CENNTRO LOGISTAR 100 Repair Manual

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Summary of Contents for CENNTRO LOGISTAR 100

Page 3 Manual are subject to change without notice, and CENNTRO does not assume any legal obligations and responsibilities. Without the written permission of CENNTRO, no unit or individual may use any form or  method to duplicate, copy or transmit this Manual on the network in any form for any purpose.
Page 5: Table Of Contents
Contents Part 1 Overview 1. Overview ..............................1 1.1 Description and instructions for use ..................1 1.1.1 General information ......................1 1.1.2 Vehicle identification number ..................3 1.1.3 Traction and raising ......................5 1.2 Maintenance .............................7 1.2.1 Maintenance interval ...................... 7 1.2.2 Maintenance content ......................
Page 6 3.4 Windshield ............................39 3.4.1 Overview ........................... 39 3.4.2 Windshield ........................40 3.5 Handle, lock, latch and mechanism ..................46 3.5.1 Rear door lock (right) ....................46 3.5.2 Door lock .......................... 48 3.6 Exterior trim panel and trims ....................50 3.6.1 Ceiling trim strip ......................50 3.6.2 Roof rack (if equipped) ....................
Page 7 5.1.6 Drive shaft ........................73 6. Power drive .............................. 77 6.1 Accelerator pedal ......................... 77 6.1.1 Overview ........................... 77 6.1.2 Accelerator pedal ......................78 6.2 Gear shift system ......................... 80 6.2.1 Shifter assembly ......................80 6.2.2 Shifter foot position ......................81 6.2.3 Shifter gear signal output logic .................
Page 8 8.2.1 Overview .........................123 8.2.2 Necessary maintenance materials ................. 124 8.2.3 Tightening torque specification ................125 8.2.4 Rear suspension inspection ..................126 8.2.5 Rear axle ........................129 8.2.6 Rear trailing arm ......................135 8.2.7 Rebound stopper and upper spring seat ...............138 8.2.8 Coil spring ........................
Page 9 9.3.2 Parking brake cable ....................181 9.3.3 Parking brake control handle ................... 183 9.4 Hydraulic braking ........................184 9.4.1 Brake fluid level ......................184 9.4.2 Brake hose or hard pipe .....................185 9.4.3 Brake bleed ........................186 9.4.4 Clean the brake hydraulic system ................188 9.4.5 Brake master cylinder ....................
Page 10 10.2.7 Inspection of steering tie rod ball pin dust cover ..........222 10.2.8 Inspection of steering shaft universal joint ............222 10.2.9 Inspection of steering tie rod ball pin ..............222 10.2.10 Steering tie rod joint ....................223 10.3 Steering column ........................225 10.3.1 Overview ........................
Page 11 11.3.3 Air heater assembly ....................255 11.3.4 Air heater ........................257 11.3.5 Evaporator assembly ....................259 11.3.6 Evaporator ........................262 11.4 Control system ......................... 264 11.4.1 Air conditioning controller assembly ..............264 11.4.2 The motor and fan assembly ................. 266 11.4.3 Speed regulating resistor ..................266 11.4.4 Servo motor ........................
Page 12 13.3.4 High brake lamp ......................301 13.3.5 Rear fog lamp ......................301 13.3.6 Rear combination lamp ................... 302 13.3.7 Element test ....................... 302 13.3.8 Rear fog lamp failure ....................304 13.3.9 Reversing lamp failure .....................306 13.3.10 Brake lamp failure ....................307 13.3.11 License plate lamp failure ..................309 13.3.12...
Page 13 15.2.3 Electrical diagnosis ....................374 15.3 PEU controller ...........................379 15.3.1 Overview ........................379 15.3.2 Definition of low voltage communication interface and pin position ..380 15.3.3 DTC fault code diagnosis ..................381 15.3.4 Removal and installation of PEU controller ............414 15.3.5 Removal and installation of slow charging harness ........
Page 15: Part 1 Overview
Overview 1. Overview 1.1 Description and instructions for use 1.1.1 General information Please read this Manual and carefully follow its instructions. To emphasize specific information, the words "Warning, Notice, and Caution" have special meanings. Please pay special attention to the words in bold. △...
Page 16 Overview Whenever oil seals, sealing gaskets, gaskets, sealing rings, lock washers, split pins, self-locking nuts, and certain other specified components are used, new ones must be used. That is, before installing these new components, the residual material on the mating surface must be removed.
Page 17: Vehicle Identification Number
Overview Strength Ordinary bolt "4T" bolt “7T” bolt Thread N·m kg·m ft-lbs N·m kg·m ft-lbs diameter 0.15 0.23 0.30 0.45 0.55 17.0 21.0 36.5 32.5 61.5 47.0 13.5 98.0 10.5 76.0 152.0 116.0 174.0 1.1.2 Vehicle identification number The vehicle identification number (VIN) is used to register a vehicle and identify the vehicle with this number.
Page 18 Overview • Located on the front of the instrument panel (VIN) plate. Drive motor identification The identification number of the drive motor is stamped on the motor nameplate. The drive motor body is simultaneously stamped with the motor number and model. △...
Page 19: Traction And Raising
Overview 1.1.3 Traction and raising Vehicle raising position Front side Rear side 1 - Front right wheel 2 – Rear right wheel Consider maintaining vehicle balance throughout the maintenance process. The balance of the vehicle on the lifting jack may change as components are removed. Before raising the vehicle, check to ensure that the end of the lifting jack rocker arm does not come into contact with the brake pipes, brackets, or any other components.
Page 20 Overview 2. When performing repairs, the safety strut must be placed under the vehicle body. Check to ensure that the vehicle body does not slide onto safety support, making the vehicle secure. △ Warning Do not push the jack onto suspension components (such as stabilizers, etc.) or vehicle floor panels, as this can cause deformation.
Page 21: Maintenance
Overview 1.2 Maintenance 1.2.1 Maintenance interval Note: ● indicates replacement ○ indicates inspection -- indicates there is no description The first The routine maintenanc maintenance e is after is after 10000 10000km Maintenance items km(6200mil Description (6200miles) /12 months /12 months (whichever (whichever comes first)
Page 22 Overview *7. Brake pedal travel ○ ○ III. Chassis, vehicle body accessories Check tire pressure and wear, correct tire pressure, and ○ ○ rotate tires if necessary Wheel, steering suspension installation ○ ○ fastening and abnormal noise 10. Fastening of drive shaft ○...
Page 23: Maintenance Content
Overview △ ! Caution The above table only lists the maintenance requirements for vehicles traveling within 20000 km (12400 miles)/24 months, and the maintenance interval for vehicles traveling over 20000 km (12400 miles)/24 months is the same as the above table. 1.2.2 Maintenance content Braking device 1.
Page 24 Overview △ ! Caution The braking system of this vehicle has been filled with the specified brake fluid before leaving the factory. When refilling, it is not allowed to use or mix different types of brake fluid, otherwise serious failures may occur. Do not use expired or used brake fluid, nor use brake fluid that has been poured out of unsealed containers.
Page 25 Overview ② Check whether the rear wheel bearings are worn, damaged, abnormal, noisy, and rattling. 2. Inspection of drive shaft protective sleeve • Drive shaft protective sleeve Check the drive shaft protective sleeve (wheel side and differential side) for leakage, detachment, cracks, or other damage, and replace the protective sleeve as necessary.
Page 26 Overview ⑧ Check the front wheel alignment (toe-in). 5. Inspection of door hinge • Door hinge Check whether the door moves smoothly without abnormal noise. If there is a fault, please lubricate as follows. Wipe the dust off the door hinge and apply a thin layer of lubricating grease.
Page 27 Overview • Vehicle body, wheels, and power transmission system Check and confirm that there are no abnormal sounds, vibrations, or any other abnormal conditions in the vehicle body, wheels, and power transmission system. • Lamps Check whether all lamps are working properly. •...
Page 29: Part 2 Vehicle Body
Vehicle body 2. Vehicle body 2.1 Vehicle body front end 2.1.1 Bracket assembly Removal △ ! Warning During the removal and installation of high voltage components, personnel with a low voltage electrician certificate can operate. Before starting work, maintenance personnel must wear labor protection equipment: insulating gloves and insulating shoes.
Page 30 Vehicle body Remove the low voltage battery. Remove the motor control unit (4 fastening bolts) Remove the PEU controller assembly (4 fastening bolts) Remove the vacuum tank (2 fastening bolts)
Page 31 Vehicle body Remove the ESC assembly Remove the fasteners on the left and right sides of the second floor bracket assembly. 10. Remove second floor bracket assembly. Installation Install in the reverse order of the removal procedure. 1. Install the second floor bracket assembly. 2.
Page 32: Front Crossbeam Assembly
Vehicle body 2.1.2 Front crossbeam assembly Removal Schematic diagram Steps Disconnect the negative cable of the low voltage battery. Disconnect the power battery. Remove the front bumper. Remove pedestrian friendly reminder module. Remove the condenser. Remove the drive motor grounding wire fastener (A).
Page 33 Vehicle body 13. Remove 2 fasteners of the stabilizer bar (A). 14. Remove the stabilizer bar. 15. Use a jack to support the drive motor. 16. Remove fasteners front crossbeam assembly. 17. Remove the front crossbeam assembly.
Page 34 Vehicle body Installation Schematic diagram Steps Install the front crossbeam assembly. Install fasteners front crossbeam assembly. Tightening torque: 65 N·m (6.5 kg·m, 47.0 ft-lbs) Remove the jack. Install the stabilizer bar. Install 2 fasteners of the stabilizer bar (A). Tightening torque: 65N·m (6.5kg·m,...
Page 35 Vehicle body Install drive motor support crossbeam. Install the drive motor lower guard. 10. Lower down the vehicle. 11. Install the drive motor front suspension bracket fasteners and 3 fasteners (B). Tightening torque: 58N·m (5.8kg·m, 41.40ft-lbs) 12. Install the drive motor grounding wire fastener (A).
Page 36: Fender Flap
Vehicle body 2.2 Fender flap 2.2.1 Front fender flap Removal Schematic diagram Steps Disconnect the negative cable of the low voltage battery. Remove the front bumper. Disconnect harness connector of the side turn (side marker) lamp. Remove the front fender flap lining plate.
Page 37: Exterior Trims
Exterior trims 3. Exterior trims 3.1 Rearview mirror 3.1.1 Rearview mirror Removal Schematic diagram Steps Remove the rearview mirror trim cover. Remove 4 fasteners of the rearview mirror. Remove the rearview mirror.
Page 38 Exterior trims Installation Schematic diagram Steps Install the rearview mirror. Install 4 fasteners of the rearview mirror. Tightening torque: 5.5N·m (0.55kg·m, 4.0ft-lbs) Install the rearview mirror trim cover.
Page 39: Doors And Cargo Container Cover
Exterior trims 3.2 Doors and cargo container cover 3.2.1 Rear door assembly (right) Removal Schematic diagram Steps Remove the limiter connecting pin by gently tapping it upwards with a hammer. 1 - Door opening limiter; 2-Pin Using a jack, place a wood block between the jack and the door panel to support the door panel.
Page 40 Exterior trims Installation Schematic diagram Steps Install the front door in the reverse order of removal. • As shown in the figure, apply sealant to the hinge mounting surface and lubricating grease the rotating parts. • When the sealing strip hardens, it can cause water leakage.
Page 41: Front Door Assembly
Exterior trims 3.2.2 Front door assembly Removal Schematic diagram Steps Remove the front fender flap. Disconnect the door harness connector and remove the corrugated pipe from the vehicle body. Remove the limiter connecting pin by gently tapping it upwards with a hammer. 1 - Door opening limiter;...
Page 42 Exterior trims Using a jack, place a wood block between the jack and the door panel to support the door panel. Unscrew the hinge mounting bolts to remove the front door assembly. 1-cloth; 2-Wood block Installation Schematic diagram Steps Install the front door in the reverse order of removal.
Page 43: Front Door Glass Lifter Assembly
Exterior trims 3.2.3 Front door glass lifter assembly Removal Schematic diagram Steps Remove the front door glass. Disconnect the harness connector of the electric motor for the power window and release the wire clip (if equipped). Remove fixing bolts of the glass lifter and take out the glass lifter through the 1 - Glass lifter assembly;...
Page 44 Exterior trims Inspection Schematic diagram Steps Check whether the sliding and rotating parts of the glass lifter require lubrication. Check the rollers for wear and damage. Check the wire rope for damage. Installation Install the front glass lifter in the reverse order of removal. △...
Page 45: Front Door Glass
Exterior trims 3.2.4 Front door glass Removal Schematic diagram Steps Remove the front door inner handle assembly. Remove the front door trim guard bolts. Lower door window glass completely, and then remove the outer sealing strip. Remove the front door trim guard and disconnect power window...
Page 46 Exterior trims Installation Schematic diagram Steps Install the door glass in the reverse order of removal. △ ! Caution When installing glass, check whether the top of the glass is in uniform contact with the glass chute and whether the movement up and down is stable.
Page 47: Power Door Lock Actuator
Exterior trims 3.2.5 Power door lock actuator Schematic diagram Steps Disconnect the harness connector of the power door lock actuator. Connect the (+) and (-) terminals of the low voltage battery to the terminals "1" and "2". If the (-) pole is connected to the wiring post “1”, it results in “locking”;...
Page 48: Key Operated Pneumatic Switch
Exterior trims 3.2.6 Key operated pneumatic switch Schematic diagram Steps Check the conductance between the switch wiring ends. Wiring end Switch position Open Close Down...
Page 49: Power Window Auxiliary Switch
Exterior trims 3.2.7 Power window auxiliary switch Schematic diagram Steps Check the conductance between the switch wiring ends. Wiring end Switch position Open Close Down 3.2.8 Power window main switch Schematic diagram Front passenger Driver window window switch switch Close Close Down Close...
Page 50: Symptom Table
Exterior trims 3.2.9 Symptom table Power window control system Fault symptom Possible causes Treatment methods Fuse damage Check the fuse All power windows do not Power window relay fault Check the power window relay work Check/replace the driver Driver window switch fault window switch Power window switch fault Check the power window switch...
Page 51: Vehicle Body Closure
Exterior trims 3.3 Vehicle body closure 3.3.1 Front cabin cover Schematic diagram Removal steps Remove the front windshield cleaning hose from the front cabin cover. Remove the front cabin cover fasteners and remove the front cabin cover with the assistance of others. Installation steps Install the front cabin cover in the reverse order of removal.
Page 52: Adjustment Of The Front Cabin Cover
Exterior trims 3.3.2 Adjustment of the front cabin cover Schematic diagram Steps Front, rear, left, right adjustment • Loosen four assembly fasteners of the front cabin cover and make adjustment. Vertical adjustment • If only one side of the front cabin cover (right and left) is not level with respect to the fender flap, tighten or loosen the front cabin cover cushion to make it level.
Page 53: Windshield
Exterior trims 3.4 Windshield 3.4.1 Overview The windshield is installed with a special type of adhesive, that is, it is composed of an urethane adhesive used together with a primer. As for windshield replacement, it is important to use an adhesive that provides surface adhesion strength and adopt appropriate procedures.
Page 54: Windshield
Exterior trims 3.4.2 Windshield Removal Schematic diagram Steps Clean the inside and outside of the glass and its surrounding parts. Remove the wiper arm. Remove the ceiling sealing strip. Cover the vehicle body around the glass with adhesive tape to prevent damage to the vehicle body.
Page 55 Exterior trims 11. Use a knife to trim the adhesive on the adhesive portion of the vehicle body to a thickness of 1-2mm. △ ! Caution Before using a knife to trim the vehicle body, wash the adhesive parts of the vehicle body with alcohol or similar substances to remove grease from them.
Page 56 Exterior trims Installation Schematic diagram Steps Use cleaning agent (gasoline) to clean the surface left on the vehicle body (or windshield edge) that needs to be bonded to the windshield. (Allow to dry for at least 10 minutes). Then remove the door trim strip from the back of the door by gripping each clip with your fingers.
Page 57 Exterior trims Install a new sealing strip onto the glass. To facilitate installation, heat the sealing strip at a temperature of 35°C (95°F) for one and a half hours. Wipe the glass surface of the part bonded to the vehicle body with a clean cloth.
Page 58 Exterior trims Apply adhesive as shown in the left figure. Width "f": approximately 16mm (0.63in.) △ ! Caution Starting from the bottom edge of the glass, be careful not to damage the primer. The adhesive applied to the bottom edge is higher than that to the other three edges, the top, right, and left.
Page 59 Exterior trims Install the ceiling sealing strip. 10. Check water seepage sprinkling water from the hose onto the window. If leakage is found, wipe the glass dry and fill the leak location with adhesive. After filling, if leakage is still found, remove the glass and follow the above installation steps to restart the installation.
Page 60: Handle, Lock, Latch And Mechanism
Exterior trims 3.5 Handle, lock, latch and mechanism 3.5.1 Rear door lock (right) Removal Schematic diagram Steps Remove the rear door trim guard bolts. Remove the rear door trim guard. Remove the sealing film. 1 - Right rear door lock assembly; 2 - Right rear door outer handle;...
Page 61 Exterior trims Adjust the gasket so that the door remains in contact with the vehicle body when closed. • In order for the door lock ring to be correctly positioned in the front and rear directions, adjustments can be made by increasing or decreasing the number of adjusting gaskets inserted between the vehicle body and the lock ring.
Page 62: Door Lock
Exterior trims 3.5.2 Door lock Removal Schematic diagram Steps Remove the front door glass. Remove the front door inner handle assembly. Remove the door trim guard bolts. Remove door trim guard disconnect power window switch harness connector. Remove the sealing film. 1 - Access control assembly;...
