communicate with the scan meter ） Burned fuse [Description] It may be the ABS ECU power Diagnosis wire broken or connector disconnected supply circuit or diagnosis wire circuit that can Damaged ABS ECU not communicate with the scan meter Scan meter faulty Can the scan meter commu-...
Page 296 III. ABS System Check Ignition Item Terminal Pole Standard Unit Switch Shift Battery Voltage 25-8 10.1 ～ 14.5 Battery Voltage 9-24 10.1 ～ 14.5 （ solenoid valve ） Power supply 0.00 ～ 0.5 insulation Ground insulation 8-24 0.00 ～ 0.5 Power supply 10.1 ～...
Page 297 Item Key Switch Action Standard Notes Note: The vacuum booster must have vacuum applied when performing the following inspection. When LF wheel can not Normally-closed Depress the pedal rotate, the pedal does LF Wheel valve inspection not descend normally-open ON （ two valves and closed valves LF wheel can rotate and pumps are...
Page 298 IV. ABS Operation Inspection 1. Check the Wheel Speed Sensor Output Voltage Check whether the clearance between the wheel speed sensor and the ring gear is within the specification For front wheel standard value, refer to "Front Wheel Sensor Installation Drawing" For rear wheel standard value, refer to "Rear Wheel Sensor Installation Drawing"...
Page 299: Section 3 Removal And Installation
Section 3 Removal and Installation I.Precautions for Removal 1. Use the scan meter to locate the fault causes before proceeding to service. 2. wipe the surface clean with the cleaning agent without mineral oil before service; be careful to keep it clean during service, only the lint-free cloth can be used to wipe the removed parts.
Page 300 8. Remove the whole HECU from the bracket. ABS HECU Assembly ABS HECU Brake Pipe Removal Schematic...
Page 301 III. HCU Replacement 1. Depress the retaining clip on the union joint side and remove the cylinder motor wire harness. 2. Remove the 4 screws as shown in the figure, the removed old screw can not be reused. 3. Separate the HCU from the ECU. 4.
Page 302 V. ABS Assembly Reinstallation Note: the plug of the ABS assembly hydraulic outlet can only be removed after the brake pipe is installed, lest the foreign object will enter the brake system. 1. Install the ABS assembly to the bracket, tighten the torque: 20+4Nm. 2.
Page 303 VII. Fill the liquid and bleed After replacing the HECU, bleed the second HECU circuit in addition to the filling and bleeding of the regular brake system. Use the scan meter to perform the following procedure: Fill the fluid and bleed based on the regular brake system until there is no air bubble in the transparent hose Connect the scan meter with the diagnostic interface Select function 04, Press OK button to confirm...
Page 304: Part Iv Air Conditioner And Inside & Outside Trim
Part IV Air Conditioner and Inside & Outside Trim Chapter 1 A/C System A/C system consists of refrigerating and heating system. The Refrigeration system mainly comprises compressor, condenser and evaporator. The refrigerant circulation absorbs the heat in the air and discharge the vapour to lower the temperature in and dehumidify the compartment.
Page 305 evaporator (6) via the expansion valve (5) for compression and generates high temperature and pressure vapor which then is cooled into liquid through the condenser (2) and dried in the receiver/drier (3), then restrict the expansion valve and enable certain amount of refrigerant liquid to be vapored into low tempera- ture and pressure vapor in the evaporator, meanwhile, absorb large amount of heat and perform heat ex- change with the air sucked in by the blower, then distribute the cooled air to the vehicle compartments.
Page 306: Section 2 Heating System
Section 2 Heating System Heating system uses mixed temperature adjustment which controls both cold and hot air and is featured in outstanding temperature adjustment performance. The cold and hot air can be completely mixed at each outlet and achieve continuous temperature adjustment. The air duct arrangement on the instrument panel is shown in Figure 2.
Page 307 1. Heating System Parameter Heating system radiating power, blower fan diameter, power dissipation and heater radiator dimension are show in the table 2. Table2 Heating System Parameter Dissipation Power/W 4000 Air Flow/(m Power Consumption /W Fan Diameter/mm Overall Radiator Dimension 159.4mm×140mm×49mm 2.
