DR Evo Electric Service Manual

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EVO Electric

Service

Manual

FOREWORD

This manual contains on-vehicle diagnosis

and service procedures for EVO electric

by DR. It is very important to read and

be familiar with thismanual thoroughly

for proper repair and maintenance. This

manual should be kept in a handy place

for quick and easy reference.

The contents in this manual, including all

illustrations and specifications, are current at

the time of printing. Any modifications

involving with repair and maintenance occur,

relevant information supplementary to this

volume will be made available at DR

dealers.

DR wi

l provide technica

l ume. Therefore, please

supp

l ementary vo

obtain the latest information about this

Manual.

DR reserves all rights. Specifications and

contents in this manual are subject to

change without notification, and DR

takes no legal obligations and responsibilities.

Any unit or individual shall not reproduce or

copy this manual in many form or by any

means, or transmit it on the network by any

form for any purpose without written

permission of DR.

l bu

l etin or

CAUTION:

This manual is only for specialized

technicians. If non-specialized or uncertified

individuals privately perform repairs or

maintenance only referring to this manual or

without proper equipment and tools, it may

damage the customer's vehicle and hurt you

and other persons nearby.

In order to prevent dangerous operation and

damage to the vehicle, be sure to follow the

instructions shown below:

- The contents in this manual must be read

thoroughly. Have a good understanding of

all the contents written in the

PRECAUTION of

"INTRODUCTION"section.

- Before performing the repair procedures,be

sure to wear safety equipment properly to

avoid personal injury.

- When performing the repair procedures,be

sure to use specified and

recommended tools to prevent damage to the

customer's vehicle. Be sure to confirm the

safety of technicians before operating

to avoid personal injury.

- If a part needs to be replaced, use DR

genuine part with the same part number.

Do not use any inferior quality part.

- Observe the "WARNING" and

"CAUTION" in this manual carefully in

order to reduce the risk of personal injury

and vehicle damage due to improper

operation during service and

maintenance.

Need help?

Do you have a question about the Evo Electric and is the answer not in the manual?

