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HAIMA 7 Repair And Service Manual

Hm484q
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  • Page 2 https://manualesdigitalesjc.com https://www.facebook.com/groups/ManualesDigitalesJC/...
  • Page 3 Abbreviation Abbreviations Air conditioner Motor ABDC After bottom dead center Maximum Anti-lock brake system Manual transmission Accessory Over-speed driving ATDC After top dead center Shut off Automatic transmission fluid Turned on Automatic transmission Power control module BBDC Before bottom dead center Power steering BTDC Before top dead center...

  • Page 4: Regular Maintenance

    Regular Maintenance Regular Maintenance Since ignition and fuel system are essential to emission and high performance of engine and related system, it is strongly recommended that these systems should be serviced at Mazda appointed maintenance stations. After recommended period, conduct inspection for regular maintenance items periodically. For items with * mark, pay attention to following: If any devices adjusted, inspect power steering and AC drive belt.
  • Page 5 Regular Maintenance Symbol Description: △＝ Inspect, and clean, adjust or replace if necessary ▲＝Replace; ◎＝Items needed to be tightened to the specified torque Maintenanc Maintenance interval is based on readings of odometer or numbers of month (whichever comes e Interval first ) Months Items...

  • Page 6: Table Of Contents

    Use of diagnostic diagram ......GI-5 Formula of torque ........GI-11 Use of fault diagnostics ......GI-6 Pliers............GI-11 Order of versions ........GI-7 Installation of radio system ......GI-12 Unit ..............GI-8 Electric system ..........GI-12 Electric parts..........GI-12 Basic operation steps ........

  • Page 7: How To Use This Manual

    How to use this manual How to use this manual Subject scope Ÿ The present manual includes all procedures of maintenance operations，which can be divided into five basic operations: Ⅰ Removal/installation Ⅱ Disassembly/assembly Ⅲ Reset Ⅳ Check Ⅴ Adjustment Ÿ Simple operations can be completed through the observation of vehicle outlook ，...
  • Page 8 How to use this manual Maintenance item Process Relevant references necessary during the installation Portions to be removed/installed Special tools Portions to be checked necessary during the after installation maintenance Maintenance steps Position where the Install in the reversing lubricant shall be order of steps 1-3 applied Tightening torque...

  • Page 9: Symbols

    How to use this manual Symbols Fault diagnostic procedure There are 8 symbols to represent the uses of Basic diagnostic flow: lubricant, grease and sealant and special tools. These symbols stand for the application of the above-said On-board diagnostic materials during the maintenance. Engine diagnostic Only for Part F Symbols...

  • Page 10: Use Of Diagnostic Steps

    Use of diagnostic steps Use of diagnostic steps Use of basic inspection Ÿ Basic inspection to be carried out prior to the diagnostics。 Ÿ The diagnostic operation shall be implemented according to the order listed in the Table. Ÿ Detailed operation of each basic inspection listed in the Table. Ÿ...

  • Page 11: Use Of Diagnostic Diagram

    Use of diagnostic steps Use of diagnostic diagram Ÿ The diagram lists out the consequence relationship of symptoms with the faults. Ÿ The diagram applies to quickly lessen the scope of diagnostic when multiple fault symptoms are in display. Ÿ According to the fault symptoms obtained based on the following Fast Diagnostic Diagram，check the fault relevant causes.

  • Page 12: Use Of Fault Diagnostics

    Use of diagnostic steps Portions where the problems are likely to occur Fast Diagnostic Diagram Portions where the corresponding symptoms are likely to display Choose the correct symptom Use of fault diagnostics List out the process of fault diagnostics, check method and specific operations. GI-6...

  • Page 13: Order Of Versions

    How to check the description Describe the inspection Reference part during the in the relevant material method of the fast detailed operation judgment of partial failure Order of versions The order of versions is shown as the following arrow. GI-7...

  • Page 14: Unit

    264kpa and 38.4psi， Positive kgf/cm pressure For the upper row in the example，2.7 is the upper limit，thus the result after the conversion will be Speed rounded in to 260 and 38；for the lower row，2.7 is the lower limit，then the result after the conversion N·m...