Page 308 4. Heater Hot Wind Location Linkage Cold Wind Location Radiator Core Radiator Core Foot Outlet Temperature Adjustment Door Working Principle To Defroster To Front Outlet Radiator Core Foot Outlet Radiator Core To Front Outlet To Defroster Foot Outlet Figure 5 Heater Door Control Diagram The heater comprises the heater radiator (heat exchanger), the plastic case forming the air duct, connecting rods adjusting different air ducts and the door.
Page 309: Section 3 A/C Controlling System
Section 3 A/C controlling system I. Introduction and Composition In order to ensure the effective opeation of the A/C system in any operating condition, some advanced electric control devices are used to protect the A/C system in adverse engine operating condition. The electrical control part consists of: A/C switch, relay, evaporator temperature sensor, water temperature sensor, pressure switch, ECU...etc.
Page 310 Color of wire: R-Red Bl-Blue Y-Yellow Lg-Light green Br-Brown B-Black P-Pink G-Green W-White Gr-Gray 1. Battery 2. Main Fuse Box 3. Alternator 4. Ignition Switch 5. Idle Rise Valve 6. Blower 7. Relay 8. Blower Regulating Resistance 9. Blower Switch 10. A/C Switch 11. A/C Low Pressure Switch 12.
Page 311: Section 4 Service Caution & Notice
Section 4 Service Caution & Notice I. Service Caution Refrigerant Treatment • During the treatment, the operator shall be careful not to inhale A/C refrigerant or lubricant vapor. Long- term exposure to the A/C environment will cause the operator's eye, nose and throat liable to stimulation. In addition, based on the consideration on the environment influence, when discharging the HFC-134a from the A/C system, we suggest using the recyclable and rechargeable devices.
Page 312: Section 5 The Refrigeration System Operation Procedure
• Compared with the early used mineral oil, the SW-100 type compressor oil is of comparatively high moisture absorption performance. If you mix the moisture object with the SW-100 type compressor oil, it will damage the Refrigeration system. Therefore, after treating the compressor oil or removing the refrigeration system components, the lid shall be covered immediately to prevent the SW-100 type compressor oil from absorbing the moisture.
Page 313 3. Check for leakage if the reading changes and vacuumize it again. 4. Refill the new HFC-134a refrigerant if the reading doesn’t change. Fill the new HFC-134a refrigerant 1. Connect the intermediate pipe to the refrigerant steel jar. 2. Open the refrigerant steel jar valve. 3.
Page 314 Check For Leakage: 1. Using leak detector, check refrigerant steel jar for leakage. • Go to Step 3 if there is no leakage. • Tighten the union joint if there is leakage at the loosened union joint and go to next step. 2.
Page 315: Section 6 Basic System
Section 6 Basic System 1. Blower Removal / Installation 1. Disconnect the negative (--) terminal cable from the battery. 2. Remove instrument panel. 3. Remove motor connector. 4. Remove the resistor connector. 5. Remove the band. 6. Remove bolt. Remove blower. 7.
Page 316 5. Remove evaporator. 6. The installation is in the reverse order of the removal. The Evaporator Installation Guide 1. Pack certain SW-100 compressor oil into the refrigerant circuit when installing a new evaporator. Refill: (approximate) 15ml {15 cc, } Check Evaporator 1.
Page 317 4. A/C Compressor Removal / Installation 1. Disconnect the negative (--) terminal cable from the battery. 2. Drain the refrigerant from the system. 3. Detach the radiator. 4. Loose the drive belt and then remove the drive belt. Notice: • If anything moisture or any foreign matter enters into the Refrigeration system for circulation, the cooling performance of the Refrigeration system will obviously deteriorate with abnormal noise.
Page 318 Check the condenser 1. Check for crack, damage or oil leakage. • Replace the condenser if any of the above-mentioned faults occurs. 2. Check if the fin area is blocked by dust. • Clean it if it is blocked. 3. Check if the fin area bends. •...
Page 319 Introduction Of The Refrigeration Pipeline Installation: 1. It is recommended to fill some SW-100 compressor oil into the refrigerating circulation when installing a new refrigeration pipe or cooling hose. Refill: (approximate) 5ml{5 cc}: Refrigeration pipe 10ml{10 cc}: Condenser hose 2. Fill compressor oil to O-ring and other connecting points. 3.
Page 320: Section 7 A/C System Faults Check & Troubleshooting