Questions and answers

Summary of Contents for DR Evo Electric

Page 1 Manual. - If a part needs to be replaced, use DR DR reserves all rights. Specifications and genuine part with the same part number. contents in this manual are subject to Do not use any inferior quality part.
Page 2 EVO - Electric Body Chassis High voltage...
Page 3 Vehicle Body System Bumpersystem Bumpersystem................................1 Safety Precaution..............................2 the electrical technicians who use medical electronic devices precautions........2 Inspection of key points before the maintenance...................3 Precautions of auxiliary restraint system "airbag" and "seat belt pretension"........3 Precautions of removing the 12V battery....................4 Matters needing attention...........................
Page 4 Vehicle Body System Safety Precaution To the electrical technicians who use medical electronic devices precautions Prohibit Operation Warning: Strong magnetic components have been assembled on this vehicle Technicians shouldn't operate electronic pacemaker or other medical electronic devices in this vehicle, or the functions of medical devices may be affected by strong magnetic components.
Page 5 Vehicle Body System function of the medical device such as cardiac pacemaker, cardioverter, defibrillator and other medical electronic devices.  If the technician uses the medical device such as cardiac pacemaker, multiplexer, defibrillator and other medical electronic equipment, the electromagnetic wave of the remote intelligent terminal may affect the function of the device.
Page 6 To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision that would result in air bag inflation, all maintenance must be performed by an authorized DR dealer. Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system.
Page 7 Vehicle Body System is in OFF state. The automatic 12V battery charge control does not start within approximately one hour when the power switch is turned ON/OFF. Matters needing attention Before the repairing which no need the power: rotate the key to LOCK gear and disconnect the 12V battery negative.
Page 8 Vehicle Body System Front bumper Attention ● The bumper is a resin material. Do not exert strength on it and avoid contact with the oil. ● Do not scratch the outer surface of the bumper during disassembly. ● When the front bumper is assembled, it is put in place with the bumper fixed bracket card.
Page 9 Vehicle Body System Hold the lower flanging of the bumper by hand to apply force outwards to separate the bumper from the fender , insert into the gap with a straight screwdriver , lift the retaining bar bracket and the bumper flange in turn from the bottom upwards(illustrated in diagram 3) , and separate the bumper and the bumper support.
Page 10 Vehicle Body System Assembly Follow the opposite sequence of the disassembly to assemble. Install anti-collision beam of front bumper and front cabin bracket Matters needing attention ● The front module and the car body are fixed by 8 bolts, and the tightening torque is 20N.m to 25N.m;...
Page 11 Vehicle Body System the wire harness on the front cabin bracket. remove the eight bolts（11254-0835F62）illustrated in diagram 9. Take down front cabin bracket assembly. the front anti-collision beam can be disassembled solely through removing the two bolts(11254-0616F62) illustrated in diagram 8. Assembly Follow the opposite sequence of the disassembly to assemble.
Page 12 Vehicle Body System Rear bumper Precautions ● The bumper is a resin material. Do not exert strength on it and avoid contact with the oil. ● Do not scratch the outer surface of the bumper during disassembly. Disassembly and Assembly Open the tail gate and remove the left and right combination lamp assembly、left and right rear wheel cover.
Page 13 Vehicle Body System Hold the lower flanging of the bumper by hand to apply force outwards to separate the bumper from the bodywork sheet metal , insert into the gap with a straight screwdriver , lift the retaining bar bracket and the bumper flange in turn from the bottom upwards , and separate the bumper and the bumper support.
Page 14 Vehicle Body System bumper bracket. Follow the opposite sequence of the disassembly to assemble.
Page 15 Vehicle Body System Rear anti-collision beam Precautions ● The rear anti-collision beam assembly and the car body are fixed by 4 nuts, and the tightening torque is 9N.m to 11N.m. Disassembly and Assembly Before removing the rear anti-collision beam,remove the rear bumper,then remove the 4 fixing nuts (13395-0800F71) of rear anti-collision beam illustrated in diagram 4.
Page 16 Vehicle Body System Door cover system 1、Tail door structure............................17 2、 Front cabin cover structure......................19 3、charging port cover structure.........................22 4、Door structure............................26...
Page 17 Vehicle Body System 1、Tail door structure Tail door structure decomposition 1、 tail door hinge 2、tail door air spring pole 3、tail door air spring pole bracket 4、tail door lock buckle 5、 tail door lock body 6、 tail door fixing dumper block 7、 tail door adjustable dumper block 8、tail door rubber strip 9、tail door metal plate assembly...
Page 18 Vehicle Body System 1、Tail door lock device disassembly Assembly 1) disassembly sequence 2) assembly sequence Remove inner trim panel Remove inner trim panel Tail door lock Tail door lock ②Tail boor lock buckle ②Tail boor lock buckle Important work－ 1、Insert the connector of electric open handle wire harness on the lock body,using the little hole of lock body as the location hole,align the hole position,fix the lock body on car body with three bolts 11293-0616F71;...
Page 19 Vehicle Body System Disas disassembly Assembly sembl 1) disassembly sequence 2) assembly sequence The assistant helps to hold the The assistant helps to hold the tail door tail door Tail door fixing bumper block Air spring pole ball joint Tail door adjustable bumper pin and bracket block Air spring pole ball joint...
Page 20 Vehicle Body System Tail door hinge device 3、 disassembly Assembly 1) disassembly sequence 2) assembly sequence The assistant helps to hold the The assistant helps to hold the tail door tail door Body side hinge Tail door side hinge Tail door side hinge Body side hinge Important work－...
Page 21 Vehicle Body System 2、 Front cabin cover structure Front cabin cover structure decomposition 1、front cabin cover assembly 2、front cabin cover hinge 3、front cabin lock 4、front cabin drawbench 5、 front cabin cover open handle 6、front cabin cover open handle base assembly 1、Front cabin cover lock device Disassembly Assembly...
Page 22 Vehicle Body System 1) disassembly sequence 2) assembly procedures: Open engine cover and support it with Open engine cover and support it with the front cabin rod the front cabin rod Front cabin open handle front cabin cover drawbench front cabin cover open handle base Clamp and connect front cabin assembly cover drawbench and the lock.
Page 23 Vehicle Body System 1) disassembly sequence 2) assembly sequence open the front cabin cover with open the front cabin cover with assistant helping assistant helping ① Hex flange bearing surface ① Hex flange bearing surface toothed bolt of front cabin side toothed bolt of body side ②...
Page 24 Vehicle Body System 3、charging port cover structure 1、Installation precautions  Prevent damage or scratch while disassembling or assembling parts  In the disassembly of some larger components, ensure at least two people should operate in case of parts fall-off.  When installing plastic parts, make sure the screws are installed in the mounting holes first,and then carefully tighten the screws.
Page 25 Vehicle Body System 2.Adjustment replacement charging port cover assembly Adjustment of charging port cover:  Take down front bumper, Refer to “front bumper assembly replacement”.  Use cross screwdriver to disassemble the charging port cover fixing screws;  Adjust the charging port cover to the appropriate position, and ensure the cooperation with the front bumper.
Page 26 Vehicle Body System Assembly: Follow the opposite sequence of the disassembly procedures. Replacement of charging port lock actuator: Disassembly:  Disassemble front bumper, Refer to “front bumper replacement”. And open charging port cover;  Turn the charging port cover lock actuator clockwise and pull it out, Place and preserve the cover actuator well after Disassembling the actuator...
Page 27 Vehicle Body System  After the installation is completed, start the vehicle and press the charging port cover starting switch, and confirm that the actuator normally operates and open the charging port cover;  The electric actuators differentiates the left and right sides, Pay attention to confirm that when installing.
Page 28 Vehicle Body System 4、Door structure Door decomposition Attention： ■The doors assembly methods are the same. ■When disassembling and assembling the door assembly, take good guard against the door and body scratch. ■After the door assembly is complete,it must to adjust to ensure the door open and close normally,The head of the hinge assembly bolt is also repainted(car body color).
Page 29 Vehicle Body System 1）Assembly Follow the opposite sequence of the disassembly procedures. Replacement of front side door hinge assembly 1) disassembly ① Disassemble door stopper, Refer to “door stopper replacement”; ② Remove the fixing bolt connecting the door and the hinge with a 12mm socket spanner.
Page 30 Vehicle Body System bolts well in one time. Replacement of front door hinge 1) disassembly ① Remove the front side door assembly Refer to “Replacement of front side door assembly” ② Remove the fixing bolt connecting the body and the hinge with a 12mm socket spanner.
Page 31 Vehicle Body System 2) assembly Follow the opposite sequence of the disassembly procedures. Attention： ■Do not touch the surface of the adhesive to reduce the effect of the reattachment weakening. ■Be careful when taking down the waterproof membrane, so as not to damage the waterproof membrane.
Page 32 Vehicle Body System Adjustment of front door lock buckle ① loosen the buckle’s screw ② move the buckle to the needed direction. Ensure the buckle is in the middle of door lock. ③ tighten the fixing bolt of buckle ④ close door and check whether side difference and clearance meet the demand. Note: replacements of components on left and right front door are the same.
Page 33 Vehicle Body System ③ Disassemble outer weather-strip of front door Attention： ■ Do not exert too much force when disassembling , which may cause parts’ deformation; ■Check the weather-strip in vision after disassembly,if there is deformation found,please replace it. 2) assembly ①...
Page 34 Vehicle Body System ② disassemble water-proof membrane Refer to “Replacement of front door waterproof membrane”. ③ disassemble inner weather-strip of front side door. Refer to “Replacement of inner weather-strip of front side door” ④ install the window regulator switch back,lift the window to the appropriate location, be easy to disassemble the fixing screw for front door window.
Page 35 Vehicle Body System Replacement of front door window glass regulator 1) disassembly ① Disassemble door inner trim panel. Refer to “replacement of front door inner trim panel”. ② disassemble water-proof membrane Refer to “Replacement of front door waterproof membrane”. ③ disassemble inner weather-strip of front side door. Refer to “inner weather-strip of front side door”...
Page 36 Vehicle Body System ① Disassemble door inner trim panel. Refer to “replacement of front door inner trim panel”. ② disassemble water-proof membrane Refer to “Replacement of front door waterproof membrane”. ③ disassemble inner weather-strip of front side door. Refer to “inner weather-strip of front side door”...
Page 37 Vehicle Body System window glass regulator”. Tightening torque: (7～11)N.m ③ Install door glass. Refer to”Replacement of front door window glass” ⑤ install inner weather-strip of front side door Refer to “Replacement of inner weather-strip of front side door” ⑥ install waterproof membrane. Refer to “Replacement of front door waterproof membrane”.
Page 38 Vehicle Body System 2) assembly install the guide rail,tighten the fixing bolt,tightening torque is (6～10)N.m ① ② install front door window glass regulator groove,install the two connecting feet first ③ Install the glass regulator of front side door Refer to “Replacement of front door window glass regulator”.
Page 39 Vehicle Body System ■Tightening torque:29～35 N•m Attention： ■Disassembly should be done in several times. Do not loosen all parts in one time. ■Please disassemble from lower part to upper part. ③ unplug the rubber sleeve of door harness, then unplug the door’s electric connector.
Page 40 Vehicle Body System ■ Assembly Follow the opposite sequence of the disassembly procedures. Replacement of rear door waterproof membrane: 1) disassembly ① Disassemble rear door inner trim panel. ② Disassemble wire harness fixing buckle. ③ separate waterproof membrane and take it down. 2) assembly Follow the opposite sequence of the disassembly procedures.
Page 41 Vehicle Body System Hint: replacement of components on left and right rear door are the same. Please lift the glass to the highest point before disassembling. Replacement of inner weather-strip of rear side door 1) disassembly ① Disassemble door inner trim panel. Refer to “replacement of rear front side door inner trim panel”.
Page 42 Vehicle Body System 2) assembly ① Make the front side door outer weather-strip align to the B column frame, and then slowly install the weather-strip well from one end. ② fasten the fixing screws of outer weather-strip of rear side door,tightening torque:3～5N.m.
Page 43 Vehicle Body System ⑥ Disassemble the fixing screw of rear door window glass lower guide rail. ⑦ take down the door window glass. 2) assembly procedures: ① install the window regulator switch back,lift the window to the appropriate location,be easy to install the fixing screw of door window glass. ②...
Page 44 Vehicle Body System 2) assembly ① put glass regulator in,install fixing nuts of rear door window glass bracket. Tightening torque: (7～11)N.m ② Install the fixing nuts of rear door window regulator motor. Tightening torque: (7 ～ 11)N.m Install rear door window glass. Refer to”Replacement of rear door window glass” ④...
Page 45 Vehicle Body System ⑤ Disassemble outer weather-strip of rear door window. Refer to “Replacement of outer weather-strip of rear door window” ⑥ Disassemble rear door window glass groove. 2) assembly ① install rear door window glass regulator groove,install the two connecting feet first ②...
Page 46 Vehicle Body System ③ install glass regulator back,lift the glass to the top. ④ Pull down the lower guide rail glass groove. ⑤ loosen the two fixing bolts of lower guide rail,take down the guide rail 2) assembly ① Install lower guide rail,fasten the upper fixing bolt,don’t fasten the lower fixing bolt temporarily.
Page 47 Vehicle Body System ③ loosen the four fixing bolts of window anti-pinch controller,take down the controller. 2) Disassembly procedures ① put in window anti-pinch controller,fasten the four mounting bolts,tightening torque （7~11）N.m. ② connect the two connectors of window anti-pinch controller. ③...
Page 48 Vehicle Body System Side wall door trim panel Disassembly and installment..................Guard plate of front sill guard................. Guard plate of rear sill guard.................. A column upper trim panel assembly..............A pillar lower protect panel assembly..............B pillar lower protect panel assembly..............B pillar upper trim panel assembly.................
Page 49 Vehicle Body System Disassembly and installment Explosive view ①Front door threshold protect panel assembly ② rear door threshold protect panel assembly ③ A column upper trim panel assembly ④ A column lower trim panel assembly ⑤ B column lower trim panel assembly ⑥...
Page 50 Vehicle Body System ①Front door trim panel assembly ② rear door trim panel assembly ③ tail door trim panel assembly ④ Front door triangle window cover assembly ⑤ front door inclined handle ⑥ Front door handrail panel ⑦ Rear door triangle window cover assembly ⑧...
Page 51 Vehicle Body System Assembly: When installing,align the clamping structure and bolt structure of both end of front door threshold protect panel with A column lower protect panel and B column lower protect panel. And aligning the fastener of threshold protect panel with threshold iron buckle, clap the buckles into the metal plate holes.
Page 52 Vehicle Body System iron buckle, and then remove the A column upper protect panel from the dashboard junction. Assembly: When installing, insert the lower end of the A column into the instrument panel, then aligning the fastener with body hole site to press in and clap tightly.
Page 53 Vehicle Body System When installing,put A pillar in installation position,clamp the buckles well,install front side door frame strip. Put the engine open handle in the installation position,fasten the buckles well. B pillar lower protect panel assembly Disassembly:  Disassemble the front threshold protect panel assembly, disassemble rear threshold protect panel assembly;...
Page 54 Vehicle Body System  Remove the front and rear door frame adhesive tapes;  Slide up the trim cover at the fixed point below the belt to expose the entire lower fixation points, and then unscrew the one fixing bolt ...
Page 55 Vehicle Body System Assembly: When installing, connect rear seat backrest lower fixing bracket and the upper end of C column protect panel with C column upper protect panel, and then press the C column lower protect panel into metal plate hole, tighten the lower screw of the C column lower protect panel with cross screwdriver.
Page 56 Vehicle Body System Assembly: When installing,connect the connection between C pillar upper trim panel and trunk light,remove rear side door frame strip、the connection between tail sealing strip and C column upper trim panel assembly,put C column upper trim panel in installation position,clamp the buckles. Tighten the two fixing screws,install the rear side door trim strip、tail sealing strip.
Page 57 Vehicle Body System Assembly: When installing,put tail door threshold assembly in the installation position,clamp the buckles well,then install 5 expansion buckles on the tail door threshold assembly,install tail door sealing strip,install spare tire cover and close the trunk cover. front door handle Removal ...
Page 58 Vehicle Body System front door armrest Disassembly:  Disassemble front door handle See front door handle  Pry the connection between front door handle and front door trim panel with a pry bar.  Disconnect wire harness connector,take down front door armrest Assembly: When installing.connect the connector,put front door armrest in installation position and fasten the buckles well,install the front door handle at last.
Page 59 Vehicle Body System Assembly: When installing,put Front door triangle window cover in installation position and clamp it tightly. front door trim panel Disassembly:  Disassemble front door armrest refer to front door armrest  Remove front door triangle window cover refer to front door triangle window cover ...
Page 60 Vehicle Body System  Pry the front door handle,and take it down  Remove the 3 fixing screws① connecting front door handle inner board and front door.  Remove the 2 fixing screws connecting front door and front door trim panel assembly.
Page 61 Vehicle Body System  Pry 8 buckles connecting front door inner trim panel and the vehicle body.  Disconnect front inner handle cable and the inner locking cable.  Disconnect main switch connecting harness of window regulator.  Remove front door trim panel assembly. Assembly: When installing,connect door wire harness and inner open handle well,then press front door trim panel into metal plate,fasten two fixing screws of...
Page 62 Vehicle Body System  Pry the connection between armrest panel and rear door inner trim panel with a pry bar.  Disconnect wire harness connection,take down door armrest Assembly: When installing,connect wire harness well,then connect armrest panel and rear door inner trim panel,fasten one screw,install the armrest panel cover. Rear door inner trim panel Disassembly: ...
Page 63 Vehicle Body System  Pry up the rear door inner handle cover.  Remove the screws in the cover. Remove rear door armrest panel refer to rear door armrest panel  assembly.  Remove the one fixing screws from the lower part of the trim panel to the door.
Page 64 Vehicle Body System First ,connect door wire harness and inner open handle well,then press rear door trim panel into metal plate,fasten one fixing screws of rear door trim panel,fasten inner open handle screw,install door armrest,at last install rear triangle window trim panel. Tail door trim panel assembly Disassembly: ...
Page 65 Vehicle Body System Dashboard Precautions..........................64 Disassembly and installment....................64 steering column trim cover...................64 instrument panel lower protection plate on the driver side........65 Auxiliary dashboard extender..................65 Auxiliary dashboard cup holder cover................66 shift cover........................66 front storage box assembly..................66 Auxiliary dashboard body.....................67 central glove box cover....................68 Central right trim panel....................68 Central left trim panel....................68 MP5 panel........................69...
Page 66 Vehicle Body System Precautions  Strictly compliance with airbag system operation matters needing attention, otherwise it will cause vehicle damage and personal injury.  The battery negative terminal must be removed before removing the wire harness and connectors, and waiting for at least 1min, otherwise it will cause damage to the vehicle.
Page 67 Vehicle Body System  Remove steering wheel assembly. Refer Steering Wheel Replacement  Remove the fixing screw of steering column lower cover.  Remove steering column upper、lower trim cover.  Install in the reverse order above.  Note that the steering column shall be placed in the center position ■...
Page 68 Vehicle Body System Glove box  Open glove box to the maximum opening angle. Pull the side wall of the glove box inwards and pull out at the same time, so that the both sides stop cylinders slide out.  Flatten the glove box and pull out the glove box from the opening of the dashboard.
Page 69 Vehicle Body System Auxiliary dashboard cup holder cover Disassembly  Pry up the cup holder cover assembly in the end of auxiliary dashboard . Assembly  put cup holder cover in installation position and clamp it tightly. shift cover  Separate the connection between shift cover and auxiliary dashboard panel,take down the cover front storage box assembly Removal...
Page 70 Vehicle Body System Assembly Follow the opposite sequence of the disassembly to assemble Auxiliary dashboard body Disassembly  Remove auxiliary dashboard cup holder cover, take down the cover.  Remove auxiliary dashboard control panel, take down the panel.  Remove front glove box ...
Page 71 Vehicle Body System central glove box cover  Pry front glove box cover with a pry bar.  Disconnect wire harness connection,take down central glove box cover Central right trim panel  Pry the fixing buckles of central right trim panel carefully ...
Page 72 Vehicle Body System MP5 panel  Disassemble the central right trim panel. Take down the central trim panel.  Disassemble the central left trim panel. Take down the central left trim panel.  Use cross screwdriver to disassemble the fixing screws of MP5 panel. ...
Page 73 Vehicle Body System  Remove glove box. Refer to “replacement of glove box”.  Remove central glove box cover,refer to “replacement of central glove box cover”  Remove auxiliary dashboard body. Refer to “replacement of auxiliary dashboard body”.  Remove central left trim panel. Refer to “replacement of central left trim panel”.
Page 74 Vehicle Body System Dashboard bracket  Remove instrument panel crossbar welding assembly. Refer Dashboard Assembly Replacement.  Disconnect all electrical equipment that is connected to the dashboard tube girder.  Disconnect dashboard wire harness.  Remove the dashboard bracket left and right fixing bolts. ...
Page 75 Vehicle Body System Soft interior trim Disassembly and Assembly..........................74 1.Ceiling..................................74 Disassembly.................................74 Installation................................76 2. Carpet.................................. 76 Carpet dismantle..............................76 Carpet assembly..............................77 3. Trunk side trim panel.............................78 Disassembly................................78 Assembly................................78 4. Clothes hanger assembly............................78 Disassembly................................78 Assembly................................79...
Page 76 Vehicle Body System Disassembly and Assembly 1. Ceiling Disassembly 1. Use cross opener to dismantle sunshade rotating shaft and fixing bolts of sub-holder, take off sunshade. 2. Remove the fixing screw and disconnect the connectors of front ceiling lamp, refer Front Ceiling Lamp Disassembly Instructions to remove the front ceiling lamp.
Page 77 Vehicle Body System 4. Dismantle door sealant, refer to “Dismantle instructions of door sealant”. 5. Disassemble top trim panel of A column, refer to “Top Trim Panel of A Column Disassembly Instructions”. 6. Disassemble top trim panel of B column, refer Top Trim Panel of B Column Disassembly Instructions.
Page 78 Vehicle Body System Installation Follow the opposite sequence of the disassembly to asseemble. Attention： ● Do not bend the ceiling assembly too much during installation ● When installing the ceiling assembly, the sun visor and the rear buckles fastening hole of the ceiling assembly shall be aligned with the corresponding holes on the car body before installing.
Page 79 Vehicle Body System 4. Disassemble lower trim panel of A/B/C column, refer to “Lower Trim Panel of A/B/C Column Disassembly Instructions”. 5. Disassemble the secondary instrument panel with reference to the “secondary instrument panel”. 6. Remove the carpet buckle with a buckle pincers. 7.
Page 80 Vehicle Body System the positive hole position. 2. Pull out the seat connecting wiring harness under the carpet and compacted the carpets of the sub dashboard and fasten the carpets with the buckles. 3. Trunk side trim panel Disassembly Dismantle the 24 buckles (symmetrically left and right) of the left and right side panel with buckle pincers, pull out the left and right side panel.
Page 81 Vehicle Body System gently and take off it from rotating axle. Assembly Follow the opposite sequence of the disassembly to assemble.
Page 82 Vehicle Body System Lighting system Outline................................83 Fault Diagnosis..............................86 Disassembly and assembly..........................93...
Page 83 Vehicle Body System Outline (1) structure summary Internal lighting parts location map 1. front roof lamp 2. Trunk lamp External lighting parts location map 1.Front left fog light 2.Left daytime traffic light 3.Left front combination lamp...
Page 84 Vehicle Body System 4.Front right fog light 5.Right daytime traffic light 6.Right front combination lamp 7.Right rear circumference combination 8.Right rear door combination lamp 9.High position brake lamp lamp 10.Left rear circumference combination 11.Left rear door combination lamp 12.Left reversing lamp lamp 13.Right reflector 14.Right reversing lamp...
Page 85 Vehicle Body System (2) the working principle Schematic diagram of electrical appliances (without CAN models) Front headlamp Front Headlamp regulating regulating Low Beam Relay motor Low beam light Light combination switch High Beam Relay High-beam lamp Warning light Turning lamp Front Fog Lamp Instrument daytime...
Page 86 Vehicle Body System Schematic diagram of electrics(with CAN models) back-up lamp Front headlamp Reverse lamp Front Headlamp switch regulating s witch Low Beam Low beam light Instrument Relay cluster High Beam Relay High-beam lamp Generator Front Fog Lamp Front fog lamp Relay Door control switch...
Page 87 Vehicle Body System (3) technical parameters Serial Name Bulb type Power Lighting color High-beam lamp 2×55W White Low beam light 2×55W White Front turn signal lamp PY21W 2×21W Amber Front position light 2×5W White Front fog lamp 2×35W White daytime running lights 2×5.6W White Rear position light/brake...
Page 88 Vehicle Body System 2. The fault diagnosis (1) Troubleshooting Table faults Cause Analysis Solution Remark phenomen Bulb filament blown Replace the lamp Fuse blown Replace the fuse. Power fails, harness Repair circuit fault Headlamps, connector loose Relay does not work Replace the relay fog lights, turn signals do not...
Page 89 Vehicle Body System (2) lighting system fuse, relay and wiring connector list Serial Lighting Fuse Relay Wire harness connector and PIN foot Left low beam E05-8 IF16 20A IR03 light Right low beam E20-8 Left high beam E05-10 IF17 15A IR04 Right high E20-10...
Page 90 Vehicle Body System Next step Steps Checking Solution Decision content specification Ignition switch placed in Confirm the fault Is the corresponding Next step Turn to step 3 the appropriate location, phenomenon light on? light switch move to the corresponding position. Check and handle the Check for intermittent loose situation of related...
Page 91 Vehicle Body System Use a multimeter to Check the input power Voltage Standard: 11 ~ measure the voltage Next step Repair or replace of corresponding relay 14 V voltage is within between the the standard? the electrical box corresponding harness connector terminals and the ground.
Page 92 Vehicle Body System Check the reversing Turn to step 7 Remove the reversing Replace the reversing Is the filament blown? lamp and check the lamp bulb,turn to next light bulb filament. step Faults exclusion Next step Check if the fault is Put the ignition switch If the back up light is removed after...
Page 93 Vehicle Body System Brake light does not work Next Steps Checking Solution Decision step content specification Confirm the fault Whether the brake Turn the ignition Handle intermittent Turn to step 3 switch OFF and problems and go to phenomenon light is on. depress the brake the next step pedal.
Page 94 Vehicle Body System Standard resistance: Check the circuit Next step Repair or replace the Measure the less than 1Ω, between the brake wiring harness resistance between resistance meets the standard? light switch and the the brake light switch brake light fuse. connector and the brake light fuse.
Page 95 Vehicle Body System 3、Disassembly and Assembly Front combination lamp assembly (1) disassembly 1. open the front cabin cover. 2. Disconnect the negative harness of the battery refer to the disconnection and connection of the battery cable 3. Disassemble Front cabin front cover, refer to front cabin front cover 4.
Page 96 Vehicle Body System (3) Adjustment 1. Adjust front combination light lighting 1). Confirm that all tires are under normal pressure. 2) Place the vehicle and tester on the same flat surface. 3) Verify that the vehicle is empty except for the driver (or placing equivalent weight at the driver's seat). 4) Turn on the front combination lamp low beam light.
Page 97 Vehicle Body System 2. Install front wheel cover Connect the battery negative cable. 4. Close front cabin cover. (3) Adjustment 1. Adjust front fog lamp lighting △ Note that the front fog light beam must be adjusted to provide the correct road lighting. △...
Page 98 Vehicle Body System 1). Disconnect daytime running lights assembly harness connector. 2). Remove the 3 fixing screws of the daytime running lights assembly and front bumper. 3). Remove daytime running lights assembly (2) Installation 1. Install daytime running lights assembly 1) .
Page 99 Vehicle Body System Rear side body combination lamp assembly (1) Disassembly 1. Open the tailgate 2. Open the front cabin cover. 3. Disconnect the negative cable of the battery refer to the disconnection and connection of the battery cable 4. Remove Rear side body combination lamp assembly 1).
Page 100 Vehicle Body System 2. Close tailgate 3. Connect the battery negative cable. 4. Close front cabin cover. Tailgate combination lamp assembly (1) Disassembly 1. Open the tailgate 2. Open the front cabin cover. 3. Disconnect the negative cable of the battery refer to the disconnection and connection of the battery cable 4.
Page 101 Vehicle Body System (2) Installation 1.Install tailgate combination lamp assembly 1). Put the tailgate combination lamp assembly into installation position, fasten 3 fixing bolts① of rear combination lamp assembly. 2). Connect the tail door combination lamp harness connector②. 3). Install the rear lights repair cover. △...
Page 102 Vehicle Body System 4). Disconnect the harness of high mounted braking lamp①. 5). Remove empennage and brake light assembly. 5. Disassemble high mounted brake lamp 1). Remove 3 bolts holding the high mounted brake light and lamp cover. 2). Disconnect rear window water pipe①...
Page 103 Vehicle Body System 2). Install high mounted brake light, fasten 3 bolts fixing lamp cover. 2. Install empennage and brake light assembly 1). Put the empennage at the installation position, connect high mounted brake light assembly①. 2). Fasten 5 fixing bolts③. 3) Connect rear washing pipe and car body water pipe②, install water pipe cover.
Page 104 Vehicle Body System License plate lamp assembly (1) Disassembly 1. Open the front cabin cover. 2. Disconnect the negative cable of the battery refer to the disconnection and connection of the battery cable Remove the license plate light assembly 1). Pry open license plate light assembly. 2).
Page 105 Vehicle Body System (2) inspection 1. Check license plate lamp 1).Check if license plate lamp filament is blown. (3) Installation Attention Install license plate light assembly 1). Screw on license plate lamp bulb. 2). Install license plate lamp base. 3). Connect license plate lamp assembly harness connector.
Page 106 Vehicle Body System Front roof light assembly (1) Disassembly 1. Open the front cabin cover. 2. Disconnect the negative cable of the battery refer to the disconnection and connection of the battery cable Remove Front roof light assembly 1). Install the front light assembly. 2).
Page 107 Vehicle Body System Inspection 1. Check front roof lamp 1).Check if front roof lamp filament is blown. (3) Installation Install the front light assembly 1). Connect front roof lamp assembly harness connector. 2). Turn front roof lamp① into mounting hole and ensure installation in place.
Page 108 Vehicle Body System Luggage compartment lamp (1) Disassembly 1. Open the tailgate 2. Open the front cabin cover. 3. Disconnect the negative cable of the battery refer to the disconnection and connection of the battery cable 4. Disassemble the trunk lamp 1).
Page 109 Vehicle Body System . Close tailgate Connect the battery negative cable. 4. Close front cabin cover. Rear reflector assembly (1) Disassembly 1. Open the tailgate 2. Open the front cabin cover. 3. Disconnect the negative harness of the battery refer to the disconnection and connection of the battery cable 4.
Page 110 Vehicle Body System Reverse lamp assembly (1) Disassembly 1. Open the tailgate 2. Open the front cabin cover. 3. Disconnect the negative cable of the battery refer to the disconnection and connection of the battery cable 4. Disassemble rear side body combination lamp assembly, refer to rear side body combination lamp assembly 5.
Page 111 Vehicle Body System △Attention Check the rear reverse lamp is intact before installation. Damage to rear reverse lamp is not allowed during installation. After installation, check if the rear reverse lamp installation is in place, if the gap with bumper is appropriate, if not in place or inappropriate, reinstall it.
Page 112 Vehicle Body System Rear fog lamp assy (1) Disassembly 1. Open the tailgate 2. Open the front cabin cover. 3. Disconnect the negative cable of the battery refer to the disconnection and connection of the battery cable 4. Disassemble rear side body combination lamp assembly, refer to rear side body combination lamp assembly 5.
Page 113 Vehicle Body System Outside rear view mirror Disassembly and Assembly..................113 Disassembly and Assembly Interior rear view mirror Disassembly Disassemble rear view mirror from the base with slotted screwdriver.
Page 114 Vehicle Body System Installation Press inner rear view mirror into the inner rear view mirror pedestal and confirm the installation is firm. Install the inner rear view mirror base. Precautions:  The inner rear view mirror is attached to the rear view mirror base. The inner rear view mirror pedestal is glued to the windshield with Plastic polyethylene acetal adhesive.
Page 115 Vehicle Body System  Mark at a position outside of the windshield with a wax pen or crayon. Draw a large circle along the inner rear view mirror pedestal outside edge on the windshield outer surface (3). The sketch map of installation of the inner rear view mirror ...
Page 116 Vehicle Body System  Place the inner rear view mirror correctly at the pre-marked position. The half rounded end pointing upward is not allowed. Press the inner rear view mirror pedestal against the windshield for 30 to 60 seconds, applying constant pressure on the windshield.
Page 117 Vehicle Body System Body component maintenance and replacement Body component maintenance and replacement............116 Vehicle body size check....................122...
Page 118 Vehicle Body System Body component maintenance and replacement Overview  This section is used to provide guidance to the technicians with higher skills and experience in the maintenance of collision vehicles, and will use the modern service tools and equipment Those who do not have the vehicle body repair skills do not attempt to use the methods in this section to repair the vehicle.
Page 119 Vehicle Body System In order to facilitate the shearing of front pillar outer panel, please prepare shear fixture. At the same time, it will also make maintenance parts can be accurately shear in the junction. Examples of searing operations with fixture are as follows. 1.
Page 120 Vehicle Body System Replacement of outboard longitudinal beam (right and left symmetrically) The solder joint as below:...
Page 121 Vehicle Body System Replacement of outboard longitudinal beam (right and left symmetrically) The solder joint as below: Replacement of outer panel of rear wall The solder joint as below:...
Page 122 Vehicle Body System Replacement of the rear part of the side wall outer panel(right and left symmetry) The solder joint as below: Replacement of the threshold part of the side wall outer panel(right and left symmetry) The solder joint as below:...
Page 123 Vehicle Body System Replacement of the B pillar of side wall(right and left symmetry) The solder joint as below: Vehicle body size check Vehicle body data In the body maintenance process, in order to guarantee the running performance of the car and the better service for you, the repair personnel...
Page 124 Vehicle Body System should check the size of body-in-white accordance to the following size. Data Numerical measured Position information value（mm） points The distance from the middle of the top cover to the middle of the upper outer plate of the ventilated cover plate.
Page 125 Vehicle Body System to rear top of the rear door frame. The width of the bottom dead center of rear 336.4 door threshold Front door frame height 952.1 The oblique diagonal length from front top to 945.5 rear bottom of the front door frame. The width of the bottom dead center of front 728.3 door threshold...
Page 126 Vehicle Body System Data Position information Numerical value measured （mm） points The length of right front suspension side 532.8 beam The hole center gap of left and right front 1179.8 shock absorber mounting plate The maximum width of the connection 1557.5 position of left and right side wall with engine bay...
Page 127 Vehicle Body System Data Position information Numerical value measured （mm） points The inner wall gap of the left and right 914.0 stringer of rear floor The hole gap of left and right 984.3 mounting plate at the side rear of the battery The gap of the left and right mounting 1130.0...
Page 128 Vehicle Body System Seat belt Attentions:................... Seat replacement................Safety belt replacement..............
Page 129 Vehicle Body System Attentions:  Pay attention to the seat fixing bolt installation sequence.  Position the seat in the final position, check the locking of each slide, and then tighten the front retaining bolt temporarily.  Place the seat in the front position, check the lock on each slide, and tighten the anchor bolt completely.
Page 130 Vehicle Body System Installation tool should be slided forward when removing the rear bolt). S=14, the seat mounting bolt tightening torque:■ 45N.m-55N.m）  Next, press the headrest release button on the headrest guide and pull up the headrest③ hard;  Finally, separate the wire harness connector buckle of the safety belt inserted reminder, then remove the seat.
Page 131 Vehicle Body System Rear seat installation Install according to the reverse procedure for disassembly. Safety belt replacement Attention：  Make sure not to damage the retractor when disassemble the safety belt.  Replace the damaged buckle on the guard panel.
Page 132 Vehicle Body System Front safety belt disassembly pillar upper ① ② Left front safety pillar lower ③ Vehicle body floor ④  First disassemble the front door sill guard panel and rear door sill guard panel, refer to front and rear door sill assembly. Slide up the belt②...
Page 133 Vehicle Body System Front safety belt installation Assemble according to the opposite sequence of the disassembly procedures. Disassembly of front safety belt latch  Remove the front seat①. (Refer the seat part)  Put the seat bottom upward, separate the plug of connecting wire harness.
Page 134 Vehicle Body System refer to the C pillar lower panel assembly  6. Dismantle 1 fixing bolt of rear row seat safety belt panel lower fixing point, dismantle the C pillar upper panel assembly refer to the C pillar upper panel ...
Page 135 Vehicle Body System Vehicle body anticorrosion sealing Anticorrosion instruction......................134 Vehicle body gumming sealing....................136...
Page 136 Vehicle Body System Anticorrosion instruction The below upgraded anticorrosion method has been realised in factory, same method is advised when repair or replace vehicle body. Anticorrosion Painting layer steel A new kind of anticorrosion Painting layer steel uses zinc-coated thin steel plate instead of traditional coated plate, improving the capability of remedy and anticorrosion ability.
Page 137 Vehicle Body System Precautions:  Do not paint the undercoat everywhere unless it is regulated area;  Do not paint around the exhaust pipe, influencing heat dissipation effect;  Do not paint at rotating part;  Paint green wax after painting the undercoat; ...
Page 138 Vehicle Body System Stone splash protection layer Vehicle body gumming sealing Below diagram shows, sealant is commonly used at smooth place without cutting or gaps in the factory sealing area. But sealant can’t be used too much, and touch is not allowed to sealant by other no-need-sealing area.
Page 139 Vehicle Body System Vehicle body front face Sealing parts...
Page 140 Vehicle Body System Vehicle body front face Sealing parts...
Page 141 Vehicle Body System Repair high-strength steel Maintenance Precautions......................140...
Page 142 Vehicle Body System Maintenance Precautions It is not recommended to heat when repairing some steel framed structure, because heating will weaken its performance; when heating is inevitable, temperature of high strength steel part shall not exceed 550 ℃. When straightening car body, should be careful to pull high strength steel, because it is extremely strong, over pulling will make other parts that connect with steel deformed, in this case, increasing measuring numbers and careful pulling the steel panel is the only way.
Page 143 Vehicle Body System When welding high strength steel, spot welding is strongly recommended at any case,minimizing the influence to its surroundings due to welding heat; Rare gas shielded welding is the second choice when spot welding can’t proceed, do not use gas welding due to its weak welding strength. The strength of spot welding position is higher than other places that don’t have welding position on high strength steel.
Page 144 Vehicle Body System following issues should be paid attention when spot welding high strength steel: electrode tip diameter shall be chosen according to metal panel thickness. Panel shall be stick to each other without sundries or intervals Restrain welding points intervals size according to the following instructions...
Page 145 Vehicle Body System Car body components： Engine compartment groups: Serial No Position name Material strength(Mpa) Shock absorber installing panel Up 440 Front wheel cover Under440 Front wheel cover reinforcing plate Up 440...
Page 146 Vehicle Body System Carling front part of the engine Up 440 compartment Front installing holder of sub-frame Up 440 Rear reinforcing plate of front part of Up 440 the engine compartment Reinforcing plate of front installing Under440 holder of sub-frame Rear installing panels of sub-frame Up 440 Reinforcing plate of rear part of the...
Page 147 Vehicle Body System Serial No Position name Material strength(Mpa) Lower beam of front floor Up 440 Connecting panel of floor carling Up 440 Upper floor of battery Under440 Front connecting panel of upper floor Up 440 of battery Connecting panel of front floor carling Up 440 Front floor Under440...