  • Page 15: Basic Operation Steps

    Basic operation steps Refill the mixed engine or transmission oil into Basic operation steps the engine or transmission. Protection of vehicle Run the engine idle for 30mins. Prior to the work, cover the fenders, seats and floor Use the fuel leaked from the illumination by UV etc., light (full-color light) and determine the type of leakage.

  • Page 16: Removal Of Parts

    Use of diagnostic steps Removal of parts Cleaning of parts All parts still usable shall be carefully and completely While the problems are being solved， the causes shall cleaned with the suitable method. be identified. Warning: The work can be started only after identified which parts or sub-assemblies have to be removed or Use of compressed air for cleaning will result in disassembled during the replacement or repair.

  • Page 17: Adjustment

    Use of diagnostic steps Adjustment Unit of torque Formula In the adjustment, use an appropriate ruler or measuring apparatus. A. The length in front of the drive part of torque wrench of special tool or apparatus B. The length of the torque wrench Rubber parts and pipe Avoid gasoline or oil to drop onto the rubber parts or pipe.

  • Page 18: Installation Of Radio System

    Installation of radio system Installation of radio system Electric system If a radio system is not properly installed or a radio Electric parts set of large power used，CIS or other systems will be Battery cable affected. When the connection is disconnected or an electric When a radio system is going to be installed on a parts removed，the negative cable of battery shall be vehicle，the following precautions shall be taken:...
  • Page 19 Use of diagnostic steps Disconnection of harness plug Ÿ To pull out two harness plugs，seize two plugs instead of harness. Terminal Check Ÿ As shown in the following figure, press or draw Slightly pull each wire and check whether it has been the snaps to pull apart the connection.

  • Page 20: Jumper Of Circuit Fault Diagnostic Tool

    Use of diagnostic steps Harness Jumper of circuit fault diagnostic tool Codes of wire color The jumper is designated to shorten the connection Double-color wire is represented by a double color with both ends of switch or ground for the inspection. code Attention: Ÿ...

  • Page 21: Lifting Of Vehicle

    Lifting of vehicle Lifting of vehicle The position to be jacked up by a jack Warning It is dangerous to jack up a vehicle in an improper way，for the vehicle may slide down from the jack and result in serious personnel injury or vehicle damage. The vehicle has to be jacked up at the defined position.

  • Page 22: Position To Be Jacked Up By The Lifter

    Use of diagnostic steps Position to be jacked up by the lifter Warning: It is dangerous to lift the vehicle in an unstable way, as the vehicle may be running down from the lifter and causing serious injury or damage to vehicles. Be sure that the vehicle is within the maximum load of support equipment.

  • Page 23: Towing Vehicle

    Towing vehicle Attention: Towing vehicle Ÿ When towing with four wheels grounded， please Trailer observe the following principles: Ÿ set the shift lever of transmission in the “N” Correctly lift and tow up the vehicle is necessary for the vehicle protection; position;...

  • Page 24: Towing Hook

    Use of diagnostic steps Towing hook Attention: Ÿ The towing hook shall be used only in case of emergency(e.g. draw out a vehicle from a ditch or snowdrift) Ÿ In use of a tow hook，a rope or chain should be used to face the towing hook.

  • Page 25: Technical Parameters

    Technical parameter Technical Parameters Vehicle Dimension HMC6440A4T0 Item Unit Parameters Overall length 4421 Overall width 1830 No load 1740 Overall height (with luggage rack) Full load 1700 Wheelbase 2619 Front wheels 1532 Tread Rear wheels 1522 P215/70 R16 Minimum ground clearance (full load) 235/70 R16 °...

  • Page 26: Technical Parameter

    Technical parameter Engine Parameters Model HMC6440A4T0 Engine model HM484Q Cylinder number and type 4-cylinder inline Valve No. of each cylinder Diameter × stroke (mm) 84.0×90.0 Gross displacement (ml) 1995 Compression ratio 10:1 Rated power/ Speed (kw/rmp) 110/6000 Max. torque/ Speed (Nm/rmp) 180/4500 Idle speed (rpm) 750±50...