Section 7 A/C System Faults Check & Troubleshooting I. A/C System Faults Check Inspection shall be made to isolate the fault area and its cause when the fault of A/C system occurs, and then specific service could be performed. Inspect the whole system before re-using A/C system after a long term of storage.
Page 321 Have a focus inspection on the following area: a. Each pipe union joint and valve connection. b. All hose, especially near the pipe union. c. Compressor shaft seal, front and rear cover, gasket, oil fill plug. d. Area on the surface of the condenser and evaporator that is scratched, bruised or damaged. e.
Page 322 II. A/C System Diagnosis and Troubleshooting Table 1 Problem Sy mp tom Possible Cause Troubleshooting Drain p roper amount of × × × × Excessive refill of refrigerant refrigerant Rep air the gas leak area, refill × × × × Too little refill of refrigerant p roper amount of refrigerant Rep air the gas leak area, refill...
Page 323 Problem Symptom Possible Cause Troubleshooting Dirt in the evaporator core, or poor fit between the Check and correct it expansion valve sensing unit and evaporator outlet Non-evaporated refrigerant Service the evaporator and its × × × × × steam enters into compressor components such as fan expansion valve opening is Adjust the expansion valve,...
Page 324 Table 2. Problem Cause and Troubleshooting of No Heating: Area Problem Cause Troubleshooting Water temperature sensor damaged Repair or replace Blower motor does not rotate Repair or replace Fan speed adjustment switch damaged Replace Output air temperature adjustment switch damaged Replace Table 3.
Page 325: Chapter 2 Inside & Outside Trim And Accessory
Chapter 2 Inside & outside Trim and Accessory Section 1 Configuration Index (I) Outside Trim And Front Accessory Door handle Windshield Front fender Radiator grill assembly (See the engine hood adjustment) Front bumper Front mudguard skirt (See front bumper removal/installation) The engine hood Fuel fill port cap (See the engine hood...
Page 326: (Ii) Outside Trim And Rear Accessory
(II) Outside Trim and Rear Accessory Rear trunk lid (See rear trunk lid removal/installation) Outer door sill under the trim board Rear trunk lid inside trim and accessory (See rear trunk lid removal/installation) Rear windshield Quarter Window glass Rear license box Rear door weatherstrip (See rear trunk lid (See rear door removal/installation)
Page 327: (Iii) Front Inside Trim
(III) Front inside trim A- pillar inside trim Front door insdie trim Instrument panel assembly Front door sill inside trim A/C panel assembl Glove compartment assembly Steering column cover Front end of auxiliary console Instrument panel end shield Auxiliary console assembly Electric outside rear view mirror Lower end shield assembly Front door power window switc...
Page 328: (Iv) Rear Inside Trim
(IV) Rear inside trim Inner rear view mirror Rear doorinside trim Interior lamp C- pillar upper inside trim Rear seat belt buckle (See rear seat belt buckle A- pillar inside trim removal/installation) rear trunk inside trim Sun visor Rear trunk lower trim cover B- pillar upper inside trim Lower rear trim assembly Rear seat...
Page 329: Section 2 Inside & Outside Trim And Accessories Removal And Installation
Section 2 Inside & Outside Trim and Accessories Removal and Installation (I) Front Bumper The structure is as shown in the figure below: 1. Front Bumper 2.Front Bumper Fixed Screw 3.Secondary Bumper Assembly Upper Buckle and Plug 4.Mounting Plate Cross Head Counter Sunk Self-tapping Screw 5.Mounting Plate Cross Head Counter Sunk Self-tapping Screw 6.Front Bumper Mounting Bracket to Body Bolt...
Page 330 1. Front Bumper Removal and Installation (1) Disconnect the negative (--) terminal cable from the battery. Disconnect fog lamp wire; (2) Remove the mudguard skirt to front bumper clip; (3) Remove the attaching bolt of the the front fender and panel and the front bumper sub-assembly; (4) Remove the front bumper set screw and the clip.
Page 331: (Ii) Engine Hood
(II) Engine Hood Engine Hood Removal / Installation For engine hood installation, see the figure Engine Hood Gas Spring Brace Engine Hood Hinge Engine Hood Lock Control Cable Engine Hood Lock Engine Hood Installation Illustration 1. Removal Warning • It is dangerous to remove the engine hood without support. The engine hood may drop and result in body injury.