Page 148 Vehicle Body System Rear floor part group: Serial No Position name Material strength(Mpa) Spare tire installing panel Under440 Rear part of rear floor left carling Up 440 Rear reinforcing plate of rear floor left Under440 carling Left carling of rear floor structure Up 440 Upper torsion beam of rear floor Up 440...
Page 149 Vehicle Body System Front beam of rear floor structure Up 440 Left connecting plate of front beam of Up 440 rear floor structure Connecting plate of rear left installing Up 440 plate of battery side Mid fixing plate of rear seat Under440 Left installing plate of rear axle Up 440...
Page 150 Vehicle Body System Serial No Position name Material strength(Mpa) Front mold plate Under440 Front mold plate beam Up440 vacuum booster installing plate Under440 Front mold plate reinforcing plate Up 440 Connecting panel of right frnot floor Up 440 carling of front mold Right reinforcing plate of front mold Up 440 beam...
Page 151 Vehicle Body System Serial No Component name Material strength(Mpa) Out panel of right side skirt Under440 Out panel of top cover Under440 Front beam of top cover Under440 Central beam of top cover Up 440 Left mid door column trim panel Up 440 Second beam of top cover Under440...
Page 152 Vehicle Body System Outer panel of left rear wheel cover Under440 Reinforcing plate of left B column out Up 440 panel Reinforcing plate of left front door Up440 column Out panel of left side skirt Under440 Dispose parts of extra high strength steel Weaken or additional connecting is forbidden;...
Page 153 Vehicle Body System Body exterior system maintenance Contents Front combination light............................152 Front turn signal lamp..............................155 Front position light..............................156 Front fog lamp................................156 Taillight..................................158 Braking lamp (high level).............................159 License plate light..............................160 Front roof light................................161 Inner rear view mirror.............................162 Outside rear view mirror............................165 Lamps and lanterns maintenance data and specification................166 Top cover outer protective device........................167 Tail gate outer protective device..........................168...
Page 154 Vehicle Body System Front combination light Disassembly and Assembly Front combination light lighting adjusting Precautions Front combination light Components location map...
Page 155 Vehicle Body System Disassembly and Assembly Removal Disconnect the battery negative. Take down front bumper, Refer to “front bumper replacement”. Remove the 4 installation points fixing screws of front combination headlamp, removal torque is 3N.m~5N.m. Carefully move front combination headlamp and remove electrical connector. Remove the front combination lamp assembly.
Page 156 Vehicle Body System Front combination light lighting adjusting Confirm that all tires are under normal pressure Place the vehicle and tester on the same flat surface. Verify that the vehicle is empty except for the driver (or placing equivalent weight at the driver's seat).
Page 157 Vehicle Body System Front turn signal lamp Precautions Disassembly and Assembly Front turn signal bulb PreCautions: ● Do not remove the front turning light from the lamp body for too long as dust, moisture, smoke, etc. entering the lamp may affect lamp performance. Install a new lamp immediately after removing the lamp in the front combination lamp reflector.
Page 158 Vehicle Body System Front position light Precautions Front position light Precautions ● front position light and DRL use LED illuminant, can’t be disassembled and replaced. Front fog lamp Disassembly and Assembly Precautions Front fog lamp Components location map...
Page 159 Vehicle Body System Disassembly and Assembly Removal Disconnect the battery negative. Disassemble front bumper. Refer to”Replacement of front bumper”. Remove the fixing screws of the fog lamp on the front bumper. Disconnect the appliances connector to remove the fog lamp assembly. Assembly Install the front fog lamp assembly.
Page 160 Vehicle Body System Taillight Disassembly and Assembly Precautions Taillight Components location map 1 rear turning lamp 2 braking lamp 3 rear position lamp 4 rear fog lamp(left fog lamp right reversing lamp) Disassembly and Assembly Removal Disconnect the battery negative. Remove the 2 bolts from trim panel of taillight.
Page 161 Vehicle Body System Braking lamp (highlevel) Disassembly and Assembly Braking lamp (high level) Components location map Disassembly and Assembly Removal Disconnect the battery negative. Disassemble coat rack. Plug out connector. Use cross screwdriver to disassemble the fixing screws. Take off High brake lights and replace. Assembly Assemble according to the opposite sequence of the disassembly.
Page 162 Vehicle Body System License plate light Disassembly and Assembly Precautions License plate light License plate light Components location map Disassembly and Assembly Removal Disconnect the car battery. Use cross screwdriver to disassemble the fixing screws of license plate light. Remove license plate light. Remove connector, replace license plate light.
Page 163 Vehicle Body System Front roof light Disassembly and Assembly Precautions Front roof light Diagram of components position of front roof lights Disassembly and Assembly Disassembly Disassemble front roof light cover. Remove 2 fixing screws of front roof lamp by sequence. Remove the front roof lamp from the roof, disconnect the connector carefully.
Page 164 Vehicle Body System Inner rear view mirror Disassembly and Assembly Precautions Inner rear view mirror Disassembly and Assembly Disassembly 1 Disassemble rear view mirror from the base with slotted screwdriver.
Page 165 Vehicle Body System Assembly Press inner rear view mirror into the inner rear view mirror pedestal and confirm the installation is firm. Install the inner rear view mirror base. Precautions ● The inner rear view mirror is attached to the interior rear view mirror pedestal. The inner rear view mirror pedestal is glued to the windshield with Plastic polyethylene acetal adhesive.
Page 166 Vehicle Body System ● Mark at a position outside of the windshield with a wax pen or crayon. Draw a large circle along the inner rear view mirror pedestal outside edge on the windshield outer surface (3). The sketch map of installation of the inner rear view mirror pedestal ●...
Page 167 Vehicle Body System Outside rear view mirror Disassembly and Assembly Outside rear view mirror Disassembly and Assembly Disassembly 1 inner trim panel Disconnect the battery negative. Carefully pry the trim panel with a slotted screwdriver. Unscrew the 3 fixing bolts of rear view mirror. Disconnect the rear view mirror connector.
Page 168 Vehicle Body System Lamps and lanterns maintenance data and specification Bulb power and light color Lamps and lanterns maintenance data and specification Bulb power and light color Lamps and lanterns specification Name Function Type Power Light color Headlamp Front position lamp Light bulb(W) 2x5W white...
Page 169 Vehicle Body System Top cover outer protective device Disassembly and installment Precautions Top cover outer protective device Disassembly and Assembly Disassembly Remove the top roof rack and trim strip. The slotted screwdriver should be wrapped with buffer belt when use it, and the the peripheral parts should be also to wrapped with buffer belt to avoid damage.
Page 170 Vehicle Body System Tail gate outer protective device Tail gate outer protective device Disassembly and Assembly Disassembly and Assembly Precautions Disassembly Unscrew the 5 nuts with the ratchet wrench and the sleeve; Remove tailgate trim and rear wing assembly (A) Assembly Assembly sequence is opposite to the disassembly sequence.
Page 171 Vehicle Body System Side window device Disassembly and Assembly Precautions Side window device Disassembly and Assembly Disassemble front triangle cover board 1 Pry open and take off the front triangle cover board(A) with screwdriver; Note: this part is irreversible disassembly, new part has to be replaced after disassembly.
Page 172 Vehicle Body System Disassemble left and right side window Cut off side window fixing adhesive with adhesive cleaning tool. Pry open side window (A) with tool, so the buckle will be off from car hole mounting place. Scrape off the remaining sealant from side window bonding surface with scraper when installation.
Page 173 Vehicle Body System Front wind shield and sealing strip device Disassembly and Assembly Precautions Front windshield glass and sealing strip device Disassembly and Assembly Disassembly O pe n the e ngine compa rtme nt cove r, ma ke s ure it is s upporte d s a fe ly. Re move the cove r for the lowe r wipe r s ha ft uns cre w the nut a nd re move the wipe r a rm D is conne ct the wa s hing pipe , re move a ll ve ntila tion cove r pa ne l fi x ing buckle s B .
Page 174 Vehicle Body System Remove fixing buckles(C) of all fenders and trim panels. Disassemble front windshield glass and sealant rubber strip. The glasses are assembled to the vehicle body with sealant, which is irreversible assembly process. If you want to remove the glass, sealant must be cut to separate the glasses from the body.
Page 175 Vehicle Body System Side window device Disassembly and Assembly Precautions Rear side window device Disassembly and Assembly Disassemble rear windshield glass Must dismantle the empennage(A) and rear windscreen wiper(B) first Disconnect the wire harness of the heating line from the glass. If there are any other wiring harness, it also needs to be disconnected.
Page 176 Vehicle Body System Wheel cover system Disassembly and Assembly wheel cover system Disassembly and Assembly Disassemble guide plate and splash guard Screw off nut(1 place) with sleeve wrench. Screw off all bolts(2/3/4 place) with sleeve wrench. Remove guide plate and splash guard. Assembly Assembly sequence is opposite to the disassembly sequence.
Page 177 Vehicle Body System Disassemble front wheel cover Remove all the plastic buckles(3/4/5/6/7 place) with buckle opener; Screw off bolts (2 place) with sleeve wrench; Screw off all screws (5 place) with cross opener; 10 Remove wheel cover. Assembly Assembly sequence is opposite to the disassembly sequence. Disassemble rear wheel cover 11 Remove all the plastic buckles(1/2/3/4/5/7 place) with buckle opener;...
Page 178 Vehicle Body System Front bumper Precautions Disassembly and Assembly Front bumper PreCautions: ● The bumper is a resin material. Do not exert strength on it and avoid contact with the oil. ● Do not scratch the outer surface of the bumper during disassembly. ●...
Page 179 Vehicle Body System Hold the lower flanging of the bumper by hand to apply force outwards to separate the bumper from the fender , insert into the gap with a straight screwdriver , lift the retaining bar bracket and the bumper flange in turn from the bottom upwards(illustrated in diagram 3) , and separate the bumper and the bumper support.
Page 180 Vehicle Body System Anti-collision beam of front bumper a nd front hood holder Precautions Disassembly and Assembly Install anti-collision beam of front bumper and front cabin bracket Precautions: ● The front module and the car body are fixed by 8 bolts, and the tightening torque is 20N.m to 25N.m;...
Page 181 Vehicle Body System Disassembly and Assembly Disassembly Before removing the anti-collision beam and the front cabin bracket,remove the front bumper and left and right headlamp, disconnect the pipes of the radiator、 condenser、 oil cooler (if assembled) on the front cabin bracket, connecting with body, and remove the wire harness on the front cabin bracket.
Page 182 Vehicle Body System Rear bumper Precautions Disassembly and Assembly Rear bumper Precautions: ● The bumper is a resin material. Do not exert strength on it and avoid contact with the oil. ● Do not scratch the outer surface of the bumper during disassembly. Disassembly and Assembly Open the tail gate and remove the left and right combination lamp assembly、left and right rear wheel cover.
Page 183 Vehicle Body System Hold the lower flanging of the bumper by hand to apply force outwards to separate the bumper from the bodywork sheet metal , insert into the gap with a straight screwdriver , lift the retaining bar bracket and the bumper flange in turn from the bottom upwards , and separate the bumper and the bumper support.
Page 184 Vehicle Body System Disassembly of rear bumper holder: The removal of rear bumper left and right fixing bracket,remove the screws （ 12442-0520F71 ） illustrated in diagram 1 with cross screwdriver,three left and right side,pull out the buckles outwards with buckle pliers,two left and right side,take down bumper bracket.
Page 185 Vehicle Body System Rear anti-collision beam Precautions Disassembly and Assembly Rear anti-collision beam Precautions: ● The rear anti-collision beam assembly and the car body are fixed by 4 nuts, and the tightening torque is 9N.m to 11N.m. Disassembly and Assembly Before removing the rear anti-collision beam,remove the rear bumper,then remove the 4 fixing nuts (13395-0800F71) of rear anti-collision beam illustrated in diagram 4.
Page 186 Vehicle Body System Side window device Reference Be careful not to scratch the surface of the plating when using the screwdriver Wear gloves to protect your hands. Front triangle cover board Disassembly procedures: 1.1 use slotted screwdriver 1 Pry open and take off the front triangle cover board(A) with toolsr; Note: this part is irreversible disassembly, new part has to be replaced after disassembly.
Page 187 Vehicle Body System Installation Sequence: 1.2 put front triangle panel aligning with car body mounting place and press. 2. Left and right side window Wear gloves to protect your hands. Be careful not to scratch the body surface; Disassembly procedures: 2.1 Cut off side window fixing adhesive with adhesive cleaning tool;...
Page 188 Vehicle Body System 3. Plastic filler cap Wear gloves to protect your hands. Be careful not to scratch the body surface; Disassembly procedures: 3.1 Pull out from the gap between C place of plastic filler cap and pedestal A of plastic filler cap with tools such as finger or slotted opener, take off with power slowly;...
Page 189 EVO Electric Body Chassis High voltage...
Page 190 Chassis Vehicle information Identification N r 1 VIN plate (in glove box) 2. VIN plate ( beam under windshield) 3 VIN plate( front left wheel package) 4 VIN plate(on the right side of metal in the tail gate) 5. VIN plate(Upper limit device of left back door) 6.
Page 191 Chassis Product plate DR AUTOMOBILES Brand: DR Vehicle type Battery volume Working voltage of battery Rated power of motor Driven motor type Number of passengers Person (s) Maximum permitted gross weight MFR Month/ Year Month (s)
Page 192 Chassis Suspension system Cautions ..............................19 1 Cautions for electric technicians using medical electrics...................191 Keypoint checking before maintenance........................191 Cautions for "safety airbag"and"safety belt preloaded"of auxiliary constraint system........191 Cautions for removing 12V battery.........................192 Preparation work ............................193 Commonly used tools..............................193 .............................19 4 Suspension system Explosion diagram..............................194 ....................19 5 Soft mat and bracket of rear suspension...
Page 193 Chassis Cautions Cautions for electric technicians using medical electrics Forbidden operation Warning: ● There are strong magnetic components in the vehicle ● If technician use medical electrics,e.g electronic pacemakers, which couldn’t be operated in the vehicle ,otherwise,the function of electrics may be effected by strong magnetic components. Cautions for normal charge Warning: ●...
Page 194 To avoid unexpected accident, we need to obey the following: ● To avoid the auxiliary constraint system invalid, all the maintenance only could be operated by DR authorized distributors because the risk of injury to people will be increased after invalid.
Page 195 Chassis Preparation work Commonly used tools Tool Diagram Instruction Power tool Install and remove bolts and nuts...
Page 196 Chassis Suspension system Explosion diagram 1 soft mat assembly of left suspension 2 power train beam 3 soft mat assembly of right suspension 4 rear suspension bracket 5 soft mat of rear suspension N·m...
Page 197 Chassis Soft mat and bracket of rear suspension Remove and installation Remove Remove connecting bolts between rear Suspension bracket and reducer. Remove connecting bolts between rear suspension Soft mat and front vice frame Take out bracket and soft mat of rear suspension Remove the connecting bolts between rear suspension bracket and soft mat, make the soft mat and bracket separate.
Page 198 Chassis Installation install connecting bolts between bracket and soft mat of rear suspension. ● Tighten torque:90～110N·m install connection bolts between rear suspension soft mat and front vice frame. ● Tighten torque:110～130N·m install connecting bolts between rear suspension bracket and reducer. ●...
Page 199 Chassis Left and right suspension soft mat assembly Remove and installation Remove Lift up the vehicle and use the tool to support power train. Remove the bracket and soft mat of rear suspension Remove the connecting bolts and nuts between left and right suspension soft mat assembly and power train supporting beam.
Page 200 Chassis Power train beam Remove and install Remove Remove connection pipe between the power train assembly components and radiator assembly , please see the "cooling system -cooling water pipe". Unplug the high and low voltage wiring harness connector which is connected with power train parts . Lifting the vehicle, use tools to support the power train assembly.
Page 201 Chassis Accelerating operation < system Preparation work............................Commonly used tools............................Remove and installation............................Explosion diagram..............................Remove..................................Install..................................Checking after installation............................
Page 202 Chassis Preparation work Commonly used tools Tool Diagram Instruction Install and remove bolts and Power tool nuts...
Page 203 Chassis emove and installation Explosion diagram 1 Accelerating pedal assembly 2 body ： N•m Remove Unplug the connection parts of the accelerating pedal assembly Remove fixed bolt of accelerating pedal assembly and take out the accelerating pedal assembly from thebody ●...
Page 204 Chassis Checking after installation check whether there is irregularities and binding for accelerating pedal within the whole itinerary. If there is, please replace. check whetehr the accelerator can return to the initial position after loosen. If not, please replace. inspect the accelerator pedal position sensor signals: ①...
Page 205 Chassis Electronic shift operating system Preparation work............................3 System description ............................. 4 Fault diagnosis ............................10 Remove and install ........................... 16...
Page 206 Chassis Preparation work Commonly used tools Tool Diagram Instruction Power tool Install and remove bolts and nuts Digital Detecting voltage signal multimeter...
Page 207 Chassis System description Description ● Replacing the traditional mechanical shift operating mechanism, electronic shift operating system use electrical signals to simulate the gear shift to realize the driver's intention to change gear. ● Electronic shift operating mechanism is located in the corresponding gear, gear signal will continue to output the signals to VCU.
Page 208 Chassis ● Receive output shift signal of electronic shift operating mechanism、simulated the driver's manipulation of intention and realize vehicle driving. Electronic shift operating mechanism Electronic shift operating mechanism has three shifts :R,N,D Shift according to the picture on the right path and press the reversing lock in driving process.( when shift first time, please step down the braking pedal) Shift according to the picture on the right path lock in driving...
Page 209 Chassis System System description ● When electronic shift operating system is in any shift, electronic shift operating system will output related shift signal. ● when there is failure in electronic shift operating mechanism, VCU will send failure code. System principle diagram Electronic shift operating...
Page 210 Chassis Stitch definition Stitch no Definition Remark Power signal of shifing mechanism, receiving through start switch. Switch Signal 1 Power, same body Switch Signal 2 Standby Switch Signal 3 Standby Switch Signal 4 Standby Standby Standby Standby...
Page 211 Chassis Logic of shift signal output： Position ③（D） Position②（N） Position ①（R） Position ①+R gear button SW1-SW4 signal Logic 1 shows the voltage range [2.9，3.4](V) Logic 1 shows the voltage range[1.4，1.9](V) Check Caution： ● when checking, put the car in the status of “ON” ●...
Page 212 Chassis Fault diagnosis Fault code Fault code Fault name Diagnosis condition Possible reason 1 harness Voltage of SW1 shift signal is SW1 shift signal with not in the range [2.9，3.4]V or P3006 2 Electronic shift operating mechanism abnormal voltage [1.4，1.9] 3 VCU 1 harness Voltage of SW 2 shift signal is...
Page 213 Chassis P3006 SW1 shift signal with abnormal voltage DTCP3006 fault check Fault code Fault name Diagnosis condition Possible reason harness Voltage of SW1 shift signal is SW1 shift signal with Electronic shift operating not in the range [2.9， 3.4]V or P3006 abnormal voltage mechanism...
Page 214 Chassis DTC P3007 SW2 shift signal with abnormal voltage DTCP3007 fault checking Fault code Fault name Diagnosis condition Possible reason harness Voltage of SW2 shift signal is SW2 shift signal with Electronic shift operating not in the range [2.9， 3.4]V or P3007 abnormal voltage mechanism...
Page 215 Chassis DTC P3008 SW3 shift signal with abnormal voltage DTC P3008 fault checking Fault code Fault name Diagnosis condition Possible reason harness Voltage of SW3 shift signal is SW3 shift signal with Electronic shift operating not in the range [2.9， 3.4]V or P3008 abnormal voltage mechanism...
Page 216 Chassis DTCP3009 SW4 shift signal with abnormal voltage DTCP3009 fault checking Fault Fault name Diagnosis condition Possible reason code harness Voltage of SW4 shift signal is not in the SW4 shift signal with Electronic shift operating P3009 abnormal voltage range [2.9，3.4]V or [1.4，1.9] mechanism Fault confirmation procedure Preparation work...
Page 217 Chassis DTCP 300A shift signal with wrong logic DTCP fault checking Fault code Fault name Diagnosis condition Possible reason harness Signal combination don’t belong Electronic shift operating P300A shift signal with wrong logic to output signal combination of mechanism shift R,shift N, shift D Fault confirmation procedure Preparation work If there is another fault happen at the same time, please put the vehicle in the status of “OFF”, check again...
Page 218 Chassis Remove and install Explosion diagram P1 Deputy instrument panel 2 Electronic shift operating mechanism 3 installing bracket of Deputy instrument panel 4 downside board assembly of the body ：N·m...
Page 219 Chassis Cautions： ● Put the vehicle in the status of “OFF” in the process of remove and installation. ● Avoid to knock and hit the electronic shift operating mechanism in the process of remove and installation. ● Put electronic shift operating mechanism away from strong magnetic things after remove, It is forbidden to put it into water or put it in the place with high humidity.
Page 220 Chassis Check after remove ● Check whether it could be operated flexibly for the electronic shift operating mechanism. If couldn’t shift normally, please replace. ● Check whether there is out stitching phenomenon, if so, please replace. ● Check whether there is deformation ,bending or loose for shift operating mechanism . If there is, please replace.
Page 221 Chassis Cooling system Preparation work............................3 Commonly used tools..........................3 System description............................4 Parts layout.............................4 System principle.............................5 Basic inspection............................. 6 Fault diagnosis............................7 Overheating reason analysis......................7 Remove and install............................8 Radiator assembly, radiator fan assembly....................8 Explosion diagram......................... 8 Remove............................8 Install............................10 Remove and Install..........................
Page 222 Chassis Preparation work Commonly used tools Name Diagram Instruction cooling system leaking Radiator cover detector detection Connect radiator cover Radiator cover detector detector,different radiator adapter cover and filling mouth...
Page 223 Chassis System description Parts layout 1 Cooling water pump bracket 2 inlet pipe of electric charger 3 up suspension of radiator 4 Radiator assembly 5 PCU inlet pipe PCU 6 Radiator fan assembly 7 downside suspension of radiator 8 Inlet pipe of radiator 9 PCU inlet pipe bracket PCU 10 PCU outlet pipe 11 Outlet pipe of radiator...
Page 224 Chassis System principle Cooling fluid direction Cooling pump Charger Radiator assembly Driving motor Basic inspection Check whether the cooling fluid is full, if not,please fill full. Please see “Maintenance-cooling system” Warning： ● It is forbidden to open radiator assembly filler when the cooling fluid at high temperature to avoid overflowed coolant injury people.
Page 225 Chassis Fault diagnosis Overheating reason analysis Symptoms Inspection item Cooling pump Pump failure Cooling pump provide power dust or confetti jam Radiating fan Poor heat dissipation damaged Mechanical damage Too much foreign Radiator pipe jam bodies (corrosion, dirt, sand, etc Cooling fan not work Fan rotate with big Radiator fan...
Page 226 Chassis Remove and install Radiator assembly, radiator fan assembly Explosion diagram 1 Front-end module assembly 2 radiator suspension bracket 3 Radiator upside suspension 4 Radiator assembly 5 Radiator fan assembly 6 Radiator inlet pipe 7 Radiator outlet pipe 8 Radiator downside suspension ：N·m Remove Warning：...
Page 227 Chassis Screw off the water radiator and radiator cap, emptying coolant. Remove radiator inlet and outlet pipe Remove air-conditioner pipe connected with Condenser.please refers to “air-conditioner system- Remove and installation”. Caution： ● Pulling on the air conditioning pipe is prohibited. Remove the radiator fan assembly and temperature sensor connector .
Page 228 Chassis Caution： ● the scratch or damage to the radiator core body is prohibited when remove . Install Install in the opposite order of remove . fill coolant, please see "maintenance - cooling system". Check after installation Check whether the radiator cap and bottle caps are tightened. Check whether there is coolant leakage with the radiator cover detector.
Page 229 Chassis Remove and Install Radiator fan assembly Explosion diagram 1 Expansion kettle hose 2 Expansion kettle cover 3 Radiator fan cover 4 Fan controller Remove Remove the expansion kettle hose and the kettle cover. Remove the fan controller and radiator fan fixed bolt, unplug the connector, remove the fan controller. Check after remove Fan controller Check whether there is a needle, curved back, breakage, cracks or other damage.
Page 230 Chassis Cooling pump Explosion diagram 1 Radiator outlet pipe 2 Charger inlet pipe 3 Power train beam 4 Cooling pump 5 Cooling pump ：N·m Remove and install Remove Warning： ● It is forbidden to open radiator cover immediately after stop the car,because cooling fluid temperature is very high, cooling fluid with high temperature may overflow from radiator filling mouth,which resulted in serious burns.
Page 231 Chassis Remove radiator outlet pipe and charger inlet pipe. Remove cooling pump bracket fixed nut, take out cooling pump and cooling pump bracket. ● Tighten torque: 30～35N·m. Caution: ● Avoid cooling pump falling or onslaught. If yes, please replace. Remove fixed bolts of cooling pump and separate cooling pump and bracket.
Page 232 Chassis Cooling pipe Parts layout 1 Charger inlet pipe 2 Radiator outlet pipe PCU outlet pipe 4 PCU inlet pipe 5 Radiator inlet pipe 6 Driving motor outlet pipe A Connect cooling pump B Connect charger C connect cooling pump D connect radiator assembly E connect charger F connect PCU G connect PCU...
Page 233 Chassis Maintenance data and specifications Cooling fluid Cooling fluid filling volume(L) ≈3.1 Expansion kettle capacity(L) 0.15 Radiator 93~121 Pressure of leak detection（kPa）...
Page 234 Chassis Front axle Preparation work............................3 Troubleshooting ............................4 Front driving shaft ............................5 Maintenance data and specification ...................... 15...
Page 235 Chassis Preparation work Special tools Actual tool shape may be different from illustration shown as following Tool Diagram Instruction Steering Remove the connecting ball transmission head Commonly used tools Tool Diagram Instruction Install and remove bolts and Power tool nuts...
Page 236 Chassis Troubleshooting Troubleshooting for noise,vibration and unsmooth(NVH) NVH troubleshooting diagram Using the table below helps to find the causes of symptoms. If necessary, repair or replace these parts. reference Possible reason and parts × × × × × × × ×...
Page 237 Chassis Front driving shaft Check and Maintenance Check whether the driving shaft and universal joint is loose and other damages. Check whether anti-dust cover has cracks and other damage Caution： ● If the driving shaft appears noise or vibration, please replace the driving shaft assembly. Anti-dust cover of driving shaft replacement Lift vehicle, remove front tire.
Page 238 Chassis Remove steering rod ball head from the steering rod. Caution： ● Use special tool to avoid to damage ball head dust-proof ● Tightening torque: 15～34N•m Loosen the fixing bolts and nuts of absorber and steering joint. ● Tightening torque: 75～90N•m Separate driving shaft from rim and bearing Caution：...
Page 239 Chassis 13 Apply the right amount of grease in the dentate hole of the universal joint subassembly,Until grease liquid from the circular groove and dentate hole. Dry the old grease with after daub lubrication fat. 14 Wrap spline with tape to avoid damage dustproof. Install the new dust Set and dustproof sleeve clamp on the driving shaft.
Page 240 Chassis Caution: ● If grease stick to dust proof fixed on the surface ,to prevent dust proof from falling off, please wipe clean. 20 Inserted flat screw driver from large diameter side of dust proof, let the air outside, and adjust the dust proof installation length, avoiding dust proof deformation.
Page 241 Chassis Remove and install Explosion diagram 1 Hub assembly 2 left front driving shaft assembly 3 Reducer assembly 4 Right front driving shaft assembly ：N·m Remove Lift the vehicle and remove the front tyre. Please see the "wheel and tyre”. Remove the wheel speed sensor from the steering joint.
Page 242 Chassis Caution: ● The angle for universal joint placed at shaft fixing end shall not be too big and please also be care do not push the moving joint too much. Check after remove Turn the universal joint to check whether it is flexible, smooth, or any serious loose. Check whether there is crack, breakage and dust proof grease leakage.
Page 243 Chassis Remove and install Explosion 1 Cir-clip 2 shell 3 snap ring 4 Trigeminal assembly 5 dust proof 6 clamp of dust proof 7 locking nut 8gasket 9 dust cover 10 wheel speed sensor gear ring Replace after remov Disassemble On the side of reducer Fixing driving shaft in vise.
Page 244 Chassis Caution： ● Marking with painting or similar materials. Please don't scratch the surface. Remove the snap ring and fork assembly. Remove the dust proof from driving shaft Use paper cloth dry the old grease on the removed parts. On the side of wheel Fixing the driving shaft in vise Caution：...
Page 245 Chassis Caution： ● Shell and fork assembly in a device. Dust proof and wheel speed sensors Check whether there are cracks or other visible damage. If yes, please replace. ● Install In the side of reducer Wrapped spline with tape to avoid damage dust proof, install the new dust proof on the driving shaft and fastening clamp at small end Caution：...
Page 246 Chassis Install the clamp into the slot as show in the picture Avoid dust proof deformed Caution： ● If grease stick to dust proof fixed on the surface , dust proof may fall off, please wipe clean. Inserted flat screwdriver from large diameter side of dust proof, let the air outside, and adjust the dust proof installation length, avoiding dust proof deformation.
Page 247 Chassis Front suspension Preparation work............................3 Special tools ............................3 Commonly used tools.........................3 Troubleshooting ............................4 Troubleshooting for noise,vibration and unsmooth(NVH)............4 NVH troubleshooting diagram ....................4 Wheel positioning............................5 Basic checking ............................. 5 Front mast check..........................5 Front suspension assembly ........................7 Front suspension layout........................7 Front mast assembly ..........................
Page 248 Chassis Explosion diagram........................21 Disassembly..........................21 Assembly............................22 Maintenance data and specification...................... 23 Wheel positioning( unloading*).......................23 Ball pin of hem arm assembly......................23 Bearing............................... 23 Fender flares height (unloading condition *)................24...
Page 249 Chassis Preparation work Special tools The factual tool shape may be different with the diagram showing. Tool Diagram Instruction Steering Remove the connecting ball transmission head rod die Helical spring Disassembly and installation puller of helical spring Commonly used tools Tool Diagram Instruction...
Page 250 Chassis Troubleshooting Troubleshooting for noise,vibration and unsmooth(NVH) NVH troubleshooting diagram Using the table below helps to find the causes of symptoms. If necessary, repair or replace these parts. Referring content Possible reason and parts Noise √ √ √ √ √ √...
Page 251 Chassis Wheel positioning Caution: ● Check wheel positioning under unloading position. ● Just adjust front beam, camber angle, kingpin caster angle and kingpin inclination angle couldn’t be adjusted. ● If the camber angle, kingpin caster angle and kingpin inclination is not in the scope of the standard, please check whether there is worn or damaged in the front suspension, front wheel hub assembly, post assembly and ball pin of hem arm assembly.
Page 252 Chassis Front suspension assembly Front suspension layout ① ② ③ ④ 1 Front mast assembly 2 Front vice frame 3 Front rim assembly 4 Hem arm assembly...
Page 253 Chassis Front mast assembly Remove and install Remove Remove front wheel, please see “wheel-wheel assembly”. Remove wheel speed sensor, please see “ braking control system-wheel speed sensor” Caution: ● Pull wheel speed sensor wiring harness is prohibited. Remove the brake hose fixed bolt and remove brake hose. Please see the "brake system - brake pipe". Remove the fixed bolts and nuts of front mast assembly and steering knuckle.
Page 254 Chassis Disassembly and assembly Explosion diagram 1 Nut 2 Decorative cover 3 upper supporting assembly 4 Nut 5 Shock absorber bearing 6 upper trampoline 7 Cushion block 8 Dust proof 9 Helical spring 10 Front shock absorber ：Replace after disassembly...
Page 255 Chassis Disassembly Caution: ● Forbid to damage the front shock absorber piston rod Use spring puller to compress spiral spring, until it separated with trampoline. Caution: ● Confirm the puller has been completely installed, and then began to compress. ● Banning to use pneumatic tools to tighten the screw spring puller.
Page 256 Chassis Front vice frame Remove and install Remove Remove tightening parts of the steering gear assembly,intermediate axle and steering knuckle.Please see “ steering system-steering assembly” Remove the downside protection board of front-tank Remove the connected nut of stabilizer bar pull rod and former post assembly. Remove the fasteners of left and right lower swing arm assembly and the steering knuckle.
Page 257 Chassis assembly. Check after remove Check whether there is a crack, rust or other visible damage. If yes, please replace. Install Install in the opposite order of remove. Installation bolt screwing order of vice frame :②→①→③ Hem arm assembly Remove and install Remove Lifting the vehicle, remove the front wheels.
Page 258 Chassis Use hammer (or the right tool) and wood tapping hem arm assembly slightly, separate hem arm assembly and steering knuckle, remove the hem arm assembly. Check after remove Visual check ● Check whether the bushing is worn or damaged. If yes, please replace. ●...
Page 259 Chassis Stabilizer bar ○ ○ ○ ○ ○ 1 Stabilizer bar 2 Fixing bracket of stabilizer bar 3 Bushing of stabilizer bar 4.Bolt 5 Rod of stabilizer bar Remove and install Remove Remove the front auxiliary frame and redirector assembly fixed on the auxiliary frame, left and right hem arm assembly parts.
Page 260 Chassis Check after remove Check whether there is deformation,wearing or other damages in stabilizer bar,stabilizer bar rod and stabilizer bar fixing bracket, if yes, please replace. Check whether there is crack, aging, wear and tear or other damage on stabilizer bar bushing, stabilizer bar rod liner .
Page 261 Chassis Front wheel hub assembly Remove and install Remove Remove front wheel, please see “wheel-wheel assembly”. Remove wheel speed sensor, please see “ braking control system-wheel speed sensor” Caution: ● Pull wheel speed sensor wiring harness is prohibited. Remove the brake hose fixed bolt and remove brake hose. Please see the "brake system - brake pipe". Remove the brake caliper assembly and suspension fixed.
Page 262 Chassis ● Check if parts deformation, cracks or other damage. If yes, please change. Install Install in the opposite order of remove ● Forbidden to repeated to use the installing nut of front mast assembly. ● Tightening parts shall be tightened under unloading condition. ●...
Page 263 Chassis Disassembly and assembly Explosion diagram ○ ○ ○ ○ ○ 1 Bearing 2 Circlip 3 Front steering knuckle 4 Fender 5 flange Disassembly Remove the flange with proper tool( such as copper hammer) Remove circlip with circle ring clipper. Remove the bearing with proper tool( such as copper hammer) Remove the fender with proper tool.
Page 264 Chassis Assembly Equipping fenders on the steering knuckle. Daub appropriate amount of grease in the steering knuckle and bearing contact . Press the new bearing into the steering knuckle, installing spring. Caution： ● No press on bearing inner ring to avoid damage to the bearings. ●...
Page 265 Chassis Maintenance data and specification Wheel positioning( unloading*) Minimum -6′ standard 24′ Camber angle maximum 54′ Left and right difference ≤30′ Minimum 3.15° standard 3.65° Kingpin caster angle maximum 4.15° Left and right difference ≤0.75° Minimum +9.5° Kingpin inclination standard +10.5°...
Page 266 Chassis Rear suspension Preparation work................................265 Special tools................................265 Commonly used tools...............................265 Troubleshooting................................266 Troubleshooting for noise,vibration and unsmooth(NVH)................266 NVH troubleshooting diagram NVH....................266 Wheel positioning.................................267 Basic checking..............................267 Front beam, extraversion..........................267 Rear suspension assembly.............................268 Rear suspension layout............................268 Rear sliding column assembly.............................269 Remove and installation............................269 Remove..............................269 Install................................269 Disassembly and assembly..........................270...
Page 267 Chassis Preparation work Special tools The factual tool shape may be different with the diagram showing. Tool Diagram Instruction Steering Remove the connecting ball transmission head rod die Commonly used tools Tool Diagram Instruction Install and remove bolts and Power tool nuts...
Page 268 Chassis Troubleshooting Troubleshooting for noise,vibration and unsmooth(NVH) NVH troubleshooting diagram NVH Using the table below helps to find the causes of symptoms. If necessary, repair or replace these parts. Referring content Possible reason and parts Rear symptom Noise √ √ √...
Page 269 Chassis Wheel positioning Caution: ● Check wheel positioning under unloading position. ● Front beam and camber angle can only be tested, cannot be adjusted ● If front beam and camber angle are not in the standard range, please check whether there is wearing, deformation or other damages in rear beam assembly, rear sliding column assembly and helical spring, if yes, please replace.
Page 270 Chassis Rear suspension assembly Rear suspension layout ○ ○ ○ ○ 1 Rear beam assembly 2 Rear sliding column assembly 3 Rear spiral spring 4 Rear hub assembly...
Page 271 Chassis Rear sliding column assembly Remove and installation Remove Remove the protection face of trunk Remove decorative roof of rear sliding column assembly remove two nuts of connecting rear sliding column assembly and body ● Tightening torque：30～45N·m Remove the installing bolts of rear sliding column assembly and rear beam assembly.
Page 272 Chassis Disassembly and assembly Explosion diagram 1 Rear shock absorber assembly 2 Dust proof 3 Buffer block 4 Nut 5 Nut 6 Nut 7.Gasket 8 Upper rubber mat B 9 Upper rubber mat A 10 Buffer block bearing Disassembly Caution: ●...
Page 273 Chassis Rear crossbeam assembly Remove and install Remove Remove rear wheel hub assembly. Please see “ rear axle- rear wheel hub assembly Remove braking pipe. Please see “braking system-braking pipe” Remove the fixing nut for parking drawing and rear crossbeam assembly. Remove the fixing bolts for rear sliding column assembly and rear crossbeam assembly.
Page 274 Chassis Rear wheel hub assembly Remove and install Remove Lift the vehicle and remove front wheel, please see “wheel-wheel assembly”. Remove rear brake clipper Remove rear brake disc Remove the connectting bolts of rear wheel speed sensor and rear hub assembly, remove rear wheel speed sensor.
Page 275 Chassis Maintenance data and specification Wheel positioning( unloading*) Minimum -26′ standard -56′ Camber angle maximum -1°26′ Left and right difference ≤30′ Minimum 0′ Front beam (one side) standard 12′ maximum 24′ Fender flares height (unloading condition *) Item Standard value Front（Hf）...
Page 276 Chassis Wheel Tips and cautions for wheel service and maintenance............275 Preparation work ..........................275 Commonly used tools .........................275 Working process ..........................276 Troubleshooting..........................277 Troubleshooting for noise,vibration and unsmooth(NVH)............. 277 NVH troubleshooting diagram................... 277 Regular maintenance .........................278 Wheel assembly ..........................278 Check ............................278 Wheel assembly balance adjustment................
Page 277 Chassis Tips and cautions for wheel service and maintenance ● The original DR wheel is specially designed for each type vehicle, is only used for specified type. ● Please use authentic DR parts,wheels, valve cap and tire nut. ● Please use after wheel balance adjustment. Please adjust wheel balance with DR original balance block.●...
Page 278 Chassis Basic check Working process Collect customer information Before check carefully ask customer concerns or driving vehicles together with the customer which is very important to solve the problem. Basic check ① key is on the shift of “LOCK”. ② Check all the tire pressure and adjust it to the specified value. Please see the “wheel - maintenance data and specification”.
Page 279 Chassis Troubleshooting Troubleshooting for noise,vibration and unsmooth(NVH) NVH troubleshooting diagram Using the table below helps to find the causes of symptoms. If necessary, repair or replace these parts. Referring content Possible reason and parts Noise √ √ √ √ √ √...
Page 280 Chassis Regular maintenance Wheel assembly Check Check the wheel whether there is bending, damage, crack, abnormal wearing and tearing or other damage. If yes, please replace. Wheel assembly balance adjustment Remove Remove wheel assembly needed to be adjusted. Remove the old balance blocks on both sides of the wheels, and clear the foreign body on the tire tread pattern.
Page 281 When install the wheel assembly, please tighten tire nut according to the regulated torque , prohibiting more than standard torque requirements. When tighten tyre nut, should be 2 to 3 times diagonal tightening in case of wheel deformation. ● Please use DR original tire nut.
Page 282 Chassis Remove and install Explosion diagram 1 wheel assembly 2 nut of tyre 3 decorative cover assembly ：N·m...
Page 283 Chassis Remove and install Remove Remove tire nut. ● Tightening torque：90～110N·m Remove wheel assembly Check after remove Tire pressure check Check tire pressure. If it is not in the standard range ,please adjust it. ● Standard value：220±10kPa Caution: ● Check the tire pressure with good performance of the tire pressure gauge .