  • Page 27: Generator Parameters

    Technical parameter Oil grade Oil type Oil grade Engine oil SAE 10W-30; API Service SL grade or above Random temperature API Service GL-4 or GL-5（SAE 75W-90） Manual transmission oil Above 10℃（50°F） API Service GL-4 or GL-5（SAE 80W-90） Power steering gear fluid DEXIRON IID or ATF-IID or ATF220 SAE J1703 or FMVSS116 Brake/clutch fluid...
  • Page 28 Technical parameter Battery Parameters (75D23L) Rated voltage 5HR capacity Weight Wheel Assembly Parameters Rim Model. 16×6.5J 16×7JJ Tire size P215/70 R16 235/70 R16 Front tire pressure Rear tire pressure Spare tire pressure Capacity of Equipments (Approximate Value) Item With oil filter Engine oil Without oil filter With A/C heater...
  • Page 29 Technical parameter Location of Engine Number Engine number is located on the slope at the front end of cylinder and it can be observed after the open of engine compartment cover. Engine Number Location of VIN (Vehicle Identification Number) TD-5...
  • Page 30 Technical parameter HAIMA SUV use universal symbols as shown in the following chart to display vehicle control signals and indication signals: Main Light High Beam Dipped Position Front Fog Rear Fog Direction Hazard Switch Indicator Beam Lamp Lamp Lamp Indicator...
  • Page 31 HM484Q Engine Service Manual...
  • Page 32 All contents of this manual are the latest information at the time of publication, and the applied data are in line with the technical standards of HM484Q series. FAW HAIMA Power Co., Ltd. reserves the right to change the engine technique features and contents relevant in this manual. The technical personnel using this manual shall pay attention to the updated information at any time.
  • Page 33 Table of Contents How to Use This Manual ......................1 Technique parameters......................2 Technique parameters of complete apparatus .............2 Technical specification of service .................3 Technical specification of service .................6 Tightening torque ......................8 Special tools ........................11 Inspection and maintenance on CBU ................13 Check of compression pressure ................
  • Page 34 Table of Contents Disassembly instructions of timing sprocket ............30 Assembly instructions of tensioner ..............31 Assembly instructions of tensioner arm ............. 31 Assembly instructions of timing sprocket ............32 Assembly instructions of cylinder head cover ............ 32 Assembly instructions of crankshaft pulley ............33 Assembly instructions of water pump pulley ............
  • Page 35 Table of Contents Check/repair of cylinder head ..................53 Check of valve and valve guide ................. 54 Replacement of valve guide ..................55 Disassembly of valve guide ................55 Assembly of valve guide ..................55 Check/repair of valve seat ..................56 Check of valve spring ....................
  • Page 36 Table of Contents...

  • Page 37: Repair Steps

    How to Use This Manual How to Use This Manual Subject scope This manual includes procedures for maintenance operations, specifically divided into the following five basic operations. ⅠRemoval/installation ⅡBreak down/installation ⅢReset ⅣCheck ⅤAdjustment Simple operations may be completed by observing the engine outlook, e.g. Removal/installation of peripheral parts, parts cleaning and visual observation etc., Repair steps 1.

  • Page 38: Technique Parameters

    Technique parameters Technique parameters Technique parameters of complete apparatus Items Parameters Remark Model HM484Q HM484Q-B Number of cylinders and Inline 4-cylinder arrangement Combustion chamber Pentroof As per cylinder Ignition order 1—3—4—2 number Looking forward from behind (the Direction of rotation Counterclockwise flywheel side is the back end)