Page 332 3. Engine Hood Adjustment Fix the engine hood to the engine hood hinge with bolts. the engine hood in vertical direction through the hinge hole. Vertically adjust the front by adjusting the engine hood bumper and adjust the engine hood master lock striker.
Page 333: (Iii) Outside Rear View Mirror
(III) Outside Rear View Mirror Attach the outside rear view mirror to the left and right doors. Integrate the outside rear view mirror with the body smoothly using specially designed rubber bushing to make it a whole. The forward and rearward folding of the rear view mirror will not be affected after being knocked.
Page 334: (Iv) Rear Trunk Lid
3.Rear trunk Lid Hinge Retainer Mounting Nut 4.Rear trunk Door Hinge Cushion 5.Rear trunk Lid Outer Panel And Reinforcement Assembly 6.Geely Logo 7.Rear License Plate Assembly 8.Rear License Plate Assembly Mounting Nut 9.Rear trunk Lid Weatherstrip 10.Rear trunk Lid inside Trim Board 1 1 . R e a r trunk Lid Cushion 12.Rear trunk Door Lock Cylinder Assembly 13.Rear trunk Lid inside Trim Board Clip...
Page 335 1.Rear trunk Lid Removal/Installation Warning It is dangerous to remove the rear trunk lid spring before supporting the rear trunk lid. The rear trunk lid may drop and result in body injury. Fully open the rear trunk lid, support the rear trunk lid before removing the brace.
Page 336: (V) Rear Bumper
(V) Rear Bumper The structure diagram is shown as the figure below: 1.Cross Pan Head Tapping Screw And Big Washer Set 2.Cross Pan Head Screw (GB973 M6X16) 3.Cross Pan Head Screw (GB973 M6X16) 4.Rear Bumper 5.Clip 6.Rear Bumper Reinforce- ment Assembly 7.Rear Bumper Mounting Bracket Assembly 8.Hexigon Bolt and Spring Washer Set 9.Hexigon Bolt Spring and Flat Gasket Set...
Page 337 2.Notice On Removing The Rear Bumper (1) Pull the rear bumper out to separate it from the bumper rail. Warning If only one side of the rear bumper is separated from the bumper rail, the bumper may drop and result in body injury. Be careful not to make the bumper drop before separating the rear bumper from the bumper rail.
Page 338: (Vi) Seat Removal, Installation And Adjustment
(VI) Seat Removal, Installation and Adjustment Front Seat See Figure Disassembly of Front Seat 1.Headrest Assembly 2. Headrest Support 3.Snap Ring 4.Front Seat Backassembly 5.Front Seat Back Cover 6.Cap Nut 7.Front Seat Coupling Plastic Gasket 8.Track Assembly 9.Front Seat Cushion Cover 10.Front Seat Cushion Assembly 11.Adjuster Assembly 12.Adjuster Hinge Cover...
Page 339 Remove the snap ring under the seat cushion. Open the front seat cushion cover. Remove the inner coversnap ring. Remove the seat cushion cover. Non-LOCK Remove bolts Remove the Headrest and Bracket Remove the Front Seat Adjuster Hinge Cover Adjuster Assembly Track Assembly Remove the Track and Adjuster Assembly Remove the Seatback Snap Ring and Set Bolt...
Page 340 Install the headrest; Install the front seat with 4 tightening bolts. Torque: 14.72~23.52N.m. Install Headrest Support Install Front and Rear Seat Snap Ring Adjuster Assembly Track Assembly Assemble the Seatback and Cushion Install Adjuster and Track Assembly 3.Adjust The seat can adjust tilt angle forward in torque 2° x 5=10°; Adjust backwards 2°...
Page 341 Remove the snap ring from the rear seat back. Open the seat back cover. Remove the inside snap ring. Remove the seat cover. Seatback Lock handle Handle Seat Remove Rear Seatback Assembly Remove Seatback Handle and Seat Remove Seatback Cover Remove Seatback Set Bolt Re-assembly a.
Page 342: (Vii) Seat Belt
(VII) Seat Belt The vehicle seat belt is compulsory for drivers and passengers for safety purpose. It is the facility to prevent the passengers from being hurt or reduce the possibility of being hurt when the vehicle is in emergent drive or traffic accident occurs.
Page 343 2. Retractor The retractor is pre-tensioner. The retractor will pre-tension the seat belt when something emergency hap- pens to prevent passengers from being hurt. It can sense the vehicle acceleration and the acceleration of the belt being pulled out. The retractor belt can be pull out and drawn back freely. It will not be locked at 12° around the safety position, but locked at over 27°.
Page 344 (8) Make sure the warning light of the airbag system on for 6s and off. If the warning light of the airbag system is not as specified, it means system fault. Check with the OBD (on- board diagnostics). 4.Rear Seat Belt Removal / Installation Warning Do not remove retractor.
Page 345: (Viii) Instrument Panel And Auxiliary Console