Page 63 Exterior trims Installation Schematic diagram Steps Install the door lock in the reverse order of removal. Install the door lock ring. • Move the lock ring up and down so that its axis is approximately in a straight line with the center (A) of the lock groove. △...
Page 64: Exterior Trim Panel And Trims
Exterior trims 3.6 Exterior trim panel and trims 3.6.1 Ceiling trim strip Removal and installation Schematic diagram Removal steps Remove the roof rack (if equipped). Remove the ceiling trim strip. Installation steps Install the ceiling trim strip in the reverse order of removal. △...
Page 65: Roof Rack (If Equipped)
Exterior trims 3.6.2 Roof rack (if equipped) Removal Schematic diagram Steps Remove the front and rear caps of the roof rack as shown in the figure. Remove the nuts. Remove the roof rack assembly. 1 - Roof rack support rod assembly; 2-Front cover of roof rack brace;...
Page 66: Side Trim Strip
Exterior trims 3.6.3 Side trim strip Schematic diagram Removal steps When the glass is fully raised, remove the trims and sealing film. Remove the door trim strip from the back of the door by gripping each clip with your fingers. Installation steps Install the door trim strip after 1 - Front door sealing strip;...
Page 67: Wiper And Cleaner
Exterior trims 3.7 Wiper and cleaner 3.7.1 Overview Front wiper and cleaner The windshield wiper is of 3-speed type and the windshield cleaner is equipped with a separate electric water pump. The cleaner tank is installed on the front inner side of the left front wing panel and is equipped with a front window cleaner pump.
Page 68: Windshield Wiper
Exterior trims 3.7.2 Windshield wiper Check the wiper/cleaner switch Schematic diagram Steps Disconnect the spiral harness and combination switch harness connector. Use a multimeter to check the continuity between each terminal. 1 - Battery; 2-Wiper motor; 3-Red conductor ; 4-Black conductor...
Page 69 Exterior trims Check the intermittent wiper relay Schematic diagram Steps Disconnect combination Wiper switch harness connector. Cleaner Intermittent Connect the (+) and (-) pole wires High of the low voltage battery to the connector terminals as shown in the figure. Place the wiper switch in the “INT”...
Page 70: Cleaner Pump
Exterior trims 3.7.3 Cleaner pump Removal Schematic diagram Removal steps Disconnect the negative (-) cable of the low voltage battery. Remove the front fender flap gasket (LH). Remove the cleaner kettle mounting nut and clamp. Disconnect the pump leads and hoses. Remove the cleaner kettle.
Page 71: Wiper Motor Assembly
Exterior trims 3.7.4 Wiper motor assembly Removal and installation Schematic diagram Removal steps Disconnect the wiper motor plug-ins. Remove wiper motor assembly mounting bolts and remove the wiper motor assembly from the wiper connecting rod. Installation steps Install the wiper motor in the reverse order of removal.
Page 72 Exterior trims Inspection Schematic diagram Inspection steps As shown in the left figure, connect the (+) pole of the low voltage battery to the "A" terminal and the (-) pole to the bracket (wiper grounded). If the motor rotates at a low speed of 45 to 55 revolutions per minute, it indicates that it is normal.
Page 73: Symptom Table
Exterior trims 3.7.5 Symptom table Fault symptom Possible causes Maintenance measures Replace the blown fuse to Wiper fuse is blown check for a short circuit Wiper motor is faulty Check the motor The wiper fails or does not return to the original Wiper control switch is Check the switch position...
Page 74: Bumper
Exterior trims 3.8 Bumper 3.8.1 Rear bumper △ ! Caution Fasteners are important accessory components that can affect the performance of crucial components and systems, and/or can affect major repair costs. If it needs to be replaced, it must use the components of the same model or equivalent. Do not use low quality replacement parts or alternative designs.
Page 75: Front Bumper Air Inlet Grille
Exterior trims 3.8.2 Front bumper air inlet grille Removal and installation Schematic diagram Removal steps Open the front cabin cover and remove the screws at the positions shown (as indicated by the arrows) in the figure. △ ! Description The disassembly sequence is from bottom to top.
Page 76: Front Bumper
Exterior trims 3.8.3 Front bumper △ ! Caution Fasteners are important accessory components that can affect the performance of crucial components and systems, and/or can affect major repair costs. If it needs to be replaced, it must use the components of the same model or equivalent. Do not use low quality replacement parts or alternative designs.
Page 77: Interior Trim
Interior trim 4. Interior trim 4.1 Interior trims 4.1.1 Roof liner Removal Schematic diagram Steps Remove the interior rearview mirror. Remove the local lighting lamp. Remove the sun visor assembly. Remove the interior lamp and partition. Remove the front passenger handle. Remove the roof liner interior trim.
Page 78 Interior trim Install the local lighting lamp, sun visor assembly, interior lamp, and roof liner interior trim. 1 - Local lighting lamp; 2 - Sun visor assembly; 3 - Front passenger handle; 4-Interior lamp...
Page 79: Seat
Interior trim 4.2 Seat 4.2.1 Seat Schematic diagram Name Removal steps Headrest assembly Headrest height Remove the seat adjustment sliding slide rail mounting sleeve bolts. Then, remove Headrest height seat assembly adjustment limit (front seat) together sliding sleeve with the seat slide Backrest inner step rail.
Page 80: Instrument Panel
Interior trim (b):23N·m(2.3kg·m, Slide rail assembly-left 17.0ft-lbs) Slide rail unlocking handle Lower slide rail mounting nut M8 Base assembly - right Base assembly - left Front safety belt buckle 4.3 Instrument panel 4.3.1 Console, instrument panel, and steering support beam Schematic diagram Removal steps Remove the shock pad of the tea cup...
Page 81 Interior trim Remove the upper assembly of the central bright strip, remove decorative edge strip screws, and then remove the lower assembly of the central bright strip. Remove the cigarette lighter assembly and gear shift cover, and disconnect the harness connector of the cigarette lighter assembly.
Page 82 Interior trim Remove the audio system. Remove the electric air conditioning controller. Remove the PAB cover plate assembly. 10. Take out the inner snap fastener of the glove remove glove assembly. 11. Remove the steering column cover assembly (including 3 mounting screws).
Page 83 Interior trim 12. First remove the left trim strip and remove the steering column lower guard board assembly (including mounting screws). 13. Remove the combination instrument cover. 14. Remove the combination instrument and disconnect its rear harness.
Page 84 Interior trim 15. Remove the instrument panel (5 fixing bolts to the vehicle body and 6 fixing bolts steering support beam) disconnect the hazard warning lamp switch. 16. Remove the steering support beam (4 steering column nuts, 2 steering column bolts, 1 steering support beam mounting bolt, and 4 Ecall mounting bolts).
Page 85: Transmission System
Transmission system 5. Transmission system 5.1 Drive shaft 5.1.1 Overview The drive shaft is one of the main components of the transmission system, and the torque of the differential is transmitted to the front wheels through both transmission shafts to drive the vehicle. Due to the continuous direction changes of the vehicle during driving, it is required that the drive shaft should have a certain amount of movement, so a universal joint is designed in the drive shaft assembly.
Page 86: Tightening Torque Specification
Transmission system 5.1.2 Tightening torque specification Tightening pressure Fastener N·m kg·m ft-lbs Oil drain plug 15.5 Oil filler plug 15.5 Ball cage type universal 40.0 joint bolt and nut Steering cross tie rod 31.5 joint slotted nut Stabilizer mounting 31.5 bracket bolt Drive shaft nut 17.5...
Page 87: Symptom Table
Transmission system 5.1.5 Symptom table Fault symptom Possible causes Maintenance measures Abnormal noise Worn or damaged drive shaft Replace The dust cover is damaged or Dust cover leakage Replace the dust cover clamp is loose 5.1.6 Drive shaft Removal Schematic diagram Steps Pry off the rivet pin and remove the drive shaft nut and washer.
Page 88 Transmission system Drain the differential oil. Use a large screwdriver to pry the drive shaft universal joint to release the split ring fixed to the differential side universal joint shaft. 1 - Drive shaft universal joint; 2-Screwdriver Remove two lateral stabilizer mounting brackets from the vehicle body.
Page 89 Transmission system Inspection and installation Schematic diagram Inspection steps Check the dust cover for damage or deterioration, and replace it if necessary. Check the split spring ring, split ring, and dust cover clamp for damage or deformation, and replace them if necessary. Installation steps Clean the front wheel shaft bearing oil seal and apply lubricating grease.
Page 90 Transmission system △ ! Caution In order to avoid excessive expansion of the dust cover and the resulting disconnection of the universal joint in the dust cover, do not pull on the drive shaft. Protect the oil seal and dust cover from damage and prevent unnecessary contact with the oil seal when installing the drive shaft.
Page 91: Power Drive
Power drive 6. Power drive 6.1 Accelerator pedal 6.1.1 Overview The accelerator pedal is one of the main components for driving motor control. The driver changes the stroke of the accelerator pedal by operating the accelerator pedal. The accelerator pedal sensor converts different position signals of the accelerator pedal into analog voltage signals.
Page 92: Accelerator Pedal
Power drive 6.1.2 Accelerator pedal Removal and installation Schematic diagram Removal steps Disconnect the negative cable of the low voltage battery. Disconnect accelerator pedal harness connector. Remove 3 fasteners of the accelerator pedal. Remove the accelerator pedal.
Page 93 Power drive Schematic diagram Installation steps Install the accelerator pedal. Install 3 fasteners of the accelerator pedal. Tightening torque: 9N·m (0.9kg·m,6.4ft-lbs) Connect the accelerator pedal harness connector. Connect the negative cable of the low voltage battery.
Page 94: Gear Shift System
Power drive 6.2 Gear shift system 6.2.1 Shifter assembly Schematic diagram Removal steps Disconnect the negative cable of the low voltage battery. Remove the center decorative bright strip assembly. Remove the shifter assembly - 1 - in the direction of the arrow. △...
Page 95: Shifter Foot Position
Power drive 6.2.2 Shifter foot position Terminal Function Remarks Schematic diagram Power Operating range supply +12V 9V-16V Spare Spare Small lamp Connected to signal vehicle+12V S gear Output 12V at signal current gear R gear Output 12V at signal current gear N gear Output 12V at signal...
Page 96: Drive Motor
Power drive 6.3 Drive motor 6.3.1 Overview The rotating magnetic field of the motor and the stator coil work together to generate torque. Like traditional gasoline engines, the motor does not have idle speed, and even when the vehicle moves from standstill to the critical state of starting, the motor can generate maximum driving torque, ensuring good acceleration for the vehicle.
Page 97 Power drive Removal and installation Schematic diagram Removal steps Turn the key switch to the "LOCK" position and disconnect the negative battery cable. Unscrew the fixing bolts of the high voltage wire protection plate - as shown by the arrow -, and remove the high voltage wire protection plate.
Page 98 Power drive Unscrew the fixing bolt connecting the UVW harness to the inside of the motor control unit- as shown by the arrow -; Unscrew the fixing nuts on the positive and negative wire harnesses of the MCU and the outer side of the motor control unit - as shown by the arrow -, disconnect the positive and negative wire harnesses of the MCU - 1 - and remove them;...
Page 99: Motor Reducer Oil
Power drive 11. Place the lifting platform truck; 12. Remove the front suspension, rear suspension, and right suspension components; 13. Slowly lower the lifting platform truck and remove the motor reducer assembly. Installation steps The installation sequence is the reverse of the removal sequence.
Page 100 Power drive Replacement of the motor reducer oil Schematic diagram Steps Unscrew the oil drain plug and gasket assembly, and use a graduated container to collect the reducer oil. △ ! Tips: The graduated container helps to determine the approximate amount of filling.
Page 101: Air Conditioning System
Air conditioning system 7. Air conditioning system 7.1 Electronic fan 7.1.1 Overview △ ! Warning During the removal and installation of high voltage components, personnel who need to obtain a low voltage electrician certificate must wear high voltage insulating gloves and also provide their own insulation protection.
Page 102: Tightening Torque Specification
Air conditioning system 7.1.2 Tightening torque specification Tightening torque Fastener N·m kg·m ft-lbs Electronic fan fixing bolt Electronic fan assembly bracket fixing bolt Condenser upper crossbeam fixing bolt 7.1.3 Electronic fan △ ! Warning During the removal and installation of high voltage components, personnel with a low voltage electrician certificate can operate.
Page 103 Air conditioning system Removal Schematic diagram Steps Disconnect the negative cable of the low voltage battery. Raise the vehicle. Remove the front bumper. Lower down the vehicle. Remove 6 fasteners of the upper crossbeam. Disconnect the electronic fan harness connector. Remove the electronic fan assembly.
Page 104 Air conditioning system Installation Schematic diagram Steps Install the electronic fan. Install 3 fasteners of the electronic fan. Tightening torque: 9N·m(0.9kg·m, 6.4ft-lbs) Install the electronic fan assembly. Connect the electronic fan harness connector. Install fasteners upper crossbeam. Tightening torque: 9N·m(0.9kg·m, 6.4ft-lbs) Install the front bumper.
Page 105: Suspension System
Air conditioning system 8. Suspension system 8.1 Front suspension 8.1.1 Overview The front suspension is a column type independent suspension. The upper end of the strut is connected to the vehicle body through a strut support. The strut and its support are separated by a rubber.
Page 106 Schematic diagram Name Strut nut Strut spring washer Strut inner support Strut rebound retaining ring Strut support Strut damping pad Strut damping pad Strut bearing seat Strut bearing Upper spring seat Strut spring seat Rebound stopper Coil spring Strut assembly △...
Page 107: Special Tools
Air conditioning system 8.1.2 Special tools 09900–06108/Snap ring pliers (closed type) 09913–75810/Bearing installer 09925–88210/Bearing extractor 09913-61110/Bearing extractor accessories 09913–65210/Steering tie rod remover 09940–53111/Bearing installer 09924–74510/Bearing mounting handle 09942–15510/Slide hammer...
Page 108 09943–17912/Front hub remover (brake 09951–18210/Bearing installer support drum remover) 09944–68210/Bearing and sealing ring 09943–77910/Control bushing remover installer...
Page 109: Necessary Maintenance Materials
Air conditioning system 8.1.3 Necessary maintenance materials Materials Purpose Wheel bearing lubricating grease Wheel bearing oil seal lip 8.1.4 Tightening torque specification Tightening torque Fastener N·m kg·m ft-lbs Strut bracket nut 65.0 Strut nut 36.5 Strut support nut 17.0 Ball joint mounting 40.0 bolt Front cantilever bolt...
Page 110: Suspension Inspection
8.1.5 Suspension inspection Stabilizer bar and/or bushing stabilizer bar Schematic diagram Inspection steps Check for damage or deformation. If there are defects, replace them. Bushing Schematic diagram Inspection steps Check for damage, wear or aging. If there are defects, replace them.
Page 111 Air conditioning system Strut shock absorber Schematic diagram Inspection steps Check for oil leakage. If a defect is found in the strut, replace the strut assembly because it cannot be disassembled. Inspection of strut function. Check the tire pressure and adjust it to the specified pressure.
Page 112 Check the bearings for wear, abnormal noise, or binding. Check whether there are cracks or deformation on the spring seat. Check whether the rebound stopper is aged. Check whether the rebound stop and strut support has wear, cracks or deformation. If defective parts are found in steps 2) to 7), replace them.
Page 113 Air conditioning system Front cantilever joint Schematic diagram Inspection steps Check for flexible rotation. Check whether the ball pin is damaged. Check whether the dust cover is damaged. Check the clearance in the ball joint. If any abnormality is found, replace the parts with new ones.
Page 114 Check whether the wheel bearing is worn. When measuring axial clearance, after removing the wheel center cover from the wheel disc, place a dial indicator in the center of the hub. Axial clearance limit value "a": 0.4mm (0.016in.). When measured value exceeds the limit value, replace the bearing.
Page 115: Oil Seal, Snap Ring, And Wheel Bearing
Air conditioning system 8.1.6 Oil seal, snap ring, and wheel bearing Removal and installation Schematic diagram Removal steps Remove the oil seal and snap ring. Once the bearing outer race is removed, replace it with a new bearing assembly (outer race, bearing, and inner race).
Page 116 After applying lubricating grease to the oil seal lip, install the wheel bearing and snap ring. “A”: Lubricating grease 3. Use a special tool to rotate the oil seal component until it is flush with the stopper surface of the steering knuckle. Special tool: (A):09924-74510...
Page 117: Steering Knuckle/Bearing
Air conditioning system 8.1.7 Steering knuckle/bearing Removal Schematic diagram Removal steps Raise the vehicle. Remove the wheel. Remove the wheel hub. Use the special tool to pull out the cross tie rod ball joint from the steering knuckle. 1 - Steering knuckle; 2-Cross tie rod ball joint Special tool: (A):09913-65210 tie rod remover Remove the wheel speed sensor (if equipped) from the steering knuckle.
Page 118 Installation Schematic diagram Steps Install the steering knuckle onto the ball joint and strut bracket on the front cantilever, and install each bolt in the direction shown in the figure. Align the steering knuckle bolt hole with the ball joint face as shown in the figure, and tighten each bolt and nut with the specified torque.
Page 119: Front Cantilever/Bushing
Air conditioning system 8.1.8 Front cantilever/bushing Removal Schematic diagram Steps Raise the vehicle. Remove the wheel. Remove the stabilizer bar split pin, slotted nut, gasket and bushing. Remove the stabilizer bar bracket (left and right) bolts. Remove the ball joint bolt. 1 - Lateral stabilizer bar;...
Page 120 Installation Schematic diagram Steps Install the bushing. Special tool: (A):09943-77910 △ ! Caution Before installing the bushing, apply soapy water around the bushing to make it easy to install. During installation, distance between the bushing on the left and right sides of the arm is equal as shown in the figure.
Page 121 Air conditioning system Install the front cantilever onto the vehicle body, tighten front cantilever bolts with the specified torque according front cantilever installation angle "a" given below. “a”: angle 10 ° ± 5 ° Tightening torque: (b):60N·m(6.0kg·m, 43.5ft-lbs) Install the stabilizer bar onto the front cantilever, and then install the bushing, washer, and nut onto the stabilizer bar.