Page 284 Chassis ① Tire should be replaced after vehicles moving after 50000 km. ② If appear any of the following one, also need to replace: ● The tire show curtain or curtain line ● Tire bulge, uplift, or layered. ● Tires were pricked, cut, or other damage, beyond repair. Caution: ●...
Page 285 Chassis Braking system Cautions for braking system maintenance................285 Preparation work..........................285 Commonly used tools ........................285 System description ..........................286 Component parts........................... 286 Parts description........................287 Basic check............................288 Diagnosis and maintenance process..................288 Fault diagnosis process details ..................288 Diagnostic work list .........................289 Troub leshooting...........................
Page 286 Chassis Master cylinder flow-line assembly ................302 Front braking pipe assembly....................303 Right front braking pipe assembly ..................307 Rear braking pipe assembly ....................307 Rear brake hose assembly....................309 Front braker..........................310 Explosion diagram......................310 Remove and install......................311 Disassembly and install .......................314 Rear Brake ..........................317 Explosion diagram......................
Page 287 Chassis Cautions for braking system maintenance ● When find force on the brake pedal heavier or lighter, please check or adjust the braking system. ● When key in the "ON" block and vacuum pump is working, the brake pedal stroke may feel very heavy or very short, this is normal phenomenon.
Page 288 Chassis System description Component parts 1 left front braker assembly 2 vacuum booster with brake master pump assembly 3 Vacuum tank assembly 4 Vacuum pump 5 vacuum pump controller assembly 6 right front brake caliper assembly 7 ABS controller assembly 8 Brake pedal assembly 9 brake line 10 parking brake handle assembly...
Page 289 Chassis Parts description Parts Function Left and right front braker 1、6 Response of the hydraulic braking force assembly Transmit pedal force and provide power, establish hydraulic braking, detect brake liquid level and output the combination Vacuum booster with brake master instrument signal.
Page 290 Chassis Basic check Diagnosis and maintenance process Fault diagnosis process details Collect customer information Before check, carefully ask customer concerns or driving vehicles together with the customer which is very important for solving the problem. Check symptom According to the infroamtion collected through interviewing with the customer ,reappear information of customer specified symptoms.
Page 291 Chassis Diagnostic work list In general, customers have their own judgment standard to a problem. Therefore, careful enough to ask to understand customer's concern is very important. Preparing interview list make diagnostic information systematic. Some times, many conditions occur at the same time resulting in failure. Interview list sample Interview list Customer...
Page 292 Chassis Troubleshooting Abnormal brake pedal feeling Fault description When press brake pedal, appear abnormal pedal feeling( such as soft or hard, etc.) Diagnosis procedure Check front and rear axle In accordance with the "maintenance - axis and suspension", check whether the front axle loose seriously. If yes, repair or replace defective parts.
Page 293 Chassis Long braking distance Failure description Braking distance is long when ABS is activated. Diagnosis procedure Tips： ● On unstable road, such as the non-paving road, sand road, snow road, etc., the braking distance of the ABS activation can be longer than without ABS, which is the normal phenomenon. Check 12V battery When key in the "LOCK"...
Page 294 Chassis Vacuum pump not work Failure description Vacuum doesn’t work and failure warning light of braking system on combination instrument is always on. Diagnosis procedure Tips： ●Vacuum pump doesn’t work without enough vacuum degree, which is normal phenomenon. Check 12V battery When key in the "LOCK"...
Page 295 Chassis Vacuum pump continuous working Failure description When don't step on the brake pedal, the vacuum pump work continuously, could continue to hear the sound of the vacuum pump work, vacuum pump surface temperature is higher. Diagnosis procedure Check 12V batter When key in the "LOCK"...
Page 296 Chassis Vacuum pump work frequently Failure description When don’t step on the brake pedal, vacuum pump work frequently and automatically. Diagnosis procedure Tips： ● Frequent press on the brake pedal, the vacuum pump will work frequently, which is the normal phenomenon.
Page 297 Chassis Other common troubleshooting table for braking system Failure Possible reason Solution Left and right ire pressure is insufficient Adjust tire pressure Wheel alignment is not correct Wheel alignment When braking, vehicles Poor contact for friction plate Adjust friction plate run partial to one side Friction surface with grease or oil Replace friction plate...
Page 298 Chassis Vacuum pump controller damaged Replace vacuum pump controller Vacuum tank assembly pressure switch damaged Replace vacuum tank assembly Vacuum tank assembly leakage Replace vacuum tank Vacuum continuous work assembly Vacuum hose air leakage Repair or replace Vacuum pump damaged Replace vacuum pump Vacuum tank pressure switch harness break Repair or replace...
Page 299 Chassis Remove and installation Brake pedal Explosion diagram 1 vacuum booster 2 bolts 3 Angle sensor 4 brake lamp switch 5 rivets 6 hex flange surface nut 7 Brake pedal assembly 8 ring 9 main pump pin...
Page 300 Chassis Remove and install Remove Remove the lower part of the dashboard. Please see the "Body systems - interior dashboard". Disconnect the brake lamp switch and angle sensor connector. Remove the main pin shaft, which is connected with the vacuum booster,Disconnect the connection with vacuum booster.
Page 301 Chassis Check after remove Brake pedal ● Check whether the main pump pin shaft hole has wearing deformation. ● Check whether brake pedal has cracks, deformation or other damage. Main pump pin shaft ● Check whether the main pump pin is damaged or deformed, if yes, please replace. Brake lamp switch ●...
Page 302 Chassis Vacuum booster with brake master pump assembly 1 Brake master pump 2 Brake liquid level switch 3 storage tank cover 4 storage tank 5 vacuum booster Remove and install Caution: ● Don't let the brake fluid splashed on paint surface, otherwise it will damage the paint. If splashed on paint surface, please immediately wash with water.
Page 303 Chassis Remove the main pump pin shaft, which is connected with the brake pedal assembly, remove the main pump pin shaft, collar, rivets. Remove the fixing nut of brake pedal and vacuum booster, take offthe vacuum booster with brake master pump assembly. Install Install in the opposite order of remove.
Page 304 Chassis Brake pipe Hydraulic pipe 1 Right front wheel 2 right front sub-pump 3 wheel speed sensor 4 vacuum booster with brake master pump assembly 5 Brake pedal 6 Right rear sub pump 7 Right rear wheel 8 left rear whee 9 left rear sub pump 10 ABS module ABS 11 left front wheel...
Page 305 Chassis 1) Remove the tubing nut, release the connections between master cylinder tubing assembly and brake master cylinder. ● Tightening torque: 16～18N·m 2) Remove the tubing nut, release the connection of master cylinder tubing assembly and ABS/ESP controller. ● Tightening torque: 16～18N·m Release two pipe clamps and two front tube clamps of fixed master cylinder of flow-line assembly.
Page 306 Chassis Remove the connecting nut of left front braking oil hose and ABS/ESP controller, remove the connection of left front braking oil hose and ABS/ESP controller. ● Tightening torque: 16～18N·m Remove the three pipe clips for fixing left front braking oil pipe assembly.
Page 307 Chassis Take off 2 front pipe clipper for fixing left/right rear braking pipe assembly Take off left rear braking pipe assembly and right rear braking pipe assembly Install ① Install left front braking oil pipe assembly. ② Install the connecting nut and clipper of left Front braking oil hose and left front braking hose.
Page 308 Chassis Install one connecting nut and clipper of left /right rear braking pipe and rear part of left /right rear braking pipe. ● Tightening torque: 16～18N·m Install left /right rear braking pipe assembly on the pipe clipper. Add braking fluid. please see “maintenance-braking fluid” Braking system exhaust, please see “maintenance-braking system exhaust”...
Page 309 Chassis Right front braking pipe assembly Remove ① Open the engine cover ② Exhaust braking fluid , please see “maintenance-braking fluid” ④ Remove right front braking hose assembly 1) Remove the connecting nut and clip of right front braking oil hose and right front braking hose, take off the connection of right front braking oil hose and right front braking hose .
Page 310 Chassis Remove connection nut of the left and right rear connect braking hard tube assembly and rear part of left and right rear brake pipe , take off the connection of left and right rear connection braking hard tube assembly and rear part of left, right rear brake pipe.
Page 311 Chassis Install ① Install according to remove order of rear brake pipe assembly. ② Add braking fluid. please see “maintenance-braking fluid” ③ Braking system exhaust, please see “maintenance-braking system exhaust” ④ Install rear wheel ⑤ Close engine cover Rear brake hose assembly Remove ①...
Page 312 Chassis Front braker Explosion diagram 1 front brake pliers 2 front brake disc 3 front brake hose 4 steering knuckle 5 sealing washer 6 brake hose perforation bolt 7 hexagon flange bolts ：Replace after remove ：N·m Caution: ● Should thoroughly clean the brake pliers, make damage caused by dust and other substances to a minimum.
Page 313 Chassis Remove and install Friction plate Remove Remove wheel, please see “Wheel” ● Tightening torque:90～110N·m Remove the fixing bolt for Brake pliers locating pin ● Tightening torque:22～32N·m Lift pump with rope , then remove the friction plate. Check after remove Check thickness of friction plate with a scale.
Page 314 Chassis Brake pliers Remove Remove wheel Remove Perforated bolt of brake hose. ● Tightening torque:25～30 N·m Remove connecting bolt for brake pliers and steering knuckle , then take off brake pliers. ● Tightening torque:65～75 N·m Install Install the brake caliper to the steering knuckle, and screw down the bolt. Caution: ●...
Page 315 Chassis Caution: ● Please refill brake fluid “DOT4” ● Reuse brake hose seal gasket is prohibited. ● Aim the brake hose and brake caliper limit and connect it. Fill brake fluid and exhaust. Please see “maintenance-brake fluid” Rotate brake disc, check whether brake pliers installed well. Install wheel.
Page 316 Chassis Disassembly and install Explosion diagram 1 vent screw dust cover 2 vent screw 3 hex flang bolts 4 pliers body 5 positioning pin 6 piston sealing ring 7 dowel pin dust cover 8internal friction piece 9 spring leaf 10 external friction piece 11 guide pin 12 piston 13 piston dust cove...
Page 317 Chassis As show in the diagram put fitable wood,then blast to the fixed bolt hole of brake hose evenly, remove piston and piston dust cover. Caution: ● Avoid finger to be clamped by piston Remove the piston sealing ring from the clamp body with flat Piston sealing ring mouth screwdriver.
Page 318 Chassis Assembly Caution: ● When assembly,the specified rubber grease shall be used. Daub polyethylene glycol ether lubricant rubber grease on the Piston sealing ring piston ring ,and install it into the cylinder. Caution: ● Ban to repeated use the piston seal ring. Piston dust proof Apply the brake fluid on the piston, apply rubber grease on piston dust cover .Cover well piston ports with piston dust proof,...
Page 319 Chassis Rear Brake Explosion diagram ③ ④ ⑤ ② ① ⑥ ⑧ ⑦ 1 rear brake caliper assembly 2 rear brake disc 3 Sealing washer 4 Brake oil hose perforated bolt 5 Rear brake hose 6 Parking brake wire drawing 7.hex flange bolt 8 Rear frame assembly ：Replace after remove...
Page 320 Chassis Remove and install Friction plate Remove Remove wheel, please see “Wheel-wheel assembly” Remove rear brake caliper 1) Loose parking brake. 2) Remove 2 fixing bolts of rear brake caliper. ● Tightening torque: 22～32N·m 3) Turn up the rear brake caliper assembly. Caution：...
Page 321 Chassis Rear brake pliers assembly Remove Remove wheel, please see “Wheel” Exhaust brake fluid, please see “Maintenance-brake fluid” Remove rear brake plier assembly. 1) Loose parking brake. 2) Remove connection of brake hose bolt and copper gaskets with rear brake hose and rear brake caliper. ●...
Page 322 Chassis Install 1`Install rear brake plier assembly 1) Put the rear brake plier assembly on the installation position , pre-tightening fixing bolt of brake plier Tightening two bolts of connecting rear brake plier assembly and rear torque frame assembly. ● Tightening torque: 65～75N·m Install connection of brake hose bolt and copper gaskets with rear brake hose and rear brake caliper.
Page 323 Chassis Check after remove Visual inspection Check whether the front wheel brake disc surface is uneven wear, crack and serious damage. If yes, please change. Beat quantity check 2) Fix front wheel brake disc on wheel hub. Caution: ● Please confirm the wheel axial clearance not too big before measuring.
Page 324 Chassis Electric vacuum booster System description Vacuum booster connect with vacuum tank through the vacuum hose , vacuum pump controller monitor the pressure in the vacuum tank through the pressure switch. When vacuum tank negative pressure is insufficient, the vacuum pump controller control vacuum pump, the suction of the vacuum tank, until the vacuum tank pressure to the limit.
Page 325 Chassis Electrical schematic diagram Vacuum pump relay Pressure switch of vacuum tank Vacuum pump controller Vacuum pump...
Page 326 Chassis Component layout ○ ○ ○ ○ ⑥ ⑦ ○ 1 Vacuum pump controller 2 vacuum hose I 3 vacuum tank bracket 4 vacuum hose II 5 vacuum tank 6 vacuum pump bracket 7 vacuum pump Remove and install Caution: ●...
Page 327 Chassis Check after remove Vacuum pump controller Check the connectors for cracking, curved needle or other damage. If yes, please replace. Vacuum hose Check whether there are cracks and aging or other damage. If yes, please replace. Tips: ● vacuum hose has a multilayer structure to ensure the tightness and durability, minor cracks on surface will not affect the usage.
Page 328 Chassis Maintenance data and specification Specification Item Specification Item Specification Rear wheel mechanical Brake Type In series Type brake bump Parking Cylinder diameter 22.22mm Brake typ Lever brake Type Vacuum booster V type layout arrangement Brake Effective diameter 255mm Type Magneto-electric booster Booster proportion...
Page 329 Chassis Technical parameters Item Standard Item Standard Limitation value value Height of brake pedal 271mm The thickness of the front brake shoe 9.5mm 7.5mm Brake pedal stroke 127.5mm Front disc thickness 25mm 23mm Space between brake lamp 0.5～ switch outside and the pedal Front /rear disc jump 0.025 0.05mm...
Page 330 Chassis Electrical parking system Cautions for Electrical parking(EPB) maintenance.............. 329 Preparation work............................ 329 Special tools ..........................329 Commonly used tools ........................329 System description..........................330 Component part..........................330 Position of component parts....................330 Description of related parts....................331 System ............................333 System description .......................333 System principle........................
Page 331 Chassis Cautions for Electrical parking(EPB) maintenance ● As a result of the dust in rear brake has an effect to human body, please use clear dust collector to clean before maintenance ,it is prohibited to use air gun blow out. ●...
Page 332 Chassis System description This car is equipped with electronic parking brake (EPB) system. EPB recognition is from EPB switch signal, controlled by the ECU's assembly, which controls the brake caliper assembly clamping and release the parking brake. EPB switch layout is in the intermediate position of the assistant instrument board, which is convenient for the pilot operation.
Page 333 Chassis Description of related parts Serial Name Function Send actual torque motor and motor speed signal Through CAN Motor controller(PCU) bus to the EPB system, which is used to start auxiliary functions for EPB. Send the wheel speed signal, two rear wheel speed pulse signal, ABS controller assembly ABS the speed signal through CAN line to the EPB system, which is used for EPB system to determine the vehicle state.
Page 334 Chassis ① ② ③ ④ 1Brake 2 outer releasing connection 3 executive mechanical 4 fixing bolt 5 Rear brake plier assembly...
Page 335 Chassis System System description When electronic parking brake works, lights on combination instrument and EPB switch will be on. When parking brake is released, lights on combination instrument and EPB switch will be off When the driver operate EPB switch, EPB switch will transfer the signal to the parking ECU assembly, which drives the executive mechanical of rear caliper assembly in parking ECU assembly, executive mechanical push rear caliper brake to realize parking and release.
Page 336 Chassis Input and output signal Parts Signal description Send the following signal through CAN line to parking ECU assembly: Motor controller(PCU) Motor actual torque signal Motor actual rotating speed signal Send the following signal through CAN line to parking ECU assembly: wheel speed signal ABS controller assembly...
Page 337 Chassis EPB operation Manual clamping When vehicle stops, pull out the EPB switch, brake caliper assembly began to apply the parking brake force. When the parking brake force reached set value, the parking status light is lit. When the vehicle under the electricity, the parking status light is extinguished, the state in the EPB switch will be off 2 minutes later.
Page 338 Chassis Automatic release When start driving and comply with the following conditions, vehicle will automatically release the parking brake. 1) Vehicle at “READY” status 2) Driver’s safty belt fasten 3) Door closed in driver’s side. 4) Shift is in “D” or “R” 5) Driver pedal down the accelerating pedal.
Page 339 Chassis Caution： When ABS fault light lit up, EPB system will no longer be anti-lock function, if pulled EPB switch at this time, EPB will impose a fixed braking force. When ABS fault light lit up, if pulled EPB switch on wet road, it will happen tail out. Please use the operation pull up and down, pull up and down again to let the vehicle stop.
Page 340 OFF ON shop for parking) maintenance When parking brake Please go to system has fault(when DR shop for parking is releasing) maintenance When EPB system has Please go to fault and EPB switch is DR shop for operating, while the maintenance system couldn’t work.
Page 341 Chassis Schematic diagram...
Page 342 Chassis Safety and invalid When EPB system has fault, fault warning light will be on in the instrument. When EPB system has fault, part of EPB function will be limited. When the system couldn’t parking, pull out or press down EPB switch, the indicator in the switch will flash and the yellow fault indicator light in the instrument will be on.
Page 343 Chassis Fault Fault Fault name Phenomenon of vehicle fault code grade Parking and releasing function of left actuator is invalid C11A07D Left actuator has fault-relay Right actuators clamps with maximum clamping force Parking and releasing function of right actuator is invalid C11A37D Right actuator has fault-relay Left actuators clamps with maximum clamping force Parking and releasing function of left actuator is invalid...
Page 344 Chassis Fault Fault Fault name Phenomenon of vehicle fault code grade input/output control chip decreasing. When parking, perform maximum clamping force, it could Acceleration sensor signal C111329 not judge the vehicle dynamic or static in the condition of invalid ABS fault. Acceleration sensor C111396...
Page 345 Chassis Stitch definition of connectors Stitch definition of connectors of parking ECU assembly Stich no Definition Stich no Definition CAN high / CAN-H Automatic parking switch signal/Autohold Can low / CAN-L EPB switch signal 3/SW3 EPB switch signal 43/SW4 Automatic parking switch indictator...
Page 346 Chassis Basic check Diagnosis and maintenance process Fault diagnosis process details Collect customer information Before check, carefully ask customer concerns or driving vehicles together with the customer which is very important for solving the problem. Check symptoms According to the information collected through interviewing with the customer ,reappear information of customer specified symptoms.
Page 347 Chassis Interview list sample Interview list Customer Original registered Plate No name date Gender Model Production Motor power Mileage date □Unable to parking □Unable to release □Abnormal noise □Unable to parking when braking □Still brake after release □ Drag ground when automatic releasing □...
Page 348 Chassis Interview list Customer Original registered Plate No name date Gender Model Production Motor power Mileage date Check result 12V battery status □Normal □Abnormal（ ) □Pending Connectors status □Normal □Abnormal（ ) □Pending Check result EPB brake status □Normal □Abnormal（ ) □Pending Friction plate status □Normal □Abnormal（...
Page 349 Chassis Fault code, circuit fault diagnosis Parking ECU assembly fault C116045、C116040、C116042、C116055、C116086、C116054、C11604C、 C116004、C116046、C116044、C11607C、C111329、C111396 Fault code Fault name Checking conditions Possible reason Parking ECU assembly control C116045 Controller fault- stack abnormally. Parking ECU assembly control C116040 Controller fault- D/a conversion abnormally. Controller hardware Parking ECU assembly control C116042...
Page 350 Chassis Preparation work If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s. Check whether pins and wiring harness connector of ECU assembly is damaged or loosen. Yes>>...
Page 351 Chassis Fault of parking executive mechanical driving circuit C11A011、C11A311、C11A07E、C11A37E、C11A07D、C11A37D、C11A063、C11A363 Fault code Fault name Checking conditions Possible reason Left actuator Parking ECU checks out the fault of C11A011 fault- control circuit parking executive mechanical driving failure circuit Right actuator has Parking ECU checks out the fault of C11A311 fault- control circuit parking executive mechanical driving...
Page 352 Chassis Perform self-diagnosis ① Delete fault code ② Put the key on "LOCK" block, waiting for more than 10 s. ③ Put the key on "ON" block. ④ Pull up and press down EPB switch separately once time. ⑤ Check whether fault code exists. Yes>>...
Page 353 Chassis Fault of parking actuator C11A418、C11A477、C11A07C、C11A37C、C11A013、C11A313、C11A070、 C11A370、C11A015、C11A315、C11A054、C11A354 Fault code Fault name Checking conditions Possible reason Harness or connectors Acutator couldn’t execute the order of Left and right rear brake caliper C11A418 Actuator has fault parking ECU assembly. assembly Parking ECU assembly Harness or connectors Parking ECU assembly checks out Actuator has...
Page 354 Chassis Preparation work If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s. Check whether pins and wiring harness connector of parking mechanical is damaged or loosen. Yes>>...
Page 355 Chassis Switch fault C113800、C113861、C11352A、C11362A、C110860、C110862 EPB Fault code Fault name Checking conditions Possible reason Parking ECU assembly checks out switch with C113800 Switch failure fault. Switch failure- unstable C113861 EPB switch status change status Switch failure-pulling EPB switch output the signal of pulling up Harness or C11352A unsmoothly...
Page 356 Chassis System electrical supplying fault U100016、U100017 Fault code Fault name Checking conditions Possible reason Supply voltage of parking ECU System voltage is U100016 Harness or connectors too low assembly＜8.5V Parking ECU assembly Supply voltage of parking ECU System voltage is 12V battery U100017 too high...
Page 357 Chassis Hard line signal fault of power-on switch C110116 Fault code Fault name Checking conditions Possible reason Parking assembly couldn’t Harness or connectors Electrical switch receive signal of power-on or there is C110116 circuit has fault different between hardline signal and Parking ECU assembly CAN signal.
Page 358 Chassis Caution： Perform self-diagnosis and clear fault codes after grounding or power supply circuit breakdown maintenance,and confirm whether the fault has been exempted. If fault unwinding, please continue to conduct diagnosis. Replace parking ECU assembly, please see “Remove and installation”. Do the zero position learning of parking ECU assembly.
Page 359 Chassis Communication fault with PCU U010087、U040186 Fault code Fault name Checking conditions Possible reason Parking assembly couldn’t U010087 Node of PCU loss receive PCU signal through CAN Motor controller Harness or connectors signal which Node of PCU with Parking ECU assembly U040186 received by parking ECU assembly is one invalid signal...
Page 360 Chassis Communication fault with ABS U012987、U048186 Fault code Fault name Checking conditions Possible reason Parking assembly couldn’t U012987 Node of ABS loss ABS controller receive ABS signal through CAN . Harness or connectors Node of ABS with One of the ABS signal which received Parking ECU assembly U048186 one invalid signal...
Page 361 Chassis Communication fault U014087、U042286 Fault code Fault name Checking conditions Possible reason Parking assembly couldn’t U014087 Node of ICM loss Combination instrument receive ABS signal through CAN . Harness or connectors Node of ABS with One of the ABS signal which received Parking ECU assembly U042286 one invalid signal...
Page 362 Chassis Communication fault with AC controller U0112687、U042886 Fault code Fault name Checking conditions Possible reason Parking assembly couldn’t Node of AC U012687 receive AC controller signal through controller loss AC controller CAN . Harness or connectors Node of AC One of the AC controller signal which Parking ECU assembly U042886 controller with one...
Page 363 Chassis CAN communication fault U007388、U000188 Fault code Fault name Checking conditions Possible reason Failure of input and out put of EPB Harness connectors U007388 communication fault system communication Connecting harness communicaiton nodes U000188 connectors of parking ECU communication fault overtime. Preparation work If carried out the other fault diagnosis before, please put the key in the "LOCK"...
Page 364 Chassis Zero positioning unlearning of parking ECU assembly Fault code Fault name Checking conditions Possible reason Zero positioning unlearning of Zero positioning unlearning of parking C116154 Parking ECU assembly parking ECU ECU assembly. assembly. Preparation work If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.
Page 365 Chassis Fault of EPB switch status C11D12、C11D14 EPB Fault code Fault name Checking conditions Possible reason EPB switch status C11D12 light- short circuit to EPB switch status light is always on. power Harness or connectors EPB switch EPB status switch Parking ECU assembly light-Open circuit or C11D14...
Page 366 Chassis Common symptom and analysis Press down EPB switch, parking couldn’t be released Carry out self-diagnosis, check whether self-diagnosis result has fault code. Yes >>check and maintenance of fault.Next step. No>> Turn to 3 Check symptoms Check whether parking could be released when pressing down EPB switch. Yes>>...
Page 367 Chassis Pulling up EPB switch, vehicle couldn’t be parking Carry out self-diagnosis, check whether self-diagnosis result has fault code. Yes >>check and maintenance of fault.Next step. No>> Turn to 3 Check symptoms Check whether parking could be done when pulling up EPB switch. Yes>>...
Page 368 Chassis No way to exit automatic parking model Carry out self-diagnosis, check whether self-diagnosis result has fault code. Yes >>Fault code、circuit fault diagnosis.Next step. No>> Turn to 3 Check symptoms Check whether it could enter into or exit automatic parking model. Yes>>...
Page 369 Chassis Vehicles slope in the parking ramp Carry out self-diagnosis, check whether self-diagnosis result has fault code. Yes >>Fault code、circuit fault diagnosis.Next step. No>> Turn to 3 Check symptoms Check whether the function for anti-slope is normal. Yes>> diagnosis finish No>>...
Page 370 Chassis Remove and installation Parking ECU assembly Explosion diagram ① ② 1Parking ECU assembly 2 Parking ECU bracket...
Page 371 Chassis Remove and installation Remove Put power-on switches on “OFF”block, start next operation. Remove rear part assembly of vice instrument board. Pull out connectors of parking ECU assembly Remove two fixing nuts of parking ECU assembly and its bracket, take out parking ECU assembly. ●...
Page 372 Chassis Parking system Preparation work............................ 371 Commonly used tools ........................371 System description ..........................371 Basic check ............................372 Diagnosis and maintenance process..................372 Fault diagnosis process details................... 372 Diagnostic work list........................ 372 Remov e an d install ..........................373 Remove ............................373 Check after remove ........................375 Install...............................
Page 373 Chassis Preparation work Commonly used tools Tool Diagram Instruction Power tool Install and remove bolts and nuts System description This vehicle is equipped with mechanical parking brake system, which is composed of parking handle, left and right parking drawing. ② ③...
Page 374 Chassis Basic check Diagnosis and maintenance process Fault diagnosis process details Collect customer information Before check, carefully ask customer concerns or driving vehicles together with the customer which is very important for solving the problem. Check symptom According to the information collected through interviewing with the customer ,reappear information of customer specified symptoms.
Page 375 Chassis Interview list sample Interview list Customer Plate No Original registered date Gender name Model Production Motor power Mileage date □Unable to parking □Unable to release □Abnormal noise □Unable to parking when braking □Still brake after release □handle button couldn’t be out □Parking light not on when pull up parking handle □Parking light is always on □...
Page 376 Chassis Remove the rear part assembly of vice dashboard. Loose adjusting nut, remove left and right parking drawing. Pull down parking handle connector, remove the fixing bolt of parking handle. ● Tightening torque：20～25N·m Remove rear wheel, please see “wheel- wheel assembly. Remove rear brake drum, please see “braking system- rear brake”.
Page 377 Chassis Remove the fixing nut in the rear part of parking drawing, remove parking drawing. ● Tightening torque：7～11 N·m Check after remove ● Check whether the parking handle button ① is flexible and return normally, if not flexible or couldn’t return back, please replace.
Page 378 Chassis Brake control system Cautions for anti-lock braking system maintenance..............377 Preparation work..........................377 Special tools..........................377 Commonly used tools........................377 System description ..........................378 Component layout ..........................378 Hydraulic principle........................379 Fault code............................380 Connector pins definition......................382 Function description........................ 383 ABS function .........................383 EBD function .........................383 Fault diagnosis............................
Page 379 In unstable pavement, such as the top dress, sand road, snow road etc., the braking distance of the ABS activation is longer than without ABS, which belongs to the normal phenomenon. ● If the tires or friction plate is not used authentic DR components, braking distance or steering stability may be worsen. Preparation work Special tools The actual tool shape may be different from illustration shown.
Page 380 Chassis System description Component layout 1 left front brake caliper assembly 2 vacuum booster with brake master pump assembly 3 Vacuum tank assembly 4 Vacuum pump 5 vacuum pump controller assembly 6 right front brake caliper assembly 7 ABS controller assembly 8 brake pedal assembly 9 brake line 10 parking brake handle assembly...
Page 381 Chassis Hydraulic principle Left front Right front Right rear Left rear 1 Brake pump 2 Left front oil inlet valve 3 Left front oil outlet valve 4 Right rear oil inlet valve 5 Right rear oil outlet valve 6 Damper 7 Oil returning pump 8 Accumulator 9 Right front oil inlet valve...
Page 382 Chassis Fault code Fault code Fault code Instruction Instruction Decimal Hexadecimal Decimal Hexadecimal C190004 0x590004 ECU with too high voltage U000500 0xC00500 CAN with too high voltage C190104 0x590104 ECU with too low voltage C000700 0xC00700 CAN with too low voltage C100004 0x500004 ECU hardware fault C100104 0x500104...
Page 383 Chassis range lost Clutter, intermittent Left rear wheel speed Valve failure, left rear valvle C003800 0x403800 sensor :(signal fault) out of C001904 0x401904 inlet range lost Clutter, intermittent Left rear wheel speed C001C04 Valve failure, right rear C00A400 0x40A400 0x401C04 sensor:power lines short valvle inlet Left rear...
Page 384 Chassis Connector pins definition Pin NO Definition Pin NO Definition Signal terminal of wheel speed sensor(left Power terminal of motor (positive) rear) wheel speed sensor output (right front Power terminal of wheel speed sensor(left wheel) front) Signal terminal of wheel speed Power terminal of valve relay sensor((right front) CAN-high...
Page 385 When ABS function failure, ABS fault warning lights lit, only activate the EBD, no ABS function. ● Please use the special diagnostic instrument provided by DR to diagnose ABS fault. EBD function Electronic brake-force distribution (EBD) automatically adjust the braking force distribution ratio of front and rear axle, increase the efficiency of the brake, and comply with ABS braking stability.
Page 386 Chassis Fault diagnosis Diagnosis process Caution: ● Shall check whether ABS is normal after the completion of the clean inspection . ● Fault code can't be cleaned up through removing ABS controller connector assembly, disconnect the battery connection or let the key in the "LOCK" block.
Page 387 Chassis Basic check Check the brake fluid level and brake lines. Please see the "maintenance - brake fluid. Check whether there is leakage for ABS controller assembly. If yes, check the following items: ① Such as ABS controller assembly pipe joints with leakage, check whether the ABS controller assembly pipe joint is loose, if loose, tighten to standard torque (16 ~ 18 n ·...
Page 388 Confirm fault reason with diagnostic instrument System instruction Diagnostic instrument could detect problems resulted from ABS and EBD system fault, and guide maintenance technician to confirm the cause of the problem. Diagnosis process Must choose diagnostic procedures matching with the model . After all the system troubleshooting, should clear ABS fault code.
Page 389 Chassis Common symptoms and analysis of ABS No communication with ABS controller assembly Typical reasons: ● Poor contact of OBD interface ● ABS controller assembly off ground ● ABS controller assembly without voltage provided by battery. ● ABS controller assembly without voltage provided by supreme electric switch. ●...
Page 390 Chassis ABS controller assembly exhaust Any of the following situations occurs, need exhaust: Press “braking system exhaust” can not meet the requirement of the pedal height or feeling. Replace ABS controller assembly. Excessive loss of brake fluid. Air may enter into ABS controller assembly. Exhaust process Necessary item ①...
Page 391 ② Select diagnosis software version matching Select diagnosis software version with vehicle. This process could diagnosis all the electric control system of DR vehicle. confirm back help start ③ Enter into automatic exhaust process. Operate Exhaust model according to tips.
Page 392 Chassis ④ First step for exhaust Exhaust model Tip: ● It is necessary to step on the brake pedal and keep the brake fluid level of the tank in the process of automatic exhaust. First step: please close all exhaust bolt and press brake pedal and hit “yes”to continue.
Page 393 Chassis ⑦ Second step of exhaust Exhaust model Caution: ● When exhaust, exhaust bottle connected with exhaust pipe must be more than 30 mm higher than the exhaust bolt . Second step: exhaust right rear wheel, please connect exhaust oil pipe, open right rear bolt, then press brake pedal.
Page 394 Chassis ⑩ In the process of exhaust。 Exhaust model In the process of exhaust, pump has been started and will keep for 20 s First page of diagnosis Start ⑪ Complete the third step。 Exhaust model Complete the third step Confirm Start ⑫...
Page 395 Chassis ⑬ In the process of exhaust。 Exhaust model In the process of exhaust, pump has been started and will keep for 20 s First page of diagnosis Start ⑭ Complete the forth step。 Exhaust model Complete the forth step Confirm Start ⑮...
Page 396 Chassis ⑯ In the process of exhaust Exhaust model In the process of exhaust, pump has been started and will keep for 20 s Complete exhaust process Start ⑰ Complete exhaust。 Exhaust model First page of diagnosis Confirm Start...
Page 397 Chassis Remove and install Wheel speed sensor Remove Front wheel speed sensor ① Lifting vehicle ② Unplug connectors ③ Remove fixing bolt of sensor and take out sensor slowly. ● Tightening torque:8～10N·m Caution: ● Pulling on wheel speed sensor wiring harness is prohibited. Rear wheel speed sensor ①...
Page 398 Chassis ABS controller assembly Remove Closed on electric switch, disconnect the battery negative. Plug out the ABS controller connector assembly. Fully press down the brake pedal and fix with pedal frame. Remove ABS controller assembly and braking hard pipe joint with the brake master cylinder assembly, mark it , use special-purpose plug insert ABS controller assembly line.
Page 399 Chassis Steering system Cautions for steering system maintenance ................399 Preparation work..........................400 Special tools ..........................400 Commonly used tools........................400 Basic check ............................401 Check............................... 401 Check middle position of steering wheel ................401 Check steering force of steering wheel................401 Check steering angle of front wheel ..................402 Learning process for steering angle of steering system to be zero..........
Page 400 Chassis Remove and install........................415 Explosion diagram........................415 Remove ..........................415 Install............................ 417 Disassembly and assembly ......................418 Explosion diagram........................ 418 Disassembly ........................418 Install............................. 419 Maintenance data and specification .....................421 Steering wheel clearance and stroke.................... 421 Steering wheel steering force .......................421 Steering angle..........................421 Steering column ..........................421 Rack stroke..........................
Page 401 Chassis Cautions for steering system maintenance ● When tightening the fixing bolt, vehicle shall be unloading and on the road, then check wheel alignment. ● Cautions for removing steering assembly Please clean completely outside of steering assembly before disassembly. Please dismantle in a clean working space to avoid the internal components from dust or other foreign body contamination.
Page 402 Chassis Preparation work Special tools The actual tool shape may be different from illustration shown. Tool Diagram Instruction Steering wheel Remove steering wheel puller Check the torque of the Pre-tighten steering column assembly measuring pinion assembly instrument rotating torque Remove install dust Clamp pliers...
Page 403 Chassis Basic check ① ② ③ ④ 1 steering wheel assembly 2 steering column assembly 3 steering shaft with universal joint assembly 4 steering assembly Check Check middle position of steering wheel Confirm the correct installation position of the steering assembly, steering column assembly and the steering wheel.
Page 404 Chassis Caution: If the steering wheel steering force is more than specified value, please check or adjust the following items: ● Whether steering rod ball head is damaged. ● Preloading of steering assembly gear and rotational torque of steering rod ball head , Please see the " steering system-steering assembly”...
Page 405 Chassis Learning process for steering angle of steering system to be zero Put vehicles in the four-wheel positioning device to ensure qualified parameter adjustment of vehicle four-wheel positioning . Adjust wheels to be straight forward and assure the steering wheel is in the middle( angle with the horizontal within0.5°) Let the diagnostic instrument connect with OBD interface, the key is in the "ON"...
Page 406 Chassis Regular maintenance Steering wheel Check Check installing status of steering wheel Confirm the installing status of steering assembly、front suspension、front axle steering column. Check whether there is a gap in the steering wheel up and down, left and right sides and axial. Steering wheel shaft end gap：0mm If the shaft end clearance beyond the specified value, please check the following items: ①...
Page 407 Chassis Steering wheel Remove and install Explosion diagram steering wheel :Replace after remove ：N·m Remove Tip: ● When connected spiral cable, cable with adhesive plaster to make the fixed part and rotational part alignment Park vehicle, make the wheel straight forward. Open front cover.
Page 408 Chassis Caution： ● when pulling out the steering wheel, please pre-tightening the fixing nut of the steering wheel on steering wheel to avoid hurt the maintenance people when pull out the steering wheel . Install Install in the opposite order of remove. Caution：...
Page 409 Chassis Steering column assembly Remove and install Explosion diagram ① ② ③ 1Meter frame assembly 2 Steering column assembly 3 Steering shaft with universal joint assembly ：N·m Remove Caution: ● Be sure to lock the regulating handle of steering column assembly before remove the steering column assembly in order to ensure the security of personnel, convenient disassembly.
Page 410 Chassis Caution: ● Lock adjusting handle Remove downside plate assembly of driver seat,please see “ body sub-manual-dashboard”.. Remove the driver airbag modules,please see “electrical system sub-manual-airbag system” Remove the steering wheel assembly,please see“steering system- steering wheel” Remove the steering column cover (up and down), please see “body manual-dashboard” Remove the spiral cable and combination switch,please see “electrical system sub-manual-combination switch”...
Page 411 Chassis ● Preloaded measuring instrument is used to measure the rotation torque of steering column assembly. Standard value of rotating torque: 0～2.0N·m If exceed standard value, please replace the steering column assembly (including motor, worm wheel mechanism, torque sensor). ● If vehicle has slightly hit, please measure the length of “L”...
Page 412 Chassis Install Install in the opposite order of remove. Caution: ● Forbid to impose excessive axial force on the steering column assembly. ● Forbid to repeating use the parts which couldn’t be used again. ● Steering wheel should be in the middle when install the steering column assembly. ●...
Page 413 Chassis Disassembly and assembly Explosion diagram ① ② ③ ④ 1 EPS motor EPS 2 EPS controller 3 Controller fixing bracket 4 Steering column Disassembly Plug out EPS controller connectors Remove the fixing bolt of controller fixing bracket and steering column,take off controller fixing bracket.
Page 414 Chassis Caution: Fix steering column with the hands or tools when loose the nut. Remove the EPS controller fixing bolt, take off the EPS controller. ● Tightening torque: 10～15N•m Remove the fixing bolt of EPS motor and steering column, take off EPS motor. Caution: ●...
Page 415 Chassis Steering shaft with universal joint assembly Remove and install Explosion diagram ：N·m Remove Caution: ● Turning the steering wheel is prohibited to avoid spiral cable twist off when separating steering column assembly and steering shaft with universal joint assembly. Parking vehicles with wheels going straight forward.
Page 416 Chassis Caution: ● Please do not insert the tools (such as a screwdriver) to thread groove of steering shaft universal joint assembly when remove the steering shaft universal joint assembly .Otherwise, it can damage the thread slot. If yes, please replace the steering shaft universal joint assembly. Remove the fixing bolt of steering shaft with universal joint and steering assembly, take off steering shaft with universal joint assembly...
Page 417 Chassis Steering assembly Remove and install Explosion diagram 1 Split pin 2 Nut 3 Steering assembly 4 Front vice frame ：Replace after remove ：N·m Remove Parking vehicles with wheels going straight forward. Remove the fixing bolt of steering shaft with universal joint and steering assembly,separating steering shaft with universal joint assembly.