  • Page 39: Technical Specification Of Service

    Technique parameters Technical specification of service Items Parameters Cylinder cover ～ ～ 124.45 124.55{4.8996 Standard 4.9035} Height (mm{in}) Maximum grinding 0.2{0.0078} allowance Deformation at joint face of Max. 0.03{0.0011} cylinder gasket (mm{in}) Max. 0.05{0.0019} Deformation at joint face of Maximum grinding manifold (mm{in}) 0.20{0.0078} allowance...
  • Page 40 Technique parameters Technical specification of service Items Parameters Valve spring 203 ～ 225 {20.71 ～ 22.95, Intake H: 38.8mm {1.528in} Height H pressure of 45.62～50.56} valve spring (N{kgf, 203 ～ 225 {20.71 ～ 22.95, lbf}) Exhaust H: 38.8mm {1.528in} 45.62～50.56} Intake Max.
  • Page 41 Technique parameters Technical specification of service Items Parameters Standard 84.00～84.03{3.3071～3.3083} Cylinder bore diameter [measured at 37mm (1.45in) Oversize: 0.25{0.01} 84.25～84.28{3.3169～3.3181} below top surface] (mm{in}) Oversize: 0.50{0.02} 84.50～84.53{3.3268～3.3279} Wearing limit (mm{in}) 0.15{0.006} Piston diameter (mm{in}) Standard 83.97～84{3.305～3.3071} [Measured at 28mm {1.1in} below Oversize: 0.25{0.01} 84.22～84.25{3.3157～3.3169} lower edge of oil ring groove,...
  • Page 42 Technique parameters Technical specification of service Items Parameters (mm{in}) Max. 0.30{0.012} 1.487～1.499{0.05854～ Standard 0.05902} Connecting rod bush size 1.612～1.624{0.06346～ 0.25{0.01} reduced size (mm{in}) 0.06394} 1.737～1.749{0.06839～ 0.50{0.02} reduced size 0.06886} Technical specification of service Items Parameters Standard 0.015～0.048{0.0006～0.0019} Connecting rod bearing gap (mm{in}) Max.
  • Page 43 200{2.0, 28} difference among cylinders 446～588{4.6～6.1, 64～ Engine oil pressure (kpa{kfg/cm , psi}[rpm]) 84}[2500] Replacement of engine oil 3.1{3.2, 2.7} Engine oil filling Replacement of engine oil and amount L{US qt,lmp qt} 3.3{3.5, 2.9} engine oil filter Engine oil grade API engine oil grade SJ or above Above –25 ℃{13℉}...

  • Page 44: Tightening Torque

    Technique parameters Technical specification of service Items Parameters ≥0.3{0.012} Thickness of prominent rivet(mm{in}) ≤0.7{0.028} radical cycle run-out(mm{in}) Flywheel ≤0.13{0.0051} Radial run-out (mm{in}) Engine oil pump Standard 0.06～0.18{0.0024～0.0070} Gap between inner rotor tooth tip to outer rotor (mm{in}) Max. 0.22{0.009} Standard 0.100～0.181{0.0040～0.0071}...
  • Page 45 45.1 33.0 (Cylinder block side) Exhaust manifold 21.6 15.8 Thermal shield of exhaust 21.6 15.8 manifold Lubrication system Oil switch 14.7 10.7 Oil filter 1.53 10.9 Oil filter connector 34.3 25.1 Oil filter Oil pan body 21.6 15.8 Oil pan 21.6...
  • Page 46 21.6 15.8 Bypass hose 21.6 15.8 Bypass tube 21.6 15.8 Cylinder block and crank connecting rod mechanisms Crankshaft pulley 16.7 118.4 Flywheel 10.3 73.1 Clutch partition Clutch compressing disc 21.6 15.8 Crankshaft rear cover 19.6 14.3 First determine the...

  • Page 47: Special Tools

    Special tool Special tools 49 T012 0A0A 49 B014 001 49 0107 680A Tappet retainer component Seal installer Engine service platform 49 L010 1A0 49 0636 100B 49 B012 0A2 Engine hook components Valve spring puller Pivot 49 L011 0A0B 49 T028 302 49 E011 1A0 Piston pin assembly kit...
  • Page 48 Special tool Special tools 49 B010 001 49 E011 002 49 G011 103 Seal installer Screw Bolt component 49 S12 710 49 E011 1A1 49 H010 401 Studded connection fixture Fixture component Seal installer 49 G033 107A 49 9200 020A 49 0187 280A Dust cover installer Belt pressure gauge...

  • Page 49: Inspection And Maintenance On Cbu

    Use of Engine Service Platform Inspection and maintenance on CBU Check of compression pressure Warning The oil temperature is very hot when the engine remains in warm-up state. In case of disassembly and assembly, be cautious of scald. Warn up the engine to the normal operating temperature; Flame out and let the engine cool down for 10mins;...