Page 122: Wheel Hub, Wheel Stud/Wheel Bearing Outer Inner Race
8.1.9 Wheel hub, wheel stud/wheel bearing outer inner race Removal Schematic diagram Steps Raise the vehicle. Remove the wheel. Loosen the rivet point of the drive shaft nut. Step on the brake pedal and secure it. Remove the drive shaft nut. 1-Drive shaft nut Remove the brake caliper bolt.
Page 123 Air conditioning system Remove the hub bolt. △ ! Caution Never remove the hub bolts unless they require to be replaced. When replacing, make sure to use new bolts. 1-Hammer; 2-Hub bolt 10. Remove the wheel bearing inner race. Special tool: (C):09913-61110 (D):09925-88210...
Page 124 Installation Schematic diagram Steps Install the hub bolt and place a new bolt into the hub hole. Slowly rotate the stud bolt to ensure that the tooth pattern is consistent with the original bolt. 1 - Hydraulic press; 2-Hydraulic press rod; 3-Hub bolt Use the special tool to install the outer inner race onto the wheel hub, with the...
Page 125 Air conditioning system Install the wheel hub onto the steering knuckle by tightening the drive shaft nut. Do not tap the wheel hub. Install the brake disc. Install the brake caliper/brake caliper holder. Tighten the brake caliper support bolt with the specified torque. Tightening torque: (b):85N·m(8.5kg·m,...
Page 126: Strut Shock Absorber Assembly
8.1.10 Strut shock absorber assembly △ ! Caution When disassembling the strut assembly, gently loosen the strut nuts before removing the strut assembly from the vehicle. This will make it easier to break down the work. However, be careful not to remove the nuts at these locations. Removal Schematic diagram Steps...
Page 127 Air conditioning system Disassembly Schematic diagram Steps Use a spring compressor to compress the strut spring until the spring seat is not under spring tension. △ ! Caution Use existing commercially available spring compressors and follow the instructions provided by the spring compressor manufacturer.
Page 128 Assembly Schematic diagram Steps Assemble in the reverse order of the disassembly process. 1 - Strut nut; 2-Strut spring washer; 3-Strut inner support; 4-Strut rebound retaining ring; 5 - Strut seat; 6-Strut damping pad; 7 - Strut damping cushion; 8-Strut bearing seat; 9 - Strut bearing; 10 - Upper spring seat;...
Page 129 Air conditioning system Install the spring seat as shown in the figure, so that the upper end of the spring matches the step portion. Then install the upper spring seat onto the spring seat as well. Install the rebound stopper onto the piston rod.
Page 130: Stabilizer Bar And Bushing
Installation Schematic diagram Steps Install in the reverse order of removal, and install the bolts in the direction shown in the figure. Tighten all fasteners to the specified torque. Tightening torque: (a):23N·m(2.3kg·m, 17.0ft-lbs) (b):90N·m(9.0kg·m, 65.0ft-lbs) △ ! Caution 1 - Strut bracket nut; 2-Strut support nut; 3-E-ring;...
Page 131 Air conditioning system Installation Schematic diagram Steps When installing stabilizer bar, loosely assemble all components while ensuring that the stabilizer bar is centered and facing each other. Refer to Figure A to check it. 1 - Mounting bushing; 2-Marking Check for correct installation in the vertical paint direction, refer to Figure B.
Page 132: Adjustment Of Wheel Camber Angle And Kingpin Caster Angle
Install the wheel and tighten the wheel nuts to the specified torque. Tightening torque: (c):85N·m(8.5kg·m, 61.5ft-lbs) Lower the jack. Check toe-in adjust necessary. 8.1.12 Adjustment of wheel camber angle and kingpin caster angle During inspection, once it is found that the wheel camber angle and kingpin caster angle do not meet the requirements, the cause must be found first.
Page 133: Toe-In Adjustment
Air conditioning system 8.1.13 Toe-in adjustment Correct the maintenance data Wheel centerline Toe-in -1 ~ +1mm(-0.040 ~ +0.039in.) Forward Wheel Body camber 0°00'±1° center Positive angle inclination Top view of wheel Kingpin Toe-in toe-in caster 3°00'±1° angle Kingpin inclination 11°50'±3° angle △...
Page 134 camber angle is negative. This inclination is measured in degrees. Preliminary inspection before adjusting front wheel alignment 1. Check whether all tires have an appropriate inflation pressure and that the tire tread wear condition is approximately the same. 2. Check whether the ball joint is loose. Check the steering tie rod joint. If it is loose, it must be fastened before adjustment.
Page 135 Air conditioning system Toe-in adjustment Schematic diagram Steps The tire toe-in is adjusted by changing Tie rod Tie rod the length of the steering cross tie rod. First, loosen the lock nuts on the right and left steering tie rod joints. Rotate the right and left steering cross tie rods by the same amount to adjust the wheel toe-in to the specified value.
Page 136 Check the toe-in and then check the steering angle using a turning radius gauge (check when replacing the tie rod and steering tie rod joint). If the steering angle is incorrect, check Turning radius whether the lengths of the right and left gauge steering cross tie rods are consistent (Figure "A").
Page 137: Rear Suspension
Air conditioning system 8.2 Rear suspension 8.2.1 Overview The rear suspension is a traction suspension device composed of coil spring, rear axle, rear shock absorber, lateral thrust rod and rear trailing arm. The lateral thrust rod is mounted to the vehicle body and rear axle through bushings to prevent lateral movement of the rear axle.
Page 138: Necessary Maintenance Materials
gasket inner friction block assembly Rear axle Rear brake hose assembly Rear hub bearing unit Bolt assembly Bolt Washer Rear brake disc Rear brake disc dust cover △ ! Caution All rear suspension system fasteners are important parts that are sufficient to affect the performance of major parts and systems, and may result in major repair costs.
Page 139: Tightening Torque Specification
Air conditioning system 8.2.3 Tightening torque specification Tightening torque Fastener N·m kg·m ft-lbs Lateral thrust rod right 42.0 mounting nut Lateral thrust rod left 32.5 mounting nut Rear shock absorber 42.0 upper mounting bolt Rear shock absorber 42.0 lower mounting bolt Rear trailing arm front 58.0 mounting nut...
Page 140: Rear Suspension Inspection
8.2.4 Rear suspension inspection Rear shock absorber Schematic diagram Inspection steps Check for deformation or damage. Check bushing wear damage. Check for oil leakage. Replace any defective parts. △ ! Warning When operating a rear shock absorber sealed with high pressure gas, the following precautions must be taken: 1.
Page 141 Air conditioning system Rear trailing arm, lateral thrust rod, rear axle and coil spring Schematic diagram Inspection steps Check cracks, deformation damage. Check the bushing for tear, wear and damage. Replace any defective parts. Rebound stopper/upper spring seat Schematic diagram Inspection steps Check cracks,...
Page 142 Wheel nut and bearing Schematic diagram Inspection steps 1.Check each wheel disc for dents, deformation, and cracks. Severely damaged wheel discs should be replaced. 2.Check whether the wheel nuts are tight and tighten them to the specified torque as necessary. Tightening torque:(a):85N·m(8.5kg·m, 61.5ft-lbs) Check whether the wheel bearings are...
Page 143: Rear Axle
Air conditioning system 8.2.5 Rear axle Removal Schematic diagram Steps Raise the vehicle. Remove the rear wheels (right and left). Support the rear axle with a jack. 1 - Rear axle; 2-Jack Loosen the rivet points (right and left) of the rear axle nut and remove the rear axle nut.
Page 144 Use the special tool to pull off the wheel hub. Remove the dust disc. 1 - Rear brake disc dust disc Remove the lateral thrust rod from the rear axle.
Page 145 Air conditioning system 10. Disconnect the wheel speed sensor and wire clip. 11. Remove the rear shock absorber lower mounting bolts (right and left). 1 - Shock absorber; 2-Lower mounting bolt 12. Gradually lower the rear axle until the coil spring can be removed. 13.
Page 146 Installation Schematic diagram Steps Center Outside side of of the vehicle Place the rear axle on a jack, and then install the rear trailing arm mounting bolts (right and left) in the direction shown in the figure. At the same time, install the nuts, but do not tighten them.
Page 147 Air conditioning system Install the rear shock absorber lower mounting bolts (right and left). Remove the jack from the rear axle. 1 - Shock absorber; 2-Lower mounting bolt Install the lateral thrust rod onto the Front rear axle. △ ! Caution Do not tighten the nut.
Page 148 Install the wheel and tighten the wheel nuts to the specified torque. Tightening torque: (d):85N·m(8.5kg·m, 61.5ft-lbs) After completing the above work, step on the brake pedal 3 to 5 times with a load of approximately 30 kg (661 lbs) to ensure proper clearance between the wheel drum and brake shoes.
Page 149: Rear Trailing Arm
Air conditioning system 8.2.6 Rear trailing arm Removal Schematic diagram Steps Raise the vehicle. Remove the rear wheel. Support the rear axle with a jack. △ ! Caution Do not support the lateral thrust rod with a jack to avoid damage to the lateral thrust rod.
Page 150 Remove the front mounting bolts of the rear trailing arm, and then remove the rear 1-trailing arm. 1-Rear trailing arm; 2-Front mounting bolt Installation Schematic diagram Steps Outside Center 车辆 Center of the side of the 外侧 vehicle side vehicle of the Center Outside...
Page 151 Air conditioning system Install the rear shock absorber onto the rear axle. Remove the jack from the rear axle. - Shock absorber; 2-Rear axle; 3 - Lower mounting bolt Install the wheel and tighten the wheel nuts to the specified torque. Tightening torque: (a):85N·m(8.5kg·m,61.5ft-lbs)
Page 152: Rebound Stopper And Upper Spring Seat
8.2.7 Rebound stopper and upper spring seat Removal and installation Schematic diagram Removal steps Remove the coil spring. Remove the upper spring seat. Remove the rebound stopper. 1-Upper spring seat; 2-Rebound stopper Installation steps Install the rebound stopper. △ ! Caution Before installing the bushing tightly, apply soapy water to the bushing.
Page 153: Coil Spring
Air conditioning system 8.2.8 Coil spring Removal Schematic diagram Steps Raise the vehicle. Remove the rear wheel. Support the rear axle with a jack to prevent it from falling. 1 - Rear axle; 2-Jack Remove the right mounting bolt and nut of the lateral thrust rod.
Page 154 Remove the rear shock absorber lower mounting bolts. - Shock absorber; 2-Lower mounting bolt Slowly lower the rear axle until the coil spring can be removed. △ ! Caution Take care not to allow the rear axle to lower too quickly, which can cause damage to the brake flexible hose.
Page 155 Air conditioning system Installation Schematic diagram Steps Install the coil spring with its closed end facing upward and open end facing downward, and ensure that its end is firmly installed on the spring seat. △ ! Caution As shown in the figure, make the spring 1 - Rear axle;...
Page 156: Rear Shock Absorber
Install the wheel and tighten the wheel nuts to the specified torque. Tightening torque: (a):85N·m(8.5kg·m, 61.5ft-lbs) Lower the jack and tighten the lower mounting bolt of the rear shock absorber and the right mounting nut of the lateral thrust rod with the specified torque when the vehicle is in an unloaded state.
Page 157 Air conditioning system Installation Schematic diagram Steps Install the rear shock absorber as Center side of the vehicle shown in the figure. △ ! Caution Do not tighten the nut and bolt. Remove the jack from the rear axle and lower the lifter.
Page 158: Lateral Thrust Rod
8.2.10 Lateral thrust rod Removal Schematic diagram Steps Raise the vehicle. Remove the mounting nut and bolt of the lateral thrust rod. Remove the lateral thrust rod. 1 - Lateral thrust rod; 2-Left mounting nut; 3 - Right mounting bolt Installation Schematic diagram Steps...
Page 159 Air conditioning system Install the lateral thrust rod onto the vehicle body, and refer to the figure for the correct installation direction of the bolts and washers. 1 - Lateral thrust rod; 2-Bushing; 3 - Lateral △ ! Caution thrust rod washer; 4 - Lateral thrust rod outer Do not tighten the nut.
Page 160: Wheel And Tire
8.3 Wheel and tire 8.3.1 Overview Tire This vehicle is equipped with tires of the following specifications: 175/60R1479H This type of tire has no inner tube. When the tire is inflated to the recommended inflation pressure and the tire load reaches the full load state, it is the best design state and the driving condition is the most satisfactory.
Page 161 Air conditioning system kgf/cm² Replace the wheel If the wheel has twists, dents, excessive lateral or radial runout, air leakage from the weld, bolt holes that are elongated, cap nuts that are not securely locked, or severe rust, they must be replaced. When the wheel runout is greater than the limit value shown in the table on the following page, undesirable vibration will occur.
Page 162 Measure wheel runout To measure wheel radial runout, an accurate dial gauge must be used. It does not matter whether the tire is mounted on the wheel. To obtain the correct measurement, the wheels must be mounted on a suitable wheel balancer. Measure the radial and lateral runout at the inward and outward positions of the rim bead.
Page 163: Tightening Torque Specification
Air conditioning system 8.3.2 Tightening torque specification Tightening torque Fastener N·m kg·m ft-lbs Wheel nut 61.5 8.3.3 Tire Tire installation and removal Use a tire changer to install or remove tires. When operating the machine, it is necessary to follow the instructions of the machine manufacturer. Do not use only manual tools or tire removal pry bars to replace tires, as this will damage the rim port or rim of the wheel.
Page 164: Wheel
8.3.4 Wheel Removal Schematic diagram Steps Loosen the nut by approximately 180° (half turn). Raise the vehicle. Remove the nut and the wheel. Inspection Schematic diagram Steps Inspect the cap nuts and wheel studs. All vehicle models use metric cap nuts and wheel studs (size: M12×1.25).
Page 165 Air conditioning system Installation Schematic diagram Steps The wheel nuts must be tightened to the specified torque in order to avoid bending the wheels or brake drums or discs, as shown in the figure. Tightening torque: (a):85N·m(8.5kg·m, 61.5ft-lbs) △ ! Caution Before installing the wheel, first remove the corrosion on the mounting surface of the wheel and the mounting...
Page 166: Maintenance And Auxiliary Adjustment
8.3.5 Maintenance and auxiliary adjustment Vehicle maintenance Welding, heating, or hammering to repair wheels is not allowed, and all damaged wheels must be replaced. Wheel stud If the stud is found to be broken, it must be replaced. Tire and wheel assembly The tires and wheels are assembled at the assembly plant.
Page 167 Air conditioning system Tire inflation The recommended inflation pressure for each vehicle model is carefully calculated to achieve comfort, proper stability, maneuverability, tread wear, tire life, and avoidance of tire damage. Every month or before driving for a long distance, the tire pressure should be checked under a cold tire condition (that is, the vehicle should be left for more than 3 hours, or driven within 1 mile).
Page 168 The tire nameplate is located under the door lock eyelet of the driver's side door, and the data related to the tire (driving identification) is recorded here for reference. The applicable maximum load, tire size, and cold tire pressure are listed on the nameplate. Tire rotation To equalize wear, rotate the tires as shown in the left figure.
Page 169 Air conditioning system shown figure, dynamic balancing refers to the situation where the weight distribution on each side of the wheel centerline is equal, so that the tire assembly does not tend to move from one side to the other during rotation. If the wheel is dynamically unbalanced, it will cause front wheel shimmy.
Page 170: Braking System
Braking system 9. Braking system 9.1 Front disc brake 9.1.1 Overview The brake caliper is a single cylinder type, with hydraulic pressure generated by the pressure acting on the brake pedal and converted into friction through the brake caliper. The hydraulic pressure also acts on the piston and the bottom of the cylinder block, pushing the piston outward while pushing (sliding) the...
Page 171 Braking system Adjust the brake clearance When braking, the piston moves forward under 1. Cylinder 2. Piston the action of oil pressure. After applying 3. Rubber sealing ring moderate pressure to the piston, the rubber sealing ring moves with the cylinder. However, Hydraulic Hydraulic pressure because a portion of the rubber sealing ring...
Page 172: Necessary Maintenance Materials
Braking system 9.1.2 Necessary maintenance materials Materials Purpose Fill the brake fluid reservoir Brake fluid Clean or apply to the disassembled brake master cylinder, caliper, and wheel cylinder components Apply to the joint surface of the brake backing plate and rear knuckle Waterproof Apply to the joint surface of the brake backing plate and the parking brake cable sealant...
Page 173: Inspection Of Front Brake Friction Block
Braking system 9.1.4 Inspection of front brake friction block Schematic diagram Steps Whenever a wheel is removed (due to tire rotation or other reasons), periodically inspect the friction pads according to the maintenance schedule. Check each end (or hole) of the brake caliper and check the thickness of the outer and inner friction blocks.
Page 174: Inspection Of Front Brake Disc
Braking system 9.1.5 Inspection of front brake disc Schematic diagram Steps Check the worn parts of the brake disc for scratches. During the inspection or replacement at the specified time, the brake disc surface of the part is normal and the brake disc wear is not very serious.
Page 175: Adjust The Brake Clearance
Braking system 9.1.6 Adjust the brake clearance Schematic diagram Steps Check the free height of the brake pedal. If the free height is not within the specification range, check and adjust it. Free height "a" of the brake pedal from the carpet: 170mm (6.69in.) Check dimension between...
Page 176: Brake Disc
Braking system 9.1.7 Brake disc Removal Schematic diagram Steps Remove the wheel. Remove clamp assembly loosening the bracket bolts (2). Drive out the brake disc with 8mm △ ! Caution bolts During removal, take care not to damage the brake hose and not to pressurize the brake pedal.
Page 177: Brake Caliper Assembly
Braking system 9.1.8 Brake caliper assembly Removal Schematic diagram Steps Remove the wheel. Remove the fixed E-ring of the brake hose. 1-E-ring Slightly loosen the brake hose nut on the brake caliper. △ ! Caution Be careful not to bend the hose when loosening the bolt.
Page 178 Braking system Disassembly Before disassembly, clean the circumference of the brake caliper body with brake fluid. Schematic diagram Steps Fill the cylinder body with compressed air from the stud hole at the fixed hose position. Under the pressure of the air, the piston will be pushed out of the cylinder.