(VIII) Instrument panel and auxiliary console 1. Instrument Panel Removal / Installation (1) Disconnect the negative (--) terminal cable from the battery. (2) Remove the instrument panel compartment. (3) Remove the front and rear auxiliary console. (4) Remove combination meter panel. (5) Remove instrument cluster.
Page 346 2. Instrument Panel Removal/Installation (1) Remove the airbag actuator at the driver side. (2) Remove the intermediate instrument panel. (3) Remove the audio device (4) Remove A/C control mechanism. (5) Remove in the order below in the figure. (6) The installation is in the reverse order of the removal. Torque: 18.6--25.5 N.m instrument panel wire harness instrument panel cross member...
Page 347 3.Side Panel Removal/Installation (1) Using the flat screwdriver wrapped with vinyl tape, disconnect the clip. (2) Pull the side panel towards yourself and remove the plate from the instrument panel and remove the side panel. (3) The installation is in the reverse order of the removal. 4.Steering Column Cover Removal/Installation (1) Remove upper cover.
Page 348 7.Intermediate Instrument Panel Removal/Installation (1) Disconnect the negative (--) terminal cable from the battery. (2) Remove intermediate instrument panel. (3) Remove the screw. (4) Using the flat screwdriver wrapped with vinyl tape, disconnect the clip. (5) Pull the intermediate instrument panel forward and then remove the clip.
Page 349 9. Auxiliary Console Removal/Installation (1) For MT vehicle, remove transmission control knob. (2) Using the screwdriver wrapped with the vinyl tape, remove the tray. (3) Using the screwdriver wrapped with the vinyl tape, remove shift boot frame. Disconnect ignition switch. (4) Remove the bolt, screw.
Page 350: (Ix) A Pillar Inside Trim And Front Door Sill
(IX) A pillar inside trim and front door sill A pillar inside trim and front door sill diagram A pillar inside trim and front door sill diagram 1. Right A Pillar Inside Trim 2. Left A Pillar Inside Trim 3. Right Front Door Sill 4.
Page 351: (X) B Pillar Inside Trim
(X) B pillar inside trim B pillar inside trim diagram: B Pillar Inside Trim Diagram 1. Right B Pillar Upper Inside Trim 2. Left B Pillar Upper Inside Trim 3. Right Deflector 4. Left Deflector 5. Right B Pillar Lower Inside Trim 6.
Page 352: (Xi) Cpillar Inside Trim And Rear Door Sill
(XI) Cpillar inside trim and rear door sill C pillar inside trim and rear door sill diagram: C pillar inside trim& rear door sill diagramdiagram 1.Right C Pillar Upper Inside Trim 2.Left C Pillar Upper Inside Trim 3. Right C Pillar Upper Inside Trim Sound Insulator 4.
Page 353: (Xii) Roof Inside Trim
(XII) Roof inside trim Roof Inside Trim Diagram: Roof inside trim diagram 1. Roof Inside Trim 2. Left Sun Visor Bracket 3. Right Sun Visor Bracket Cross Semi- Countersunk Screw 5. Left Sun Visor Assembly 6. Right Sun Visor Assembly C r o s s Counter Sunk Tapping Screw 8.
Page 354: (Xiii) Carpet And Heat Insulator
(XIII) Carpet and Heat Insulator Carpet and Heat Insulator Diagram Carpet and Heat Insulator Diagram 1. Carpet 2. Cowl Lower Sound Insulator 3. Cowl Upper Sound Insulator Cowl Outer Panel Heat Insulator 5. Foot Pedal 6. Cross Pan Head Screw 7.
Page 355: (Xiv) Rear Trunk Inside Trim
(XIV) Rear trunk Inside Trim Rear trunk inside Trim Diagram : Rear trunk Inside Trim Diagram 1. Right Rear Quarter Trim 2. Left Rear Quarter Trim 3. Lower Rear Board Trim Assembly 4. Spare Tire Press Plate Assembly 5. Rear trunk Stuck Plate 6. Right Rear Combination Lamp Access Hole Cover 7.
Page 356: (Xv) Engine Hood Inside Trim
Take out the rear trunk carpet, spare tire cover board and the rear trunk miscelleaneous box. Screw the spare tire press plate assembly to take out the spare tire. 2. Installation Clip the rear trunk inside trim onto the corresponding hole in the reserve order of the removal; Install the right rear and left rear combination lamp access hole cover;...
Page 357: (Xvi) Door
(XVI) Door Front Door Front Door Components: 1.Front Door 2.Front Door Hinge 3.Front Door Lock And Door Lock Actuator 4.Front Door Inner Trim Board 5.Power Window Motor 6.Power Window Actuator 7.Door Inside Handle 8.Protection Device 9.Door Outside Handle 10.Front Door Lock Hole 11.Front Door Glass 12.Door Window Regulator Run 13.