Page 418 Chassis ● Forbid to turning steering wheel to avoid cut the spiral cable when separating steering shaft with universal joint and steering assembly. Lifting vehicle Remove front wheel Split pin Remove steering tie rod ① Remove split pin of steering tie rod. ②...
Page 419 Chassis Install Install in the opposite order of remove. Caution: ● Clean steering proof ① and front board ② sealing surface when installing steering assembly. ② ① ● Make steering gear cover and body closely when installing steering assembly . ●...
Page 420 Chassis Disassembly and assembly Explosion diagram ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ① ⑩ ⑨ ② 1 Steering tie rod 2 Nut 3 Inner tie 4 Rack sleeve 5 Steering cover 6 Shield damping ring 7 Shield seat 8 Steel band elastic hoop 9 Rack dust proof 10 Rack dust cover band Disassembly Remove the steering gear cover, shield damping ring and shield seat.
Page 421 Chassis Steering tie rod and inner tie Spring balance Swing torque of ball joint: hook the parts as shown in the diagram and pull the spring balance. When the ball stud and inner ball joint start moving, reading the Inner ball joint Spring spring balance values.
Page 422 Chassis Caution: ● Forbid to repeat to use the rack dust cover. Install rack dust cover clip ① on rack dust cover Tighten with Clamp pliers. Caution: ● Forbid to repeat to use rack dust cover clip. ● As shown in the diagram, please install rack dust cover clamp in the groove of dust cover clamp, tighten clamp till the gap less than 3 mm.
Page 423 Chassis Maintenance data and specification Steering wheel clearance and stroke Item Standard Steering wheel clearance Steering wheel free stroke Steering wheel steering force Item Standard Steering wheel steering force ≤25 Steering angle Item Standard Max inner wheel angle 35.1±1.5 Max outer wheel angle 30.6±1.5 Steering column Item...
Page 424 Chassis Ball joint axial clearance Item Standard Outer ball joint ≤0.15 Inner ball joint ≤0.15 Inner rod length Item Standard Rack middle place 80±1...
Page 425 Chassis Steering control system Cautions for steering control system ..................424 Preparation work ..........................424 Special tools ..........................424 System description..........................425 Component layout.......................... 425 System principle..........................426 System principal diagram ......................426 Description ..........................426 Electric booster steering system fault warning light ............427 Safety- invalid.......................... 427 Protective function.........................
Page 426 Chassis Cautions for steering control system ● When turn steering wheel quickly,could hear the noise around steering wheel, which is the voice of the steering control system to work normally. If turn the steering wheel slowly , appear harsh noise, which is regarded as the abnormal phenomena.
Page 427 Chassis System description Component layout ① ② ③ ④ ⑤ ⑥ 1 Steering wheel assembly 2 Steering column 3 EPS motor 4 EPS controller 5 steering shaft with universal joint 6 Steering assembly assembly...
Page 428 Chassis System principle Chassis System principal diagram Electric signal Ignition lock Fault signal Combination board Speed signal controller Booster torque Torque signal Torque sensor signal EPS motor Ready signal CAN signal Description EPS controller receives the speed signal, the electrical signal, steering torque signal, control EPS motor and provide the best power steering torque .
Page 429 Chassis Electric booster steering system fault warning light Turn the key to "START" from the "LOCK", ,the vehicle at “READY” status, steering control system self-check. If it is normal, the system enter the working state; If not, electric booster steering system fault warning lights lit, the system has no power.
Page 430 Chassis Electrical principle Electrical Battery switch EPS controller Steering Torque torque signal sensor Booster torque signal motor...
Page 431 Chassis Stitch definition Vehicle signal Torque sensor Power terminal Motor terminal 电源端口电机端口扭矩传感器端口 terminal 整车信号端口 terminal Stitch no Definition Measuring status Reference Remark Power signal （-）,ground Power signal（+） 9-16V Motor output（-） No moving for steering wheel 5-7V Motor output（+） No moving for steering wheel 5-7V Sensor main angle Key is in “ON”,steering wheel...
Page 432 Chassis Fault code reading Steering control system fault, fault is stored within the EPS controller, which could read through diagnosis instrument or "flash code" . Serial No Fault code Description C1611 Main signal of torque sensor is out of range C1612 Vice signal of torque sensor is out of range C1613...
Page 433 Chassis Basic check Diagnostic and maintenance process Fault diagnostic process details Collect customer information Before check, carefully ask customer concerns or driving vehicles together with the customer which is very important for solving the problem. Check symptom According to the information collected through interviewing with the customer ,reappear information of customer specified symptoms.
Page 434 Chassis Diagnosis working list In general, customers have their own judgment standard to a problem. Therefore, careful enough to ask to Chassis understand customer's concern is very important. Preparing interview list make diagnostic information systematic. Some times, many conditions occur at the same time resulting in failure. Interview list sample Interview list Customer...
Page 435 Chassis Fault code、circuit fault diagnosis Torque sensor of C1611 、C1612、C1613、C1614、C1317 Fault Item Instruction Possible reason Main signal of torque sensor is out of C1611 Torque sensor range Vice signal of torque sensor is out of C1612 Torque sensor range Harness or connectors Main signal and vice signal of torque Torque sensor C1613...
Page 436 Chassis Speed signal C1641、U1002 Chassis Fault Item Instruction Possible reason C1641 Speed signa Speed signl invalid fault Harness or connectors U1002 Speed signa Speed signal accepting overtime EPS controller Preparation work If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.
Page 437 Chassis EPS motor C1651 Fault Item Instruction Possible reason Harness or connectors C1141 EPS motor Motor short circuit EPS motor EPS controller Preparation work If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.
Page 438 Chassis EPS controller C1632、C1661、C1662、C1665、C1667 Fault Item Instruction Possible reason C1632 EPS controller EEPROM data consistency of failure EPS controller C1661 EPS controller Relay open C1662 EPS controller calibration error Of current middle point C1663 EPS controller Current sensor overflow C1665 EPS controller The control unit internal fault C1667...
Page 439 Chassis Battery voltage fault C1621、C1622 Fault Item Instruction Possible reason Harness or connectors C1621 Battery voltage Battery voltage too high ＞17.5V EPS controller fuse C1622 Battery voltage Battery voltage fault Power supply circuit 12V battery Preparation work If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.
Page 440 Chassis CAN communication U1000 Fault Item Instruction Possible reason CAN communication BUS-OFF fault or CAN report sending U1000 communication overtime EPS controller Preparation work If carried out the other fault diagnosis before, please put the key in the "LOCK" block, check again after waiting for at least 10 s.
Page 441 Chassis Common symptom and analysis Steering heavily or too light Carry out self-diagnosis, check whether self-diagnosis result has fault code. Yes >>EPS fault diagnosis and maintenance.Next step. No>> Turn to 3 Check symptom Check whether there is abnormal symptom such as “heavier”or “too light” Yes>>...
Page 442 EVO Electric Body Chassis High voltage...
Page 443 Windscreen Wiper Washing System Safety Precautions.................................442 Precaution for Technicians Using Medical Electric....................442 Key Part Check before Maintenance and Repair....................442 Precautions for SRS "Air Bag" and "seat belt pre-tensioner................442 Precautions for removing 12V battery.......................443 Common Precautions.............................443 Preparations..................................444 Commonly Used Service Tools.............................444 Windscreen Wiper System............................445 Schematic Diagram..............................445 Installation..................................448...
Page 444 Safety Precautions Precaution for Technicians Using Medical Electric Operation Prohibition Warning： Parts with strong magnet is used in this vehicle.  Technicians using a medical electric device such as pacemaker must never perform operation on the  vehicle, as magnetic field can affect the device function by approaching to such parts. Normal charge precaution Warning：...
Page 445 Unless it is allowed in Service Manual, please do not use the electronic test equipment on the relevant circuit of SRS. The harness of SRS uses yellow or orange harness or harness connector, which can be easily recognized. Precautions for using power tools (air or electric power) and hammers. When the power switch is turned on, do not use the pneumatic or electric tools or hammer to hammer the ...
Page 446 Preparations Commonly Used Service Tools Tool Instructions Install and remove the bolts and Power Tool nuts...
Page 447 Windscreen Wiper System Windscreen Wiper Position Schematic Diagram Front Windscreen Wiper Relay Combination Switch-Windscre Front Windscreen en Wiper Switch Items Wiper Relay Front Windscreen Wiper Motor...
Page 448 Remove Open the engine compartment cover, unscrew the blanking caps(A) of the front windscreen wiper and M8 bolts(B), remove the front wiper arm and blade. After unscrewing the bolts, remove the front wiper arm and balde(A). If it is necessary to remove the wiper blade, open the cover(A),push the wiper blade downwards.
Page 449 Remove the ventilation panel, for the specific methods, please refer to the maintenance section of the ventilation panel. After removing the ventilation panel(shown as the following diagram), disconnect the motor and the ball joint A of the rod, unscrew four M6 bolts(B), remove the connecting rod assembly. Unscrew the two M6 bolts(A), remove the motor assembly.
Page 450 Cautions: Before removing the windscreen wiper motor and connecting rod assembly, make sure that the  connecting rod stays at stop position automatically. In the process of removal, the blade will be damaged if violent operation is developed on it, which will influence the scrape and brushing effects. Installation Install in the reverse step of removal, here we will not go into details.
Page 451 Terminal 3 、 4 is connected with the battery positive terminal(+), terminal 1 is connected with battery negative terminal(-). Shown in the following diagram, check whether the motor is normal or not. Cautions: Position Terminal Generally speaking, the pollution sources come from the insects 、 sap and the hot wax disposal of the ...
Page 452 Washing System Inspection Connect the washing motor on the water tank, inject water into the water tank. Cautions: Before injecting water into reservoir tank, check whether the filter has been mixed with foreign matters or  contaminated. Clean the filter according to requirement. Connect the battery positive (+) and negative(-) wires to the corresponding positive and negative terminals, check the motor for normal working conditions, check whether the washing motors works or not.
Page 453 Remove the washing motor. Unscrew three M6 bolts(Q1460616), remove the washing liquid pot. Q1460616 Installation Install the washing liquid pot. Cautions: Before installing the washing motor, check it for impurities or contamination, if necessary, clean the filter  and washing motor. Connect the washing motor and hose.
Page 454 Windscreen wiper washer system inspection Step Measures Normal Result Abnormal Result The windscreen wiper is working at lower speed. As long as the washer switch stays at ON position, the washer Turn the ignition switch to ON will spray detergent to the windshield. The washer is out of position.
Page 455 Diagnostic Procedure of the windscreen wiper/washing system Malfunction Mode: regardless of the windscreen wiper switch on any gear, the windscreen wiper and washer are out of work Step Treatment method Check the fuse of engine compartment fuse box、 fuse of the cab fuse To Step 2 To Step 3 box for melting.
Page 456 Malfunction Mode: only the low gear of the front windscreen wiper is out of work Step Troubleshooting Method Check the windscreen wiper motor terminal 3 and 1 for breakover. To Step 3 To Step 2 Replace the windscreen wiper motor To Step 3 Check the circuits of windscreen wiper motor terminal 3 and the To Step 5...
Page 457 Malfunction Mode: Only the intermittent gear of the front windscreen wiper is out of work Step Troubleshooting Method Turn the windscreen wiper switch to the intermittent gear, check whether the conduction of the windscreen wiper combination switch To Step 3 To Step 2 terminal is normal or not: terminal 2 and 3 is conducted, terminal 8 and 10 is conducted...
Page 458 Malfunction Mode: the washer is out of work Step Troubleshooting Method Check whether the washing motor battery is normal or not, turn on the ignition switch, the voltage between the washing motor plug To Step 3 To Step 2 positive terminal and the grounding is the battery voltage Repair or replace the power supply circuit of the washing motor, To Step 3 whether the malfunction has been troubleshot or not.
Page 459 Electric Horn Common Precautions..............................458 Preparations..................................458 Commonly used service tools............................458 Malfunction Diagnosis..............................461 Removal and Installation..............................463...
Page 460 Common Precautions Before the serving, which is not need to use the power supply: turn the power switch to LOCK position,  disconnect the 12V storage battery negative terminal. After disconnecting 12V storage battery negative terminal, the storage memory of radio and other control ...
Page 461 Components Position...
Page 462 Schematic Diagram The control method of horn is to control delivery point, the pick-up of horn relay is controlled by horn switch or body controller, then power is delivered from relay to horn, thereby the horn works. The horn is always grounding.
Page 463 Malfunction Diagnosis (1) List of Malfunction Diagnosis Check after-sales installation device that may have influence on horn operation. Check the system components that are easier to be contacted or visible to confirm that whether there is obvious damage or condition that may lead to malfunction. If the horn does not work, before replacing the horn, check and repair the bad contact or disconnection malfunction of power supply or switch ground circuit.
Page 464 （II）Flow Chart of Malfunction Diagnosis Horn Does Not Work Malfunction Phenomenon: Horn does not work Check disconnection Check the state of horn fuse Fuse blows out or malfunction of fuse circuit EF06 in engine and replace it compartment Press、release horn switch, measure the resistance between terminal 12 of Adjust horn switch harness connector M17 of horn switch...
Page 465 Removal and Installation Removal Open front compartment cover Disconnect battery negative cable. Refer to Disconnection and Connection of Battery Cable Remove front shield of engine. Refer to Front Shield of Engine Remove front wheel cover. Refer to Front Wheel Cover Remove top plate of front bumper Remove front bumper assembly Remove tweeter assembly...
Page 466 Vehicle Power Supply Common Precautions..............................465 Commonly Used Service Tools............................465 Schematic Diagram................................466 Removal and Installation..............................467 Malfunction Diagnosis..............................468...
Page 467 Common Precautions Before the serving, which is not need to use the power supply: turn the power switch to LOCK position,  disconnect the 12V storage battery negative terminal. After disconnecting 12V storage battery negative terminal, the storage memory of radio and other control ...
Page 468 Schematic Diagram...
Page 469 Removal and Installation Removal Open engine compartment cover Disconnect battery negative cable. Refer to Battery Cable Disconnection and Connection Remove Vehicle Power Supply 1). Pry off vehicle power supply 2). Disconnect harness connector of vehicle power supply. 3). Take down vehicle power supply. Installation Installation of Vehicle Power Supply 1).
Page 470 Malfunction Diagnosis Vehicle Power Supply Inspection Abnormal Step Countermeasures Normal Results Results As the negative pole is charged with Insert vehicle power supply into power Vehicle power electricity, vehicle power supply will supply socket, stop this operation supply does not skip to the edge of vehicle power until you hear clicking sound work...
Page 471 Switch System Common Precautions...............................470 Combination Switch.................................471 Power Window Switch..............................477 Rearview Mirror Adjustment Switch..........................479 Headlamp Adjustment Switch............................481 Dimmer Switch.................................483 TRIP Switch..................................484 Immediate Charge Switch..............................485 EPB Switch（Such as Equipment)..........................487 AUTOHOLD Switch（Such as Equipment).......................488 Mode Switch..................................489 Clock Spring..................................492...
Page 472 Common Precautions Before the serving, which is not need to use the power supply: turn the power switch to LOCK position,  disconnect the 12V storage battery negative terminal. After disconnecting 12V storage battery negative terminal, the storage memory of radio and other control ...
Page 473 Combination Switch Instruction Diagram of Combination Switch Assembly 1-Lamplight Control Switch 2-Self-Returning Switch 3-Wiper Control Switch Lamplight Control Switch The lamplight control switch controls the lamplight signal of left, right steering lamp, headlamp, front fog lamp, side turning lamp, overtaking lamp. As headlamp is under working mode, it also can realize two functions of turning high beam to low beam, turning low beam to high beam.
Page 474 Front Fog Lamp Turn front fog lamp switch to “ON” position, front fog lamp is on and front fog lamp signal displays on instrument. Only as front fog lamp switch stays “ON” position, driver can operate the rear fog lamp on sound control panel and rear fog lamp will be on.
Page 475 Component Test Check the conducting state for all the terminals of the wire connectors according to the following diagram. If the conducting state of all the wire connectors terminals is not in accordance with the following diagram, replace the switch. Steering/Lane Changing Fog Lamp Switch Lamplight Switch...
Page 476 Replacement Cautions: Remove the battery negative terminal and wait for at least 3 minutes before removing the electrical  appliance connectors, if not, the vehicle will be led to damage. When removing and installing the component parts, please use rag to protect the component parts to be ...
Page 477 Disconnect combination switch connector. Connector Remove the two mounting bolts of the combination switch. Mounting Bolt Pull out the combination switch assembly. Installation Step Install in the reverse order of removal. Tightening torque of mounting bolts: 2 N·m  Test after Installation Operate the lamplight handle of the combination switch, test the working conditions for all the lamps and switches: When the lamplight rotating handle is “OFF”, all the exterior illuminating lamps and the night illuminating...
Page 478 When the lamplight handle is in the small lamp position, press the front(rear) frog lamp switch, all the front(rear) frog lamp will be on. When the lamplight handle is in the headlamp position, the headlamp lower beam will be on, while all the small lamps will keep lighted state, rotate the handle downward by 6 degrees, the high beam will be on instantaneously, the switch will automatically reset after releasing.
Page 479 Power Window Switch Overview Power window system can lift or descend relevant window glasses through operating power window switch on each door trim panel. The main switch on driver side door trim panel can help driver lift or descend window glasses on each passenger side, and lock each single switch on passenger side.
Page 480 Replacement Removal Use the cross screwdriver to take down the bolt in the middle of armrest panel Use the slotted screwdriver to pry up the armrest panel. Disconnect the harness connector on the power window control switch. Use the cross screwdriver to remove the power window control switch.
Page 481 Rearview Mirror Adjustment Switch Rearview mirror adjustment switch is used to adjust the angle of left, right rearview mirror based on driver’s needs. Turn the middle shifter of rearview mirror adjustment switch to left, right side, then left, right rearview mirror can be adjusted up, down, left and right.
Page 482 Please check all the switch positions for breakover when the battery is out of work, if not, replace the switch. Connector Model: Harness Model: Installation Install in the reverse order of removal. Cautions: Check whether all the keypad functions are normal or not after installation. ...
Page 483 Headlamp Adjustment Switch Headlamp adjustment switch can be adjusted by roller wheel from 0 gear to fifth gear, headlamp lamplight height can be adjusted from high to low. Schematic Diagram of Component Removal and Installation Removal Remove the driver left lower side bracket； Pull out the headlamp adjustment switch connectors；...
Page 484 Connector Terminal Model: Wiring Diagram: Schematic Diagram of Electrical Appliance...
Page 485 Dimmer Switch Rotate switch button to adjust backlight luminance of vehicle interior electric devices. Schematic Diagram of Component Removal and Installation Removal Remove the driver left lower side bracket； Pull out the dimmer switch connectors； The dimmer switch is clamped on the left lower bracket, press the clamp block, pull out the switch. Installation Install in the reverse order of removal.
Page 486 Wiring Diagram: Outgoing Line and Wiring Diagram Connector Model: Load: Harness Model: PWM Pulse Signal Output TRIP Switch Switch Replacement Removal Remove the driver left lower side bracket； ② Pull out the TRIP switch connectors； ③ The TRIP switch is clamped on the left lower side guard plate, press the clamp block, pull out the switch. Inspection after removal Please check all the switch positions for breakover when the battery is out of work, if not, replace the switch.
Page 487 TRIP Switch Replacement Removal Remove the driver left lower side guard plate; ② Pull out the immediate charge switch connector; ③ Immediate charge switch is locked and connected on left downward side guard plate, press locked and connected block, take down switch. Inspection after removal Please check all the switch positions for breakover when the battery is out of work, if not, replace the switch.
Page 488 connector and taking off the switch. Check after disassembly When not working, please check whether the status of each gear is correct. If it is not conductive, replace the switch. Switch side Harness end ECO circuit connection Open (press) 2 Installation Install in reverse order of removal.
Page 489 EPB Switch（Such as Equipment) Removal: Take down switch panel, remove switch connector, use cross screwdriver to remove two mounting bolts, then EPB switch can be taken down. Pin Definition of Switch and Principle of Circuits: Schematic Diagram of Circuit Installation: Install in the reverse order of removal.
Page 490 AUTOHOLD Switch（Such as Equipment) Removal: Take down switch panel, remove switch connector, press the plastic snaps between switch and bracket, take down AUTOHOLD switch. Pin Definition of Switch and Principle of Circuits as shown in the following: Installation: The bracket inserts switch into mounting hole, press it downward until snap flicks.
Page 491 Mode Switch Switch Removal: After removing mode switch panel, remove switch connector, press the two snaps between mode switch and switch panel, then take down mode switch. Definition of Switch Pin Installation: Insert switch into switch mounting hole directly, press switch downward until snap flicks. Parking aid switch Switch Removal: After removing the mode switch panel, remove the switch connector and press the two latches between the parking assist switch and the switch panel to remove the parking assist switch.
Page 492 Pin definition Route diagram Pin number Pin definition Control loop Wire harness ILL（+） mating connector IDN（+） model: Control loop MG651044 IDN（-） ILL（-） Installation: Insert the switch directly into the mounting hole of the switch. Press the switch down until it snaps open.
Page 493 Caution lamp switch Switch Removal: After removing the warning light switch panel, remove the switch connector and press the two clips between the warning light switch and the switch panel to remove the warning light switch. Switch pin definition Termi Stall Back light power Right lamp...
Page 494 Clock Spring Schematic Diagram of Component Removal of Airbag Clock Spring Disconnect the storage battery negative terminal and wait for at least 3 minutes. Remove the driver air bag module, pull out the connectors.
Page 495 Remove the mounting bolts of the steering wheel, pull out the steering wheel. Cautions: The mounting bolts is able to be pulled out only when the steering wheel becomes loose, otherwise, the  steering wheel may lead to risk or severity of injuries. Disconnect the horn connectors.
Page 496 Pull out the clock spring of the air bag. Install clock spring of airbag Install in the reverse order of removal. Cautions: Pull out the SRS clock spring from the package, check the clock spring for damage, check whether the ...
Page 497 Definition of Clock Spring Connector As Shown In The Following: Pin Definition of Clock Spring Connector Steering Side Column Side 14 Channel Airbag Reserved Steering Wheel Horn Power Supply (-) Main Line 2 Main Line 1 Backlight Power Supply Power Supply (+) Airbag Reserved Column...
Page 498 Sound System Common Precautions..............................497 Component Position...............................497 Working Principle................................498 Malfunction Diagnosis..............................499 Removal and Installation...............................500 Removal and Installation of MP5........................500 Removal and Installation of Noise Reduction Module..................501 Removal and Installation of Multimedia Connector Assembly...............501 Removal and Installation of Multimedia Connector Cover................502 Removal and Installation of AntennaDevice......................502 Removal and Installation of AntennaAssembly..................506 Removal and Installation of AudioSpeaker Device..................507...
Page 499 Common Precautions Before the serving, which is not need to use the power supply: turn the power switch to LOCK  position, disconnect the 12V storage battery negative terminal. After disconnecting 12V storage battery negative terminal, the storage memory of radio and other ...
Page 500 Working Principle Reverse Gear Signal Reversing Lamp Switch Viewing Screen(Configure) Reversing Switch GPS Navigation Antenna(configure) Steering Wheel Clock Audio Control Button Spring System Radio Antenna Combinati Wheel Speed Signal Instrument AUX/USB...
Page 501 Malfunction Diagnosis List of Malfunction Diagnosis Check the after-sales installation device that may have influence on system operation. Check easily accessible or visible system component to find out whether there is obvious damage or situation that may lead to malfunction. For all the out-of service malfunctions of loudspeaker, conduct key inspection of the positions that are easily short-to-ground in the loudspeaker circuit, which will be helpful to troubleshoot malfunctions rapidly.
Page 502 Removal and Installation Removal and Installation of MP5 Open front compartment cover Disconnect battery negative cable. Refer to Disconnection and Connection of Battery Cable Remove decorative plate assembly on the right side of center. Refer to Decorative Plate Assembly On Right Side of Center Removal MP5 panel assembly.
Page 503 Removal and Installation of Noise Reduction Module Removal Remove four mounting bolts 12431-03123 of noise reduction module connecting with front ceiling lamp. Inspection after removal Check noise reduction module for damage or crack. If does, please replace it. Installation Install in the reverse order of removal The tightening torque of installing four mounting bolts of noise reduction module is 4N·m～5N·m.
Page 504 Installation Install in the reverse order of removal. Removal and Installation of Multimedia Connector Cover Removal Open front compartment cover Disconnect battery negative cable. Refer to Disconnection and Connection of Battery Cable Remove multimedia connector cover 1). Pry off multimedia connector cover. 2).
Page 505 Inspection after Removal Check GPS antenna support for damage or crack, if does, please replace it. Installation Install in the reverse order of removal. Cautions： Tightening torque of installing the bolt of GPS antenna is 2.5N·m～3N·m.  Transition Cable of Antenna Removal Open front compartment cover Disconnect battery negative cable...
Page 506 22. Remove Transition Cable Forepart of Antenna 1). Disconnect connector between transition cable forepart of antenna （amplifier）and main harness. 2). Disconnect harness connector ② between transition cable forepart of antenna (amplifier) and rod-type antenna assembly. 3). Disconnect butt joint ① between transition cable forepart of antenna (amplifier) and rod-type antenna assembly.
Page 507 4). Plug out fixed clip between transition cable forepart of antenna and vehicle body, take down transition cable forepart of antenna. Clip： Clip： Installation Install in the reverse order of removal.
Page 508 Removal and Installation of Antenna Assembly Removal Open front compartment cover Disconnect battery negative cable. Refer to Disconnection and Connection of Battery Cable Remove upward decorative plate assembly (right) of column A. Refer to Upward Decorative Plate Assembly of Column A Remove threshold backplate assembly (right) of front door.
Page 509 Removal and Installation of Audio Speaker Device Removal Plug out woofer connector firstly, then remove three mounting bolts Q2714213 of woofer connecting with door panel. Plug out tweeter connector firstly, then remove two mounting bolts 12431-03129 connecting with trim panel of high pitched A column. Inspection after removal Check woofer and tweeter supports for crack or damage.
Page 510 Reversing Assist System Common Precautions.............................509 Commonly Used Service Tools..........................509 Component Position................................510 Malfunction Diagnosis..............................511 Removal and Installation..............................514 Reversing Radar Controller..........................514 Sensor Assembly..............................515...
Page 511 Common Precautions Before the serving, which is not need to use the power supply: turn the power switch to LOCK position,  disconnect the 12V storage battery negative terminal. After disconnecting 12V storage battery negative terminal, the storage memory of radio and other control ...
Page 512 Component Position Reversing Radar Controller Assembly Sensor Assembly...
Page 513 Malfunction Diagnosis List of Malfunction Diagnosis Malfunction Analysis of Malfunction Reason Countermeasures Remark Phenomenon Reversing switch has not been Replace reversing switch connected Refer to System does not work Poor connection between harness Check harness for correct System as reversing and main power supply connection with power supply Out of...
Page 514 Flow Chart of Malfunction Diagnosis System Out of Service Next Step Inspection Judgement Step Countermeasures Content Standard Confirm Whether you can Deal with malfunction Ignition switch stays ON gear, shift hear buzzer intermittent Turn to phenomenon transmission to reversing gear warning sound or malfunction, step 3...
Page 515 Sensor Out of Service Next Step Judgement Step Inspection Content Countermeasures Standard Ignition switch stays ON gear, shift transmission to Whether you Deal with Confirm malfunction reversing gear, place can hear intermittent Turn to Step 3 phenomenon suitable barrier in the warning tone of malfunction, turn rearpart of vehicle within...
Page 516 Removal and Installation Reversing Radar Controller Removal Open front compartment cover Disconnect battery negative cable Remove tailgate threshold assembly. Refer to Tailgate Threshold Assembly. Remove threshold backplate assembly of rear door. Refer to Threshold Backplate Assembly of Rear Door Remove rear seat cushion assembly. Refer to Rear Seat Assembly Remove rear seat backrest assembly.
Page 517 Install rear seat cushion assembly Install rear door threshold assembly Install tailgate threshold assembly 10. Connect battery negative cable 11. Close front compartment cover Sensor Assembly Removal Open front compartment cover Disconnect battery negative cable. Refer to Disconnection and Connection of Battery Cable Remove quarter combination lamp assembly.
Page 518 Installation Install sensor assembly 1). Install sensor body ③ from front of rear bumper, install rubber pad ②and snap ring ① along the harness built in sensor body. 2). Rotate snap ring ① clockwise as pressing sensor body, make rubber pad and rear bumper fit closely together. △Caution Triangle mark of snap ring should be aligned with triangle mark of sensor assembly, that is to say, they are tightened up closely.
Page 519 SRS System Overview.....................................520 Principle....................................521 Removal and Installation..............................522 Driver SRS Assembly............................522 Co-pilot SRC Assembly............................524 Air Bag Control Unit (ACU).............................524 SRS System Diagnosis............................527 Repair....................................528 Disposal Method................................528...
Page 520 Never make the air bag drop. Never use the air bag if it has been dropped. Only get the original replacement parts from DR authorized distributor. After removing the SRS, make the front face up and put it in the smooth place. Do not put any articles on the front.
Page 521 Preparations Commonly used service and special tools are in need during the maintenance and repair. Special Tool Diagram Tools Diagram Function Ignition Tools Ignite the air bag Module Harness Diagnosis Inspector Inspector Check the simulator Simulator connector of the harness resistance...
Page 522 Overview Generally speaking, the SRS system is the air bag system, the “SRS” identification will be found on the trim cover of the air bag or the places where being the air bags; Driver Airbag (Driver Airbag-DAB): When the front collision happening, the air bag will protect the driver’s upper torso, in some degree, it will protect the driver from moving forward.
Page 523 Principle Conditions of Airbag Deployment Collision Angle Diagram that may lead to airbag deployment The frontal collision with enough impact force that deviates from vehicle center line within 30 degrees may result in airbag deployment. Position Diagram of Airbag System Components Position Diagram of Airbag Components 1-Driver Side Airbag 2-Passenger Side Airbag...
Page 524 Schematic Diagram of Restraint System Action Removal and Installation Driver SRS Assembly Component Driver airbag assembly is located in steering wheel.
Page 525 Caution： Place the driver air bag module with gasket side facing upward when removing the driver air bag  assembly or installing a new driver air bag assembly. Do not measure the air bag resistance, which may lead to igniting the air bag accidentally. ...
Page 526 Co-pilot SRC Assembly Component Parts Diagram The co-pilot SRC assembly is embedded in the interior instrument panel on the co-pilot side. Location Diagram of the co-pilot SRC Assembly Installation Cautions： Do not place or post any items on the air bag surface. ...
Page 527 Terminal Diagram of ACU...
Page 528 Pin Designation Pin Description Terminal 4 Loops DBT+ Driver Seat Belt Pretensioning Positive Gold DBT- Driver Seat Belt Pretensioning Negative Gold PBT+ Copilit Seat Belt Pretensioning Positive Gold PBT- Copilit Seat Belt Pretensioning Negative Gold Vbat Power Supply Positive Gold Grounding Gold Malfunction Indicator Lamp...
Page 529 Removal of Air Bag Control Unit (ACU) Turn off the ignition switch, disconnect the storage battery negative terminal, wait for 3 or more minutes until the complete discharge of interior capacitive storage of ACU. Remove the vice instrument panel(see Removal and Installation of Vice Instrument Panel). Remove the three mounting bolts of ACU, loosen and pull the harness connector of ACU, pull out the ACU.
Page 530 Repair If the air bag is not ignited under the condition that the vehicle crash under lower speed. side collision. rollover. rear-end collision, inspect the following items: Check the ACU body and mounting bracket for dent. crack or deformation.  Check the connector for damage and check the terminal for deformation.
Page 531 360 panoramic parking assist system Overview.....................................530 Principle....................................530 Removal and Installation..............................532 Calibration process................................535 Disposal Method................................537...
Page 532 360 panoramic parking assist system The 360 panoramic system has four wide-angle cameras around the vehicle that can cover all field of view around the vehicle. The multi-channel video images collected at the same moment are processed into a 360-degree top view of the vehicle, and finally displayed on the MP5 screen. Let the driver clearly see the presence of obstacles around the vehicle and understand the relative position and distance of obstacles to help the driver easily park the vehicle.
Page 533 ③rear camera terminal and pin definition Power supply positive Power Supply Grounding Video+ Positive video Video- Negative video ④Controller terminal and pin definition Video Output+ CVBSoutput+ Camera VCC1 rear Camera power input BAfter BGND1 Camera input Camera VCC2 before Camera power input BGND2 before Camera input Camera VCC3 left...
Page 534 Right camera signal Camera IN 3 right input Right camera signal AGND3 right input Left camera signal Camera IN 4 left input Left camera signal AGND4 left input ECU activation signal ACC ON input power input 2, camera and controller replacement 1, removal steps 1) Front camera disassembly a.
Page 535 Front camera Front connector camera 2）Left and right camera disassembly Left and right cameras and left and right rearview mirrors are not combined, and the left and right rearview mirror assemblies are replaced when the camera is replaced. 3）Rear camera disassembly a、Remove the rear bumper assembly.
Page 536 Camera Panoramic Rear bumper 4）Controller removal a、Remove the sub-dashboard assembly, see "Disassembly of the sub-dashboard"; b、Unplug the controller connector; c、Remove the controller fixing nut; d、Take out the controller. Panoramic Controller Controller 3. Installation: Install according to the reverse procedure of disassembly.
Page 537 4, common faults and maintenance methods (1) The system does not work Specific performance: When the "AVM" button is pressed or the car enters the reverse working state, the DVD screen does not switch to the 360 p anoramic parking screen. Cause of the malfunction: 360 panoramic parking system does not work, often the working power is not connected.
Page 538 4. Spread the left side of the correction fabric to ensure that the black area of t he left side corrective fabric overlaps with the black frame side of the front side corrective fabric. The overlapping area is the standard black frame.
Page 539 3）Calibration process:...
Page 540 Proc Instructions Vehicles drive into the calibration station and park the STAT Check whether the door and rear door are properly closed, Festen the left and right rearview mirrors are not folded, the The calibration signal is triggered by a diagnostic Trigger instrument or a host computer;...
Page 541 focal points of the two black squares or the vertices of the black squares. Calibrat ion point 5. Directly click on the left screen to automatically zoom in on the area near the current point for user fine-tuning. Denotes the position of the calibration point, which represents the calibration point selected by the current user.
Page 542 To switch the four camera images, click on the area around the body.  When you zoom in on the area around the calibration point, if you want to cancel this operation, click  on the other area of t he screen and the calibration point will return to the original position. Left and right images on the calibration interface can only display information for one calibration point ...
Page 543 Front view 1 Front view 2 Front view 5 Front view 3 Front view 4 3. After all the five points of the front view image are calibrated, click on the left side of the car body and follow the operation of step 2 to fully calibrate the five points as shown in the figure below. Left view 1 Left...
Page 544 Rear view 1 Rear view 2 Rear view 5 Rear view 4 Rear view 3 5. After all the 5 points of the rear view image are calibrated, click on the right side of the car body and follow the operation of step 3 to fully calibrate the 5 points as shown in the figure below. Right view 2 Right view 5 Right view 1...
Page 545 completely covers the blurred area. In the same way, if there is a blind spot in the rear view, click the rear of the car and continue to click slowly until the black shadow completely covers the blurred area; when the left/right side also has a blind spot, click on the sides of the car body and click cover the blind spot.
Page 546 Reversing radar system Outline......................545 System interface definition...............546 Fault Diagnosis..................547 Assembly....................553 Reversing camera system...............555 Tire pressure monitoring................557 Working principle................559 Fault diagnosis.................562 PEPS......................568 Overview..................568 Component mounting position............568 Keyless access to ECU and bracket position.....568 Car low frequency antenna..........569 Spare antenna..............569 PEPS button..............569 ESCL and snap ring............570 System principle diagram...............571 Component inspection..............571...
Page 547 Reversing radar system 1. Outline (1) structure summary The reversing radar system consists of a sensor, a control module and an alarm device. The reversing radar system is based on the principle of ultrasonic distance measurement and computer data blur processing technology to determine whether there are obstacles in the reversing direction of the car, and to indicate the distance of the nearest obstacle.
Page 548 As shown in the figure, the reversing radar system consists of the following components: ■Control module; ■ sensor module; Buzzer (integrated in the meter). System interface definition 1.Connectors of control module: Table 1 controller module plug-in signal definition Connector Signal name Function Remark schematic...
Page 549 N.C. N.C. N.C. GND-SEN Sensor ground Ground 2. Camera connector ： Table 2 Probe plug signal definition Radar sensor connector Definition of the horn connector (component side) Remark shape and pin sequence R+(power positive) Reserved GND (power negative) Signal Injection: AMP 967439-1 3.
Page 550 it in time Sensor cable is broken Check harness for damage Battery voltage is abnormal Check the battery voltage is normal Turn off the system and reconnect all Unable to display Connector position is incorrect connectors correctly obstacle distance Check if the sensor cable touches Sensor harness is disturbed the exhaust pipe or muffler Boot no beep, the...
Page 551 (2) the fault diagnosis flow chart 1. System dis-function Next step Steps Checking content Solution Decision specification Confirm the fault Turn the ignition switch ON Can you hear Handle intermittent phenomenon and put the transmission in buzzer alarm? problems and go to Go to step 3 reverse gear.
Page 552 Replace the reverse Replace the new parking radar controller. Is sensor controller. Turn the Can you hear Troubleshooting. the fault cleared? key switch ON and put the the buzzer vehicle in reverse gear. beep?
Page 553 2 Sensor foes not work Next Steps Checking Solution Decision step content specification Turn the ignition switch Confirm the fault Is it possible to hear Handle intermittent ON, engage the phenomenon Go to step 3 parking alert sounds? problems and go to transmission in the next step reverse, and place...
Page 554 Replacing the Replace the new reversing radar reversing radar Can detect obstacles? Troubleshooting. sensor, sensor. Put the ignition troubleshooting? switch in the ON position and the transmission is engaged in the reverse gear to enter the reverse position.
Page 555 4. reversing radar controller assembly demolition (1) Disassembly 1 Open the engine compartment cover. 2 Disconnect the negative port.of the battery 3. Remove rear door sill assembly See rear door sill assembly ② 4. Remove the rear door sill guard plate assembly See the rear door sill guard plate assembly 5.