Page 179 Braking system Inspection Schematic diagram Steps Check whether the cylinder cover is cracked, scratched, damaged. damaged, replace it. Check whether the sealing ring is cracked, scratched, damaged. damaged, replace it. Piston sealing ring Directly facing 3-groove side at the brake pad side Excessive or uneven gasket wear indicates that the piston cannot move back and forth freely.
Page 180 Braking system Before installing the piston and piston sealing ring, apply the same type of brake fluid to them. After reinstalling the brake pipe, bleed the braking system. The piston sealing ring is used to seal the piston and oil cylinder, and can adjust the clearance between the brake pad and the brake disc.
Page 181 Braking system Pull the piston out of the oil cylinder a little, but not all, to ensure that the protective sleeve is correctly installed in the groove in the oil cylinder. △ ! Caution The surface B of the protective sleeve should be on the same horizontal plane as the surface A of the oil cylinder.
Page 182 Braking system Installation Schematic diagram Steps Install the brake hose onto the brake caliper. Apply lubricating grease to the brake caliper pin and install the clamp on the brake caliper bracket. △ ! Caution When using rubber lubricating grease at temperatures below-30℃(-22℉), its viscosity will not change much even at -40℃(-40℉).
Page 183: Brake Pad
Braking system 9.1.9 Brake pad Removal Schematic diagram Steps Remove the wheel. Remove the brake caliper bolt pin. -Brake caliper; 2-Brake mounting bolt; 3-Brake disc Remove the brake caliper body from the brake caliper bracket. △ ! Caution Hook up the brake caliper body with a metal hook or use similar methods to prevent excessive bending, twisting, or pulling of the brake hose.
Page 184 Braking system Inspection Schematic diagram Steps Check the thickness of the brake pad. △ ! Caution Do not use abrasive paper to polish the brake pad gasket. If the gasket is polished with abrasive paper, hard particles of the abrasive paper will deposit on the gasket and damage the brake disc.
Page 185 Braking system Installation Schematic diagram Steps Install the brake pad and caliper. 1-Clamp; 2-Brake ruler; 3-Brake disc; 4-Clamp pliers Install the brake caliper and tighten the brake caliper clamp bolt pin to the specified torque. △ ! Caution Ensure that the protective sleeve is securely installed in the slot.
Page 186: Symptom Table
Braking system 9.1.10 Symptom table Brake fault diagnosis table Fault symptom Possible causes Maintenance measures Oil leakage from the brake lines Find the leakage and repair Oil contamination on the brake Clean or replace disc or pedal Determine the cause and Brake overheating repair Repair to realize proper...
Page 187: Rear Disc Brake
Braking system 9.2 Rear disc brake 9.2.1 Overview Rear brake assembly △ ! Caution Replace all components, including repairing accessories to maintain the brake, and lubricate the components as specified. △ ! Warning If the hydraulic components are removed or the brake pipe is disconnected, exhaust the braking system in a timely manner.
Page 188 Braking system When removing any components or disconnecting pipelines, exhaust must be performed. When replacing brake pads, the specified torque values apply to fasteners that are dry and free of lubricating oil. Schematic diagram Name Right rear brake caliper assembly Left rear brake caliper assembly Brake caliper body Brake disc...
Page 189 Braking system Removal and installation of the parking brake cable Schematic diagram: Front Upside Upside Inside Clamp: D View: B Clamp: C Inside View: H View: F Grey ring Front View: A Upside Rear side Clamp: A In the same position View: M on the right and left Upside...
Page 190 Braking system Schematic diagram Installation steps Apply sealant to the sealing ring as shown in the figure. “A”: sealant 99000-31090 Install the parking brake cable with its gray ring side on the right. Connect the cable to the parking brake control handle.
Page 191: Necessary Maintenance Materials
Braking system 9.2.2 Necessary maintenance materials Materials Purpose Fill the brake fluid reservoir Brake fluid Clean or apply to the disassembled brake master cylinder, caliper, and wheel cylinder components Apply to the joint surface of the brake backing plate and rear knuckle Waterproof Apply to the joint surface of the brake backing plate and the parking brake sealant...
Page 192: Symptom Table
Braking system 9.2.4 Symptom table Fault symptom Possible causes Maintenance measures Oil leakage from the brake lines Find the leakage and repair Poor contact of friction block Repair to realize proper contact The brake friction block has oil Replace spots or is soaked in water Insufficient braking The brake bushing gasket is force...
Page 193: Parking Brake And Actuation
Braking system 9.3 Parking brake and actuation 9.3.1 Parking brake Inspection Schematic diagram Steps Grasp the parking brake lever firmly and pull upward with 20-25kg (44-451bs) of force. As the brake lever is used as above, count the number of pawls in the "A" section area shown in the figure.
Page 194 Braking system Adjust Schematic diagram Steps Before adjusting the cable, make sure the following: △ ! Caution Forward ① There is no air in the brake control system. ② The brake pedal travel is normal. ③ Press the brake pedal with a load of approximately 30 kg (661 lbs) for a few minutes.
Page 195: Parking Brake Cable
Braking system 9.3.2 Parking brake cable Removal Schematic diagram Steps Use pointed-nose pliers to grip the metal block at the end of the parking brake cable and pull it back firmly to disengage the parking brake cable from the return spring bracket slot.
Page 196 Braking system Installation Schematic diagram Steps Apply sealant to the sealing ring as shown in the figure. “A”: Sealant Install the parking brake cable with its gray ring side on the right. Connect the cable to the parking brake control handle. Do not adjust the control handle at this point.
Page 197: Parking Brake Control Handle
Braking system 9.3.3 Parking brake control handle Removal Schematic diagram Steps Remove the parking brake housing. Disconnect the parking brake switch wire. △ ! Caution Do not disassemble the parking brake switch, but remove or install it as a unit. Remove the nuts securing the parking brake cable.
Page 198: Hydraulic Braking
Braking system 9.4 Hydraulic braking 9.4.1 Brake fluid level Inspection Schematic diagram Steps Make sure to use the specified special brake fluid or the brake fluid recommended in the accompanying user manual. It is strictly prohibited to use the brake fluid of any other brand.
Page 199: Brake Hose Or Hard Pipe
Braking system 9.4.2 Brake hose or hard pipe Inspection Schematic diagram Steps brake hose assembly must inspected for road hazards, cracks and wear in the housing, leakage and air out. Lighting and mirrors are required for adequate inspection. If any of the above conditions are found on the brake hose, the hose needs to be replaced.
Page 200: Brake Bleed
Braking system 9.4.3 Brake bleed Schematic diagram Steps △ ! Caution Brake fluid can seriously damage the Right brake Right brake painted part. If brake fluid occasionally caliper caliper splashes on the surface of the painted Rear Front part, immediately wipe off the brake fluid. Bleeding requires the release of air Left brake caliper Left brake caliper...
Page 201 Braking system When repeatedly pressing the brake plate several times and holding it still, counter tighten the vent plug by one-third to half a turn. Press the brake pedal several times and slightly loosen the vent plug when the pedal is pressed. When there is almost no hydraulic pressure in the wheel cylinder, retighten the vent plug.
Page 202: Clean The Brake Hydraulic System
Braking system 9.4.4 Clean the brake hydraulic system Whenever a new component is installed on the brake hydraulic system, it is recommended to thoroughly clean the brake hydraulic system with clean brake fluid. It is also recommended to periodically replace the brake fluid. 9.4.5 Brake master cylinder Inspection Schematic diagram...
Page 203: Excessive Pedal Travel
Braking system 9.4.7 Excessive pedal travel Schematic diagram Steps Start the vehicle. Press the brake pedal for a few minutes. Apply approximately 30 kg (661 lbs) of force to the brake pedal and measure the clearance "c" at the front of the brake pedal.
Page 204: Symptom Table
Braking system 9.4.8 Symptom table Fault symptom Possible causes Treatment methods Oil leakage from the brake lines Find the leakage and repair Oil contamination on the brake Clean or replace disc or pedal Brake overheating Determine the cause and repair Abnormal contact of friction plate Repair to realize proper contact The brake shoe friction plate has...
Page 205: Brake Pedal Free Height Adjustment
Braking system 9.4.10 Brake pedal free height adjustment Schematic diagram Steps Check the free height "a" of the brake pedal. Free height "a" of the brake pedal from the carpet: 170mm(6.69in.) If the free height is not within the specifications, check adjust following items 2 and 3.
Page 206: Front Brake Hose/Conduit
Braking system 9.4.11 Front brake hose/conduit Removal and installation Schematic diagram Removal steps Remove the conduit P valve Upside Clamp: R Clamp: R Clamp: G Front connected to the brake master cylinder. Clamp: R Clamp: R Right side Front Lift the vehicle and remove the tires 1.
Page 207: Rear Brake Hose/Conduit
Braking system 9.4.12 Rear brake hose/conduit Removal 1. Lift the vehicle and remove the tires and wheels. △ ! Caution When only removing the conduit and P valve connected to the brake master cylinder, the above operation is not required. Remove dirt and foreign matters from the fixed positions of the hose and conduit ends, and then remove the brake hose or conduit.
Page 208: Replacement Of Esc Unit
Braking system 9.4.13 Replacement of ESC unit Removal and installation Schematic diagram Removal steps Turn the key switch to the "OFF" position. Remove all components that may interfere with the removal of the ESC unit. Remove the vehicle wiring harness from the ESC hydraulic electronic control unit.
Page 209 Braking system Each new ESC unit has a sealing strip attached to the pipe junction. While proceeding to step 4, remove the seal to prevent brake fluid from flowing out. Install the brake pipe to the correct position on the ESC unit and tighten it to 16–22N·m(1.6–2.2kg·m, 11.4–15.6ft-lbs).
Page 210: Brake Fluid Reservoir Assembly
Braking system 9.4.14 Brake fluid reservoir assembly Removal Schematic diagram Steps Disconnect the negative and positive wires of the low voltage battery and remove the battery. Disconnect reservoir wiring connector. Clean the area around the reservoir cap and use a fluid aspirator or similar device to suck out the brake fluid.
Page 211 Braking system Disassembly Schematic diagram Steps Use the special tool to remove the pins that secure the brake master cylinder block and reservoir. Special tool: (A):09922-89810 Remove the reservoir and the 2 ring carriers △ ! Caution Do not use any mineral oils such as kerosene or gasoline when cleaning and assembling components.
Page 212: Brake Booster
Braking system 9.5 Brake booster 9.5.1 Overview Vacuum booster assembly Name Name Name Servo air chamber Servo air chamber Control valve push rod front housing rear housing Air filter element Air filter Air valve spring seat Air valve return Control valve Control valve spring spring spring retainer...
Page 213 Braking system of the brake master cylinder to generate high hydraulic pressure. If any related component in the vacuum booster is faulty, the pressure of the brake can increase without the aid of the booster. Even so, the brake force still pushes the push rod of the brake master cylinder through the control valve push rod, the vacuum booster air valve, the valve base, and the vacuum booster piston push rod in turn, so that the braking operation itself does not fail.
Page 214: Tightening Torque Specification
Braking system 9.5.2 Tightening torque specification Tightening torque Fastener N·m kg·m ft-lbs Electronic vacuum pump fixing bolt Electronic vacuum pump 10.7 bracket fixing bolt 9.5.3 Necessary maintenance materials Materials Purpose Brake fluid Hydraulic working medium 9.5.4 Vacuum booster piston push rod and brake master cylinder piston Installation Schematic diagram Steps...
Page 215 Braking system Install the vacuum booster onto the buffer plate as shown in the left figure, and then connect the fork of the vacuum booster to the brake pedal arm using a connecting pin and a split pin. Tighten the vacuum booster connecting nut to the specified torque.
Page 216 Braking system Check the operation of the vacuum booster There are two ways to perform this inspection, using a test instrument or not using a test instrument. Generally, the operating condition of the vacuum booster can be roughly determined without a test instrument. △...
Page 217 Braking system Check without a test instrument Check air tightness Schematic diagram Steps Start the vehicle. Shut down vehicle after minutes of operation. Under normal braking conditions, step on the brake pedal with the same force several times and observe the pedal travel. If the pedal descends deeper for the first time and the stroke decreases during the second and several more depressions, it indicates that the...
Page 218 Braking system Check the action After shutting down the vehicle, step on the brake plate several times with the same force and ensure that the brake plate travel does not change. Start the vehicle when the brake pedal is pressed. If the pedal travel is increased a little, the performance is good.
Page 219: Electronic Vacuum Pump
Braking system 9.5.5 Electronic vacuum pump Removal Schematic diagram Removal steps Disconnect the negative cable of the low voltage battery. Raise the vehicle. Remove the brake booster vacuum pipe. Remove 4 fasteners of the electronic vacuum pump and bracket assembly (as indicated by the arrow).
Page 220 Braking system Installation Schematic diagram Installation steps Install the electronic vacuum pump. Install the electronic vacuum pump bracket fasteners. Tightening torque: 11N·m(1.1kg·m, 7.9ft-lbs) Connect the electronic vacuum pump assembly harness connector. Install the electronic vacuum pump and bracket assembly. Install 4 fasteners of the electronic vacuum pump and bracket assembly.
Page 221: Vacuum Tank
Braking system 9.5.6 Vacuum tank Removal and installation Schematic diagram Removal steps Disconnect the negative cable of the low voltage battery. Remove the vacuum pump controller assembly - 1 -. Remove 2 brake booster hoses above the vacuum tank- 2 -. Remove 2 fasteners under the vacuum tank (as indicated by the arrow).
Page 222: Steering System
Steering system 10. Steering system 10.1 Power steering 10.1.1 Overview The electric power steering system (EPS) consists of an electric power steering module, a vehicle speed sensor, a noise suppressor, and other components installed in the steering column. The EPS module of the system determines the magnitude and direction of steering assistance based on the signals from the torque sensor and the vehicle speed sensor, and drives the motor to assist in steering operations.
Page 223 Steering system Terminal location and definition Terminal Terminal Connection Terminal Terminal Connection location name terminal name location name terminal name Power supply Power supply ground voltage -Motor output +Motor output Auxiliary torque Main torque signal signal Sensor power GND1 Sensor ground VCC1 supply PWM-P...
Page 224 Steering system EPS module EPS module is installed on the upper left side of the steering support beam. EPS module is a precision device composed microcomputer, (analog/digital) converter, and a 1/0 (input/output) device. It is an essential component of an electrical control system because its functions include not only main functions...
Page 225 Steering system On-board diagnostic system (self diagnostic function) When the key switch is turned to the "ON" position and the vehicle is started, the EPS control module can diagnose faults in the Average vehicle speed following components and display the results by turning on or flashing the "EPS"...
Page 226: Electrical Diagnosis
Steering system 10.1.2 Electrical diagnosis Use a dedicated diagnostic instrument to diagnose and detect fault codes, and find the cause of the fault through fault code prompts. Fault code list and cause analysis Trigger conditions Recovery conditions (criteria used to (criteria used to Fault Maintenance...
Page 227 Steering system T1 (main) Test the signal torque Abnormal T1 duty (12.5%<T1 duty and power Sensor fault, C112E4 abnormalit ratio (T1 duty ratio<87.5%), and the supply of the Sensor no signal ratio>87.5% system is powered on sensor, and feedback abnormal or<12.5%), t>1s again check the...
Page 228 Steering system P (main) Test the signal angle and power signal P cycle abnormality P cycle returns to Sensor fault, C11313 supply of the abnormalit Sensor (P cycle>1.15ms normal (0.85ms<P no signal sensor, and y: cycle or<0.85ms), t>0.2s cycle<1.15), t>0.25s feedback check the abnormalit...
Page 229 Steering system Angle signal Test the signal abnormalit and power Sensor fault, C11332 y: large PS angle follow>30°, PS angle follow<30°, supply of the Sensor no signal difference t>0.1s t>0.0025s sensor, and feedback between P check the and S sensor signals Angle Test the signal...
Page 230 Steering system Excessive The motor current ECU fault, C11441 Power Measured value>75A, Check ECU and motor is<75A, and the system drive motor supply t>0.032s drive motor current is powered on again fault When the target When the target current is greater than Motor current is greater ECU fault,...
Page 231: Steering Connecting Rod
Steering system Internal C11494 storage Internal storage area ECU fault Check ECU read/write data read/write error fault VMCU At least one network Check the CAN vehicle Vehicle speed is U1A508 ECU/Net MCU_VEH_SPD is valid fault, network and speed invalid for a duration work within the cycle of the MCU_VEH_S...
Page 232: Tightening Torque Specification
Steering system 10.2.2 Tightening torque specification Tightening torque Fastener N·m kg·m ft-lbs Steering shaft joint bolt 18.0 Steering gear housing bolt 18.0 Upper bracket bolt 18.0 Steering tie rod joint slotted nut 31.5 Steering tie rod joint lock nut 32.5 Steering pinion bearing screw plug 69.0 Steering tie rod...
Page 233: Special Tools
Steering system 10.2.4 Special tools 09913–65210/Tie rod remover 09913-50121/Oil seal remover 09944–26010/43mm socket (pinion bearing 09943–78210/Rack cushion installer plug remover) 09944–48210/Rack shaft pad remover 09925–98210/Bearing installer 09944 – 18211/Pinion torque detection kit...
Page 234: Lubrication Of Steering Components
Steering system 10.2.5 Lubrication of steering components After disassembling the internal components of the steering gear housing, before reassembling them, it is necessary to clean them all and lubricate the lubricating parts indicated in the illustration. Super lubricating grease (E), or lithium lubricating grease (suitable for -40℃~130℃...
Page 235: Inspection Of Steering Rack Dust Cover