Page 358 1.Front Door Removal/Installation (1) Disconnect the negative (--) terminal cable from the battery. (2) Remove the front fender and remove the front door hinge. (3) Remove the connector (See Notice on Removing the Connector for detailed information) (4) Remove front door hinges (5) Remove the front door (6) The installation is in the reverse order of the removal.
Page 359 1.The Front Door Inner Trim Board Removal/Installation (1) Remove the set screw. (2) Remove the front door inner trim board assembly. (3) Disassemble the inner trim board assembly as required (4) The installation is in the reverse order of the removal. 2.Front Door Glass Removal And Installation (1) Lift the front door window glass, make the distance between the front window glass top and rear door top weatherstrip...
Page 360 (2) Get the window regulator from the hole in the lower door Front Door Componen t Power Window Glass Regulator Actuator Power Window Glass Regulator Motor 4.Front Door Lock And Door Lock Actuator Removal/In- stallation (1) Remove front door component. (2) Remove the screw and then remove the front door lock and the door lock actuator.
Page 361 Rear door Rear door Component 1.Rear Door 2.Rear Door Hinges 3.Rear Door Lock And Door Lock Actuator 4.Rear Door Inner Trim Board 5.Power Window Motor 6.Power Window Actuator 7.Door Inside Handle 8.Door Outside Handle 9.Rear Window Glass 10.Quarter Window 11.Window Glass Regulator Run 12.Glass Run 13.Quarter Window Weatherstrip 14.
Page 362 Rear Doorinside Trim Rear Doorinside Trim Component: 1.Rear Doorinside Trim Board Assembly 2.Rear Door Lock Inner Handle Assembly 3 . C o n t r o l l e r Trim Board 4.Door Handle 5.Set Screw 1.Rear doorinside trim board removal/installation (1) Remove the set screw.
Page 363 2.Rear window glass removal/installation Rear Door Weatherstrip (1) Fully drop down the rear window glass. Glass Guide (2) Remove the rear window glass frame. (3) Remove the bolt. (4) Remove the window glass channel from the glass guide (5) Insert your hand into the rear door service hole and lift out the Window Glass Channel rear window glass.
Page 364 (2) Take out the rear door glass regulator from the square hole under the door; Power Window Glass Regulator Actuator Rear Door Component Power Window Glass Regulator Motor 4.Rear door lock and door lock actuator removal/in stallation (1) Remove the rear door component. (2) Remove the screw and then remove rear door lock and the door lock actuator.
Page 365 Door Adjustment 1. Measure clearance between the front door or the rear door and the vehicle body. 2. Loose the front door or the rear door hinges assembly bolt or door lock striker assembly screw and reinstall it to the door if the measured result is not as specified in the technical standard. Clearance a: 5mm b: 5mm...
Page 366: Part V Body
Part V Body Chapter 1 General Information Section 1 Body Structure An automobile body is mainly composed of the main body, removable sheet metal parts, interior and exterior trim parts, and body accessories. I. Main Body The main body is mainly composed of the front sheet metal, cowl parts, floor assembly, LH/RH side wall assembly, Rear back panel assembly, trunk shelf assembly and roof panel assembly, etc.
Page 367 (I) Front Sheet Metal, Cowl Parts The main function of the front sheet metal and the cowl parts is forming an engine compartment to supply the engine and accessories with a protective cover and to absorb the most energy when vehicle encounters frontal impaction, protecting mud from being splashed by the front wheels, and meeting the requirements of body design in appearance.
Page 368 6. Cowl Upper Assembly Cowl upper assembly is mainly composed of cowl upper outer plate, cowl upper LH/RH end plate assembly, instrument panel mounting plate, steering column mounting bracket upper/lower plate, cowl lower inner plate, ventilator cover, etc., by welding them together. Front Figure 5-2 Dismantle diagram of front sheet metal and cowl parts 1 Front Cross Member...
Page 369 (II) Floor Assembly Floor assembly is the base of the main body and an important structure component to link with assemblies and for load transfer and bearing. The vehicle running performance depends on its intensity and rigidity. Figure 5-3 is the dismantle diagram of the floor parts. Floor assembly is composed of front floor assembly and rear floor assembly.
Page 370 (III) Side Wall Assembly LH/RH side wall assembly is frame structure. It is mainly composed of parts such as LH/RH front pillar sub- assembly, LH/RH central pillar reinforcement, LH/RH upper side rail, LH/RH floor side rail outer panel, LH/ RH side wall inner/outer panel...etc., by welding them together. Figure 5-4 is the dismantle diagram. Left Front Right...