Page 556 5. Sensor assy disassembly (1) Disassembly 1 Open the engine compartment cover. 2 Disconnect the negative harness of the battery refer to the disconnection and connection of the battery 3. Disassemble rear side body combination lamp assembly, refer to rear side body combination lamp assembly Disassemble rear bumper assembly 5.
Page 557 Reversing camera system 1. Outline (1) structure summary The reversing image system mainly consists of a rearview camera and an MP5 main unit. The camera is powered by the IGN signal. When the R-range signal is detected through the CAN bus node, the system starts immediately.
Page 558 TPMS includes the following parts as shown in picture: ■Reversing camera ■MP5 4.System interface definition 1.Connectors of control module: Table 1 controller module plug-in signal definition Reversing camera connector shape Definition of the horn connector (component side) Remark and pin sequence Reverse feed;...
Page 559 Tire pressure monitoring 1. Outline (1) structure summary Tire pressure monitoring system can monitor the pressure and temperature in the tire, give alarm in time when the setting value is exceeded (the alarm indicator is indicated by the instrument light), help the driver to grasp the condition of the tire in real time and reduce the traffic accidents caused by the tire failure, increasing vehicle driving safety.
Page 560 High temperature When the system is running, one or more tire temperatures are higher than 85 °C and a high temperature alarm is issued; the temperature returns to normal and the high temperature alarm is released. Sensor battery low power When the system is running, one or more of the tire pressure sensors have a battery level lower than a certain value and a low-power alarm is issued.
Page 561 Components location: 1. Tire Pressure Monitoring Sensor 2. Tire Pressure Monitoring Controller 3. Combination Instrument (2) the working principle sensor sensor system Tire pressure Controlle Combinat Vehicle sensor sensor Description: 433.92Hz RF Tire pressure detection system schematic...
Page 562 (III) Definition of System Interface Definition 1. Check if the power supply of the tire pressure monitoring system controller is normal (9V ~ 16V). 2. The terminal of the tire pressure monitoring system control module is defined as follows: Controller terminal definition table Tire pressure monitoring Connector definition Note...
Page 563 After a long time of parking, the tire pressure is normal and there is no obvious change. No sensor data has been received for 20 consecutive minutes. The TPMS lamp is on. After the vehicle is running, the sensor starts transmitting data and the TPMS lamp point goes out.
Page 564 Number faults phenomena Cause Analysis Solutions The ignition switch The original receiver of the vehicle is not To the DR shop, professionals are is ON, the tire learning binding. required to use hand-held learning pressure warning tools to reacquire all tire sensor IDs...
Page 565 The high-frequency receiving module of the Check the receiving controller at the receiving controller is damaged and has not DR shop. If you need to replace the received any sensor data for 20 consecutive receiving controller, you must re-learn minutes.
Page 566 (2) the fault diagnosis flow chart The tire pressure monitoring system (TPMS) indicator light is on Next step Steps Checking content Solution Decision specification Check the battery Use a multimeter to Standard value: 11 ~ Next step Check battery or voltage measure the battery charging system...
Page 567 Tire pressure warning indicator does not light when car tire pressure is seriously insufficient Steps Checking content Solution Decision specification Next step Check the battery Use a multimeter to Standard value: 11 ~ Next step Check battery or voltage measure the battery charging system voltage.
Page 568 3. Tire pressure monitoring controller (1) Disassembly 1 Open the engine compartment cover. 2 Disconnect the negative harness of the battery refer to the disconnection and connection of the battery 3. Dismantle the sub instrument panel house refer to sub instrument panel 7.Disassemble the tire pressure monitoring controller 1).
Page 569 (2) Installation 1. Install tire pressure monitoring controller 1). Install the tire pressure monitoring sensor from inside the rim. 2). Install the tire and tighten the tire pressure monitoring sensor fixing nut from the outside of the rim. △Caution The sealing rubber of the sensor is tightly fitted with the rim to ensure the tightness of the tire.
Page 570 PEPS system 1.Overview of the system Passive Entry & Passive Start (PEPS) means a keyless entry and keyless entry system that uses state-of-the-art RFID radio frequency technology and a vehicle identification code recognition system to provide a comfortable and completely new driving experience with user-friendly convenience. The PEPS system consists of the following units: keyless entry electronic control unit, low-frequency antenna in the car, spare antenna, integrated entry sensor in the door handle, pushbutton ignition switch, keyless access to...
Page 571 Located on the right side of the instrument panel beam 2 ) Car low-frequency antenna The front low-frequency antenna is located in the middle of the instrument panel beam, the low-frequency antenna is located in the rear seat, and the tailgate low-frequency antenna is located in the rear guard bar.
Page 572 Electron Electronic PEPS button Steering steering column steering column column lock snap lock ring Located on the direction column 6 ) Electronic steering column lock and snap ring Located on the direction column 3.System principle diagram...
Page 573 4.Component inspection Connector terminal definition: PEPS button Serial Description Note Start switch signal 1 Start switch Start switch signal 2 Start switch text backlight SWIL (white) INDG Start switch backlight (green)
Page 574 Start switch backlight INDA (amber) Spare antenna Seria Descriptio Note l No. ANT+ Antenna positive ANT- Antenna negative Car low-frequency antenna Seria Descriptio Note l No. ANT+ Antenna positive ANT- Antenna negative External handle sensor Seria Descriptio Note l No. ANT+ Antenna positive ANT-...
Page 575 PEPS controller Serial Descriptio Note J1-1 Battery positive J1-2 IG1D IG1 Relay Drive - High J1-3 ACCD ACC Relay Drive - High J1-4 IG2D IG2 Relay Drive - High CAN_HS_ J1-5 High speed CAN low CAN_HS_ J1-6 High speed CAN high Right front wheel speed signal J1-7 (hard line signal)
Page 576 J2-11 Start switch(1) RESERV J2-12 Reserved J2-13 Start switch(2) J2-14 CLG5 Front antenna + J2-15 CG7B Rear internal antenna - J2-16 CLG7 Rear internal antenna + +TSW_O J3-1 Trunk unlock switch Left front door handle antenna J3-2 CG1B Left front door handle antenna J3-3 CLG1 J3-4...
Page 577 V. Replacement of parts 5.1 PEPS Controller Removal. a) Disconnect the battery negative; b) Remove the dashboard panel; c) Disconnect the connector of the PEPS controller; d) Remove the bolts that secure the keyless entry to the electronic control unit bracket; e) Remove the PEPS controller and its holder from the tube beam.
Page 578 5.2.3 Rear bumper LF antenna removal a) Disconnect the negative pole of the battery; b) Remove the rear bumper; c) After disconnecting the low frequency antenna connector; d) Remove the low frequency antenna from the rear impact beam Rear anti-collisi on beam Rear vehicle low frequency...
Page 579 a) Disconnect the negative pole of the battery; b) Remove the inner door panel of the front door; c) Remove the front door handle; d) Disconnect the integrated sensor access connector in the door handle; e) Take the integrated entry sensor in the door handle out of the door handle. 5.5 PEPS start switch disassembly a) Disconnect the battery negative;...
Page 580 Serial Meter indicating Inspection object phase (P/N relay is located in the outdoor relay box). Please turn ignition Confirm that the ignition switch has been turned off to OFF switch to OFF Key outside the Function indicating, not detected key inside the vehicle vehicle When the key has no power, the key is put into the back cup to start, Please replace smart...
Page 581 Modul Perform actions Matters needing attention Learning ESCL When learning ESCL, confirm normally in OFF state 1.ESCL must be replaced with a new ESCL, remember not to interchange with other vehicles, or the vehicle will not be able to point. Replace ESCL 2.
Page 582 Seria error Definition of error code Troubleshooting method l No. code U0129 Loss of ABS communication U0140 Loss of BCM communications Check if the ESCL power supply, ground, and Lin wiring U0329 ESCL communication lost harnesses are conducting. U1300 Software configuration error Replace PEPS controller Driving side low frequency Check that the driver's side door handle antenna harness is...
Page 583 Seria error Definition of error code Troubleshooting method l No. code If there is no 12V power supply, please check the IG1 relay circuit. 3. Check that the ACC, IG2, IG1 relay circuit harnesses are conducting. 1. Erase the ESCL instruction through the diagnostic device (This instruction needs to be executed for 15 minutes and the ESCL enters self-protection entire vehicle is to be turned off)
Page 584 Seria error Definition of error code Troubleshooting method l No. code B1306 Security code is not written B1516 HSU overload failure Replace door handle antenna B1517 HSU switch failure Replace door handle antenna...
Page 585 EVO Electric Body Chassis High voltage...
Page 586 High Voltage High Voltage Electric mantainance manual GENERAL INFORMATION ............................584 HOW TO USE THIS MANUAL............................585 HOW TO USE THIS MANUAL..........................585 Description................................586 Terms..................................586 Units...................................586 Contents.................................587 Relation between Illustrations and Descriptions..................587 HOW TO FOLLOW TROUBLE DIAGNOSES....................589 Description..............................589 How to Follow Test Steps in Trouble Diagnosis..................589 HOW TO READ WIRING DIAGRAMS......................590 Connector Symbols............................590 SWITCH POSITIONS.............................592...
Page 587 High Voltage Precautions for hoses...........................603 CAUTIONS AS TO HIGH VOLTAGE........................604 How to Cut Off High Voltage........................604 High Voltage Precautions...........................606 Post the Warning Label of "HIGH VOLTAGE COMPONENTS IN REPARING DO NOT TOUCH".607 Layout of High Voltage Components......................608 Insulated Protective Wear and Insulating Tools..................608 Handling of Damaged Vehicles........................609 How to Handle Damaged Vehicles in Specified Conditions..............610 Vehicle...
Page 588 High Voltage HOW TO USE THIS MANUAL Description This volume explains “Removal Disassembly Installation Inspection and Adjustment” and “Trouble Diagnoses”. Terms Description Violation operation may cause a death or serious personal injury. DANGER Example Touching high voltage components without using the appropriate insulated protective equipment WARNING Violation operation may cause a death or serious personal injury.
Page 589 Fixing bolts of power train and suspension 50-70 N·m Contents The contents are listed on the first page of every chapter.  The small illustrations show the important steps such as inspection use of special tools knacks of work  and hidden or tricky steps which are not shown in the previous large illustrations.
Page 590 Components The large illustrations are exploded views (see the following) and contain components standard parts tightening torques lubrication points assembly method and other information necessary to repairs. Components shown in an illustration may be identified by a circled number.When this style of illustration is used the text description will follow the illustration.
Page 591 HOW TO FOLLOW TROUBLE DIAGNOSES Description Trouble diagnoses indicate work procedures required to diagnose problems effectively.Observe the following instructions before diagnosing. Before performing trouble diagnoses read the “work flow” in each section.  After repairs re-check that the problem has been completely eliminated. ...
Page 592 Questions and results Questions and results are listed in each test group. Action Next test action is based on test results of each group. HOW TO READ WIRING DIAGRAMS Connector Symbols Connector symbols are shown from the terminal side and the harness side.See the following picture Terminal side diagram shows the view from front ...
Page 593 Description Number Item Description Battery ground Vehicle battery ground Battery 12V battery 12V Fuse Fuse and its available current value Relay Internal controlling principle of relay Relay control Working condition of relay Alphabetic characters show to which harness the connector is placed Connector number Numbers show the connector number Power supply...
Page 594 MULTIPLE SWITCH The continuity of multiple switch is described in two ways as shown below. The switch chart is used in schematic diagrams.  The switch diagram is used in wiring diagrams.  Connector information Left front fog light Connector No. Connector Name Left font fog light Connector Type...
Page 595 Connector Alphabetic characters show to which harness the connector is placed number Numbers show the connector number Connector Definition of connector name name Connector Connector property type Connector Projection of connector outline Terminal Information of connector terminal (see 1 and 2 in the picture) number Wire color code B=black W = white R = red G = green L = blue Y = yellow LG light green =...
Page 596 ABBREVIATIONS Abbreviation Name Air conditioner system Air conditioner controller Battery cut-off unit Off-board charger Diagnostic trouble code DC/DC Direct current converter Defrost E-Drive Electric- drive AC compressor controller HVAC Main device of air conditioner Combination instrument Battery controller On board diagnositics Motor controller T-BOX Remote intelligent terminal...
Page 597 TIGHTENING TORQUE OF STANDARD BOLTS AND SCREWS Tightening Torque Table Grade 4.8（4） 8.8（8） 10.9（10） Name Size Remarks Tightening torque （N.m） 1～1.5 2～3 3～3.8 2～3 4～7 6～8 3～6 7～11 10～13 6～8 12～16 17～22 8～11 18～32 25～35 M8×1 6～12 20～34 27～38 17～22 36～55 50～63 M10×1.25...
Page 598 Screw tightening torque table Tightening torque （N.m） Remarks Name Size 1～1.5 1.5～2.5 2～3 3.5～5.5 Screws 3～4 6～9 8～11 16～22 13～22 25～30 Tightening Torque of Key Parts Tightening torque Name （N•m） Fixing bolts of gear shifting operating mechanism 30～35 Self-lock nut of drive shaft 240～260 Fixing bolts between rear suspension cushion and sub-frame 130±10...
Page 599 M6 bolt 10～15 Assembly of brake pipes M8 bolt 20～25 Fixing bolts of brake caliper 65～75 Fixing bolts between brake handle and vehicle floor 20～25 Fixing bolts/nuts between front column and steering knuckle / 110～130 Fixing bolts(assembly in X direction) between lower suspension arm and 130～150 sub-frame Fixing bolts between stabilizer and sub-frame...
Page 600 40～50 Mounting bolts between battery pack bracket Ⅱ and vehicle body 60～80 Mounting bolts between battery pack bracket Ⅰ and bracket Ⅱ Mounting bolts between off-board charger and cross member 15～20 Fixing bolts between charging socket and cable bonding terminal 15～20...
Page 601 MOTOR SERIAL NUMBER Motor code Dimensions Items Parameters (mm) Overall length 4135 Overall width 1750 Overall height 1560 Wheelbase 2490 Front tread 1515 Rear tread 1500 Wheels & Tires Wheels 6.5J×16 Tires 205/55R16...
Page 602 To avoid the SRS failure and collision accident after the failure which could cause personal injury  or death all maintenance must be performed by an authorized DR dealer. Improper maintenance including incorrect removal and installation can lead to personal injury ...
Page 603 Never use any electrical test equipment on any circuit related to the SRS unless instructions in  this Service Manual.SRS wiring harness can be identified by yellow and /or orange harness Precautions When Using Power Tools (Air or Electric) and Hammers When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the power ...
Page 604 General Precautions Before jacking up the vehicle apply wheel chocks  or other tire blocks to the wheels to prevent the vehicle from moving.After jacking up the vehicle support the vehicle weight with safety stands at the points designated for proper lifting before working on the vehicle.This operation should be done on a level surface.
Page 605 When repairing the fuel oil water vacuum or Seat  exhaust systems check all affected lines for cover leakage. Fender cover Before servicing the vehicle Protect fenders upholstery and carpeting with appropriate covers.Take caution that keys buttons or similar things do not scratch paint. Do not scratch hose.
Page 606 CAUTIONS AS TO HIGH VOLTAGE How to Cut Off High Voltage Be sure to follow the procedure below and shut off the high voltage before performing inspection or servicing of the high voltage system. Turn power switch OFF. Disconnect 12V battery negative terminal. Disconnect service plug...
Page 607 d、 Turn the service plug handle according to the direction in picture and then remove the service plug. Danger touch high voltage components without using the appropriate protective equipment will cause electrocution. Warning Immediately protect high voltage connectors and terminals with insulating tape. ...
Page 608 High Voltage Precautions Warning Because electric vehicles contain a high voltage battery there is risk of electric shock electric  leakage or similar accidents if the high voltage component and vehicle are handles incorrectly be sure to follow the correct work procedures when performing inspection and maintenance. Must turn the key to “LOCK”...
Page 609 Post the Warning Label of "HIGH VOLTAGE COMPONENTS IN REPARING DO NOT TOUCH" To call the attention of other workers indicate “High voltage work in progress.Do not touch!” on vehicles where work is being performed on the high voltage systems. DANGER HIGH VOLTAGE REPAIR WORK IS IN PROGRESS.DO NOT TOUCH! Person in charge _________________...
Page 610 Layout of High Voltage Components Position of Parts DC charging socket Drive control device High voltage distribution device On board charger Power cell assembly High voltage main cable assembly Drive motor assembly AC charging socket Caution If there are parts in this sheet attached with high-voltage labels.at time when a part needs to be replaced or when a label had become peeled be sure to apply the new label in the same position and facing in the same direction.
Page 611 Daily Inspection This inspection is performed before and after use the worker need to check for deterioration and damage of these protective devices. Insulated gloves  Inspect the insulated gloves for scratches holes and tears.(Visual check and air leakage test) Hold glove and fold as shown in the figure Fold three or four times preventing air from escaping from the glove Squeeze glove to check that the glove has no holes...
Page 612 How to Handle Damaged Vehicles in Specified Conditions High voltage system shut-down procedure The first step for a damaged vehicle is to shut down high voltage system.Any of the following procedures can shut down the high voltage system. If the vehicle is heavily damaged for example the battery is deformed broken or cracked insulating protective wear must be used and otherwise you must not touch the high voltage harness.
Page 613 Procedure A Turn the switch to LOCK. Does the low-voltage fuse box open? Warning Be sure the high voltage system is disconnected when the key is in “LOCK” or “ACC”.  Be sure the remote air conditioner remote charging and timing charge are OFF. ...
Page 614 Procedure 1 Turn the key to “LOCK” Check the state of READY indicator if it is ON the high voltage system is active.READY Be sure the READY indicator lamp is OFF. Disconnect the 12V battery negative terminal.Insulate the battery negative terminal with insulated tape. Wait 10 minutes to complete discharging the high voltage condenser after the power switch has been turned OFF.
Page 615 Disconnect service plug a、 Open the carpet cover above the service switch b、 Remove the installation bolts of service cover and take the service plug cover off c、 Open the service plug second buckle 、...
Page 616 Wait 10 minutes to complete discharging the high voltage condenser after the power switch has been turned OFF. Perform the first response action for emergencies. Vehicle Fire Warning If it is possible use large amount of water from a fire hydrant to extinguish the fire.Do not use a small amount of water because small amount of water will make toxic gas produced by a chemical reaction between battery electrolyte and water.
Page 617 Caution Every time the vehicle is lifted up maintain the complete vehicle curb condition.  Since the vehicle’s center of gravity changes when removing main parts on the front side (engine  transmission suspension etc.) support a jack up or equivalent tools point on the front or rear side of the vehicle..
Page 618 Normal Towing Methods If you need to tow the vehicle please contact with DR authorized dealer or professional towing service company.Improper towing methods may damage the vehicle. Three normal methods to tow the vehicle Flatbed —...
Page 619 Rear...
Page 620 SERVICE INFORMATION FOR CIRCUIT FAULTS How to Effiently Diagnose Circuit Fault Work Flow Step Description Get detailed information about the conditions and the environment when the fault occurred The following are key pieces of information required to make a good analysis WHAT vehicle model engine vehicle controller battery management system and other systems (air conditioner).
Page 621 Control Units and Electrical Parts Precautions Never reverse battery terminals.  Install only parts specified for a vehicle.  Before replacing the control unit check the input and output functions of the components.  Do not apply excessive force when disconnecting a connector. ...
Page 622 Measuring from Harness Side Standard type (not waterproof type) connector Connector should be measured from harness side with T pin.“T” If the connector has a rear cover such as a  ECM connector remove the rear cover before measuring the terminal. Do not measure waterproof connector from ...
Page 623 Prepare a male terminal and 10cm of wire.10CM Caution Use a male terminal which matches the female terminal. Disconnect the suspected faulty connector and Male Wire hold it terminal side up. terminal While holding the wire of the male terminal try to insert the male terminal into the female terminal.
Page 624 Most waterproof connectors are provided with a  Wire seal rubber seal between the male and female connectors.If the seal is missing the waterproof Connector housing performance may not meet specifications. Rubber seal The rubber seal may come off when connectors ...
Page 625 Fault Simulation Test Introduction Sometimes the symptom is not present when the vehicle is brought in for service.So we have to re-create the conditions present at the time of the fault.Doing so may help avoid unnecessary fault diagnosis.The following section illustrates ways to simulate the conditions/ environment under an electrical fault.This section is divided into six following topics Vehicle vibration ...
Page 626 Sensor & Relay Gently shake the sensors and relays in the system you are inspecting. This test may indicate a loose or poorly mounted sensor or relay. Front compartment There are several reasons a vehicle or motor vibration could cause an electrical complaint.Some of the things to check for are Connectors not fully seated.
Page 627 Heat sensitive Sometimes customers may have this problem during Heating test hot weather or after car has sat for a short time.In such cases you will want to check for a heat sensitive Heat gun condition. Do not heat above 60℃ （140°F） To determine if an electrical component is heat sensitive heat the component with a heat gun or equivalent.
Page 628 Water Intrusion The fault may occur only during high humidity or in Water intrusion test rainy/ snowy weather.In such cases the fault could be caused by water intrusion on an electrical part.This can be simulated by soaking the car or running it through a car wash.
Page 629 Testing for “Opens” in the Circuit Before you begin to diagnose and test the system you should rough sketch a schematic of the system.This will help you to logically walk through the diagnosis process.Drawing the sketch will also reinforce your working knowledge of the system.
Page 630 No voltage the open is between the solenoid and the relay (point C). Any circuit can be diagnosed using the approach in the previous example. Testing for “Shorts” in the Circuit To simplify the discussion of shorts in the system please refer to the following schematic. Resistance Check Method Disconnect the battery negative terminal and remove the blown fuse.
Page 631 Voltage the short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). No voltage back to the checking steps and check power of fuse block. Ground Inspection Ground connections are very important to the proper operation of electrical and electronic circuits.Ground connections are often exposed to moisture dirt and other corrosive elements.The corrosion (rust) can become an unwanted resistance.This unwanted resistance can change the way a circuit works.
Page 632 Measuring Voltage Drop---Accumulating Method Connect the DMM across the connector or part of the circuit you want to check.The positive probe of the  DMM should be closer to power and the negative probe closer to ground. Operate the circuit. ...
Page 633 Input - Output Voltage Chart In case of high resistance such as single Terminal No. Items Condition Value [V] strand [V] * Lower than battery voltage approx.8 Switch ON Battery voltage (Example) Switch Switch LOCK Approx.0 Approx.0 Switch ON Battery voltage Approx.0 (inoperative lamp) Lamp Switch LOCK...
Page 634 DIAGNOSTIC TOOL CHECKING SYSTEM FOR NEW ENEERGY VEHICLE Description When the diagnostic tool is connected with the vehicle OBD (A) it will communicate with the control unit  and do the diagnostic tests.OBD（A） 1:Left lower of instrument panel Refer to “Diagnosis Operation Manual of New Energy Vehicle” for more detailed information. ...
Page 635 System Application DTC& Data self-diagnosis System Self-diagnosis communication Configuration reading monitoring result identification diagnosis confirmation Vehicle √ √ √ √ √ √ √ controller Motor √ √ √ √ √ √ controller Battery √ √ √ √ √ √ controller panel √...
Page 636 New Energy Vehicle Diagnostic Tool Data Link Circuit Inspection Procedure If the diagnostic tool cannot diagnose the system properly please check the following items. Symptom Check item Diagnostic tool cannot Check the power supply and ground circuit of diagnostic tool access all systems Power supply and ground circuit of system controller ( for detailed circuit refer to ...
Page 637 Battery Connectors controller between harnesses Front compartment harness Remote intelligen t end Multi-med ia player A/C panel Instrument main harness Diagnostic port Combination instrument Front Vehicle compartment controlle harness Front compartment compress control harness On-board charger Motor controller...
Page 638 Between front compartment control harness and front compartment wiring harness Connector No. Connector Name Connectors between wiring harness Terminal No. Color of wiring Signal Name CANLd CAN High CANHd CAN High Between front compartment wiring harness and instrument CAN Connector No. Connector Name Connectors between wiring harness Terminal No.
Page 639 Connector number Connector name ABS controller Connector type 1-1379208-2 Terminal No. Wire color Signal name AB01 ABS motor power supply positive AB06 Right Front Wheel Speed Sensor ground AB08 Left Front Wheel Speed Sensor ESP1 ESC Switch AB1G ABS motor power ground CANLd CAN low AB05 Right Front Wheel Speed Sensor...
Page 640 AB12x Right Rear Wheel Speed Sensor ground BR03 brake light switch input AB03x Left Rear Wheel Speed Sensor signal wire AB2G controller ground Battery controller（LBC） Connector number Connector name Connector type RT061619PNHEC03 Terminal number Wire color Signal name CANHk CAN_H signal communication CANLk CAN_L signal communication CANGED CAN shielded ground...
Page 641 VC100 Precharge relay control BM17 Fan power ground BM09 LBC power ground CANHa Inner CAN high CANLa Inner CAN low BX08 High voltage interlock signal 1 VC39 High voltage interlock signal 2 BM11 LBC fan power supply BM04a LBC power Remote intelligent terminal (T-Box) Connector number Connector name...
Page 642 Vehicle cotroller(VCU) connector 2 Connector number Connector name VCU Connector 2 Connector type 1473252-1 Terminal number Line color Signal name VC83 Self-holding SSO control signal VC85 Brake pedal sensor 2 ground VC86 Charge indicator 1 (yellow) VC91 Fast charge relay control signal VC92 DCDC enable VC96 Brake pedal sensor 1 power VC98 Brake pedal sensor 2 power...
Page 643 CANH-2 CANL-2 CAMHj CAMLj Motor controller Connector number FC01 Connector name Motor controller Connector type 770680-1 Terminal number Line color Signal name PU01 motor controller 12V power supply positive PU01a motor controller 12V power supply positive VC92 DCDC enable PU11 DCDC failure feedback PU16 motor controller 12V power supply negative CANL CAN_L signal communication...
Page 644 Air conditioning compressor controller Connector number FC02 Connector name compressor controller Connector type 194180010 Terminal No. Wire color Signal name CM06 solenoid valve 1 relay 12 power supply positive CND 12V power supply negative CANHg CAN_H signal communication CANLg CAN_L signal communication AC02 compressor controller ON power CM02 solenoid valve 1 relay 12 power supply positive on-board charger...
Page 645 SC01 12V output signal(activate charger) CANHg CAN_H signal communication CANLg CAN_L signal communication CH03 output 12V wake-up signal CS08 12V power supply negative control panel A Connector number Connector name control panel A Connector type HS'G:172850-2 Terminal No. Wire color Signal name AC02 (AC power supply)
Page 646 ACA14 (new return air motor negative) ACA15 (temperature motor negative) ACA16 (Temperature Motor adjustment) ACA17 (temperature motor positive) CANHz MP5C3 interface Connector number Connector name MP5C3 interface Connector type HG'S:2005071-2 Terminal No. Wire color Signal name BU02bx (reverse signal) MG02 (Microphone control) CANHp CANLp MG06 (MIC input)
Page 647 Terminal No. Wire color Signal name IL01 BB18a IC3G GND EP07 shielded ground VSP07 VSP/-PWM TI01i Back light + TI03e Back light - HI02b Highlight + IC3Ga high beam light- FG02a front fog lamp + FG05b rear fog lights + Turn left at + Turn right at + EP07 speed output...
Page 648 Terminal number Line color Signal name CANLa high voltage battery internal CAN low AI02x airbag diagnosis CANLx-2 fast charge CAN low CANLv vehicle CAN low BR01a Brake signal CANLx-2 fast charge CAN high CANHa high voltage battery internal CAN high DI2G ground DI1G ground CANHv vehicle CAN high...
Page 649 Power Battery System Safety Precaution..................654 Safety Precaution..................654 Instruction....................654 Precautions for the electrical technicians who use medical electronic devices....................... 654 Inspection of key points before the maintenance........ 655 Precautions of auxiliary restraint system "airbag" and "seat belt pretension"....................655 Precautions of removing the 12V battery......
Page 650 Battery Distribute Unit (BDU)..............669 Service switch................... 671 High risk identification................671 System......................673 System Instructions.................. 673 System circuit diagram................677 Operation Precautions................690 Power battery assembly................690 System diagnosis..................691 EV diagnostic tool functions..............691 LBC diagnostic information..............692 Power Battery System................
Page 651 Diagnostic steps..................712 P31BD EEPROM Fault................713 DTC Logic....................713 DiagnosticSteps..................713 P31B2, P315D critical insulation failure, insulation failure....714 DTC Logic....................714 Diagnostic steps..................714 P31AE cell voltage is excessively high........... 717 DTC logic....................717 Diagnostic steps..................717 P31AD cell voltage is excessively low............ 720 DTC logic....................
Page 652 DTC Logic....................733 Diagnostic steps..................733 Malfunction of P31A3 Battery single cell’s critically-low voltage..734 DTC logic....................734 Diagnostic steps..................734 P317D Single cell spray explosion............737 DTC Logic....................737 Diagnostic steps..................737 P317C/P317B static cell’s self-discharge check 100Ω/50Ω....739 DTC Logic....................
Page 653 P3146 Battery cell dynamic voltage difference is excessively high..754 DTC logic......................754 Diagnostic steps....................754 P3139 Mis-closing of balance..............756 DTC Logic..................... 756 Diagnostic steps................... 756 P3138 Mis-opening of balance..............757 DTC Logic..................... 757 Diagnostic steps................... 757 P3137 MISMATCHING ERROR OF CELL VOLTAGE AND TOTAL VOLTAGE.......................
Page 654 P312C temperature sensor fault............766 DTC Logic....................766 Diagnostic steps..................766 Components inspection................ 768 P312B temperature sensor fault............771 DTC Logic....................771 Diagnostic steps..................771 Components inspection................773 P312A current sensor fault............
Page 655 Left-front module assy................802 LBC......................816 Quick-plug pipeline assy................ 825 Gas Tightness Inspection..............863 Left-front module assy................867 Rear module assy................... 867 Disassembly and assembly of battery cell.......... 890 Maintenance data and instructions............897 Power Battery assembly................ 897...
Page 656 Safety Precaution Safety Precaution Instruction Please follow the instructions to ensure safety and proper service. These instructions are not introduced separately in each chapter. Precautions for the electrical technicians who use medical electronic devices Prohibit operation Warning:  Strongly magnetic components have been assembled on this vehicle. ...
Page 657 cardioverter, defibrillator and other medical electronic devices.  If the technician uses the medical device such as cardiac pacemaker, multiplexer, defibrillator and other medical electronic equipment, the electromagnetic wave of the remote intelligent terminal may affect the function of the device. The possible effect of the remote intelligent terminal on the medical electronic devices must be checked by the manufactures of the medical electronic devices .
Page 658 All maintenance can only be operated by the DR authorized distributors. Non-standard maintenance on auxiliary restraint system, including non-standard disassembly and installation, may lead to accidental triggering of the auxiliary restraint system and personal injury. For removal of air bag module, please refer to “SRS AIR BAG”.
Page 659  Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
Page 660 wearing a pacemaker or other medical device is close to these parts, the medical device may be affected by the magnets. Such persons must not perform work on the vehicle. PROHIBITED ITEMS TO CARRY DURING THE WORK Because this vehicle uses components that contain high voltage and powerful magnetism, due not carry any metal products which may cause short circuits, or any magnetic media (cash cards, prepaid cards, etc.) which...
Page 661 Place the warning sign saying "High voltage parts under maintenance, do not touch" Before maintaining the high-pressure parts, please place “High voltage parts under maintenance, do not touch” Warning sign on apparent position to remind other staff. Note： When the part is replaced, or when a label has been damaged, be sure to stamp the new product label on the same position and direction.
Page 662 Preparation work Preparation Special tools Tool name Use description Voltage Balancing Equipment Voltage balance Battery’s lifting table Battery Lifter Grinding machine Polished battery cell Normal tools Tool name Use description Insulated gloves (To ensure the Disassembly and protection of an assembly of the high electricity of 1000V / voltage parts...
Page 663 Disassembly and Insulated shoes assembly of the high voltage parts Disassembly and assembly of the high voltage parts Protection glasses Prevent flares and protect eyes while repairing circuits Disassembly and Insulated caps assembly of the high voltage parts Insulation Tester Measuring voltage and (Megohm meter) insulation resistance...
Page 664 System Instructions Components Components’ positions A. Rear seat foot position (middle part) B. right-front position of battery assembly C. Rear position of battery assembly D. Middle position of battery assembly E. Front position of battery assembly F. Right-front position of battery assembly : The front of the vehicle...
Page 665 Sequence Component Function Power battery Refer to “Power battery assembly”section assembly Service switch; Refer to “Service Switch”Section Left-front Refer to “left-front module assy” section module assy Temperature Refer to “Temperature Sensor”Section sensor 7 Temperature Refer to “Temperature Sensor”Section sensor 1 Temperature Refer to “Temperature Sensor”Section sensor 5...
Page 666 sensor 6 Temperature Refer to “Temperature Sensor”Section sensor 9 Battery Refer to “Battery controller”Section controller Power Battery assembly 1 Power battery assembly is & 3 series circuits. The rear module installed under the vehicle body. assy are made by 11 modules of 42 2 power battery assy includes multiple circuits &...
Page 667 Battery controller（LBC） 1 Battery controller is installed inside of battery assembly; 2.Battery Controller is the core component of a battery management system, which monitor the voltage, current, temperature of battery cells and vehicle information and the high voltage system insulation and report to VCU, VCU control battery to charge and discharge by given information;...
Page 668 Check the battery status Cell voltage Temperature Current High voltage insulation Total voltage Status of monitor board Balance battery voltage Prevent overcharge and over discharge Prevent over-current Prevent thermal out-control Prevent high voltage short circuit Activate vehicle controller unit (VCU) Quick-plug pipeline assy 1 quick-plug pipeline assy is assembled inside power battery assy.
Page 669 To module 16 Left-front module assy Rear module assy Maint enanc To module Right-front module assy To module 22 cathode of To module 17 module To anode of ECU module From module maintenance Anode terminal Cathode module To module 5 terminal...
Page 670 Battery cell 18650 cylindrical battery cell production technology is mature, which is a standard model of the product with the following characteristics: High energy density Low internal resistance and low heat releasing, which can improve battery life and power; Small, flexible installation. Temperature Sensor Battery assembly has eight internal temperature sensor, Battery cell temperature sensor (5 units) is fixed on the surface of the...
Page 671 The resistance value of the temperature sensor decreases while temperature increasing. Battery Distribute Unit (BDU) BDU is mounted on the front of the central power battery assembly, consists with the main contactor, precharge contactors, heating contactors, heat fuse, current sensors and pre-charge resistance. Main contactor control the connection between the power and high-voltage system;...
Page 672 bronze array. As the main contactor is closed and discharging, power battery assembly supplies the electrical energy to every high voltage components in the vehicle;as energy is recycled or battery is charging,the exterior unit will supply electrical energy to power battery assembly.
Page 673 Service switch; Service switch is located in the middle of the surface of the battery assembly, open bottom end of the central passage carpet cover and the service switch can be found and operated. Before the high-voltage parts for inspection and maintenance, disconnect the service switch can ensure the high voltage disconnected.
Page 674 : vehicle’s front end...
Page 675 System System Instructions System framework Battery system Battery cell Battery module temperature Insulation detection Charger Total voltage Current detection Monitor heat out-of-control Control VCU wakeup Input and output signal list Input signal list Transmission unit Signal name Malfunction Diagnosis signal Vehicle controller Vehicle CAN Malfunction clear signal...
Page 676 The lowest temperature position signal Insulation resistance signal Signal of heat out-of-control status Battery assembly current signal Service switch voltage interlock signal Instruction Battery controller functions mainly includes the following: Monitor battery assembly status and report to VCU, prevent over voltage, over discharge, over current and other fault.
Page 677 avoid damage , battery controller detects the voltage of each single cell information and send it to VCU, VCU ensure them work within a reasonable voltage range. Items Control Strategy Operating conditions Control the When the cell voltages reach to the maximum voltag charging current charging voltage, the charging current progressive...
Page 678 Balancing function The balancer can adjust the battery cell to target value, the controller detects the battery cell voltage information, and turn on the balancing switch , forms a discharge circuit, reducing the high-voltage battery cell charging current until its voltage down to the same level with other battery cells.
Page 679 System circuit diagram Maintenance Switch...
Page 680 Black Gray Terminal Terminal Function instruction Function instruction number number...
Page 681 Terminal Function instruction Terminal number Function instruction number...
Page 682 Terminal Function instruction Terminal Function instruction number number...
Page 683 Terminal Function instruction number Terminal Function instruction number Blocking Wakeup signal Constant power...
Page 684 Terminal Function instruction Function instruction Terminal number number...
Page 685 Terminal Function instruction number Terminal Function instruction number Terminal Terminal Function instruction Function instruction number number...
Page 686 Terminal Terminal Function instruction Function instruction number number Terminal Function instruction Terminal number Function instruction number...
Page 687 Terminal Terminal Function instruction Function instruction number number Terminal Function instruction number Terminal Function instruction number...
Page 688 Terminal Terminal Function instruction Function instruction number number Terminal Function instruction number Terminal Function instruction number...
Page 689 Terminal Terminal Function instruction Function instruction number number Terminal Function instruction number Terminal Function instruction number...
Page 690 Terminal Terminal Function instruction Function instruction number number Terminal Function instruction Function instruction number Terminal Terminal Function instruction number number...
Page 691 Wiring harness arrangement...
Page 692 Operation Precautions Power battery assembly To extend battery life, avoid large rate charging; Use the slow charge mode charging; Avoid emergency deceleration or rush acceleration; Avoid direct sunlight and stay away from heat. Storage battery assembly  Horizontal;  Avoid double-stacked; ...
Page 693 System diagnosis EV diagnostic tool functions "EV diagnostic tool -LBC" to be completed by the following functions. The main function Items function Cell voltage inquiry Quick and accurate query cell number and the corresponding voltage Monomer Quick and accurate query temperature number temperature inquiry and its corresponding temperature System self-test...
Page 694 LBC diagnostic information Power Battery System Power Battery System Test value based on the diagnostic tool Caution： Cell voltage of Battery cell number 02-96 and 01 are the same when SOC is 5% and 95%. Temperature range of battery 2/3/4/5/6/7 can be regarded as the same with battery 1.
Page 695 stationary) 25 ℃ READY Ambient 20-40℃ (water inlet’s Temperature 8 (vehicle temperature temperature) stationary) 25 ℃ READY Ambient 20-40℃ (water outlet’s Temperature 9 (vehicle temperature temperature) stationary) 25 ℃ READY Ambient Temperature 20-40℃ (heater (vehicle temperature temperature) stationary) 25 ℃...
Page 696 Security – Failure When VCU detect fault in battery assembly, VCU will protect the battery assembly by controlling the power input and output, for different fault types and failure mode, the process is different. Safety-failure mode Mode A: forbid DC charging Mode B: forbid AC charging Mode C: forbid driving Model D: cut off the high voltage...
Page 697 Battery discharge Battery fault P31A9 current is too large indicator Malfunction of Battery Battery fault P31A8 Charging Over-current indicator Malfunction of total P31A7 voltage severe under-voltage Malfunction of × × Battery fault P31A6 excessively high total indicator voltage Power battery single ×...
Page 698 Insulation check Battery fault P312D system short-circuit indicator SHORT CIRCUIT Battery fault ERROR OF indicator P312C TEMPERATURE SENSOR AND GND SHORT CIRCUIT Battery fault ERROR OF indicator P312B TEMPERATURE SENSOR AND VCC TWO-PATH Battery fault INCONSISTENCE indicator P312A ERROR OF CURRENT SENSOR Alert of battery cell’s P311F...