Steering system Steering rack side Steering pinion side tie Steering rack side tie protective sleeve wire wire Rack protective sleeve Steering pinion side Steering pinion side clip bracket mounting pad Steering rack side Steering rack side Steering gear housing bracket mounting seat bolt Upper mounting...
Page 236: Inspection Of Steering Tie Rod Ball Pin Dust Cover
Steering system 10.2.7 Inspection of steering tie rod ball pin dust cover Schematic diagram Steps Check each dust cover for tears. If any tear is found, replace it with a new dust cover. 10.2.8 Inspection of steering shaft universal joint Schematic diagram Steps Check the steering shaft joint for wear,...
Page 237: Steering Tie Rod Joint
Steering system 10.2.10 Steering tie rod joint Removal Schematic diagram Steps Remove the wheel. Tie rod joint Steering knuckle Remove the split pin and steering tie rod Hexagon nut ball pin slotted nut from the steering knuckle. Split pin Use the special tool to remove the steering tie rod joint from the steering knuckle.
Page 238 Steering system Installation Schematic diagram Steps Install the steering tie rod joint lock nut and steering tie rod joint onto the steering tie rod. Align the lock nut with the mark on the thread of Tie rod the steering tie rod. Mark on thread Lock nut Tie rod joint...
Page 239: Steering Column
Steering system Check and adjust the front wheel toe-in, confirm that the front wheel toe-in is appropriate, and then tighten the lock nut of the steering tie rod joint to the specified torque. Tightening torque: (b):45N·m(4.5kg·m, 32.5ft-lbs) Install the wheel. 10.3 Steering column 10.3.1 Overview In addition to the steering function, this dual tube type steering column has the...
Page 240: Tightening Torque Specification
Steering system 10.3.2 Tightening torque specification Tightening torque Fastener N·m kg·m ft-lbs Steering shaft nut 23.5 Steering column mounting nut 10.5 Steering shaft joint bolt 18.0 Steering lock mounting bolt 10.0 10.3.3 Inspection of steering column damage in the accident △...
Page 241 Steering system Check the steering shaft joint and steering shaft for damage. For example: crack, fracture, malfunction, or excessive clearance. If any fault is found, replace the steering column lower joint assembly or the steering column assembly. Check whether the steering shaft rotates freely.
Page 242: Steering Shaft Lower Joint
Steering system 10.3.4 Steering shaft lower joint Removal Schematic diagram Steps Turn the steering wheel so that the front tires of the vehicle are in a straight forward direction. Turn the key switch to the "LOCK" position and remove it. △...
Page 243 Steering system Steering column Steering column nut Steering column lower nut Remove the steering shaft joint bolt, and then remove the steering shaft lower joint. Steering shaft joint bolt Steering shaft lower joint...
Page 244 Steering system Installation Schematic diagram Steps As shown in the figure, align the part of the steering shaft lower joint with the bolt hole of the upper joint, and then install the lower joint shaft to the upper joint. Steering shaft Confirm that both the front wheel and Steering shaft lower steering wheel are straight ahead, and then...
Page 245 Steering system Tighten the steering shaft joint bolt with the specified torque. Tightening torque: (b):25N·m(2.5kg·m, 18.0ft-lbs) Steering shaft joint bolt Steering shaft lower joint Install the steering shaft joint cover. Steering shaft joint cover Install the steering column hole cover. Steering column hole...
Page 246: Steering Column
Steering system 10.3.5 Steering column △ ! Caution Once the steering column is removed from the vehicle, it is extremely vulnerable to damage. When the end of the steering column assembly falls, it may damage the steering shaft or loosen the plastic shear pin that maintains the length of the steering column. Tilting the steering column assembly can cause the steering column to bend or deform.
Page 247 Steering system Disconnect plug-ins from following components. Spiral harness combination switch assembly. Key switch. Electric power steering system components (if equipped). Parking anti-theft system components (if equipped). Suspension control Steering shaft upper system components (if equipped). joint bolt Steering joint cover Remove the steering column mounting nuts (4).
Page 248 Steering system Inspection Schematic diagram Steps Check whether two fuse holders are fully seated against the steering column bracket. Check the clearance between the fuse holder and the steering column bracket. The clearance between them must 0.0mm(0.0in.). If looseness or clearance is found, replace the steering column assembly.
Page 249 Steering system Installation Schematic diagram Steps As shown in the figure, align the position "A" of the lower joint of the steering shaft with the bolt hole "B" of the upper joint of the steering column. Then insert the steering column upper Steering shaft lower joint joint into the steering shaft lower joint shaft.
Page 250 Steering system If the spiral harness and combination switch assembly were removed, install the spiral harness and combination switch assembly. Refer to “Spiral harness and combination switch assembly”. Connect all plug-ins that are removed during "removal". Install the steering column hole cover. Install the steering wheel.
Page 251: Steering Wheel
Steering system 10.4 Steering wheel 10.4.1 Overview Schematic diagram Name Steering wheel 10.4.2 Special tools 09944–36011 Steering wheel remover...
Page 252: Inspection Of Steering Force
Steering system 10.4.3 Inspection of steering force Schematic diagram Steps The vehicle is parked on a level road, and the steering wheel is placed in a straight forward position. Check whether tire inflation pressure meets the specified requirements (refer to the tire indication). Start the vehicle.
Page 253: Steering Wheel
Steering system 10.4.5 Steering wheel △ ! Caution When removing the steering wheel, allow the spiral harness to rotate freely, but do not rotate the spiral harness (on the combination switch) more than the allowed number of turns (approximately two and a half turns clockwise or counterclockwise from the center position, respectively), otherwise the wire coil will break.
Page 254 Steering system Installation Schematic diagram Steps Check whether the vehicle wheels (front tires) are facing straight ahead and whether the spiral harness is in the middle. Refer to “Spiral harness”. △ ! Caution These two states are prerequisites for installing the steering wheel. If the steering wheel is not installed in the above state, the spiral harness will break when the steering wheel is turned.
Page 255 Steering system...
Page 256: Air Conditioning Control System
Air conditioning control system 11. Air conditioning control system 11.1 System overview 11.1.1 Maintenance instructions for vehicle air conditioning system • When repairing the air conditioning system, the negative cable of the battery must be disconnected, and the environment and tools should be kept clean. •...
Page 257: Instructions For Use Of Refrigerant Oil
Air conditioning control system • Vehicle air conditioning refrigerant has less corrosion to metals, high stability, and is insoluble in water; low freezing point, suitable for low temperature work; and it is easy to detect leakage. Please use the vehicle air conditioning refrigerant correctly and take protective measures to avoid causing harm to the human body;...
Page 258 Air conditioning control system intensity of drivers, and improve driving safety. Air conditioning systems utilize the heat transfer effect of air to transmit heat in the air to the place with low temperatures; when the evaporator is at a low temperature, it absorbs external heat and uses the refrigerant as a conductive medium to be pumped away by the compressor.
Page 259 Air conditioning control system reduce the temperature of the compartment. Ventilation function of air conditioning system: • Ventilation of air conditioning system refers to the introduction of fresh air from outside the vehicle during vehicle operation, and the discharge of dirty air inside to the outside to maintain the freshness of the air inside the vehicle, while also preventing fogging of the window glass.
Page 260: Fault Symptoms And Troubleshooting Measures
Air conditioning control system 11.2 Fault symptoms and troubleshooting measures 11.2.1 The pressure of air conditioning system is too high Inspection steps Inspection results Preliminary inspection Normal Faulty Operation method Adjust the Check whether the refrigerant is Proceed Excessive refrigerant amount excessive to Step 1 refrigerant...
Page 261: The Pressure Of Air Conditioning System Is Too Low
Air conditioning control system 11.2.2 The pressure of air conditioning system is too low Inspection steps Inspection results Preliminary inspection Normal Faulty Operation method Check the air conditioning Proceed Air conditioning Repair or replace the pipeline for leakage to Step 1 pipeline leaks faulty pipeline Check the refrigerant...
Page 262: No Cooling Air Sent From The Air Conditioner
Air conditioning control system 11.2.3 No cooling air sent from the air conditioner Inspection steps Inspection results Preliminary inspection Normal Faulty Operation method Check whether the air Air conditioning Proceed Replace the air conditioning controller is controller to Step 1 conditioning controller damaged.
Page 263: Abnormal Noise Of Compressor
Air conditioning control system Check whether the motor The motor and Proceed Repair or replace the and fan assembly operate fan assembly to Step 7 motor and fan assembly normally do not operate Check the temperature Normal Faulty Operation method sensor Check whether the Proceed...
Page 264: Intermittent Cold Air
Air conditioning control system 11.2.5 Intermittent cold air Inspection steps Inspection results Operation Check the refrigerant Faulty method Vacuumize the Check whether there is Moisture in the air conditioning Proceed moisture in the refrigerant refrigerant system and to Step 1 circulation circuit circulation circuit replace the dry...
Page 265: Insufficient Refrigeration
Air conditioning control system 11.2.6 Insufficient refrigeration Inspection steps Inspection results Check the circuit fault of the air Normal Faulty Operation method conditioning system Check the poor Poor connection of connection of the air Proceed Repair and check the the air conditioning conditioning system to Step 1 faulty circuit...
Page 266: Low Cold Air Output Speed
Air conditioning control system 11.2.7 Low cold air output speed Inspection steps Inspection results Preliminary inspection Normal Faulty Operation method Check whether there are Foreign Proceed Clean or repair the air foreign matters at air outlet of matters at air to Step 1 outlet the air conditioner...
Page 267: Cold Air Only Available At High Vehicle Speeds
Air conditioning control system 11.2.8 Cold air only available at high vehicle speeds Inspection steps Inspection results Preliminary inspection Normal Faulty Operation method There is air in Check whether there is air refrigerant The air conditioning in the refrigerant Proceed circulation system is vacuumized circulation circuit or...
Page 268: Electric Air Conditioner
Air conditioning control system 11.3 Electric air conditioner 11.3.1 Overview of air heater Schematic diagram Name Air heater Right housing heater Left housing of air heater motor assembly Speed regulating resistor Air inlet box assembly Air inlet box bracket 11.3.2 Overview of evaporator assembly Schematic diagram Name Evaporator assembly...
Page 269: Air Heater Assembly
Air conditioning control system 11.3.3 Air heater assembly Removal and installation Schematic diagram Removal steps Remove steering support beam assembly. Disconnect the PTC assembly connection plug. Remove assembly harness rubber plug cover - 1 - in the direction of the arrow.
Page 270 Air conditioning control system Disconnect the motor and fan assembly connection plug. Unscrew the fixing screws of the air heater and evaporator assembly. Unscrew the fixing bolts - as shown by the arrow - and remove the air heater. Installation steps The installation sequence is the reverse of the removal sequence.
Page 271: Air Heater
Air conditioning control system 11.3.4 Air heater Removal and installation Schematic diagram Removal steps Remove the air heater. Unscrew the fixing screws and remove the motor and fan assembly. Unscrew the fixing screws and remove the speed regulating resistor. Remove the fixing clip from the air heater housing.
Page 272 Air conditioning control system Remove the air heater housing fixing clip - arrow A -, and unscrew the air heater housing fixing screw - arrow B -. Remove the fixing clip from the air heater housing- as shown by the arrow -. Detach the heater housing.
Page 273: Evaporator Assembly
Air conditioning control system Take out the PTC assembly in the direction of the arrow. Installation steps The installation sequence is the reverse of the removal sequence. 11.3.5 Evaporator assembly Removal and installation Schematic diagram Removal steps Use the air conditioning refrigerant charging discharging machine...
Page 274 Air conditioning control system Unscrew the fixing nut and disconnect the condenser outlet pipe 2 - 1 -. Remove the rubber plug cover - 1 - in the direction of the arrow. Disconnect the servo motor connection plug. Unscrew the fixing bolts and remove the air inlet box assembly - 1 -.
Page 275 Air conditioning control system Disconnect the evaporator temperature sensor connection plug. Unscrew the fixing screws of the air heater and evaporator assembly. 10. Unscrew the fixing bolts, take out the air conditioning outlet pipe - 2 -, and remove the evaporator assembly - 1 -. Installation steps The installation sequence is the reverse removal...
Page 276: Evaporator
Air conditioning control system 11.3.6 Evaporator Removal and installation Schematic diagram Removal steps Remove the evaporator assembly. Remove the evaporator cover fixing clip. Remove the evaporator cover fixing clip.
Page 277 Air conditioning control system Remove the evaporator assembly cover and remove the evaporator core - 1 - in the direction of the arrow. Remove the evaporator temperature sensor - 1 - from the evaporator core - 2 -. Installation steps The installation sequence is the reverse of the removal sequence.
Page 278: Control System
Air conditioning control system 11.4 Control system 11.4.1 Air conditioning controller assembly Removal and installation Schematic diagram Removal steps Disconnect the negative battery cable. Remove the center decorative bright strip assembly (upper). Unscrew the fixing screws and remove the central upper panel - 1 -. Disconnect the fixing clip of the cooling and heating air door cable - as shown by the arrow - and disconnect the cooling and...
Page 279 Air conditioning control system Disengage the mode knob cable fixing clip and disengage the mode knob cable -1-. Unscrew the fixing screws and take out the air conditioning control panel assembly - 1 -. △ ! Tips: Carefully take out the air conditioning controller assembly until the air conditioning controller assembly connection plug can be disconnected.
Page 280: The Motor And Fan Assembly
Air conditioning control system 11.4.2 The motor and fan assembly Removal and installation Schematic diagram Removal steps Remove the air heater assembly. Unscrew the fixing screws and remove the motor and fan assembly-1-. Installation steps The installation sequence is the reverse of the removal sequence.
Page 281: Servo Motor
Air conditioning control system 11.4.4 Servo motor Removal and installation Schematic diagram Removal steps Disconnect the negative battery cable. Remove the glove box assembly. Disconnect the servo motor connection plug. Unscrew the fixing screws and remove the servo motor-1-. Installation steps The installation sequence is the reverse of the removal sequence.
Page 282: Cooling Pipeline System
Air conditioning control system 11.5 Cooling pipeline system 11.5.1 Overview △ ! Caution • The refrigerant must be completely evacuated before performing maintenance on the air conditioning refrigeration system pipelines. • Use the special equipment to evacuate the refrigerant. • Wear goggles and gloves when evacuating refrigerant.
Page 283 Air conditioning control system Symptom table Fault Possible causes Maintenance measures symptom The fuse in the high voltage distribution Replace the fuse box is damaged Abnormal power Compress Check and repair the power battery voltage battery voltage or does Compressor control Check and repair compressor control line not work line...
Page 284 Air conditioning control system Overview of the compressor assembly Schematic diagram Name Electric compressor assembly Compressor bracket Bolt Removal and installation of electric compressor assembly Schematic diagram Removal steps Disconnect the negative battery cable. Use the air conditioning refrigerant charging discharging machine extract the refrigerant.
Page 285 Air conditioning control system Unscrew the fixing bolt and disconnect the compressor discharge pipe - 1 -. Bolt – as shown by the arrow- tightening torque: 10~14N·m △ ! Tips: Every time the refrigerant pipeline is removed, all sealing rings on the refrigerant pipeline must be replaced.
Page 286: Condenser Assembly
Air conditioning control system 11.5.3 Condenser assembly Removal and installation △ ! Tips: Every time the refrigerant pipeline is removed, all sealing rings on the refrigerant pipeline must be replaced. After removing the refrigerant circulation pipeline, pay attention to using sealing plugs to seal the air conditioning circulation pipeline.
Page 287 Air conditioning control system Removal and installation of condenser fan assembly Schematic diagram Removal steps Disconnect the negative battery cable. Remove the condenser fan plug fixing clip and disconnect the condenser fan connection plug - 1 -. Unscrew fixing bolts condenser bracket remove...
Page 288 Air conditioning control system Removal and installation of the compressor suction pipe assembly △ ! Tips: Every time the refrigerant pipeline is removed, all sealing rings on the refrigerant pipeline must be replaced. After removing the refrigerant circulation pipeline, pay attention to using sealing plugs to seal the air conditioning circulation pipeline.
Page 289 Air conditioning control system Removal and installation of compressor discharge pipe assembly △ ! Tips: Every time the refrigerant pipeline is removed, all sealing rings on the refrigerant pipeline must be replaced. After removing the refrigerant circulation pipeline, pay attention to using sealing plugs to seal the air conditioning circulation pipeline.
Page 290 Air conditioning control system Unscrew the compressor discharge pipe bracket fixing bolt. Bolt – as shown by the arrow- tightening torque: 7~9N·m Unscrew the fixing nuts between the compressor discharge pipe and the condenser, and disconnect the compressor discharge pipe assembly and remove it - 1 -.
Page 291 Air conditioning control system Removal and installation of condenser outlet pipe assembly △ ! Tips: Every time the refrigerant pipeline is removed, all sealing rings on the refrigerant pipeline must be replaced. After removing the refrigerant circulation pipeline, pay attention to using sealing plugs to seal the air conditioning circulation pipeline.