  • Page 50: Check Of Oil Pressure

    Use of Engine Service Platform Check of oil pressure Warning As waste oil is carcinogenic, wash your skin with soap and clean water after the work. The oil temperature of warm-up engine is very hot and easily scalding, operate after the engine shut down and cooled down. Remove the oil pressure switch.

  • Page 51: Check Of Engine Oil Pressure

    Use of Engine Service Platform Check of engine oil pressure Park the vehicle on a flat ground; Warm up the engine to the normal temperature and then shut down; Wait for 5mins. Pull out the dipstick and observe the oil level and state, check whether it remains between the scales F and L.

  • Page 52: Replacement Of Oil Filer

    Use of Engine Service Platform Oil volume L{US qt, lmp qt} Items Volume Oil replacement 3.1{3.2, 2.7} Oil and filter replacement 3.3{3.5, 2.9} Engine oil grading: more than API/SL. Oil viscosity option standard Oil viscosity grade Higher than –25℃{13℉} SAE 10W–30 –30 ℃～37 ℃{–22 ℉～98 ℉}...

  • Page 53: Use Of Engine Service Platform

    Use of Engine Service Platform Use of Engine Service Platform Upper Service Platform of Engine Fit the support sliding arm of special tools at the exhaust side of cylinder block and tighten the fastening bolt (as shown in Fig.). Support sliding arm Bolt Install special tools as per the position shown in Fig.

  • Page 54: Lower Service Platform Of Engine

    Use of Engine Service Platform Install the engine on the service platform. Engine service platform Place the engine into a designated container. Replace by new drain plug spacer and tighten the drain plug. Tightening torque: 30～41N·m{3.1～4.2kgf·m, 22～30ft·lbf} Lower Service Platform of Engine Unload the engine from the service platform in the reversing order with that of the upper service platform of engine.

  • Page 55: Generator And Starter

    Generator and Starter Generator and starter Lubrication system of Engine Warning When disassembling/assembling a generator on the CBU, you should remove first the battery cable, otherwise the terminal B of generator will get in touch with the bodywork , cause sparks and result in personnel injury and electrical component damage.

  • Page 56: Tension Check Of Engine Belt

    Generator and Starter Measuring Generato Water pump pulley point Crankshaft pulley Tension check of engine belt Attention The tension check may replace the deflection check. The tension pulley shall be checked in 30mins after the engine cooled down or shut down. Use a special tool to check the belt tension between two driving wheels.

  • Page 57: Check Of Engine

    Generator and Starter Measuring point Engine Water pump Crankshaft pulley Deflection mm{in} [The force of 98N{10kgf, 22lbf} shall be applied in-between] 6.5～7.5 7.0～9.0 Alternator belt {0.26～0.29} {0.28～0.35} Belt pressure gauge At the time of measurement At the time of installation Tension N{kgf, lbf} 686～834...

  • Page 58: Lubrication System Of Starter

    Generator and Starter Lubrication system of starter Warning When removing and installing the starter on the CBU, if the negative cable of battery is not loosened, the starter terminal B will produce sparks by the access into connection or the contact with the body, this will cause personnel injury and result in the electrical component damage, thus you should firstly remove the negative cable of battery when doing the following operations.

  • Page 59: Ignition And Control Systems

    Ignition and control systems Ignition and control systems Lubrication system of ignition and PVC valve Caution When removing the ignition coil and spark plug, it is very easy to tear up the extension bar sheath, therefore, disassemble it when the replacement is necessary.

  • Page 60: Check Of Pvc Valve

    Ignition and control systems Check of PVC valve Dismantle the PCV valve. Confirm the ventilation of PCV valve behaves as shown in the Table. Replace if abnormal. Table of ventilation Testing condition Result of testing Blow into the joint A Air outlets from the joint B Blow into the joint B No air outlets from the joint A...

  • Page 61: Disassembly/Assembly Of Control System Parts

    Ignition and control systems Disassembly/assembly of control system parts Disassemble as per the order shown in Fig. Assemble in the reversing order of disassembly. Crankshaft position sensor (See——Check of Crankshaft Position Sensor) Oil control valve Water temperature sensor (See—— Instructions of Removal and Installation) Knock sensor Injector...