Page 699 large Battery cell × dynamic voltage P3146 difference is excessively high P3139 Mis-closing of balance Battery fault P3138 Mis-opening of balance indicator MISMATCHING ERROR OF CELL P3137 VOLTAGE AND TOTAL VOLTAGE Loosening of cell Battery fault P3134 voltage acquisition indicator cable BATTERY CELL Battery fault...
Page 700 DTCindex Failure Name P31E4 P31E3 P31E2 P31E1 P31E0 P31DF P31DE P31DD LBC hardware failure P31DC P31DB P31DA P31D9 P31D8 P31D7 P31D6 P31D5 P31D4...
Page 701 P31D3 P31D2 P31D1 P31D0 P31CF P31CE P31CD P31CC P31CB P31CA P31C9 P31BD EEPROM Malfunction P31B2 Critical insulation malfunction Power battery single cell voltage is too P31AE high Power battery single cell voltage is too P31AD high P31AB Battery cell temperature is excessively low P31AA The battery temperature is too high P31A9...
Page 702 Overcurrent Malfunction of total voltage severe P31A7 under-voltage Malfunction of excessively high total P31A6 voltage P31A3 Power battery single cell voltage is too low P317D Single body spray explosion Still single-body self-discharge P317C check_100Ω Still single-body self-discharge P317B check_50Ω P3179 Fire P3177 12V power supply is excessively high...
Page 703 Loosening of cell voltage acquisition P3134 cable BATTERY CELL VOLTAGE INSPECTION P3133 ERROR- AD TRANSFER ERROR No PWM signal change during insulation P312F check P312E. Insulation check system short-circuit GND P312D. Insulation check system short-circuit VCC SHORT CIRCUIT ERROR OF P312C.
Page 704 Harness Diagram Harness Diagram...
Page 705 Terminal Wire Wire Signal name Terminal Wire Wire Signal name VC83 Self-holding SSO control CANHk CAN-H signal VC85 Brake pedal sensor 2 CANHk CAN-H signal VC86 charging indicator 1 CANGED shielded VC91 Fast charge relay control 0.85 BM04 High level VC92 DCDC enable 1.25 VC107 B+ relay control...
Page 706 Basic check Diagnostic and maintenance workflow Work process Detailed flow Obtain symptom information Use the Diagnostic Worksheet to ask the customer for details about the symptoms (status and environment at the time of the accident / failure). (Please refer to the following. "Diagnostic working list") >>...
Page 707 Worksheet" is helpful in verifying the failure. Verify the relevance of symptoms and conditions that trigger the failure >> Go to step 5 Confirm symptoms Try to diagnose the symptoms described by the customer. Also check the normal operation and the "safety - failure" mode sheet related symptoms relevant to “safety-failure”...
Page 708 Is there symptomatic description? Yes >> Go to step 7. No>> Using diagnostic tools to monitor the data of relevant sensors. Check the defective parts by means of the diagnostic procedure Check the defective parts by means of the diagnostic procedure Is there a faulty part? Yes >>...
Page 709 Diagnostic working list Instruction Error information of charging system can be acquired by understanding working conditions correctly. Generally, customer has his own judging standard on the failure. Therefore, by consulting user’s description on failure or problem, technicians can understand failure better. All error information can be classified by applying diagnostic working list.
Page 710 □No effect □City □Highway □Suburbs Road □Flat road □Collision □When turning (left / right) Conditions □Other □No effect Gear Mode □N Gear □R Gear □D Gear □No effect □Switch ON → OFF ON→OFF □Switch OFF → ON OFF→ON □READY □Driving □Slow down Travel Mode □Before parking □After parking...
Page 711 Replace the battery assembly follow-up work Description When the battery assembly is replaced, VCU battery status information must be updated.
Page 712 Battery cell charge equalization Instruction When a battery cell is not normal, we need to replace the battery pack. After the replacement, we need to charge the new cell to balance it, and make it equal with other battery cells. Work Steps Check the target voltage value Use diagnostic tool to read the battery cell voltage.
Page 713 .Check the module voltage Removed the module from the balancer. Use a multimeter to check the voltage and verify. Target voltage ± 10mV. Go to Step 6. Check the cell voltage After the battery assembly is installed, check the replaced cell voltage value. Voltage differential to target value: ±...
Page 714 DTC / Circuit Diagnosis P31E4 to P31C9 LBC hardware failure DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons number conditions for failure Failure happens P31E4 to LBC hardware LB C hardware  LBC P31C9 failure controller DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the key to "ON"...
Page 715 P31BD EEPROM Fault DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons number conditions for failure Failure occurs when EEPROM P31BD recording or reading  LBC Malfunction EEPROM DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the key to "ON" , wait for more than 2 seconds. 2.
Page 716 P31B2, P315D critical insulation failure, insulation failure DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons number conditions for failure Severely low insulation  Wiring harness with Severe resistance value high voltage P31B2 Insulation between high voltage ...
Page 717  Before the maintenance switch is disconnected, the key must be placed in the "LOCK" or unplugged.  Check or maintain the high pressure system before disconnecting the service switch. And no one is allowed to turn off the maintenance switch during the inspection and maintenance process.
Page 718 YES >> Replace LBC, refer to the "Dismantling and assembling of battery assembly-LBC" NO >> Refer to reference document to handle the failures, if it is serious insulation failure, go to step 4, otherwise the detection end. Removal of Power Battery Assembly 1.
Page 719 P31AE cell voltage is excessively high DTC logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure  VCU Power battery  Battery cell cell voltage single cell  LBC P31AE exceeds the allowable voltage is too ...
Page 720 starting the high voltage system operation, be sure to wear insulation protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.
Page 721 installation of Battery assembly-Module layout ", refer to the "battery assembly dismantling and assembling -modular layout." 4. Dismantle the module assembly, identify abnormal flexible connection on the cell.
Page 722 P31AD cell voltage is excessively low DTC logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure Cell voltage is lower Voltage than allowed  Battery cell P31AD battery cell work voltage  LBC too low ...
Page 723 Yes >>charge the battery group by recovering programs No, please replace abnormal battery cell. Please refer to “disassembly and installment of battery cell”...
Page 724 P31AB BATTERY TEMPERATURE TOO LOW DTC Logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure Battery cell  Cold weather Power battery temperature is  Long time parking P31AB temperature too low excessively  Temperature sensor signal failure DTC diagnostic procedures...
Page 725 Whether detected other DTC? NO >> Replace LBC, refer to the "Dismantling and assembling of battery assembly-LBC".
Page 726 P31AA BATTERY TEMPERATURE TOO HIGH DTC Logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure  Drive motor or VCU  Battery cell  Fan battery Power battery  Temperature Sensor P31AA temperature temperature ...
Page 727 Use the "EV diagnostic tool" inquiry LBC diagnostic service information 1.Turn the key to ON. 2. Check the diagnostic results. Whether detected other DTC? Detected P3179 >> Go to "P3179- diagnostic process." NO >> Replace LBC, refer to the "Dismantling and assembling of battery assembly-LBC".
Page 728 P31A9 serious battery discharge over-currentfault DTC Logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure Power battery Battery  Current Sensors discharge current discharge  Wiring harness with P31A9 exceeds current high voltage normal operating excessive ...
Page 729 protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching. ...
Page 730 Yes >> Replace the vehicle high voltage cable. No >> Go to step 4. Remove the battery assembly to check whether the power battery assembly short-circuited 1. Turn the key to "LOCK" or pull out. 2. Remove the battery assembly, refer to "Removal and installation of battery assembly-Battery assembly".
Page 731 Malfunction of Battery Charging critical over-current DTC Logic DTC diagnostic logic diagnostic The possible reasons for Failure Name number conditions failure Critical Over-current when over-current  Battery cell Charging P31A8 during  Current Sensors discharging braking battery’s  LBC energy recovery charging DTC diagnostic procedures Perform DTC confirmation procedure...
Page 732 protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching. ...
Page 733 Yes >> Replace the vehicle high voltage cable. No >> Go to step 4. Remove the battery assembly to check whether the power battery assembly short-circuited 1. Turn the key to "LOCK" or pull out. 2. Remove the battery assembly, refer to "Removal and installation of battery assembly-Battery assembly".
Page 734 Malfunction of P31A7 total voltage’s critical under-voltage DTC Logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure total voltage is excessively low, Total pressure  LBC P31A7 outside under-voltage  User habits normal voltage range DTC diagnostic procedures Perform DTC confirmation procedure...
Page 735 Malfunction of P31A6 total voltage’s critical over-voltage DTC Logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure total During charging, the voltage total voltage  VCU P31A6 excessively excessively high, out  LBC high of normal range DTC diagnostic procedures Perform DTC confirmation procedure...
Page 736 Malfunction of P31A3 Battery single cell’s critically-low voltage DTC logic DTC diagnostic logic Failure DTC diagnostic The possible reasons for number Name conditions failure Power Battery cell voltage is  Long time parking battery too low to reach the  Battery cell P31A3 single cell...
Page 737 switch during the inspection and maintenance process. Before starting the high voltage system operation, be sure to wear insulation protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.
Page 738 1. Turn the key to "LOCK" or pull out. 2. Remove the battery assembly, refer to "Removal and installation of battery assembly-Battery assembly". 3. Search for the cell position in the battery module according to the battery cell number, refer to "Removal and installation of Battery assembly-Module layout ", refer to the "battery assembly dismantling and assembling -modular layout."...
Page 739 P317D Single cell spray explosion DTC Logic DTC diagnostic logic The possible reasons DTC number Failure Name diagnostic for failure conditions detect Single body thermal P317D  Battery cell spray explosion instability failure DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the key to "ON"...
Page 740 protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching. ...
Page 741 P317C/P317B static cell’s self-discharge check 100Ω/50Ω DTC Logic DTC diagnostic logic The possible reasons DTC number Failure Name diagnostic for failure conditions Still single-body Single cell’s P317C self-discharge  Battery cell self-discharge check_100Ω Still single-body Single cell’s P317B self-discharge  Battery cell self-discharge check_50Ω...
Page 742 switch during the inspection and maintenance process. Before starting the high voltage system operation, be sure to wear insulation protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.
Page 743 P3179 fire DTC Logic DTC diagnostic logic The possible reasons DTC number Failure Name diagnostic for failure conditions Fires on single P3179 Fire cell is detected  Battery cell by LBC DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the key to "ON" , wait for more than 2 seconds. 2.
Page 744  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.  When the maintenance switch is disconnected, the key is forbidden to "ON"...
Page 745 P3177 12V lead-acid cell voltage is excessive DTC Logic DTC diagnostic logic The possible reasons DTC number Failure Name diagnostic for failure conditions P3177 12V lead-acid lead-acid cell P3177 cell voltage is  DC/DC voltage below 18V excessive DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the key to "ON"...
Page 746 shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.  When the maintenance switch is disconnected, the key is forbidden to "ON" or "START".
Page 747 P3176 12V lead-acid cell voltage is excessively low DTC Logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure P3176  12V battery battery  Harness、connector lead-acid cell P3176 voltage is below voltage  DC/DC excessively low ...
Page 748  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.  When the maintenance switch is disconnected, the key is forbidden to "ON"...
Page 749 Check harness for failure. Multimeter positive lead Multimeter negative lead Voltage value KEY signal Terminal Connector number Ground Approximate 12V LBC Power Supply Signal Terminal Connector number Ground Check if the result is normal. YES >> Replace LBC, refer to the "Dismantling and assembling of battery assembly-LBC".
Page 750 P316E HIGH VOLTAGE INTERLOCKING ERROR DTC logic DTC diagnostic logic Failure DTC diagnostic The possible reasons for number Name conditions failure The high High voltage  Service switch; voltage interlock signal on P316E  Harness interlock the service switch is ...
Page 751 Removal of Power Battery Assembly 1. Turn the key to "LOCK" or pull out. 2. Remove the battery assembly, refer to "Removal and installation of battery assembly-Battery assembly". Check the conduction of the high voltage interlock cable between the service switch pedestal to the battery controller. 1.Use the multimeter to check the conduction of the high voltage interlock cable between the service switch pedestal to the battery controller.
Page 752 P3160 unbalanced battery temperature fault DTC Logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure Power battery LBC detected  Temperature sensor P3160 temperature is battery temperature  Fan imbalanced is not balanced  User habits DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the key to "ON"...
Page 753 P3147 CELL STATIC DIFFIRENTIAL PRESSURE TOO LARGE DTC logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure  LBC  High voltage Static differential LBC detected the connecting cell is too static differential of P3147 copper bar cell is too large...
Page 754 inspection and maintenance process. Before starting the high voltage system operation, be sure to wear insulation protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.
Page 755 The corresponding Corresponding terminal terminal of prior cell Consistent（±10mV） of cell number. number. Check if the result is normal. YES >> Replace LBC, refer to the "Dismantling and assembling of battery assembly-LBC". NO >> Replace battery cell, refer to the "dismantling and assembling the battery cell."...
Page 756 P3146 Battery cell dynamic voltage difference is excessively high DTC logic DTC diagnostic logic DTC number Failure Name DTC diagnostic The possible conditions reasons for failure  LBC  High voltage Battery cell LBC detected connecting dynamic voltage dynamic battery P3146 copper bar difference is...
Page 757 assembly-LBC". Use the "EV diagnostic tool 'Check the battery cell information 1. Check the abnormal battery cell voltage and corresponding number. Removal of Power Battery Assembly 1. Turn the key to "LOCK" or pull out. 2. Remove the battery assembly, refer to "Removal and installation of battery assembly-Battery assembly".
Page 758 P3139 Mis-closing of balance DTC Logic DTC diagnostic logic DTC number Failure Name DTC diagnostic The possible reasons conditions for failure Balanced Mis-closing of P3139 Control Circuit  LBC balance Failure DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the key to "ON" , wait for more than 10 seconds. 2.
Page 759 P3138 Mis-opening of balance DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons number conditions for failure Mis-opening of Balanced Control P3138  LBC balance Circuit Failure DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the key to "ON" , wait for more than 10 seconds. 2.
Page 760 3.Search for the cell position in the battery module according to the battery cell number, refer to "Removal and installation of Battery assembly-Module layout ", refer to the "battery assembly dismantling and assembling -modular layout." 4. Dismantling the module assembly, identify abnormal monomer and replacement, refer to the "dismantling and assembling the battery cell."...
Page 761 P3137 MISMATCHING ERROR OF CELL VOLTAGE AND TOTAL VOLTAGE DTC logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons number conditions for failure Mismatching LBC detected there is error of cell obvious deviation P3137  LBC voltage and between cell voltage total voltage and total voltage...
Page 762 P3134 LOSSENING ERROR OF CELL VOLTAGE ACQUISITION CABLE DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons number conditions for failure Loosening error  LBC Poor contact of LBC P3134 of cell voltage  Voltage cell acquisition cable acquisition cable acquisition cable DTC diagnostic procedures...
Page 763 protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching. ...
Page 764 P3133CELL VOLTAGE INSPECTION ERROR- AD TRANSFER ERROR DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons for number conditions failure Voltage LBC cell voltage inspection detected there is P3133  LBC error-AD transfer error during AD error transferring DTC diagnostic procedures Perform DTC confirmation procedure...
Page 765 P312F Insulation Detection Circuit DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons number conditions for failure The amplitude of LBC Malfunction of collector’s insulation P312F Insulation  LBC inspection voltage value inspection remains unchanged DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the key to "ON"...
Page 766 P312E Insulation Detection Fault DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons for number conditions failure LBC collector’s Malfunction of insulation inspection P312E Insulation  LBC voltage value is near inspection DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the power switch ON and wait for 5min or more.
Page 767 P312D Insulation Detection Fault DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons number conditions for failure LBC collector’s Malfunction of insulation inspection P312D Insulation  LBC voltage value is near 5V inspection power voltage. DTC diagnostic procedures Perform DTC confirmation procedure 1.Turn the power switch ON and wait for 5min or more.
Page 768 P312C temperature sensor fault DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons for number conditions failure LBC check the  Wire harness voltage value of Temperature connector P312C battery sensor failure  Temperature sensor temperature sensor ...
Page 769 protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching. ...
Page 770 No >> replace the abnormal temperature sensor. Components inspection Check the temperature sensor 1.Remove the temperature sensor. 2.Use multimeter to measure the resistance value in two ends of abnormal temperature sensor. Multimeter negative Multimeter positive lead Resistance value (Ω) lead Terminal Terminal Connector...
Page 771 Multimeter negative Multimeter positive lead Resistance value (Ω) lead Terminal Terminal Connector Connector Refer to temperature number number table Multimeter negative Multimeter positive lead Resistance value (Ω) lead Terminal Terminal Connector Connector Refer to temperature number number table Multimeter negative Multimeter positive lead Resistance value (Ω) lead...
Page 772 25℃ 45℃ 4.9K Check if the result is normal. Yes>> inspection end. No >> replace the abnormal temperature sensor.
Page 773 P312B temperature sensor fault DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons number conditions for failure LBC collector’s  Wire harness inspection shows the connector Temperature voltage of battery P312B  Temperature sensor failure temperature sensor sensor is near the voltage ...
Page 774 starting the high voltage system operation, be sure to wear insulation protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.
Page 775 Yes>> GO TO 5. No >> replace the abnormal temperature sensor. Components inspection Check the temperature sensor 1.Remove the temperature sensor. 2.Use multimeter to measure the resistance value in two ends of abnormal temperature sensor. Multimeter negative Multimeter positive lead Resistance value (Ω) lead Terminal...
Page 776 number number table Multimeter negative Multimeter positive lead Resistance value (Ω) lead Terminal Terminal Connector Connector Refer to temperature number number table Multimeter negative Multimeter positive lead Resistance value (Ω) lead Terminal Terminal Connector Connector Refer to temperature number number table Multimeter negative Multimeter positive lead...
Page 777 0℃ 25℃ 45℃ 4.9K Check if the result is normal. Yes>> inspection end. No >> replace the abnormal temperature sensor.
Page 778 P312A current sensor fault DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons for number conditions failure Deviation of measuring value at  Wire harness Current Sensor connector P312A two inspection paths fault  Current Sensors of current ...
Page 779 inspection and maintenance process. Before starting the high voltage system operation, be sure to wear insulation protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.
Page 780 Yes >> Go to step 4 No >>Repair the harness or connector. Replace LBC 1.Replace the LBC; please refer to “disassembly and assembly of battery pack-LBC”. Use the "EV diagnostic tool" inquiry LBC diagnostic service information 1.Turn the power switch ON and wait for 10s or more. 2.Read LBC temperature information.
Page 781 P3129 current sensor fault DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons number conditions for failure Voltage of current  Wire harness Current Sensor sensor is abnormal, connector P3129. fault which is lower than  Current Sensors normal value.
Page 782  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.  When the maintenance switch is disconnected, the key is forbidden to "ON" or "START".
Page 783 Replace LBC 1.Replace the LBC; please refer to “disassembly and assembly of battery pack-LBC”. Use the "EV diagnostic tool" inquiry LBC diagnostic service information 1.Turn the power switch ON and wait for 10s or more. 2.Read LBC temperature information. Does the error still exist? Yes>>...
Page 784 P3128 current sensorfault DTC Logic DTC diagnostic logic Failure Name DTC diagnostic The possible reasons for number conditions failure Voltage of current  Wire harness Current Sensor sensor is abnormal, connector P3128. fault which is higher than  Current Sensors normal value.
Page 785  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.  When the maintenance switch is disconnected, the key is forbidden to "ON" or "START".
Page 786 Replace LBC 1.Replace the LBC; please refer to “disassembly and assembly of battery pack-LBC”. Use the "EV diagnostic tool" inquiry LBC diagnostic service information 1.Turn the power switch ON and wait for 10s or more. 2.Read LBC temperature information. Does the error still exist? Yes>>...
Page 787 P311F CELL STATIC DIFFIRENTIAL PRESSURE TOO LARGE DTC logic DTC diagnostic logic DTC diagnostic The possible reasons for Failure Name number conditions failure  LBC  High voltage Alert of battery cell’s LBC detected the connecting P311F. dynamic voltage static voltage copper bar difference...
Page 788 switch during the inspection and maintenance process. Before starting the high voltage system operation, be sure to wear insulation protection equipment, including gloves, shoes and glasses.  Make sure other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching.
Page 789 of LBC. The corresponding Corresponding terminal terminal of prior cell Consistent（±10mV） of cell number. number. Check if the result is normal. YES >> Replace LBC, refer to the "Dismantling and assembling of battery assembly-LBC". NO >> Replace battery cell, refer to the "dismantling and assembling the battery cell."...
Page 790 Powerbattery Assembly’sDisassembly and assembly Power battery assembly Exploded view 1. Power cell assy 2.iso-electrical connection bonding 3. Cell anti-collision beam 4. Power cell assy’s lower guard plate I 5. Plastic split cotter pin 6. Power cell assy's lower guard plate II 7.
Page 791 Power cell assy’s disassemblyand assembly Warning:  Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
Page 792 Open the front hatch, and get the coolants according to the “maintenance routine” for air conditioner system. After lifting the vehicle, remove the anti-collision beam, lower guard plateⅠand Ⅱ. Pull out the high voltage cable connector ① of battery pack. Warning: To prevent hazards during disassembly, please be sure to wear protective gear.
Page 793 Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Remove the clamp ① between cell’s water inlet&outlet aluminium pedestal and cell’s water-pipe connecting pipe Warning: · To prevent hazards during disassembly, please be sure to wear...
Page 794 Remove the mounting bolts of battery pack as the picture showed.And remove the A Bolt first. : The front of the vehicle Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Warning: DO NOT remove four C Bolts in the above picture. Put the tray on the surface of lifting device.
Page 795 Lift up the tray to the lower surface of battery and make them slightly contacted with each other.
Page 796 Caution： ·Use transporting fixing bolts to fix the tray and battery pack. Remove the mounting bolts of battery pack as the picture showed. And remove the B Bolt first. : The front of the vehicle Warning: To prevent hazards during disassembly, please be sure to wear protective gear.
Page 797 : The front of the vehicle Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 11 Lower down the tray and remove the battery pack ① from the vehicle. Warning: To prevent hazards during disassembly, please be sure to wear protective gear.
Page 798 Installation of Power battery assembly When replace a new battery pack, please refer to the following steps. Write down the replacing date on the sealed package of new battery pack. Divide the sealing strip with tracking date into two pieces, and stick on the battery pack and “Battery Replace Record Sheet”...
Page 799 Warning: To prevent hazards during assembly, please be sure to wear protective gear. Mount fixing C bolts and remove the tray. : The front of the vehicle Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Remove the alignment pins from the vehicle body.
Page 800 Warning: To prevent hazards during assembly, please be sure to wear protective gear. Mount fixing B Bolt of battery pack. : The front of the vehicle Warning: To prevent hazards during assembly, please be sure to wear protective gear. Mount fixing A Bolt of battery pack. : The front of the vehicle...
Page 801 Warning: To prevent hazards during assembly, please be sure to wear protective gear. Rotate metal sleeve clockwise and insert the sleeve into low-voltage harness connector. Stop the insertion when the clicking sound appears. Assemble the clamp ① between water-pipe assy’s flange and external pipelines.
Page 802 protective gear. 11 Mount the lower protecting base Ⅰand Ⅱ of battery. 12 Install cell’s anti-collision beam. 13 Lower down the vehicle and fill the coolants according to the “maintenance routine” for air conditioner system. 14 Install the service switch Refer to "Overview - How to disconnect high voltage".
Page 803 Removal and Installation of Power Battery Assembly Power battery assembly Explosive view Power battery assembly...
Page 804 1. Service switch plug 2. Service switch socket 3. Upper housing assy 4. Sealer pad 5.LBC 6. LBC bracket 7. Right-front module assy 8.BDU upper housing 9. BDU pedestal 10. High-voltage harness connector 11. Sealer pad of high-voltage connector 12.sealer pad of low-voltage connector 13.
Page 805 Right-26-series high-voltage guard cover I 2.copper bar of flexible connection between modules 3.Right-26-series high-voltage guard cover 4.right fixing parts of right-26-series 5.monitoring plate of thermal Ⅱ run-away 6.module’s pressing plate 7.pull rod of right-26-series 8. 5-Series cell module 9.left fixing parts of right-26-series 10.3-series cell module ：N·m (kg-m,ft-lb) Module Layout...
Page 806 Rear module assy 1. 44-Series outer cover plate I 2. 44-Series right fixing parts 3. 44-Series high-voltage guard cover I 4. 44-Series high-voltage guard plate II 5.copper bar of flexible connection betwenn modules 6. 4-Series cell module 7. 44-Series outer cover board II 8. 44-Series pull rod 9. 44-Series end plate 10.
Page 807 Module Layout...
Page 808 BDU Disassembly and assembly Warning:  Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
Page 809 the intrusion of rain, snow, sand, and other substances. The environment must be ventilated and prevent the entry of sweat during work, and also prevent condensation from occurring as a result of high temperature and humidity. No entry of foreign materials In addition to being indoors, the environment must not permit the entry during disassembly work of metal powders, oil, or foreign substances resulting from causes such as servicing of...
Page 810 workers do not enter the work space. BDU Removal Clean the dust and pollution on the surface of battery pack. Remove the fixing reinforcing plate ① of service switch. Warning: To prevent hazards during disassembly, please be sure to wear protective gear.
Page 811 Plug out the BDU low voltage harness connector and remove the upper housing of BDU ①. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. Remove high voltage connecting nut of BDU front end, and then cut off the flexible connection ①...
Page 812 Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. Remove high voltage connecting nut of BDU rear end, and then cut off the flexible connection ① of high voltage input. Danger: Please operate insulating protection of high voltage connection immediately after removing the high voltage connection.
Page 813 use insulating tools. Remove the BDU fixing bolts ①, and remove the BDU foundation support. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. Assembly of BDU 1.Mount the BDU foundation support and fix it on lower housing with bolts. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and...
Page 814 To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. 3 Mount the high voltage connecting nut of BDU front end. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools.
Page 815 5. Install the maintenance switch Warning: To prevent hazards during assembly, please be sure to wear protective gear. BDU: check Gas Tightness Inspection 1.Remove a vent valve, and then mount the gas nozzle chuck (A). Warning: To prevent hazards during inspection, please be sure to wear protective gear.
Page 816 Caution： Carefully operate the gas-pressure meter to prevent the falling down. 3. Install the maintenance switch Danger: There still will be risk of shock even you touch the high voltage components with protective gear.
Page 817 Warning: To prevent hazards during inspection, please be sure to wear protective gear. 5.Add 1.6kPa air pressure into the battery to do the air tight test. Please continue for about 1 minute. Caution： Slowly operate the inflator during the inflating. Do not let the air pressure exceed 1.6kPa.
Page 818 Confirm Power Battery System State Install power battery assembly Connect the high voltage and low voltage connections between power battery assembly and the vehicle. Turn off the service switch; Connect the 12V battery negative cable. Turn the key to “START” gear and confirm that the vehicle works normal. LBCDisassembly and assembly Warning: ...
Page 819  When the maintenance switch is disconnected, the key is forbidden to turn to "ON" or "START". Work Environment for Internal Disassembly and Assembly of Power Battery Assembly Must be an indoor environment The work environment must be able to be isolated from the outside by shutters or other means to prevent workers do not enter the work space.
Page 820 Disassembly of LBC 1.Remove the battery pack, and please refer to “Disassembly and Assembly” of power battery assembly. 2.Remove the fixing reinforcing plate ① Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 3. Remove the fixing bolts A and nuts B according to the sequence, then remove the upper housing of power battery pack.
Page 821 To prevent hazards during disassembly, please be sure to wear protective gear. 4. Disconnect the LBC low-voltage harness connector ①. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. 5. Removal of LBC Set Bolt①.
Page 822 LBC Assembly The working flow of LBC assembly is opposite to the flow of disassembly. 1 Mount the LBC fixing bolts. Warning: To prevent hazards during assembly, please be sure to wear protective gear. 2 Mount the LBC low voltage harness connector. 3 Tighten the fixing bolts and nuts according to the sequence in the following picture, then mount the upper housing of power battery pack.
Page 823 To prevent hazards during assembly, please be sure to wear protective gear. 5. Install the maintenance switch Warning: To prevent hazards during assembly, please be sure to wear protective gear. Gas Tightness Inspection 1.Remove a vent valve, and then mount the gas nozzle chuck (A). Warning: To prevent hazards during inspection, please be sure to wear protective gear.
Page 824 Warning: To prevent hazards during inspection, please be sure to wear protective gear. Caution： Carefully operate the gas-pressure meter to prevent the falling down. 3. Install the maintenance switch Danger: There still will be risk of shock even you touch the high voltage components with protective gear.
Page 825 4.Use polyethylene tape (A) or other means to seal another air vent, in order to prevent the air getting inside Warning: To prevent hazards during inspection, please be sure to wear protective gear. 5.Add 1.6kPa air pressure into the battery to do the air tight test. Please continue for about 1 minute.
Page 826 Equipotential test After installation of power battery assembly, use multimeter to measure the resistance value between housing(A) and body（B）. Standard : ≤0.1 Ω Danger: To prevent hazards during inspection, please be sure to wear protective gear. Confirm Power Battery System State Install power battery assembly Connect the high voltage and low voltage connections between power battery assembly and the vehicle.
Page 827 Quick-plug pipeline assy Disassembly and assembly of quick-plug pipeilne Warning:  Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly.
Page 828 the intrusion of rain, snow, sand, and other substances. The environment must be ventilated and prevent the entry of sweat during work, and also prevent condensation from occurring as a result of high temperature and humidity. No entry of foreign materials In addition to being indoors, the environment must not permit the entry during disassembly work of metal powders, oil, or foreign substances resulting from causes such as servicing of...
Page 829 Disassembly of quick-plug pipeline assy 1 Clean the dust and pollutants on the surface of power battery. 2.Remove the fixing reinforcing plate ① of service switch. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Remove the fixing bolts A and nuts B according to the sequence, then remove the upper housing of power battery pack.
Page 830 protective gear. 4 Plug out the BDU low-voltage harness connector and remove the upper housing of BDU ①. 5 Remove high-voltage connecting nut on BDU’s front end, and then cut off the flexible connection ① of high-voltage output. Danger: To prevent shock hazards during, please be sure to wear insulative protection gear.
Page 831 use insulating tools. 6 Remove the guard cover ① of high-voltage’s flexible connection on BDU’s rear-end. Danger: Please operate insulating protection of high voltage connection immediately after removing the high voltage connection. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools.
Page 832 Danger: Please operate insulating protection of high voltage connection immediately after removing the high voltage connection. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. 8 Remove the BDU fixing bolts ①, and dismantle the BDU pedestal support. Warning:...
Page 833 To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. 9 disconnect all second locking device of quick-plug connector, then dismantle the branch pipe ① of water-outlet quick-plug pipeline on module’s front end. 10 disconnect main pipe ①...
Page 834 11 disconnect the connector and dismantle the main pipe ① of water-outlet quick-plug pipeline 12 disconnect all second locking device of quick-plug connector, then dismantle the branch pipe ② of water-outlet quick-plug pipeline. 13 Remove the high-voltage guard cover ①. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and...
Page 835 use insulating tools. 14 dismantle the mounting bolt ① and ② of service switch’s bracket. 15 disassemble the mounting bolt ① of service switch, and dismantle the mounting bracket ② of service switch 16 disassemble the mounting bolt ① of service switch’s flexible connection, and dismantle the service switch assy.
Page 836 Danger: Please operate insulating protection of high voltage connection immediately after removing the high voltage connection. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. 17 dismantle the high-voltage connecting guard plate ① and high-voltage guard cover ②.
Page 837 immediately after removing the high voltage connection. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. 18 dismantle the mounting bracket ① of module high-voltage flexible connection, then disassemble the flexible connection ②. Danger: Please operate insulating protection of high voltage connection immediately after removing the high voltage connection.
Page 838 Danger: Please operate insulating protection of high voltage connection immediately after removing the high voltage connection. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. 20 dismantle the mounting bracket ① of module high-voltage flexible connection, then disassemble the flexible connection ②.
Page 839 Danger: Please operate insulating protection of high voltage connection immediately after removing the high voltage connection. Warning: To prevent hazards during disassembly, please be sure to wear insulating protective gear and use insulating tools. 21 dismantle the quick-plug connector ① of water-inlet quick-plug pipeline, then disconnect branch pipe ②...
Page 840 Assembly of quick-plug pipeline assy Pre-insert branch pipe ① into module's liquid-cooling flat tube. Warning: To prevent hazards during assembly, please be sure to wear protective gear. Assemble rubber part ① on the main pipe of water-outlet quick-plug pipeline, then mount the pipeline assy on the pipe clamp. Warning: To prevent hazards during assembly, please be sure to wear protective gear.
Page 841 Note： During each disassembly/assembly process, ensure the assembling is firm and tight (the clip should be clamped into snap neck). Warning: To prevent hazards during assembly, please be sure to wear protective gear. assemble the branch pipe ① of water-outlet quick-plug pipeline assy, then lock the locking device.
Page 842 6 connect the branch pipe ①, and main pipe ② of water-outlet quick-plug pipeline assy. Then assemble the branch pipe ① and lock the locking device. 7 assemble the branch pipe ① of front module’s water-inlet quick-plug pipeline. 8 assemble the rubber part ① on the main pipe of water-inlet quick-plug pipeline.
Page 843 9 assemble the branch pipe ① of rear module's water-inlet quick-plug pipeline assy 10 assemble the branch pipe ① and main pipe ② of rear module’s water-inlet quick-plug pipeline assy. Air tightness check of pipeline assy 1 assemble barometer (A).
Page 844 Warning: To prevent hazards during inspection, please be sure to wear protective gear. Caution： Carefully operate the gas-pressure meter to prevent the falling down. 2. Inflate quick-plug pipeline assy with air until the air pressure reaches to 250KPa. Maintain the pressure for 300 seconds, and the air-leak amount should be ≤2.73mL/min.
Page 845 To prevent hazards during inspection, please be sure to wear protective gear. Gas Tightness Inspection 1 Remove a vent valve, and then mount the gas nozzle chuck (A). Warning: To prevent hazards during inspection, please be sure to wear protective gear. 2.Mount gas pressure meter (A).
Page 846 protective gear. Caution： Carefully operate the gas-pressure meter to prevent the falling down. 3. Install the maintenance switch Danger: There still will be risk of shock even you touch the high voltage components with protective gear. 4.Use polyethylene tape (A) or other means to seal another air vent, in order to prevent the air getting inside...
Page 847 Warning: To prevent hazards during inspection, please be sure to wear protective gear. 5.Add 1.6kPa air pressure into the battery to do the air tight test. Please continue for about 1 minute. Caution： Slowly operate the inflator during the inflating. Do not let the air pressure exceed 1.6kPa.
Page 848 Danger: To prevent hazards during inspection, please be sure to wear protective gear. Confirm Power Battery System State Install power battery assembly Connect the high voltage and low voltage connections between power battery assembly and the vehicle. Turn off the service switch; Connect the 12V battery negative cable.
Page 849 Left-front module assy Left-front module assy’s disassemble andassembly Warning:  Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly.
Page 850 the intrusion of rain, snow, sand, and other substances. The environment must be ventilated and prevent the entry of sweat during work, and also prevent condensation from occurring as a result of high temperature and humidity. No entry of foreign materials In addition to being indoors, the environment must not permit the entry during disassembly work of metal powders, oil, or foreign substances resulting from causes such as servicing of...
Page 851 Disassembly of left-front module assy Clean the dust and pollutants on the surface of power battery. Remove the fixing reinforcing plate ① of service switch. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Please dismantle the bolt ① and nut ② by following instructions on the picture below, then dismantle the upper housing of power battery assy.
Page 852 To prevent hazards during disassembly, please be sure to wear protective gear. Disassemble BDU. Please refer to “disassembly and assembly of BDU” for details. Danger: There still will be risk of shock even you touch the high voltage components with protective gear.
Page 853 Warning: To prevent electric shock, please use insulated tape to wrap up the terminal of high-voltage connection after disassembly. Disassemble the flexible connection ① between left-front module assy and rear module assy. Danger: There still will be risk of shock even you touch the high voltage components with protective gear.
Page 854 Danger: There still will be risk of shock even you touch the high voltage components with protective gear. Warning: To prevent electric shock, please use insulated tape to wrap up the terminal of high-voltage connection after disassembly. Plug out the connector A of LBC low-voltage harness. Warning: To prevent hazards during disassembly, please be sure to wear protective gear.
Page 855 Disassemble the upper cover ① of harness fixing plate, then remove lower cover ② and low-voltage harness ③. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 10 Disassemble the upper cover ① of harness fixing plate, then remove low-voltage harness connector ②...
Page 856 To prevent hazards during disassembly, please be sure to wear protective gear. 11 Disassemble fixing bolt ① of service switch bracket, and remove the bracket ② of service switch’s flexible connection. Warning: To prevent hazards during disassembly, please be sure to wear protective gear.
Page 857 To prevent hazards during disassembly, please be sure to wear protective gear. 13 Disassemble fixing bolt ① of left-front module’s metal plate. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 14 Disassemble the fixing nut ① of left-front module assy.
Page 858 Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 15 Remove left-front module assy, and put the module assy on workbench. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Make sure that a piece of insulation paper has been placed on the working table.
Page 859 16 Disassemble the high-voltage connection of left-front module assy by following the steps below. Disassemble the guard cover ① of left-front module assy. Danger: There still will be risk of shock even you touch the high voltage components with protective gear. Perform the operation alone.
Page 860 Danger: There still will be risk of shock even you touch the high voltage components with protective gear. Perform the operation alone. Operations by multiple people may cause electric shock. Disassemble the fixing nut ① of left-front module assy, then remove the fixing part ②...
Page 861 Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Installation of left-front module assy Hint The assembling procedures of left-front module assy is opposite to the disassembling procedures. 1. Assemble left-front battery module assy according to position shown in picture, then tighten the long pull-rod on module’s front and rear end.