Page 292 Air conditioning control system Removal and installation of condenser outlet pipe 2 # assembly △ ! Tips: Every time the refrigerant pipeline is removed, all sealing rings on the refrigerant pipeline must be replaced. After removing the refrigerant circulation pipeline, pay attention to using sealing plugs to seal the air conditioning circulation pipeline.
Page 293 Air conditioning control system Unscrew the fixing bolts and remove the condenser outlet pipe 2 # assembly - 1 Installation steps The installation sequence is the reverse removal sequence, noting following: △ ! Tips: Fill the air conditioning refrigerant into the air conditioning refrigerant charging and discharging machine.
Page 294: Distribution System
Air conditioning control system 11.6 Distribution system 11.6.1 Central vent assembly Removal and installation Schematic diagram Removal steps Disconnect the negative battery cable. Remove the center decorative bright strip assembly (upper). Unscrew the fixing screws and remove the central upper panel - 1 -. Unscrew the fixing screws and remove the central vent assembly - 1 -.
Page 295: Air Conditioning Vent Assembly (High Configuration)
Air conditioning control system Disconnect the hazard warning switch connection plug and remove the central vent assembly. Unlock the locking element and remove the hazard warning switch - 1 -. Installation steps The installation sequence is the reverse removal sequence, noting following: After installation, check the function of the...
Page 296: In-Vehicle Entertainment System
In-vehicle entertainment system 12. In-vehicle entertainment system 12.1 Speaker 12.1.1 Overview Terminal view and terminal definition Terminal view and terminal definition of the Plug-in pin definition plug-in Schematic diagram Function Function Grounding Left front speaker+ Left front speaker- Right front speaker+ Right front ILL-...
Page 297: Audio System
In-vehicle entertainment system 12.1.2 Audio system Installation Schematic diagram Steps bracket Align the audio head unit fixing clip fixed shrapn with the audio head unit bracket on the steering fixed tube beam to ensure that the audio head unit fixing bracket can be correctly inserted into the audio head unit fixing clip, and gently push the audio head unit into the instrument panel.
Page 298 In-vehicle entertainment system mounting bolt Install the audio head unit into the mounting bolt bracket and use two bolts and two screws to secure the audio head unit to the instrument panel. Two front door speakers are installed on the left and right front doors.
Page 299 In-vehicle entertainment system Antenna amplifier Clip floor harness (fixing sheath antenna feeder) Installation of antenna amplifier and feeder: Assemble the antenna amplifier assembly on the rear side inner panel. Antenna feeder sheath Feeder clip Assemble the upper portion of the CCB feeder and plug it into the audio head unit.
Page 300: Lighting System
Lighting system Lighting system 13.1 Front lighting 13.1.1 Front lighting Installation position of front lighting Front Front turn signal Daytime running combination lamp lamp lamp Installation mode of front lighting Headlamp The high beam bulb in the headlamp is H1; the low beam bulb is H3; the front position lamp bulb is W5W, and the bulb type used for the front turn signal lamp is PY21W.
Page 301 Lighting system Daytime running lamp The bulbs used for daytime running lamps are LED bead light sources.
Page 302: Headlamp
Lighting system 13.1.2 Headlamp ① Headlamp Element Type A reflecting mirror. Adjust the alignment of Headlamp the light beam by adjusting the reflecting mirror. ② Headlamp adjustment Element X value Headlamp To be determined after testing If the lamp housing, light distribution mirror, reflecting mirror, mounting leg, etc. are broken or leaking, replace the lamp.
Page 303 Lighting system (2) Automatic headlamp controller terminal definition Effective Rated Terminal Function level current IMO- IMO+ Power supply High level positive pole CAN_H CAN_L Small lamp relay Output 250mA drive low level Automatic Low level headlamp active switch IGN and sensor High level power supply 500mA...
Page 304 Lighting system (3) Definition of light sensor electronics Maximum Terminal Function current Sensor power 50mA supply (VCC) Sensor signal 1 10mA (SR1) Sensor signal 2 10mA (SR2) Sensor grounding 50mA wire (VSS) (4) Automatic headlamp controller terminal pin position IMO controller (12V) Power supply positive pole Headlamp relay drive output negative...
Page 305: Element Test
Lighting system 13.1.3 Element test Element test shall be applied to the following relays: relays - high beam lamp, fog lamp Schematic diagram Steps Check the contact condition of the relay under normal conditions. • Measure the resistance between pins 3 and 5 (VFE0023129).
Page 306: Headlamp Adjustment
Lighting system 13.1.4 Headlamp adjustment Schematic diagram Steps Preparation: • Place the vehicle on a level surface. • Check whether the headlamp works properly, and replace damaged components if necessary. • Adjust headlamp level switch several times to check its function, then place the switch in position.
Page 307: Turn Signal Indicator Lamp Failure (Warning Lamp Circuit)
Lighting system Horizontal adjustment (the figure shows the left side). • Adjust the lower beam so that the cut-off line generated by the lower beam is within the shadow area shown in the following figure. △ ! Caution Some astigmatism of the low beam lamp may be above the 15 °...
Page 308: Symptom Table
Lighting system 13.1.6 Symptom table Low beam lamp Fault symptom Possible causes Maintenance measures Fuse damage Replace the fuse Conductor or grounding fault Replace Low beam lamp does not light Bulb burnout Replace Light control switch damage Replace Low beam lamp relay damage Replace High beam lamp Fault symptom...
Page 309 Lighting system Fog lamp Fault symptom Possible causes Maintenance measures Replace the main fuse and Main fuse is blown check for short circuit Fog lamp relay damage Replace the relay Bulb damage Replace Fog lamp does not light up Fog lamp switch damage Replace Conductor or grounding fault Replace...
Page 310: Interior Lighting
Lighting system 13.2 Interior lighting 13.2.1 Front interior lamp failure (line 2) Check the fuse Disconnect the harness end plug-in pin Measure the voltage between pin 1 of the ceiling harness end plug-in and body grounding Is the voltage displayed as battery voltage? Check the lamps and replace them if necessary Find and repair the front interior lamp...
Page 311 Lighting system Q2: Check the interior lamp power supply Turn switch "ON" position. Disconnect the ceiling lamp plug-in and measure the voltage between the harness terminal 1 of the interior lamp plug-in and the ground Is the voltage displayed as battery voltage? Front interior lamp Go to Q3 Detect the circuit between the harness...
Page 312: Rear Lighting
Lighting system 13.3 Rear lighting 13.3.1 Rear lighting Installation position of rear lighting High brake lamp Rear interior lamp Rear combination lamp License plate lamp Rear fog lamp Installation mode of rear lighting Rear combination lamp The reversing lamp bulb type in the rear combination lamp is P21W, the bulb type Rear fog lamp used for the position/brake lamp is P21/5W,...
Page 313 Lighting system High brake lamp License plate lamp The high brake lamp is composed of 12 The bulb type used for the license plate 0.1W LEDs (Everlight). lamp is W5W. Clip fixing point 1 High brake lamp mounting nut Clip fixing point 2 Rear interior lamp The bulb type used for the rear interior lamp assembly is C5W.
Page 314: Rear Interior Lamp
Lighting system 13.3.2 Rear interior lamp The bulb type used for the rear interior lamp Q2734816A hydrogen assembly is C5W. embrittlement removal 13.3.3 License plate lamp If the lamp housing, light distribution mirror, reflecting mirror, mounting leg, etc. are broken or leaking, replace the lamp. △...
Page 315: High Brake Lamp
Lighting system 13.3.4 High brake lamp If the lamp housing, light distribution mirror, reflecting mirror, mounting leg, etc. are broken or leaking, replace the lamp. △ ! Description Description of water leakage: After lighting the lamp for 10 minutes, there should be no water droplets on the lamp shade, and water mist is allowed in places where the light cannot reach.
Page 316: Rear Combination Lamp
Lighting system 13.3.6 Rear combination lamp If the lamp housing, light distribution mirror, reflecting mirror, mounting leg, etc. are broken or leaking, replace the lamp. △ ! Description Description of water leakage: After lighting the lamp for 10 minutes, there should be no water droplets on the lamp shade, and water mist is allowed in places where the light cannot reach.
Page 317 Lighting system Reversing lamp fault diagnosis Fault symptom Possible causes Maintenance measures Fuse damage Replace the fuse Reversing lamp relay Replace Reversing lamp does not light Bulb burnout Replace Gearshift lever Check the gearshift lever Instrument panel fuse box Replace Combination instrument Replace lamp fault diagnosis...
Page 318: Rear Fog Lamp Failure
Lighting system Rear fog lamp switch Terminal Close Switch Switch Release Release Press Release Press Press 13.3.8 Rear fog lamp failure Inspection items Detailed steps/results/measures N1: Check the fuse Check the fuse Is fuse intact? Go to N2 Fuse box Replace the fuse.
Page 319 Lighting system Find and repair the wiring between the plug terminal of the light control switch and the fog lamp according to the circuit diagram. If necessary, replace the light control switch, and test and run the system to check whether it is normal.
Page 320: Reversing Lamp Failure
Lighting system 13.3.9 Reversing lamp failure Inspection Detailed steps/results/measures items G1: Check the fuse Turn the key switch to the "OFF" position. Is fuse intact? Go to G2 Fuse box Replace the fuse. If the fuse continues to blow, locate and repair the short circuit according to the circuit diagram.
Page 321: Brake Lamp Failure
Lighting system Measure the voltage between the body harness plug-in pin connected to the front body harness and the body grounding point Is the voltage displayed as battery voltage? Replace the lamp Find and repair the circuit between the pins of the floor harness plug-in according to the circuit diagram, and test and run the system to check whether it is normal.
Page 322 Lighting system Go to F3 Find out whether the integration system is normal according to the circuit diagram. Repair the circuit between the fuse and the brake lamp switch plug-in pin, test and run the system. F3: Check the brake lamp switch signal voltage Turn the key switch to the "ON"...
Page 323: License Plate Lamp Failure
Lighting system 13.3.11 License plate lamp failure Inspection items Detailed steps/results/measures E1: Check the power supply of the floor harness 1. Turn the key switch to the "ON" position. Disconnect the back door harness plug-in from the vehicle body harness Turn to the position lamp position Measure the voltage between the body harness plug-in pin connected to the back door harness and the body grounding point...
Page 324: Position Lamp Failure
Lighting system 13.3.12 Position lamp failure Inspection Detailed steps/results/measures items D1: Check the fuse Turn the key switch to the "ON" position. Check the fuse. Is fuse intact? Go to D2 If the fuse continues to blow, replace the fuse and locate and repair the short circuit according to the circuit diagram.
Page 325: Symptom Table
Lighting system 13.3.13 Symptom table Position lamp and license plate lamp Fault symptom Possible causes Maintenance measures Fuse damage Replace the fuse The relay is damaged Replace Lamp does not light up Light control switch Replace Conductor or grounding fault Replace Instrument panel fuse box Replace...
Page 326: Lighting Switch
Lighting system Rear fog lamp Fault symptom Possible causes Maintenance measures Fuse damage Replace the main fuse Rear fog lamp relay Replace Rear fog lamp is not lit Light control switch damage Replace Conductor or grounding fault Replace Instrument panel fuse box Replace 13.4 Lighting switch 13.4.1 Hazard warning switch...
Page 327 Lighting system Remove 4 fasteners of the audio head unit. Disconnect the audio head unit harness connector. Remove the audio head unit. Remove 4 fasteners of the central air outlet panel. Disconnect the hazard warning switch harness connector. Remove the hazard warning switch.
Page 328 Lighting system Installation Schematic diagram Steps Install the hazard warning switch. Connect the hazard warning switch harness connector. Install 4 fasteners of the central air outlet panel. Connect the harness connector of the audio head unit and install the audio head unit.
Page 329 Lighting system Install 4 fasteners of the audio head unit. Install the center decorative bright strip. Install the negative cable of the low voltage battery.
Page 330: Hazard Warning Switch
Lighting system 13.4.3 Hazard warning switch Inspection and maintenance a. The hazard warning switch does not work and check whether the lamp is damaged. b. Check whether the hazard warning switch is on or off according to the gear table. c.
Page 331 Lighting system...
Page 332: Power Supply System
Power supply system Power supply system 14.1 Battery 14.1.1 Low voltage battery Battery pressing plate Battery screw Battery bracket assembly Battery tray Battery assembly The low voltage battery mainly provides uninterrupted power supply for the electronic control system, while providing power protection for the starting system during vehicle startup.
Page 333 Power supply system staying overnight, consider the cause of the failure from the following aspects: 1. The electrical equipment in the vehicle is not turned off. 2. The use of low voltage battery is unreasonable, including failing to keep the low voltage battery cable terminals clean and tight, or loosening the low voltage battery mounting bracket.
Page 334: Low Voltage Battery
Power supply system electrolyte, immediately and thoroughly rinse with water. Always keep low voltage battery out of the reach of children. Keep the low voltage battery cable posts clean. Cable joints, especially at positive (+) terminals, are easily corroded. There is corrosion or rust at the contact of the wire, which can hinder the flow of current.
Page 335: Definition Of Low Voltage Communication Interface And Pin Position
Power supply system It not only ensures the safe and reliable use of the battery, but also fully utilizes the battery capabilities and extends its service life. • Auxiliary components: mainly include electronic components inside the power battery, such as fuse, relay, relay, heater, pre-charging resistor, plug-in, current sensor, etc., as well as auxiliary components other than electronic appliances, such as sealing strip, insulating materials, etc.
Page 336: Dtc Fault Code Diagnosis
Power supply system 14.2.3 DTC fault code diagnosis DTC fault code list Fault Fault Definition Definition code code Alarm level 2 for excessive voltage U007488 CAN BUSOFF detected P130030 difference between single batteries Discharge battery low Alarm level 3 for excessive voltage P130001 P130031 temperature alarm level 1...
Page 337 Power supply system Charge battery high Alarm level 2 for battery pack P130012 P130042 temperature alarm level 3 insulation Alarm level 1 for excessive Alarm level 3 for battery pack P130014 temperature difference of P130043 insulation battery pack Alarm level 2 for excessive P130015 temperature difference of P130046...
Page 338 Power supply system Alarm level 1 for high total BMS low power supply voltage fault level P130026 P130070 voltage of battery pack Alarm level 2 for high total BMS high power supply voltage fault P130027 P130071 voltage of battery pack level 3 Alarm level 3 for high total BMS receiving MCU message timeout...
Page 339 Power supply system Before performing this diagnosis procedure, connect a diagnostic instrument to read the data list. Checking and analyzing the accuracy of various data will help quickly eliminate faults. Steps Content (a) Turn the key switch to the "ON" position.
Page 340 Power supply system (a) Check whether the harness Check the connection Replace the harness communication communication line loose, Go to step 5 and its connector line aging, or falling off or has other abnormal conditions. Check (a) Check whether the shield ring of Replace the faulty electromagnetic the high voltage harness is falling...
Page 341 Charge and heat the Check (a) Check whether the ambient vehicle or move the Go to ambient temperature of the vehicle is too vehicle to a warmer step 3 temperature. low (lower than -15℃). environment Contact CENNTRO authorized service center.
Page 342 Power supply system P130004 Charge battery low temperature alarm level 1/P130005 Charge battery low temperature alarm level 2/P130006 Charge battery low temperature alarm level 3 DTC definition Possible fault DTC definition (in English) code (in Chinese) causes Charge battery P130004 low temperature CHARGE BATT_TEMP_LOW_ALARM level1 The ambient...
Page 343 3 temperature. low (lower than 5℃). environment Contact CENNTRO authorized service center. P130007 Discharge battery high temperature alarm level 1/P130008 Discharge battery high temperature alarm level 2/P130009 Discharge battery high temperature alarm level 3...
Page 344 Power supply system DTC definition Possible fault DTC definition (in English) code (in Chinese) causes Discharge battery high P130007 DISCHARGE BATT_TEMP_OVER_ALARM level1 temperature alarm level 1 ambient Discharge temperature is battery high P130008 DISCHARGE BATT_TEMP_OVER_ALARM level2 too high. temperature Internal alarm level 2 failure of Discharge...
Page 345 3 temperature. high. environment Contact CENNTRO authorized service center. P130010 Charge battery high temperature alarm level 1/P130011 Charge battery high temperature alarm level 2/P130012 Charge battery high temperature alarm level 3...
Page 346 Power supply system DTC definition Possible fault DTC definition (in English) code (in Chinese) causes Charge battery high P130010 CHARGE BATT_TEMP_OVER_ALARM level1 temperature alarm level 1 The ambient Charge battery temperature is high too high. P130011 CHARGE BATT_TEMP_OVER_ALARM level2 temperature Internal alarm level 2 failure of power...
Page 347 3 temperature. high. environment Contact CENNTRO authorized service center. P130014 Alarm level 1 for excessive temperature difference of battery pack/P130015 Alarm level 2 for excessive temperature difference of battery pack/P130016 Alarm level 3 for excessive temperature difference of battery pack...
Page 348 Diagnosis steps: If this fault occurs, please contact CENNTRO authorized service center immediately. P130017 Single battery low voltage alarm level 1/P130018 Single battery low voltage alarm level 2/P130019 Single battery low voltage alarm level 3 DTC definition (in...
Page 349 (a) Check whether the total voltage of the Go to Check the power Charge the battery voltage. vehicle power battery is too low. step 3 Contact CENNTRO authorized service center.
Page 350 Power supply system P130020 Single battery high voltage alarm level 1/P130021 Single battery high voltage alarm level 2/P130022 Single battery high voltage alarm level 3 DTC definition (in Possible fault DTC definition (in English) code Chinese) causes Single battery high P130020 voltage alarm level BATT_SINGLE_OVER_VOLT_ALARM level1...