  • Page 62: Removal/Installation Instructions Of Water Temperature Sensor

    Ignition and control systems Removal/installation instructions of water temperature sensor Use a special tool to disassemble/assemble the water temperature sensor. Special sleeve Check of crankshaft position sensor Check of clearance Attention Do the following checks only when necessary. Confirm that the crankshaft speed sensor has been correctly installed. Use a feeler to measure the clearance between the platform of signal wheel protrusion and crankshaft speed sensor.

  • Page 63: Intake And Exhaust Systems

    Intake and Exhaust Systems Intake and exhaust systems Removal/installation of intake and exhaust systems Disassemble as per the order shown in Fig. Assemble in the reversing order of disassembly. Thermal shield of exhaust manifold Exhaust manifold Exhaust manifold gasket Throttle body Positioning Sealant ring of throttle body (See groove...

  • Page 64: Installation Instructions Of Throttle Body Sealant Ring

    Intake and Exhaust Systems yes, it shall be replaced. Installation instructions of throttle body sealant ring At the installation time, you shall properly put the sealant ring into the groove of throttle body and enable the error proofing mark to clamp into the positioning groove of throttle body. Positioning groove Error proofing mark Caution;...

  • Page 65: Timing Sprocket

    Timing sprocket Timing sprocket Lubrication system of timing sprocket Remove the engine belt (See——Generator). Remove the camshaft position sensor and crankshaft position sensor (See——Ignition and Control Systems). Remove the ignition coil (See——Ignition). Remove the cylinder head cover (See——Cylinder Head Cover). Remove the timing sprocket casing (See——Timing Sprocket Casing).

  • Page 66: Lubrication System Of Tensioner

    Timing sprocket Lubrication system of tensioner Disassembly as per the order shown in Fig. Assemble in the reversing order of disassembly. Instructions to the removal of tensioner Unscrew the tensioner bolt. Slowly take out the tensioner (prevent a sudden pop-up of plunger). Disassembly instructions of crankshaft pulley Use a special tool to fix the crankshaft for disassembly.

  • Page 67: Assembly Instructions Of Tensioner

    Timing sprocket Remove the upper timing sprocket rail. Assembly instructions of tensioner Repress the detent by use of a bench vice (direction shown in Fig.) and insert a hard wire into the lockhole to lock up the tensioner. Lockhole Direction of detent repression Detent Fit the tensioner on the cylinder block and tighten the bolt.

  • Page 68: Assembly Instructions Of Timing Sprocket

    Timing sprocket Timing mark Timing mark Assembly instructions of timing sprocket Intake side Exhaust side Rotate the intake/exhaust camshafts so as to bring 2 timing marks on the intake and exhaust VVTs to a specified angel. Install the timing sprocket rail. Install the timing sprocket.

  • Page 69: Assembly Instructions Of Crankshaft Pulley

    Timing sprocket Assemble the cylinder head cover bolt in the reversing order of the disassembly instructions of cylinder head cover (See——Disassembly of Cylinder Head Cover) Assembly instructions of crankshaft pulley Use a special tool to fix crankshaft for further assembly. Smear oil on the contact surface between the crankshaft pulley and oil seal.

  • Page 70: Lubrication System

    Lubrication system Lubrication system Apply sealant all around Removal/installation of oil pan before installation Drain out the engine oil (See——Check on the CBU, Replacement of Engine Oil). Disassemble as per the order show in Fig. below Need to replace parts Assemble in the reversing order of after removal disassembly.

  • Page 71: Assembly Instructions Of Oil Pan

    Lubrication system Assembly instructions of oil pan Fissure Caution If the bolt is reused, the sealant on the old thread has to be removed. The screw with old thread sealant Old sealant may damage the screw hole. Add continuously sealant around the inside of oil pan bolt hole and make the Oil pan end overlapped.

  • Page 72: Removal/Installation Of Timing Sprocket Casing

    Lubrication system Removal/installation of timing sprocket casing Remove the crankshaft pulley (See——Crankshaft Pulley). Remove the cylinder head cover (See——Disassembly instructions of Cylinder Head Cover). Remove the oil pan (See——Oil Pan, Removal/Installation of Oil Pan). Remove the oil pan body (See——Removal/Installation of Oil Pan Body). Remove the water pump (See——Removal/Installation of Water Pump).