Page 862 Danger: To prevent shock hazards during, please be sure to wear insulative protection gear. Warning: To prevent shock hazards, be sure to wrap the connection terminal with insulated tape, so as to prevent electric shock during assembling process. 2. Assemble side metal plate ① of left-front battery module.
Page 863 Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 3. Assemble the fixing parts on left-front module’s two sides○ 1 . Warning: To prevent hazards during assembly, please be sure to wear protective gear. 4. Assemble hexagon flange locking nut ① of non-metallic inserts on left-front module assy.
Page 864 Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 5. Assemble high-voltage guard cover and flexible connection ①. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 6. Assemble left-front module’s quick-plug pipeline ① on front end, and ② on rear end.
Page 865 Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Gas Tightness Inspection 1 Remove a vent valve, and then mount the gas nozzle chuck (A). Warning: To prevent hazards during disassembly, please be sure to wear protective gear.
Page 866 2.Mount gas pressure meter (A). Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Caution： Carefully operate the gas-pressure meter to prevent the falling down. 3. Install the maintenance switch Danger: There still will be risk of shock even you touch the high voltage components with protective Power Battery System-...
Page 867 gear. 4.Use polyethylene tape (A) or other means to seal another air vent, in order to prevent the air getting inside Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 5.Add 1.6kPa air pressure into the battery to do the air tight test. Please continue for about 1 minute.
Page 868 Caution： DO NOT let the soapsuds contact the service plug. Equipotential test After installation of power battery assembly, use multimeter to measure the resistance value between housing(A) and body（B）. Standard : ≤0.1 Ω Danger: To prevent hazards during inspection, please be sure to wear protective gear.
Page 869 Rear module assy Rear module assy’s disassemblyand assembly Warning:  Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly.
Page 870 the intrusion of rain, snow, sand, and other substances. The environment must be ventilated and prevent the entry of sweat during work, and also prevent condensation from occurring as a result of high temperature and humidity. No entry of foreign materials In addition to being indoors, the environment must not permit the entry during disassembly work of metal powders, oil, or foreign substances resulting from causes such as servicing of...
Page 871 High Voltage Disassembly of rear module assy Clean the dust and pollutants on the surface of power battery. Remove the fixing reinforcing plate ① of service switch. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Please dismantle the fixing bolt ①...
Page 872 protective gear. Pull out the low-voltage harness connector ① of rear battery module assy. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Remove the fixing snap joint ① of low-voltage main harness on rear module assy, then remove the low-voltage main harness ②. Warning: To prevent hazards during disassembly, please be sure to wear...
Page 873 protective gear. Disassemble the high-voltage guard cover ① and flexible connection ② between left-front&right-front module assy and rear module assy. Danger: The risk of electric shock still exists even when you touch high-voltage parts with protective gear. Perform the operation alone. Operations by multiple people may cause electric shock.
Page 874 Warning: To prevent hazards during disassembly, please be sure to wear protective gear Disassemble the high-voltage guard cover A of flexible connection between rear module assy and service switch. Then remove flexible connection B and C. Danger: The risk of electric shock still exists even when you touch high-voltage parts with protective gear.
Page 875 To prevent electric shock, please use insulated tape to wrap up the terminal of high-voltage connection after disassembly. Disassemble the rear module’s quick-plug pipeline ① on upper-end, and ② on lower-end. Please refer to “quick-plug pipeline” for details. Warning: To prevent hazards during disassembly, please be sure to wear protective gear 10 Dismantle rear module assy’s fixing part and lower housing assy’s fixing bolt A and B.
Page 876 protective gear 11 Remove rear module assy ①, then place the assy on workbench. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Make sure that a piece of insulation paper has been placed on the working table.
Page 877 Danger: The risk of electric shock still exists even when you touch high-voltage parts with protective gear. Perform the operation alone. Operations by multiple people may cause electric shock. Disassemble the high-voltage guard cover ① and its fixing bolt on the rear module assy, then remove the flexible connection’s copper bar.
Page 878 high-voltage parts with protective gear. Perform the operation alone. Operations by multiple people may cause electric shock. 13 Disassemble the fixing nut ① of left fixing parts on rear module assy. Warning: To prevent hazards during disassembly, please be sure to wear protective gear Disassemble the fixing nut ①...
Page 879 protective gear. 15 Disassemble the fixing nut of rear module assy’s pull rod, then remove the pull-rod ①. Warning: To prevent hazards during disassembly, please be sure to wear protective gear 16 16 remove the module ①. Warning: To prevent hazards during disassembly, please be sure to wear protective gear...
Page 880 Assembly of rear module assy Caution： When replacing module assy, please perform equalizing charge to the module. Please refer to “module’s equalizing charge” for details. When the module is replaced, please perform the following steps: Write down the replacing date on the sealed package of new battery pack.
Page 881 Check the assembling condition for battery module. Make sure the assembling process is carried out with correct installation method. Warning: To prevent hazards during assembly, please be sure to wear protective gear. Fix the left fixing parts ①. Warning: To prevent hazards during assembly, please be sure to wear protective gear.
Page 882 Warning: To prevent hazards during assembly, please be sure to wear protective gear. Install the flexible connection of rear module assy according to the following steps: ①Assemble the copper bar ① of front/rear flexible connection. Danger: The risk of electric shock still exists even when you touch high-voltage parts with protective gear.
Page 883 cause electric shock. High-voltage guard cover ① of rear flexible connection. Warning: To prevent hazards during assembly, please be sure to wear protective gear. Caution： Make sure that there is no error of mounting positions. Make sure that the connection place is not loosening up after assembly. Assemble the bolt A and nut B of rear module assy Warning: To prevent hazards during assembly, please be sure to wear...
Page 884 protective gear. Assemble the rear module’s quick-plug pipeline ① on upper-end, and ② on lower-end. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Assemble the bracket ① of service switch’s flexible connection. Warning: To prevent hazards during assembly, please be sure to wear...
Page 885 protective gear. Assemble the connecting strip B, C and the high-voltage guard cover A on service switch Danger: The risk of electric shock still exists even when you touch high-voltage parts with protective gear. Perform the operation alone. Operations by multiple people may cause electric shock.
Page 886 Danger: The risk of electric shock still exists even when you touch high-voltage parts with protective gear. Perform the operation alone. Operations by multiple people may cause electric shock. Warning: To prevent hazards during disassembly, please be sure to wear protective gear.
Page 887 Warning: To prevent hazards during assembly, please be sure to wear protective gear. 12 Tighten the fixing bolts and nuts according to the sequence in the following picture, then mount the upper housing of power battery pack. : The front of the vehicle Warning: To prevent hazards during assembly, please be sure to wear protective gear.
Page 888 Warning: To prevent hazards during assembly, please be sure to wear protective gear. Gas Tightness Inspection 1 Remove a vent valve, and then mount the gas nozzle chuck (A). Warning: To prevent hazards during disassembly, please be sure to wear protective gear.
Page 889 Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Caution： Carefully operate the gas-pressure meter to prevent the falling down. 3. Install the maintenance switch Danger: There still will be risk of shock even you touch the high voltage components with protective gear.
Page 890 4.Use polyethylene tape (A) or other means to seal another air vent, in order to prevent the air getting inside Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 5.Add 1.6kPa air pressure into the battery to do the air tight test. Please continue for about 1 minute.
Page 891 Caution： DO NOT let the soapsuds contact the service plug. Equipotential test After installation of power battery assembly, use multimeter to measure the resistance value between housing(A) and body（B）. Standard : ≤0.1 Ω Danger: To prevent hazards during inspection, please be sure to wear protective gear.
Page 892 Disassembly and assembly of battery cell Disassembly and assembly of battery cell Warning:  As the electric vehicle contains a high voltage battery, if the high pressure components and vehicles are handled incorrectly, there is a risk of electric shock, shock, leakage or similar accidents, so be sure to follow the correct procedures to check and maintain.
Page 893 temperature and humidity. No entry of foreign materials In addition to being indoors, the environment must not permit the entry during disassembly work of metal powders, oil, or foreign substances resulting from causes such as servicing of other vehicles. If there is any risk of the above, use a plastic curtain or other means to block off the work area, or take other necessary steps.
Page 894 Disassembly and assembly of battery cell To disassemble module assy, please refer to “disassembly and assembly of left-front module assy” and “disassembly and assembly of rear module assy” for details. Prepare auxiliary line-drawing fixture for the disassembly of battery cell. Warning: To prevent hazards during disassembly, please be sure to wear protective gear.
Page 895 To prevent haza rds during disassembly, please be sure to wear gear. uxiliary line-drawing device to draw up a round line ①. Warni ent hazards during disassembly, please be sure to wear protective gear. Prepare small sander ①. Warning:...
Page 896 To prevent hazards during disassembly, please be sure to wear protective gear. Polish the surface of the aluminum plate, ABS plate and cell under the round line ①. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Use plastic stick ①...
Page 897 Warning: To prevent hazards during disassembly, please be sure to wear protective gear. Apply fixing glue on the battery cell’s surface, then clean the redundant glue. Use plastic stick to place electrode on the collector plate ①. Warning:...
Page 898 To prevent hazards during disassembly, please be sure to wear protective gear. 10 Use laser-weld to weld up the aluminum terminal on battery cell’s anode ①. Warning: To prevent hazards during disassembly, please be sure to wear protective gear. 11 Use laser-weld to weld up the aluminum terminal on battery cell’s cathode.
Page 899 Maintenance data and instructions Maintenance data and instructions Power Battery assembly Items Instruction Type Ternary li-ion battery Structure 42 parallel 96 series (4032 cells) Voltage platform (V) About 345.6 Weight (kg) About 318 a（mm） 1176 Profile b（mm） 1039 Size c（mm） d（mm）...
Page 900 Charging system Content Safety Precaution.........................901 Safety Precaution........................901 Instruction........................901 Precautions for the electrical technicians who use medical electronic devices..901 Inspection of key points before the maintenance............902 Precautions of auxiliary restraint system "airbag" and "seat belt pretension"..902 Precautions of removing the 12V battery..............903 Precautions of high-voltage..................903 Place the warning sign saying "High voltage parts under maintenance, do not touch"..........................905...
Page 901 Diagnosis and preparation....................931 Work Procedures......................931 Procedures of diagnosis and repair................932 Diagnostic working list....................936 Regular Maintenance.......................939 Charging socket assembly....................939 On-board charger......................940 DTC/Diagnostics on circuit.......................942 Charging connection and grounded circuit..............942 Diagnostic Procedure.....................942 P3301 220V AC input over-voltage...................945 DTC logic........................945 DTC Diagnostic Procedure..................945 P3301 220V AC input under-voltage................946 DTC logic........................946 DTC Diagnostic Procedure..................946...
Page 902 DTC Diagnostic Procedure..................957 P330d Abnormal resistance of CC circuit..............958 DTC Logic........................958 DTC Diagnostic Procedure...................958 P330e CP loop circuit is abnormal.................960 DTC Logic........................960 DTC Diagnostic Procedure..................960 P330f Electronic lock unlock failure................962 DTC Logic........................962 DTC Diagnostic Procedure...................962 P33010 Electronic lock locking failure................964 DTC Logic.........................964 DTC Diagnostic Procedure..................964 P3311 AC charging socket over temperature.............966...
Page 903 Safety Precaution Safety Precaution Instruction Please follow the instructions to ensure safety and proper service. These instructions are not introduced separately in each chapter. Precautions forthe electrical technicians who use medical electronic devices Prohibit operation Warning:  Strongly magnetic components have been assembled on this vehicle. ...
Page 904 Always observe the following items for preventing accidents’ happening: Please avoid the failure of the auxiliary restraint system, and the risk causing the casualties will increase in the collision accidents after the failure. All maintenance can only be operated by the DR authorized distributors.
Page 905 Non-standard maintenance on auxiliary restraint system, including non-standard disassembly and installation, may lead to accidental triggering of the auxiliary restraint system and personal injury. For removal of air bag module, please refer to “Air bag system”chapter. Do not use any electrical test devices to test any circuit of the auxiliary restraint system unless these tests are in the instructions described in the service manual.
Page 906 accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.  Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
Page 907 affected by the magnets. Such persons must not perform work on the vehicle. PROHIBITED ITEMS TO CARRY DURING THE WORK Because this vehicle uses components that contain high voltage and powerful magnetism, due not carry any metal products which may cause short circuits, or any magnetic media (cash cards, prepaid cards, etc.) which may be damaged on your person when working.
Page 908 Preparation work Normal tools Tool name Use description Insulated gloves (To ensure the protection of Disassembly and assembly an electricity of 1000V / of the high voltage parts 300A) Disassembly Leather gloves assembly of high voltage (Using leather gloves that parts can tighten the wrist) 2.
Page 909 Energy-saving wrench Module assembly Electric wrench Disassembly of spare parts...
Page 910 Systeminstruction Components Components’ positions : The front of the vehicle Sequ Name Function ence DC charging socket Please refer to “DC charging socket” assembly Car Charger Please refer to “Car charger” AC charging socket Please refer to “AC charging socket” assembly Charging indicator Please refer to “Charging indicator light”...
Page 911 charging type, connect the AC charging plug or DC charging plug to the corresponding charging socket, and start charging after the connection is correct. Test circuit will be generated when charging port is connected. When failure happens in connection, VCU will check the failure. On-board charger Transform the external AC power into DC for battery’s charging.
Page 912 Charging indicator is assembled on instrument panel’s central part, which is on front windscreen’s bottom side. It can indicate different status of charging. Serial Function Indicator’s status Ready for charging Yellow light In charging Green light Full charging Green light blinks for 1 minute Charging complete/uncharge Extinguished...
Page 913 Warning mark for high-voltage 1. The warning mark for high-voltage is stamped on vehicle charger’s upper cover. 2. After replacing charger, please check whether the mark is on original position. System System Instructions Instruction Vehicle charger applies secondary conversion system, including PFC conversion (adjust circuit for power factor) and AC/DC rectifier.
Page 914 PFC is a circuit for increasing power factor. It can improve the efficiency of transforming AC into DC. Description of charging control For more information on charging control, please refer to “AC charging control” and “DC charging control” sections. Charging mode This vehicle has AC charging mode and DC charging mode.
Page 915 During AC charging mode (normal charging) and fixed-time charging hasn’t been set, the charging will start when charging socket is connected to charging socket. AC charging mode (low-life charging) In the AC charging mode (long-life charging), the power battery charge cut-off voltage will be lower than the charge cut-off voltage in the normal charge mode to increase the service life of the power battery.
Page 916 Principles and operations Vehicle Charger Vehicle charger applies Inrush current-limit circuit and EMI filter circuit to prevent DC network’s fluctuation and high-frequency’s interference on facility. Rectifying circuit will transform the AC into DC. PFC is a circuit for increasing power factor. It can improve the efficiency of transforming AC into DC.
Page 917 Do not put themnear heat source. Fall-off or shock is prohibited. Do not place heavy objects on charging cable. Precautions for charging Please use specific plug for DR vehicle only; 2. Check whether water, dust or other materials exist inside plug and socket。 Warning: ...
Page 918 9. Make sure charging plug is pulled out if you need to turn the key on “READY”. Note: The key cannot be turned on “READY” when charging socket and plug are connected 10 To prevent fire accidents or electric shock caused by electric leakage, please use normal charging plug that is water-proof.
Page 919 CHR diagnosis information Vehicle Charger Ref. value The value displayed in the diagnostic tool Ref. value Note:  All data listed below may differ from actual value, as these figures are calculated by vehicle charger according to the signal uploaded from relevant sensors.
Page 920 cathode contactor Non-DC charging disconnected AC charging process Vehicle Charger 12V wake-up Non-AC charging charging pile’s connection is OK, normal charging charging Household charging signal connection normal charging No connection Charger’s Charger’s internal temperature -40℃~85℃ temperature Charger’s output AC charging 200V~ 420V voltage Connector layout...
Page 921 socket, normal charging process Vehicle Chargin connected g control Output socket, normal confirm charging process Signal feedbac Output ------------ Vehicle door 12V- Input locked Vehicle door 12V+ Input 12V- locked CCOUT resistance (connect detected original VCU to Output 1.5K/680Ω/220Ω collect the CC resistanc e port)
Page 922 Input/outpu Charger is working ------------ CANL Input/outpu Charger is working ------------ CANH Output HVIL2+ Output HVIL2- Thermist Charger is working or 1 Input Resistance positive terminal Thermist Charger is working or 1 Input Resistance negative terminal (empty foot) (empty foot) (empty foot) Electroni...
Page 923 High Voltage PIN3) Electroni c lock power supply 1 Input Charger is working (connect electroni c lock PIN1) Constant power Input constant input power Input/outpu DC charging ------------ Input/outpu charging ------------ process Connector of ------------ ------------ DC charging Charging socket (low Input 2.3V-2.7V...
Page 924 Safety-failed list Safety-failed list If failure happens in vehicle charger, please refer to “safety-failed list” for solution. The solution methods are different with respect to different failures and failure modes. Failure mode Mode A: charging prohibited, failure can be cleared automatically Mode B: charging prohibited, failure can be cleared automatically after rebooting.
Page 925 Output Charger’s output current P3308 × over-current is too high Temperature Charger’s temperature P3309 × sensor failed sensor is broken VCU cannot Abnormal P330a receive × communication messages Abnormal Abnormal VCU current P330b × current order order Abnormal Abnormal VCU voltage P330c ×...
Page 926 DTC index Failure Name Failure Light P3301 AC over-voltage —— P3302 AC under-voltage —— P3303 Battery over-voltage —— P3304 Battery under-voltage —— P3305 PFC under-voltage —— P3306 PFC over-voltage —— P3307 over-temperature —— P3308 Output over-current —— P3309 Temperature sensor failure ——...
Page 927 shed shed Keep extingui extingui extinguis Power hasn’t been lighting shed shed connected Keep Keep flicker extinguis charging lighting lighting Half-connected (S2 Keep Keep Keep extinguis disconnected for 10 lighting lighting lighting seconds continuously) Keep Keep extinguis Keep Communication error lighting lighting lighting...
Page 928 Diagram AC charging plug AC charging Electric air On-board Power High voltage Vehicle Combinatio Electronic lock power supply 1 pin Electronic lock power supply 2 pin Temperature electronic lock feedback 1 pin detection 1 pin Temperature 12V+ constant Vehicle Lead-acid DC charging plug DC charging Vehicle Charging system...
Page 929 Terminal Wire color Wire diameter Signal name AC power supply (L) Neutral (N) Ground line (PE) Connector number Connector name AC charging socket assembly low voltage plug Connector type PP0447701 Terminal Wire color Wire diameter Signal name 0.75 Temperature control 1 (WK1) 0.75 Temperature control 2 (WK2) 0.75...
Page 930 Connector number Connector name On-board charger high voltage input connector Connector type DY3F1203SNF Terminal Wire color Wire diameter Signal name AC power supply (L) Yellow Neutral (N) Black Ground line (PE) Connector number Connector name On-board charger high voltage output connector Connector type DY3F1002SNF...
Page 931 Connector number Connector name Connector for vehicle charger (low voltage) Connector type RT001619SN03 Terminal Wire color Wire diameter Signal name CCOUT (connect the original VCU to collect the CC resistance port) NC (empty pin) 12V output wake-up signal CANL CANH HVIL2 HVIL2 Thermistor 1 positive terminal...
Page 932 Thermistor 1 negative terminal NC (empty pin) NC (empty pin) NC (empty pin) Electronic lock feedback 1 pin (connect the electronic lock PIN2) Electronic lock power supply 2 pin (connect the electronic lock PIN3) Electronic lock power supply 1 pin (connect the electronic lock PIN1) 12V constant power Connector number...
Page 933 Terminal Wire color Wire diameter Signal name Basic check Diagnosis and preparation Work Procedures...
Page 934 Procedures of diagnosis and repair Obtain symptom information Use the Diagnostic Worksheet to ask the customer for details about the symptoms (status and environment at the time of the accident / failure). (Refer to the below. "Diagnostic working list") >> Go to step 2...
Page 935 Check the DTC of on-board charger 1.Check the DTC of on-board charger. If DTC is detected, please carry out operations below: -Record DTC and freeze the data - Check the relationship between the failure reason detected by the DTC and the symptoms described by the customer.
Page 936  If DTC hasn’t been checked again, freezing data will be helpful to check failures.  If no relevant failure check procedure is listed in maintenance manual, please check spare parts’ function. If spare parts’ function is abnormal,please refer to “DTC check procedure” for details Whether DTC is detected ? Yes>>...
Page 937 When the DTC is detected in step 2, perform the "DTC confirmation step" or "Full function check" again, and then confirm that the fault has been properly repaired. If the symptoms are described by the customer, confirm the symptoms identified by referring step 3 and step 4, and check that the symptoms described by the user are not detected.
Page 938 Diagnostic working list Instruction Error information of charging system can be acquired by understanding working conditions correctly. Generally, customer has his own judging standard on the failure. Therefore, by consulting user’s description on failure or problem, technicians can understand failure better. All error information can be classified by applying diagnostic working list.
Page 939 Remaining power Cannot charge Charge interrupted Slow charging Fixed-time charging unavailable Remote charging unavailable Cannot be charged immediately Other Detailed syndrome DC charging pile display information (if any) A/C unavailable Poor A/C performance Battery capacity loss Other Detailed syndrome Ordinary road highway mountain road bumpy road...
Page 940 Position Voltage Fuse current Other information With remaining power Without remaining power Remaining power Q/N/O operating method Gears / operations （ → ） Weather Environmental conditions Temperature ℃ Always Once Sometimes （happened for times） Other R / Q / Occurrence frequency N / O After the key is in the "OFF"...
Page 941 Regular Maintenance Charging socket assembly Check Checking method Eye-check on following items:  Whether crackle exists.  Whether dust/foreign material exists.  Whether damage exists.  Whether sealing ring is normal. Note: Compulsory check to ensure no  breakage exists on sealing ring. ...
Page 942 On-board charger Warning:  As the electric vehicle contains a high voltage battery, if the high pressure components and vehicles are handled incorrectly, there is a risk of electric shock, shock, leakage or similar accidents, so be sure to follow the correct procedures to check and maintain.
Page 943  Electric shock may occur if touching high-voltage part without proper protection Warning: Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly. Standard: 5V or under 5V Test insulated resistance of vehicle charger  Disconnect the high-voltage connection of vehicle charger ...
Page 944 DTC/Diagnostics on circuit Charging connection and grounded circuit Diagnostic Procedure Check the fuse Check if the following fuses are blown. Fuse position Fuse type AC charging fuse High voltage junction box DC charging fuse Check if the fuses are blown. Normal >>Change the fuse.
Page 945 A or B Ground 1 or 2 Check if the result is normal. Yes >>go to step 4 No >>repair or replace the failed vehicle charger Check whether AC charging socket is conducted 1. Check whether AC charging socket is conducted Whether AC charging socket Socket port...
Page 946 No >>repair or replace the failed vehicle charger Test CAN communication signal of vehicle charger 1. Connect vehicle charger’s high-voltage connector and disconnect the low-voltage connector 2. Connect AC charging socket 3. Test the voltage between CANH and CANL Car Charger Vehicle Charger Voltage Connector...
Page 947 P3301 220V AC input over-voltage instruction 220V AC power will supply energy for vehicle charger. Unstable AC power may affect vehicle charger’s performance. DTC logic DTC diagnosis logic Failure The possible causes for DTC diagnostic conditions number Name failure 220V AC ...
Page 948 P3301 220V AC input under-voltage instruction 220V AC power will supply energy for vehicle charger. Unstable AC power may affect vehicle charger’s performance. DTC logic DTC check logic Failure The possible causes for DTC diagnostic conditions number Name failure 220V AC ...
Page 949 the charger will back to normal working when AC power is restored. P3303 The on-board charger output is over-voltage Instruction The on-board charger has output capacity (200V~420V). If vehicle charger detects the output port’s voltage exceeds its output capacity, the charger will shut down output automatically and protect its hardware.
Page 950 2. Confirm vehicle can be charged normally. P3304 The on-board charger output is under-voltage Instruction The on-board charger has output capacity (200V~420V). If vehicle charger detects the output port’s voltage is lower than its output capacity, the charger will shut down output automatically and protect its hardware. DTC logic DTC diagnosis logic Failure...
Page 951 P3305 vehicle charger PFC is over-voltage instruction When under normal charging, vehicle charger’s PFC output voltage has a certain range (330V~410V). When vehicle charger detects PFC output voltage exceeds 410V, vehicle charge will shut down output automatically and protect its hardware. DTC logic DTC diagnosis logic Failure...
Page 952 1. Confirm vehicle can be charged normally P3306 The on-board charger PFC is under-voltage Instruction When under normal charging, the on-board charger PFC output voltage has a certain range (330V~410V). When vehicle charger detects PFC output voltage is lower than 330V, vehicle charge will shut down output automatically and protect its hardware.
Page 953 P3307 The on-board charger is over-temperature Instruction The on-board charger normal working temperature ranges from -40℃~85℃. The charger will shut down output if the actual temperature is out of range so as to protect its hardware. DTC logic DTC diagnosis logic Failure The possible causes for DTC diagnostic conditions...
Page 954 No >> Replace the water pump. 3. Confirm whether the coolant is used up 1.Confirm whether the coolant is used up Yes >> Add the coolant. No >> Replace vehicle charger Confirm conditions 1. Confirm whether vehicle can be charged normally...
Page 955 P3308 On-board charger output over-current Instruction If output current exceeds a certain extent, vehicle charger will shut down its output so as to protect hardware. DTC logic DTC check logic Failure The possible DTC diagnostic conditions number Name causes for failure ...
Page 956 P3309 The on-board charger temperature sensor failure Instruction The on-board charger will transfer the temperature information to charger’s controller through temperature sensor. If temperature exceeds a certain range, vehicle charger will limit power output or stop working. At the same time, the on-board charger sends the temperature information to the VCU, and the VCU controls the start and stop of the pump according to the temperature information of the on-board charger, so that the on-board charger works in an...
Page 957 Confirm conditions 1. Confirm whether vehicle can be charged normally P330a cannot receive VCU message instruction Vehicle charger cannot receive VCU message before charging. Charger has no output and wake-up signal will not close, with uploading “VCU message cannot received” DTC logic DTC check logic Failure...
Page 958 P330b Abnormal VCU current order Instruction Vehicle charger will adjust output current according to the order from VCU if working normally. If the order from VCU has exceeded charger’s output capacity, the charger will upload failure of abnormal VCU current order. DTC logic DTC diagnosis logic DTC diagnostic...
Page 959 P330c Abnormal VCU voltage order Instruction Vehicle charger will adjust output voltage according to the order from VCU if working normally. If the order from VCU has exceeded charger’s output capacity, the charger will upload failure of abnormal VCU voltage order. DTC logic DTC diagnosis logic DTC diagnostic...
Page 960 P330d Abnormal resistance of CC circuit Instruction CC resistance is abnormal or cannot be detected while vehicle charger is working. Vehicle charger will upload failure of CC loop circuit abnormal. DTC Logic DTC diagnosis logic DTC diagnostic The possible causes for Failure Name number conditions...
Page 961 confirm whether poor connection exists in CC circuit 1.confirm whether poor connection exists in CC circuit Yes>>replace AC charging socket or plug No >> Replace vehicle charger Confirm conditions 1. Confirm vehicle can be charged normally 2. Confirm vehicle charger will not upload P330d...
Page 962 P330e CP loop circuit is abnormal Instruction When the on-board charger is powered on or during normal operation, the duty cycle of the CP circuit is abnormal, and the on-board charger reports an abnormal CP circuit fault. DTC Logic DTC diagnosis logic DTC diagnostic The possible causes for Failure Name...
Page 963 Confirm whether poor connection exists in CP loop circuit 1.Confirm whether poor connection exists in CP loop circuit Yes>>replace AC charging socket or plug No >>go to step 3 3.Check if the charging pile works normally 1.Check if the charging pile works normally. Yes >>...
Page 964 P330f Electronic lock unlock failure Instruction The on-board charger unlocks the electronic lock according to the key unlock request signal. If the electronic lock cannot be unlocked, the on-board charger reports the electronic lock unlocking fault. DTC Logic DTC diagnosis logic DTC diagnostic The possible causes for Failure Name...
Page 965 Yes >> Replace or repair low-voltage line. No >> Go to step 3. Confirm whether the electronic lock is abnormal 1.Confirm whether the electronic lock is abnormal. Yes>> Replace the electronic lock. No >> Replace vehicle charger. Confirm conditions 1. Confirm vehicle can be charged normally 2.
Page 966 P33010 Electronic lock locking failure Instruction The on-board charger is based on the key unlock request signal or the electronic lock when the power is turned on. If the electronic lock cannot be locked, the on-board charger reports the electronic lock locking fault. DTC Logic DTC diagnosis logic DTC diagnostic...
Page 967 Yes >> Replace or repair low-voltage line. No >>go to step 3 Confirm whether the electronic lock is abnormal 1.Confirm whether the electronic lock is abnormal. Yes>> Replace the electronic lock. No >> Replace vehicle charger Confirm conditions 1. Confirm vehicle can be charged normally 2.
Page 968 AC charging socket over temperature Instruction The normal operating temperature of the AC charging socket is -40°C~100°C. The outlet exceeds this temperature range. The on-board charger will shut down the output and protect the charging socket. DTC Logic DTC diagnosis logic Failure The possible causes for DTC diagnostic conditions...
Page 969 1.Confirm whether the low-voltage line connection is abnormal. Yes >> Replace or repair low-voltage line. No >>go to step 3 Confirm whether the socket is abnormal 1.Confirm whether the socket is abnormal. Yes>> Replace the socket. No >> Replace the vehicle on-board charger. Confirm conditions 1.
Page 970 AC charging socket temperature sensor fault Instruction The normal working temperature of the AC charging socket is -40°C~100°C. When the socket temperature sensor is abnormal, the on-board charging device reduces the power output. DTC Logic DTC check logic DTC diagnostic The possible causes for Failure Name number...
Page 971 System diagnosis Vehicle Charger Symptom list The check items as Symptom Solutions following: Confirm whether output exists in external power timing device output exists equipped external external power supply power, the output power will exist only within timing range. Confirm whether Incorrect connection of charging plug connects charging plug...
Page 972 Note: if power battery is full, the charging will not proceed If power battery is full, charging will stop automatically Confirm battery The battery temperature temperature is lower is too high than 65 ℃ 12V lead-acid battery Charging battery needs feed Vehicle failure Check VCU error code The check items as...
Page 973 vehicle Confirm the key is on charging state “LOCK” before charging Either AC charging or AC charging and DC DC charging will be OK charging both Note: AC charging and connected charging cannot proceed simultaneously No Action Note: if power battery is full, the charging will not Power battery is full proceed If power battery...
Page 974 timer time on timer are correct Fixed-time charging Set fixed-time charging hasn’t been set The check items as Symptom Solutions following: Confirm whether output exists in external power timing device output exists equipped external external power supply power, the output power will exist only within...
Page 975 High Voltage than 65℃ 12V lead-acid battery Charging battery needs feed Vehicle failure Check VCU error code Confirm phone signal exists at your current Vehicle cannot receive position charging signal Confirm phone signal exists vehicle’s position The check items as Symptom Solutions following:...
Page 976 Confirm battery Power battery temperature lower temperature too high than 65℃ Vehicle failure Check VCU error code Confirm m charging Connector hasn’t been connector is connected connected properly properly vehicle Confirm the key is on charging state “LOCK” before charging Confirm battery Power...
Page 977 Confirm battery Power battery temperature lower temperature too high than 65℃ Vehicle failure Check VCU error code...
Page 978 Disassembly and installment On-board charger Exploded view : The front of the vehicle ：N·m 1.Power assembly joist 2.High-voltage terminal box 3.Vehicle charger4.AC charging socket assembly Disassembly and assembly of vehicle charger Warning:  Electric vehicles contain a high voltage battery, There is a risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly.
Page 979 follow the correct work procedures when performing inspection and maintenance.  Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.  Be sure to put the removed service plug in your pocket and carry it with you so that another person does not accidentally connect it while work is in progress.
Page 980 : The front of the vehicle Warning: Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly. Charger’s disassembly procedures are as follow: 1. Check the high voltage circuit voltage. ① Disconnect all high-voltage harness connectors around the high-voltage junction box.
Page 981 ② test the voltage between high-voltage connector’s pins Warning: Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly. Standard: 5V or under 5V Attention： Please use multimeter with measuring range exceeding 500V while testing voltage 2.
Page 982 5. Disconnect the high-voltage cable input connector ① and output connector ② of the car charger. Rotate the connector housing counterclockwise to release the plug and socket. Pull the plug horizontally out of the socket. : The front of the vehicle Warning: Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly.
Page 983  Unplug high-voltage output connector by following procedures marked in picture below 6. Disconnect low-voltage harness connector①, press snap joint, loosen socket and plug, then pull out plug from socket. : The front of the vehicle  Unplug low-voltage harness connector by following procedures marked in picture below...
Page 984 Warning: Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly. 7. Disassemble fixing bolt① of vehicle charger ① Warning: Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly. 8.
Page 985 Warning: Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly. assembly Assembly procedure is opposite to disassembly procedures Warning: Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly. After replacing charger, please check whether the mark (A) is on original position.
Page 986 charger and ground. Ensure the charger’s functions are normal. Warning: Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly. The resistance between charger and ground: 0.1Ω If the result cannot match the standard, please check whether damage, oil stain, or whether stains and other conducting material exist on bolts Clean all foreign materials on vehicle charger if any...
Page 987 AC charging socket assembly Exploded view 1. AC charging socket 2. Charging socket support 3. High-voltage connector 4. Low-voltage connector 5. Fixing strip Disassembly and assemblyof AC charging socket Warning:  As the electric vehicle contains a high voltage battery, if the high pressure components and vehicles are handled incorrectly, there is a risk of electric shock, shock, leakage or similar accidents, so be sure to follow the correct procedures to check and maintain.
Page 988  Make sure that other people will not touch the vehicle while service personnel is operating high-pressure system. When maintenance work is suspended, the high-voltage part should be under insulation protection to prevent other people from touching. Attention： When the maintenance switch is disconnected, the key is forbidden to "ON"...
Page 989 Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly. assembly Assembly procedures of AC charging socket is opposite to disassembly procedures confirmation After assembly of AC charging socket finished, please check whether charging can proceed normally Danger: Make sure to wear protective equipments before disassembly so as to prevent potential damage during disassembly and assembly.
Page 990 Warning:  As the electric vehicle contains a high voltage battery, if the high pressure components and vehicles are handled incorrectly, there is a risk of electric shock, shock, leakage or similar accidents, so be sure to follow the correct procedures to check and maintain. ...
Page 991 Disassembly 1. After lifting up vehicle, disassemble power battery assembly. Please refer to “disassembly of power battery” for details Warning: To prevent hazards during disassembly, please be sure to wear protective equipments. 2. Pull out high-voltage connector①. : vehicle front Warning: To prevent hazards during disassembly, please be sure to wear protective equipments.
Page 992 Warning: To prevent hazards during disassembly, please be sure to wear protective equipments. 3. Remove the DC charging socket assembly strip 1, then remove the ground bolt 2, then pull out the 6-pin low-voltage plug, and finally remove the strip 4. : The front of the vehicle Warning: To prevent hazards during disassembly, please be sure to wear...
Page 993 Warning: Ensure to wear protective equipments before disassembly so as to prevent potential damage during disassembly. Installation Assembly procedures of DC charging socket is opposite to disassembly procedures Confirmation After assembly of DC charging socket finished, please check whether charging can proceed normally Danger: Make sure to wear protective equipments before disassembly so as to prevent...
Page 994 Battery Cooling System Safety precaution ........................994 Preventive measure for the electrical technicians who use medical electronic devices ........................994 Key points inspection before maintenance ..............995 Precautions concerning the auxiliary restraint system "airbag" and "seat belt pretension" ........................995 Precaution for Removing 12V Battery .................996 System description ........................997 Components layout ......................997 System principle ......................998...
Page 995 view ......................1006 Explosive Disassembly and assembly ...................1007 Cooling water pipeline ....................1008 Components layout ....................1008 Reparation data and specification ..................1008 Coolant ..........................1008...
Page 996 Safety precaution Preventive measure for the electrical technicians who use medical electronic devices Prohibitions Warning: ● The vehicle has components with strong magnetic. ● If the technician needs to use medical electronic devices, for example, the automatic electronic defibrillator, then he can not operate in the vehicle, otherwise, the function of the device may be effected by the strong magnetic components.
Page 997 In order to avoid failure of the auxiliary restraint system which may increase the possibility of casualty in an collision All the reparation can only be operated by the DR authorized distributors. Nonstandard reparation of the auxiliary restraint system, including nonstandard disassembly and assembly, may accidentally activate the auxiliary restraint system and cause personal injury.
Page 998 operate on the sensor accessory areas which are close to the airbag diagnose sensor and other sensors of the airbag system. Violent vibrations may activate these sensors, ignite the airbag and cause serious damage. ● When using a power tool or a hammer, rotate the key to LOCK gear, plug off the negative terminal of the 12V lead-acid storage battery, wait for at least one minute, then start the maintenance.
Page 999 System description Components layout ① ○ ○ ⑦ ○ ○ ② ○ ③ ○ ⑥ ⑨ ○ ⑤ ⑩ ④ 1 Expansion kettle 2 Inlet tube bracket of battery water pump 3 Inlet tube of battery pump 4 Cooling water pump 5 Electronic water pump bracket 6 Outlet tube of battery pump 7 Battery cooler 8 Bracket of battery cooler 9 outlet tube of battery cooler 10 Water heater 11 Bracket of water heater 12 Outlet tube of water heater 13 Aluminum connecting tube 14.
Page 1000 System principle Water Heat Battery exchanger pack Water Water Basic inspection 1 Check whether the coolant is filled up. If not ,please fill up. Please refer to the chapter “maintenance-cooling system”. Warning: Do not open the filling port of the expansion kettle assembly when the temperature of the coolant is very high in case of hurt caused by spilt coolant.