Page 351 Contact CENNTRO authorized service center. P130023 Alarm level 1 for low total voltage of battery pack/P130024 Alarm level 2 for low total voltage of battery pack/P130025 Alarm level 3 for low total voltage...
Page 352 Power supply system DTC definition (in Possible fault DTC definition (in English) code Chinese) causes Alarm level 1 for low P130023 total voltage of BATT_SINGLE_LOW_VOLT_ALARM level1 The power battery pack battery is too Alarm level 2 for low P130024 total voltage of BATT_SINGLE_LOW_VOLT_ALARM level2 Internal battery pack...
Page 353 3 Contact CENNTRO authorized service center. P130026 Alarm level 1 for high total voltage of battery pack/P130027 Alarm level 2 for high total voltage of battery pack/P130028 Alarm level 3 for high total...
Page 354 Check the power (a) Check whether the total voltage of the Go to as air battery voltage. power battery is too high. step 3 conditioners, and reduce the power of the power battery Contact CENNTRO authorized service center.
Page 355 Power supply system P130029 Alarm level 1 for excessive voltage difference between single batteries/P130030 Alarm level 2 for excessive voltage difference between single batteries/P130031 Alarm level 3 for excessive voltage difference between single batteries DTC definition (in Possible fault DTC definition (in English) code Chinese) causes...
Page 356 (a) Start the vehicle, turn on high voltage electrical equipment such as air conditioners, Contact Perform a slow CENNTRO and minimize the power of the power battery. charging cycle on the authorized (b) Charge the vehicle until it is fully charged service vehicle.
Page 357 Diagnosis steps: If this fault occurs, please contact CENNTRO authorized service center immediately. P130035 Alarm level 1 for battery pack charging overcurrent/P130036 Alarm level 2 for battery pack charging overcurrent/P130037 Alarm level 3 for battery pack charging overcurrent...
Page 358 Power supply system Diagnosis steps: △ ! Warning Before inspecting the high voltage system, be sure to take safety measures, such as wearing insulating gloves and disconnecting the high voltage line of the power battery to prevent electric shock. Disconnect the power battery high voltage line to prevent other technicians from accidentally reconnecting it while you are working on the high voltage system.
Page 359 P130040 DISCHARGE_CUR_OVER_ALARM level3 discharging overcurrent Diagnosis steps: If this fault occurs, please contact CENNTRO authorized service center immediately. P130041 Alarm level 1 for battery pack insulation/P130042 Alarm level 2 for battery pack insulation/P130043 Alarm level 3 for battery pack insulation...
Page 360 Power supply system DTC definition (in Possible fault DTC definition (in English) code Chinese) causes Alarm level 1 for Insulation INSULATION_RESISTANCE_LOW_ALARM P130041 battery pack fault of high level1 insulation voltage device Alarm level 2 for Insulation INSULATION_RESISTANCE_LOW_ALARM fault of high P130042 battery pack level2...
Page 361 (c) Disconnect the body connectors of the or wires. compressor, PTC, and MCU one by one to check whether they can return to normal. If not, check whether the insulation resistance of the PEU is abnormal. Contact CENNTRO authorized service center.
Page 362 Power supply system P130046 High voltage interlock circuit break fault DTC definition (in DTC definition (in DTC code Possible fault causes Chinese) English) Harness and High voltage interlock connector P130046 HVIL Circuit_Break circuit break fault Internal failure of power battery Diagnosis steps: △...
Page 363 (b) Check whether high voltage harness interlock step 3 connector. interlock harness aging, damaged, connector broken or has other abnormal conditions. harness. (c) Check whether the PEU box cover can contact the switch inside the PEU. Contact CENNTRO authorized service center.
Page 364 Power supply system P130050 SOC too low alarm level 1/P130051 SOC too low alarm level 2/P130052 SOC too low alarm level 3 DTC definition (in Possible fault DTC code DTC definition (in English) Chinese) causes SOC too low alarm P130050 SOC_TOO_LOW_ALARM level1 level 1 The power battery...
Page 365 P130055 Single battery voltage detection hardware fault level 3 DTC definition (in DTC code DTC definition (in Chinese) Possible fault causes English) Single battery voltage Internal failure of P130055 detection hardware fault level power battery Diagnosis steps: If this fault occurs, please contact CENNTRO authorized service center immediately.
Page 366 Internal failure of P130057 hardware fault level 3 power battery Diagnosis steps: If this fault occurs, please contact CENNTRO authorized service center immediately. P130057 Temperature detection hardware fault level 3 DTC definition (in DTC definition (in DTC code Possible fault causes...
Page 367 P130062 Precharging fault Precharge_Fault battery Diagnosis steps: If this fault occurs, please contact CENNTRO authorized service center immediately. P130067 Heating timeout fault level 3 Temperature detection hardware fault level DTC definition (in Possible fault DTC code DTC definition (in English)
Page 368 Power supply system P130070 BMS low power supply voltage fault level 3 DTC definition (in Possible fault DTC definition (in English) code Chinese) causes Battery voltage is too low Harness connector fault BMS low power supply P130070 BMS_VOLT_LOW_ALARM level3 DC/DC module voltage fault level 3 fault Internal...
Page 369 4 connector. falling off or have other abnormal conditions. connector. Check the PEU Replace the (a) Check whether the PEU controller DC/DC Go to controller DC/DC module is faulty. step 5 module. controller Contact CENNTRO authorized service center.
Page 370 Power supply system P130071 BMS high power supply voltage fault level 3 DTC definition (in Possible fault DTC definition (in English) code Chinese) causes The battery voltage is too BMS high power supply P130071 BMS_VOLT_HIGH_ALARM level3 high voltage fault level 3 DC/DC module fault Diagnosis steps:...
Page 371 DC/DC module is faulty. step 4 controller. module. Contact CENNTRO authorized service center. U130187 BMS receiving MCU message timeout fault level 3/U130387 BMS and OBC communication fault level 3 DTC definition DTC definition (in English) Possible fault causes code...
Page 372 Power supply system wearing insulating gloves and disconnecting the high voltage line of the power battery to prevent electric shock. Disconnect the power battery high voltage line to prevent other technicians from accidentally reconnecting it while you are working on the high voltage system.
Page 373: Procedure For Disconnecting And Connecting High Voltage Power
Power supply system (a) Check whether harness Check Replace the connection of the CAN communication Go to communication harness and its line is loose, aging, or falling off or has step 5 line. connector other abnormal conditions. (a) Check whether the shield ring of Check Replace the faulty electromagnetic...
Page 374: Removal And Installation Of Power Battery System Assembly
Power supply system Disconnect power battery high voltage wire connection plug - as shown by the arrow -. Installation steps The installation sequence is the reverse of the removal sequence. 14.2.5 Removal and installation of power battery system assembly Removal and installation △...
Page 375 Power supply system Schematic diagram Removal steps Turn the key switch to the "LOCK" position disconnect negative battery cable. Unscrew the fixing bolts of the high voltage wire protection plate - as shown by the arrow -, and remove the high voltage wire protection plate.
Page 376 Power supply system Unscrew the power battery grounding wire fixing bolt - as shown by the arrow -. Bolt – as shown by the arrow- tightening torque: 8~10N·m Lift the battery bracket to make contact with the battery. Unscrew the power battery fixing bolt - as shown by the arrow -.
Page 377 Power supply system 2. Wipe a small amount of electrolyte clean with a cloth. 3. Sprinkle baking soda (NaHCO3) onto the leaked electrolyte. 4. Detect with PH test paper, and the color is blue, which is OK. 5. Use dry sand, soil, sawdust, waste cotton yarn, and other materials to absorb the electrolyte.
Page 378: Removal And Installation Of Power Battery High Voltage Line
Power supply system 14.2.6 Removal and installation of power battery high voltage line Removal and installation △ ! Danger Wait for 15 minutes after disconnecting the negative battery cable. △ ! Danger When disassembling and repairing accessories with high voltage electricity, it is necessary to prepare high voltage protective equipment (insulating shoes, insulating gloves, insulating hooks, and insulating pads).
Page 379 Power supply system battery high voltage wire connection plug - as shown by the arrow -. Unscrew the fixing screw - as shown by the arrow - and remove the upper cover plate of the PEU controller- 1 -. △ ! Caution During installation, it is necessary to confirm that the sealing strip on the upper cover plate of the PEU controller is...
Page 380: Power Distribution And Control System
Power distribution and control system Power distribution and control system 15.1 Pedestrian friendly reminder module 15.1.1 Function introduction This vehicle is equipped with a pedestrian friendly reminder system, which mainly has the following functions: Travel reminder: When the vehicle is traveling at a speed below 20km/h (12.4 mph), the speaker outside the vehicle emits a warning tone to remind pedestrians to...
Page 381: Working Schematic Diagram
Power distribution and control system 15.1.2 Working schematic diagram Micro Power transcei pass Speaker controller amplifier filter 15.1.3 Working principle The AVAS module receives data from the CAN transceiver through a microcontroller, which parses the data and obtains vehicle information such as gear, vehicle speed, enable signal, sound source selection, etc.;...
Page 382 Power distribution and control system Technical parameters Items Parameters Voice coil impedance 8Ω±15% Resonant frequency 250± 20% Hz Characteristic sensitivity 93±3 dB Effective frequency range F0 ~ 20K Hz -10 dB Rated input power 2.4W Maximum input power Interface definition Product plug port Detail B Zoom:...
Page 383: Installation Position
Power distribution and control system 15.1.5 Installation position △ ! Caution Non professional personnel are prohibited from disassembling the low speed warning tone system. When plugging in and out the harness plug-in of the low speed warning tone system, the electric vehicle key switch must be disconnected. Do not apply the low speed warning tone system to a power supply that does not match the nominal voltage of the low speed warning tone system, as this may result in the low speed warning tone system not working properly or being burned out.
Page 384: Emergency Call Terminal System (Ecall)
Power distribution and control system 15.2 Emergency call terminal system (ECALL) 15.2.1 Overview The vehicle emergency call system includes an emergency rescue terminal, SOS button, microphone, and speaker. It cooperates with vehicle components such as car engine, safety bag, and 112 service centers and public rescue service agencies to achieve rescue service functions.
Page 385: System Architecture
Power distribution and control system 15.2.2 System architecture (1) Working principle PSAP (112 Service Center) Wireless network signal Hard wire Audio system SOS button and SOS status indicator lamp Hard wire Mute Emergency rescue terminal Audio Safety air bag Dome microphone Audio Emergency call speaker The vehicle emergency call system includes an emergency rescue terminal, SOS button,...
Page 386 Power distribution and control system (3) Interface definition Terminal main plug-in (24PIN) Definition Termi Definition mina Definition Definition description description Speaker output Speaker output SPEAKER+ SPEAKER- positive negative MIC shield grounding MIC1+ MIC1 input positive Mute signal MUTE output SOS integrated module signal grounding Button_ECAL...
Page 387 Power distribution and control system STATE_GREE eCALL status indicator lamp CAN1H CAN1 bus high CAN1L CAN1 bus low Vehicle ignition signal Power supply Power supply input DVDD_VCAR_IN PGND input negative positive pole pole SOS switch plug-in (10PIN) Terminal Name Function MIC+ MIC positive MIC-...
Page 388: Electrical Diagnosis
Power distribution and control system 15.2.3 Electrical diagnosis Recovery Conditions Trigger Conditions Faults (Criteria used to (Criteria used to Possible Corrective Displa DTC Meaning Attribut determine that a determine an “active” Fault Causes Action failure condition failure condition) is no longer present ) The main power The main...
Page 389 Power distribution and control system Connection When detecting the Standby Reconnect the s are loose Reconnect B1E020 Other full scale 3.3V of AD battery is not standby the standby pin, it is judged that it Faults connected battery disconnecte battery is not connected Start the Detect that the...
Page 390 Power distribution and control system Detect that the ad The ad value SOS button Replace the B1E040 Signal value corresponding returns to the Hardware short circuit ECALL Faults to the button is normal range fault to ground controller smaller than 100 (350-3002) The SIM card If the module has...
Page 391 Power distribution and control system 1500 short circuit microphone to GND harness for a short circuit to ground Detect that Check the AD Detect that the AD Microphone whether Microphone sampling sampling value of the harness microphone B1E080 short circuit Signal value of the microphone is greater...
Page 392 Power distribution and control system Check for Open circuit fault No fault open circuit detected in i2c detected in Speaker in the B1E090 Speaker open Signal register value of the i2c harness speaker circuit Faults power amplifier chip register value disconnecte harness or for 4 consecutive...
Page 393: Peu Controller
Power distribution and control system 15.3 PEU controller 15.3.1 Overview PEU controller integrates the on-board charger module (OBC), DC/DC converter (DC/DC), and high voltage power distribution module (PDU), and integrates the components that need to be assembled multiple times in the original production process to improve assembly efficiency and production efficiency.
Page 394: Definition Of Low Voltage Communication Interface And Pin Position
Power distribution and control system 15.3.2 Definition of low voltage communication interface and pin position The low voltage communication terminal view of the PEU controller (viewed from the outside to the inside of the PEU controller) and terminal definitions are as follows: Function Function Function...
Page 395: Dtc Fault Code Diagnosis
Power distribution and control system 15.3.3 DTC fault code diagnosis DTC fault code diagnosis list Fault Fault Fault Definition Definition Definition code code code DC/DC input P148222 Fan fault P148220 OBC internal fault P160001 undervoltage Too high battery DC/DC input P14804B overtemperature P148227...
Page 396 Power distribution and control system U010087 Loss of communication between OBC and BMS CAN/P160087 Loss of communication between DC/DC and BMS CAN/U007788 Busoff fault DTC code DTC definition detection Triggering conditions Possible fault causes conditions Loss of Under non BUSOFF communicati status, no valid BMS CAN terminal...
Page 397 Power distribution and control system Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF" DTC inspection position. Go to step 2 system is normal (d) Turn the key switch to the "ON"...
Page 398 Power distribution and control system P148222 Fan fault DTC detection Possible fault DTC code Triggering conditions definition conditions causes The fan status is inconsistent P148222 Fan fault Fan damage with the command Diagnosis steps: △ ! Warning Before inspecting the high voltage system, be sure to take safety measures, such as wearing insulating gloves and disconnecting the high voltage line of the power battery to prevent electric shock.
Page 399 Power distribution and control system fault/P148004B OBC overtemperature warning/P14894B OBC overtemperature fault DTC detection Triggering Possible fault DTC code DTC definition conditions conditions causes DC/DC DC/DC temperature is P160011 overtemperature greater than warning 100℃, T>2000ms 1. Fan damage DC/DC 2. The DC/DC temperature is temperature...
Page 400 Power distribution and control system Checking and analyzing the accuracy of various data will help quickly eliminate faults. Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF"...
Page 401 Power distribution and control system P148116 OBC input undervoltage DTC detection DTC code DTC definition Triggering conditions Possible fault causes conditions AC power supply fault Input voltage is Charging gun fault OBC input greater than 35V P148116 Harness and undervoltage and less than 90V, connector T>600ms...
Page 402 Power distribution and control system Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF" position. The system is DTC inspection Go to step 2 normal...
Page 403 Power distribution and control system P148117 OBC input overvoltage DTC detection Triggering DTC code DTC definition Possible fault causes conditions conditions AC power supply fault Input voltage is Charging gun and OBC input P148117 greater than charging interface fault overvoltage 265V, T>600ms Harness and connector OBC or DC/DC...
Page 404 Power distribution and control system Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF" position. The system is DTC inspection Go to step 2 normal...
Page 405 Power distribution and control system P148217 OBC output overvoltage DTC detection Triggering DTC code DTC definition Possible fault causes conditions conditions Output voltage The power battery OBC output P148217 is greater than voltage is too high overvoltage 144V, T>600ms Module fault Diagnosis steps: △...
Page 406 Power distribution and control system Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF" position. (d) Turn the key switch to the "ON" position Go to step 2 system is inspection...
Page 407 Power distribution and control system P148216 OBC output undervoltage DTC detection Triggering DTC code DTC definition Possible fault causes conditions conditions The power battery voltage is too low Output voltage OBC output Open circuit P148216 is less than 65V, undervoltage between power battery T>600ms and OBC...
Page 408 PEU is loose, falling off or has other harness controller. abnormal conditions. connector Contact CENNTRO Check the power (a) Check whether the power battery Go to step authorized service battery voltage. voltage is too low. center...
Page 409 Power distribution and control system P148219 OBC output overcurrent (software) DTC detection Triggering DTC code DTC definition Possible fault causes conditions conditions OBC load abnormality OBC output Output current is Is there a short P148219 overcurrent greater than circuit at the OBC output (software) 24A, T>600ms terminal...
Page 410 Power distribution and control system Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF" position. (d) Turn the key switch to the "ON" position Go to step 2 system is inspection...