Page 371 (IV) Rear Back Panel Parts Rear back panel assembly is mainly composed of parts such as rear back panel, rear back panel reinforcement, trunk lock mounting plate, trunk lid cross member, etc., by welding them together. Figure 5-5 is the dismantle diagram.
Page 372 (V) Roof Panel Assembly Roof panel assembly is mainly composed of parts such as roof panel, roof front cross member, roof central reinforcement, roof rear cross member, etc., by welding them together. Shown as the dismantle diagram 5- 6.Roof interior trim is mounted inside; and an insulation mat is pasted in its interlayer. Cohesive binder is applied between the front/central/rear cross member and the roof panel in many points.
Page 373 II. Removable Sheet Metal Parts (I) Engine Hood, Front Fender 1. Engine hood is mainly used to protect the engine, meet the whole vehicle design, and make the mainte- nance convenient. It also has an effect of isolating the engine noise. The engine hood has a double-insurance lock system.
Page 374 (III) Door Assembly The door adopts limit hinges. The hinge is mounted on the front pillar of the door frame. A door is mainly composed of the door outer and inner plate, anti-impact bar and door reinforcement plate. The structure of the door is complicated, because it is a movable part. It is designed to form a sealed compartment with the main body and relevant parts, and also convenient for drivers and passengers to get in and out of the vehicle.
Page 375 Figure 5-11 Dismantle Diagram of Rear Door Plate 1 Rear Door Inner Plate 2 Rear Door Window Glass Rail 3 Rear Door Inner Upper Reinforce- ment Plate 4 Rear Door Inner Middle Reinforcement Plate 5 Rear Door Upper Hinge 6 Rear Door Lower Hinge 7 Rear Door Hinge Reinforcement Door Anti-impact Bar Assy.
Page 376: Chapter 2 Body Repair
Chapter 2 Body Repair Section 1 Body Damage Forms and Requirements for Repair I. Body Damage Forms The body damage forms are deformation caused by crash, overload, fatigue and corrosion, and tearing, rusting, water & dust leaking. The damage of the body is caused not only by overload, also by being often in an abnormal operating status when the door or other parts are damaged.
Page 377 2. Crashed By Outside Force Ahead Or From The Left Side (Figure 5-14) Figure 5-14 Crashed By Outside Force Ahead Or From The Left Side Figure 5-14 shows the situation when the front is pressed or the left side is crashed by outside force. Under this kind of situation, the outside force spreads from the left (or right) of the hood to the front suspension mounting place, to get this part easily deformed.
Page 378 4. Crashed By Perpendicular Outside Force In the Middle of The Vehicle (Figure 5-16) Outside force FIGURE 5-16 Perpendicular outside Force in the Middle of the Vehicle Figure 5-16 shows the situation when the middle of the vehicle is pressed by perpendicular outside force. So, the places should be inspected are as follows: Front window side pillar upper and lower mounting place;...
Page 379: Section 2 Typical Technology Of Body Panel Repair
Section 2 Typical Technology Of Body Panel Repair The flow line of the repair technology is as follows: Appearance assessment Disassembly Paint removal Appraisal Panel repair Painting Assembly Section 3 Repair after Body Damage Body repair methods include calibration, reshaping, strengthening, partial replacement and renewing of a whole part.
Page 380 II. Repair of Body Outer Plate 1. Types Of Outer Plate Damage 1 1 1 1 1 Break or crackle The body always vibrates as the vehicle runs; and it bears an alternating load. When the vehicle suddenly accelerates, sharply turns and emergently brakes, the body will be affected by inertia force. When the vehicle runs on a rough road, the body will get bent and deformed by torsion.
Page 381 2. Repair Of Outer Plate 1 1 1 1 1 Repair of crackle The crackle on the metal outer plate can be repaired by CO2 gas Protecting welding. When welded, the two sides of the metal plate should be aligned, and then spot-weld on the outside of the outer plate. If the crackle length is less than 50mm, it should be welded from the crackle end, and along the run of the crackle and the outside edge.