Page 411 Power distribution and control system P148214 OBC output short circuit DTC detection Triggering DTC code DTC definition Possible fault causes conditions conditions OBC load Output current abnormality OBC output is greater than OBC output P148214 short circuit 44A, single terminal short circuit trigger PEU controller internal fault...
Page 412 Power distribution and control system Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF" position. (d) Turn the key switch to the "ON" position Go to step 2 system is inspection...
Page 413 Power distribution and control system P148223 OBC output open circuit DTC code DTC definition detection Triggering conditions Possible fault causes conditions Before outputting the OBC output line voltage, the target voltage OBC output open circuit P148223 is less than 30V, the open circuit controller output current is less than...
Page 414 Power distribution and control system P148227 The power battery voltage is too high Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF" position. (d) Turn the key switch to the "ON"...
Page 415 <65V too low connected reversely Diagnosis steps: If this fault occurs, please contact CENNTRO authorized service center immediately. P160003 DC/DC output overvoltage DTC detection Possible fault DTC code DTC definition Triggering conditions...
Page 416 Power distribution and control system Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF" position. The system (d) Turn the key switch to the "ON" position Go to step 2 is normal inspection...
Page 417 Power distribution and control system shock. Disconnect the power battery high voltage line to prevent other technicians from accidentally reconnecting it while you are working on the high voltage system. After disconnecting the high voltage line of the power battery, wait for at least 5 minutes before contacting any high voltage connectors or terminals.
Page 418 Power distribution and control system P160005 DC/DC output overcurrent (software) DTC detection Triggering DTC code DTC definition Possible fault causes conditions conditions Unstable load DC/DC output Output Line fault P160005 overcurrent current >180A, controller (software) T>100ms internal fault Diagnosis steps: △...
Page 419 Power distribution and control system Charge the (a) Check whether the voltage of battery is too battery and low. turn off high Check (b) Check whether there are high power Go to step power low DC/DC load. low voltage electrical appliances and the voltage electrical appliances are aging or have electrical...
Page 420 Contact Check the (a) Check whether power battery CENNTRO Go to step power battery voltage is too high. authorized voltage. service center Replace the (a) Replace the PEU controller assembly.
Page 421 Power distribution and control system Diagnosis steps: △ ! Warning Before inspecting the high voltage system, be sure to take safety measures, such as wearing insulating gloves and disconnecting the high voltage line of the power battery to prevent electric shock.
Page 422 Power distribution and control system P160007 DC/DC input overcurrent DTC detection Possible fault DTC code DTC definition Triggering conditions conditions causes load Input current is DC/DC input abnormality P160007 greater than 24A, overcurrent Module T>600ms internal fault Diagnosis steps: △ ! Warning Before inspecting the high voltage system, be sure to take safety measures, such as wearing insulating gloves and disconnecting the high voltage line of the power battery to prevent electric shock.
Page 423 Power distribution and control system Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF" position. (d) Turn the key switch to the "ON" position Go to step 2 system is inspection...
Page 424 Power distribution and control system insulating gloves and disconnecting the high voltage line of the power battery to prevent electric shock. Disconnect the power battery high voltage line to prevent other technicians from accidentally reconnecting it while you are working on the high voltage system. After disconnecting the high voltage line of the power battery, wait for at least 5 minutes before contacting any high voltage connectors or terminals.
Page 425 Power distribution and control system P160009 Battery undervoltage DTC detection DTC code Triggering conditions Possible fault causes definition conditions Battery voltage is too low Battery The battery voltage DC/DC output line P160009 undervoltage is less than 8.5V open circuit controller internal fault Diagnosis steps: △...
Page 426 Power distribution and control system Charge or (a) Check whether the voltage of battery is too low. Check replace Go to step (b) Check whether the battery is leaking liquid or the battery. damaged. battery. Replace (a) Check whether the circuit between the positive and Check negative output ports of the PEU controller 12V and the Go to step...
Page 427 Power distribution and control system Checking and analyzing the accuracy of various data will help quickly eliminate faults. Steps Content (a) Turn the key switch to the "ON" position. (b) Use the diagnostic instrument to clear the PEU controller fault code. (c) Turn the key switch to the "OFF"...
Page 428: Removal And Installation Of Peu Controller
Power distribution and control system 15.3.4 Removal and installation of PEU controller Removal and installation △ ! Danger There is high voltage and high temperature inside the product. Please do not touch internal components, which may cause electric shock or burns. △...
Page 429 Power distribution and control system Disconnect the power battery high voltage wire connection plug-as shown by the arrow-. Disconnect the low voltage harness connection plug of the PEU controller-as shown by the arrow-. Unscrew the fixing screw-as shown by the arrow-and remove the upper cover plate of the PEU controller-1-.
Page 430 Power distribution and control system Unscrew the connecting fixing bolts between the positive and negative poles of the MCU harness and the interior of the PEU controller-as shown by the arrow-. Unscrew the connection fixing screw of the MCU harness on the outer side of the PEU controller-as shown by the arrow-, and disconnect the MCU harness from the PEU controller.
Page 431 Power distribution and control system Unscrew the fixing screws connecting the high voltage cable of the power battery to the outer side of the PEU controller-as shown by the arrow-, and disconnect the MCU harness from the PEU controller. 10. Disconnect cable-PEU controller connection plug-as shown by the arrow-.
Page 432 Power distribution and control system 12. Disconnect slow charging harness-PEU controller connection plug-as shown by the arrow-. 13. Remove the protective cover of the low voltage positive output harness-as shown by the arrow-. 14. Unscrew the fixing bolt of the low voltage positive output harness-as shown by the arrow-.
Page 433: Removal And Installation Of Slow Charging Harness
Power distribution and control system 15. Unscrew the fixing bolt of the low voltage negative harness-as shown by the arrow-. 16. Unscrew the fixing bolt-as shown by the arrow-and remove the PEU controller-1-. Bolt – as shown by the arrow-tightening torque: 10~14N·m Installation steps The installation sequence is the reverse of...
Page 434 Power distribution and control system Schematic diagram Removal steps Turn the key switch to the "LOCK" position and disconnect the negative battery cable. Unscrew the fixing bolts of the high voltage wire protection plate-as shown by the arrow-, and remove the high voltage wire protection plate.
Page 435 Power distribution and control system Disconnect clips slow charging harness. Remove the left side interior trim panel assembly,-as shown by the arrow-. Remove the rubber plug cover-1-in the direction of the arrow. Open the charging port cover, unscrew the fixing bolt-as shown by the arrow-, remove the slow charging seat assembly-1-, and pull out the slow charging harness from the charging port.
Page 436: Removal And Installation Of Ptc Cable
Power distribution and control system 15.3.6 Removal and installation of PTC cable Removal and installation △ ! Danger There is high voltage and high temperature inside the product. Please do not touch internal components, which may cause electric shock or burns. △...
Page 437 Power distribution and control system Disconnect the power battery high voltage wire connection plug-as shown by the arrow-. Disconnect cable-PEU controller connection plug-as shown by the arrow-. Disconnect cable-PEU connection plug-as shown by the arrow-.
Page 438: Removal And Installation Of Compressor Harness
Power distribution and control system Remove the PTC cable fixing clip - as shown by the arrow - and remove the PTC cable - 1 -. Installation steps The installation sequence is the reverse of the removal sequence. 15.3.7 Removal and installation of compressor harness Removal and installation △...
Page 439 Power distribution and control system Schematic diagram Removal steps Turn the key switch to the "LOCK" position and disconnect the negative battery cable. Unscrew the fixing bolts of the high voltage wire protection plate-as shown by the arrow-, and remove the high voltage wire protection plate.
Page 440: Removal And Installation Of Mcu Harness
Power distribution and control system Disconnect the compressor harness - PEU controller connection plug - as shown by the arrow -. Remove the compressor harness fixing clip - as shown by the arrow - and remove the compressor harness - 1 -. Installation steps The installation sequence is the reverse of the removal sequence.
Page 441 Power distribution and control system no secure connection. Schematic diagram Removal steps Turn the key switch to the "LOCK" position and disconnect the negative battery cable. Unscrew the fixing bolts of the high voltage wire protection plate-as shown by the arrow-, and remove the high voltage wire protection plate.
Page 442 Power distribution and control system Unscrew the connecting fixing bolts between the positive and negative wire harnesses of the MCU and the interior of the PEU controller- as shown by the arrow -. Unscrew the connection fixing screw of the MCU harness on the outer side of the PEU controller-as shown by the arrow-, and disconnect the MCU harness from the PEU controller.
Page 443: Motor Control Unit Assembly
Power distribution and control system Unscrew the fixing nuts on the positive and negative wire harnesses of the MCU and the outer side of the motor control unit-as shown by the arrow-, disconnect the positive and negative wire harnesses of the MCU-1-and remove them; Installation steps The installation sequence is the reverse of the removal sequence.
Page 444: Dtc Fault Code Diagnosis
Power distribution and control system 15.4.2 DTC fault code diagnosis DTC fault code list Fault code Definition Fault code Definition Bus undervoltage software P056016 P1C0997 Locked rotor protection fault KL30 power supply voltage P1C0016 P0A5D19 Hardware overcurrent fault undervoltage fault Software overcurrent fault KL30 power supply overvoltage P0A5F19...
Page 445 Power distribution and control system P056016 Bus undervoltage software fault DTC triggering Possible fault DTC monitoring conditions definition conditions causes Abnormal undervolt Bus voltage battery P05601 No battery fault; lower than 65V voltage Signal VCU_bMCUEnable=1; software for 100ms Harness fault fault Maintenance recommendations: 1.
Page 446 Power distribution and control system DTC monitoring conditions triggering Possible fault causes definition conditions Motor short circuit Abnormal rotary Software No phase current sensor transformer angle overcurre Software sampling circuit fault Abnormal phase nt fault detection P0A5F1 No current sensor bias current signal (phase current...
Page 447 Power distribution and control system Maintenance recommendations: 1. Confirm that the 12V power supply is normal; 2. Replace the motor control unit. P100722 Motor overspeed fault DTC monitoring DTC triggering DTC definition Possible fault causes conditions conditions Sudden load Motor No rotary Motor reduction (slipping)
Page 448 Power distribution and control system DTC monitoring DTC triggering Possible fault causes definition conditions conditions Long term high load operation of No battery fault motor No motor Harness temperature sensor Motor Motor abnormality P0A2F4 fault overtempera temperature >1 Abnormal motor Detection one second 55℃...
Page 449 Power distribution and control system Maintenance recommendations: 1. If recoverable after cooling, no processing is required; 2. If it still appears after cooling, check the wiring harness and thermal sensitivity; 3. Replace the motor control unit. P0A3F01 Rotary transformer abnormality fault DTC monitoring Possible fault DTC triggering conditions...
Page 450 Power distribution and control system Maintenance recommendations: 1. Replace the harness; 2. Replace the rotary transformer; 3. Replace the motor control unit. P0A2A13 Motor temperature sensor fault DTC triggering Possible fault DTC monitoring conditions definition conditions causes The sampling Motor Battery voltage in the value of the MCU internal...
Page 451 Power distribution and control system Refer to “Loss of communication between OBC and BMSCAN” for treatment. P100446 EEPROM fault DTC triggering monitoring Possible fault causes definition conditions conditions Abnormal 12V power supply MCU reading and MCU internal harness or P10044 EEPROM writing EEPROM hardware circuit fault...
Page 452 Power distribution and control system 3. Confirm the software version when the rotation angle is normal; 4. Replace the motor control unit. P0A5D19 Hardware overcurrent fault DTC triggering monitoring Possible fault causes definition conditions conditions Motor short circuit Abnormal rotary transformer angle Battery Hard wire overcurrent...
Page 453 Power distribution and control system P1C1213 Motor control unit temperature sensor abnormality alarm DTC triggering Possible fault DTC definition DTC monitoring conditions conditions causes Motor control The sampling value unit Battery voltage in of the controller MCU internal P1C121 temperature the normal range;...
Page 454 Power distribution and control system P10034B IGBT overtemperature warning (NTC) DTC triggering DTC monitoring conditions Possible fault causes definition conditions Long term heavy IGBT Battery voltage in the The controller load operation of MCU overtempe normal range; temperature Abnormal P10034B rature No battery fault;...
Page 455 Power distribution and control system P056317 Bus overvoltage warning DTC monitoring DTC triggering Possible fault causes definition conditions conditions Abnormal disconnection of Battery Bus voltage overvolta high voltage circuit during P056317 voltage in the higher than power generation normal range 130V for 100ms warning Abnormal battery voltage...
Page 456 Power distribution and control system P100517 Bus voltage hardware overvoltage fault DTC triggering monitoring Possible fault causes definition conditions conditions Bus overvoltage hard Abnormal disconnection voltage P10051 wire signal detected of high voltage circuit during hardware (hardware detects power generation overvolta bus voltage>141V) Abnormal battery voltage...
Page 457: Removal And Installation Of The Motor Control Unit
Power distribution and control system 15.4.3 Removal and installation of the motor control unit Removal and installation △ ! Danger There is high voltage and high temperature inside the product. Please do not touch internal components, which may cause electric shock or burns. △...
Page 458 Power distribution and control system Disconnect the power battery high voltage wire connection plug-as shown by the arrow-. Disconnect the low voltage connection plug of the motor control unit - as shown by the arrow Unscrew the fixing screw - as shown by the arrow - and remove the upper cover plate of the motor control unit- 1 -.
Page 459 Power distribution and control system Unscrew the connecting fixing bolts between the positive and negative wire harnesses of the MCU and the interior of the motor control unit- as shown by the arrow 1-. Unscrew the fixing bolt connecting the motor harness to the inside of the motor control unit- as shown by the arrow 2-;...
Page 460: Electrical Accessories
Electrical accessories Electrical accessories 16.1 Electrical box 16.1.1 Front cabin electrical box 16.1.2 Instrument fuse box Reversing camera...
Page 461: Terminal Definition
Electrical accessories 16.2.1 Terminal definition Terminal Name Function Schematic diagram Camera power CAM_POW supply+ Camera power supply grounding wire- CAM_CVBS Camera video Camera shielding VGND ground...
Page 462: Edr
Electrical accessories 16.3 EDR 16.3.1 Overview The EDR controller is installed between the front seats, under the central trim box. Monitor, collect, and record data on the vehicle and passenger protection system before, during, and after a collision event. 16.3.2 Terminal definition Terminal Function Schematic diagram...
Page 463: Electrical Diagnosis
Electrical accessories 16.3.3 Electrical diagnosis Use a dedicated diagnostic instrument to diagnose and detect fault codes, and find the cause of the fault through fault code prompts. Fault code list and cause analysis Recovery Trigger Conditions Conditions Faults (Criteria used to (Criteria used to Attribut determine an...
Page 464 Electrical accessories After collecting Clear using the brake hard Brake The collected the diagnostic wire signal, hard wire Networ brake hard wire (tester) U010086 continuously signal k fault signal is at a low DTC self press (turn on) fault level recovery after 40 and hover for 3 IGN cycles...
Page 465 Electrical accessories Clear using TBD has not TBD has received the diagnostic Throttle received data data Networ (tester) U010084 signal corresponding to corresponding to k fault DTC self loss 10 consecutive 1 consecutive recovery after 40 frames frame IGN cycles High ECU ECU power power...
Page 466: Vehicle Anti-Theft
Electrical accessories 16.4 Vehicle anti-theft 16.4.1 Overview The IMMO controller integrates automatic headlamp functions, as well as central door lock (remote control) and vehicle anti-theft functions Component location IMMO controller Anti-theft coil Maintenance process Schematic diagram Steps Controller disassembly (integrated into IMMO controller) •...
Page 467: Remote Control Function Learning
Electrical accessories 16.4.2 Remote control function learning At most two transmitters can be learned. The learning steps are as follows: 1. When the remote control receiver is in the disarmed state, all doors are closed, and the left front door is opened twice within 10 seconds (open - close - open) 2.
Page 468 Electrical accessories...

CENNTRO LOGISTAR 100 Repair Manual

1 Overview

2 Vehicle Body

3 Exterior Trims

4 Interior Trim

5 Transmission System

6 Power Drive

7 Air Conditioning System

8 Suspension System

9 Braking System

10 Steering System

11 Air Conditioning Control System

12 In-Vehicle Entertainment System

13 Lighting System

14 Power Supply System

15 Power Distribution and Control System

16 Electrical Accessories

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Summary of Contents for CENNTRO LOGISTAR 100