Page 382 Illustration 5-18 Panel Flattening (A) A Concave Point B Protrusion Point C Knocking Point Illustration 5-19 Panel Flattening (B) 1 Hammer 2 Panel Parts 3 Backing Block Figure 5-20 Heat and flatten the protrusion 1 heating point At the beginning of knocking it, make your force slightly greater. In the finishing period of repair, make your force softer and try your best to reduce the beating times.
Page 383 can make a reshaping repair according to lever principle by making use of different clearances. To repair by prying without disassembling parts can maintain the original assembling quality and improve the working efficiency. 4 4 4 4 4 Repair of outer plate breakup welding Outer plate being breakup welding is caused by bad welding between welding wire and metal plates.
Page 384: Section 4 Features And Composition Of Automobile Body
Section 4 Features and Composition of Automobile Body I. Features of Body Because the body is integral body construction, the main body is concurrently used as frame to support all load. The 3-compartment-5-door layout adopted gets the space availability the biggest and favorable to arrange the space of drivers and passengers.
Page 385 1. Material Of punching Parts In order to improve the rigidity of the body, high-tensile steel plate is adopted in many key parts of the body to reinforce the body on the place that force concentrates (Figure 5-22). (Figure 5-22) High-Tensile Steel Plates 1.
Page 386 In order to avoid corroding and effectively extend the service life of the punching parts, galvanized steel sheet with different specifications is widely adopted on the body (Figure 5-23). (Figure 5-23) Galvanized Steel Plates 1. LH/RH Mudguard Reinforcement 2 Cowl Upper Baffle 3 Radiator Support 4 LH/RH Front Mudguard...
Page 387 Figure 5-24 COWL 1. Cowl 2. Heat Insulating Protecting Board 3. Front Cross Member 4. Heat Insulating Pad 5-24...
Page 388 Adopt sound insulating material to reduce the noise in the compartment. For the heat, vibration and sound insulation of the body, they are a systematic engineering. Besides you take measures on effectively improving the rigidity of the body and sealing technique, the following measures can be taken in the body design and manufacturing: a.
Page 389 4. Surface Treatment Of Body The consideration of the body surface treatment is very strict, careful and considerate. Although it is not high-grade car, it is nearly the same with the high-grade car on the surface treatment. 1 1 1 1 1 Application of Galvanized Steel Plate In order to prevent the steel plates from rusting, all outside punching parts are made by galvanized steel plate.
Page 390: Section 5 Painting Technique After Body Repair
Section 5 Painting Technique after Body Repair Partial painting is needed when the vehicle crashes, parts rust, surface bubbles and color changes. The painting techniques after repair are as follows: I. Base Treatment (Pre-Treatment) 1. Peel the layer of painting and the coating on the panel. 2.
Page 391 V. Final Paint Applying 1.Apply final paint. Apply fast drying final paint for 3 or 4 times and synthetic resin paint for 2 or 3 times. 2. Air dry or heat dry. VI.Polishing 1. After painting, you can polish with wax to remove the repairing paint shadow for decoration consideration. 2.
Page 392: Section 6 Service Data For Body
Section 6 Service Data For Body I. Service Data For Body (Table 5-1) TABLE 5-1 Service Data For Body Content Service Data Reshaping clearance between engine hood inner and outer plate 3mm±0.5mm Clearance between LH/RH fender and hood 5mm(0,-1mm) Clearance between LH/RH headlamp and hood 7mm±0.5mm Clearance between front bumper and fender ≤...

This manual is also suitable for:

Ck mr479q 2007 Ck mr479qa 2007 Ck mr481q 2007

Geely CK Series 2007 Workshop Manual

Chapter 1 Engine Assembly (MR479Q, MR479QA, MR481QA)

Chapter 2 Engine Components Replacement (MR479Q, MR479QA, MR481QA)

Chapter 3 Lubrication System (MR479Q, MR479QA, MR481QA)

Chapter 4 Fuel System (MR7131A, MR7151A, MR7161A)

Chapter 5 Exhaust System (MR7131A, MR7151A, MR7161A)

Chapter 7 Clutch (MR7131A, MR7151A, MR7161A)

Chapter 8 Maunal Transaxle Assembly (MR7131A, MR7151A, MR7161A)

Chapter 9 General Engine Troubles and Their Troubleshooting

Chapter 10 Engine Management Unit

Chapter 6 Rear Suspension System

Quick Links

Troubleshooting

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Summary of Contents for Geely CK Series 2007

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Table of Contents