  • Page 73: Disassembly Instructions Of Oil Pump Seal

    Fit the sprocket casing and tighten the bolts as per the order shown in Fig. Specification and torque of mounting bolt Specification Length of bolt stem (mm) Mouting torque (N·m) 1、2、5、6、7、8 18.6～25.5 3、4 18.6～25.5 9、10 37.3～52 11、12...

  • Page 74: Assembly Instructions Of Oil Filter

    Lubrication system Assembly instructions of oil filter Install the oil filter spacer as shown in the left diagram. Tighten the bolts as per the order shown in the right Fig. Inside the oil pan Break down/installation of oil pump and timing sprocket casing Remove the timing sprocket casing (See——Removal/installation of Timing Sprocket Casing).
  • Page 75 Lubrication system Standard clearance of pump body: 0.100～0.181{0.0040～0.0071} Max.clearance of pump body: 0.22mm {0.009in} Standard lateral clearance: 0.040～0.095mm{0.0016～0.0037in} Max. lateral clearance: 0.14mm {0.055in}...

  • Page 76: Check Of Pressure Spring

    Lubrication system Check of pressure spring Apply pressure on the spring and check the spring height. Replace the pressure spring if necessary. Pressure: 82.6～90.4N{8.43～9.22kgf, 18.56～ 20.31lbf} Standard height: 35.15mm [1.3839in] Cold system Removal/installation of thermostat Disassemble as per the order shown in Fig.

  • Page 77: Removal/Installation Of Cooling Water Pipe

    Cylinder head and valve mechanisms thermostat in water. Check the thermostat. If non-conform to the provisions, replace the thermostat. — Close the valve at room temperature. — Warm up and open the valve. Items Engine Initial temperature(℃{℉}) 80～84{176～183} Fully opened temperature(℃{℉}) 95{203} ≥8.5{0.33} Fully opened stroke(mm{in})

  • Page 78: Removal/Installation Of Water Pump

    Cylinder head and valve mechanisms Part replacement is Removal/installation of water pump necessary after the disassembly Remove the engine belt. (See——Engine Belt) Disassemble as per the order shown in Fig. Assemble in the reversing order of disassembly. Bolt Water pump Cylinder head and valves Removal/installation of cylinder head Remove the intake/exhaust manifold (See——Intake/Exhaust System).
  • Page 79 Cylinder head and valve mechanisms Smear prior to the installation Smear prior to the installation Smear prior to the installation Smear prior to the installation of cylinder head Part replacement is necessary after the disassembly Intake VVT(please refer to Removal/ Installation Instructions) Exhaust VVT(please refer to Removal/ Installation Instructions)

  • Page 80: Vvt Disassembly Instructions Of Intake And Exhaust

    Cylinder head and valve mechanisms VVT Disassembly instructions of intake and exhaust As shown in Fig. Disassemble by jamming the hexagonal casting on the camshaft with a wrench Remove the VVT fixing bolt. VVT fixing bolt Slight swing the VVT and carefully take it out from the camshaft. Disassembly instructions of camshaft Check and adjust the valve clearance when necessary (See this section, Valve Clearance).

  • Page 81: Disassembly Instructions Of Cylinder Head

    Max.length: 105.5mm {4.154in} Tighten the cylinder head bolt, in 2–3 steps as per the order shown in the Fi.g, Tightening torque: 17.2～22.0N·m{1.75～2.25kgf·m, 12.7～16.2ft·lbf} Mark each bolt head. Tighten the bolt as per the order shown in the Fig.2, and turn each bolt for 85°～95° based...

  • Page 82: Assembly Instructions Of Camshaft

    Fit all camshaft bearing caps on the journals to which they correspond respectively Tighten with hand, the camshaft bolts marked in the Figure with the numbers 5, 7, 2 and 4. Tighten the camshaft cap bolt in 2-3 steps in the order shown in the Fig.
  • Page 83 Cylinder head and valve mechanisms Smear a little oil on the insertion part Positioning hole of VVT assembly (inner/outer) of VVT assembly Camshaft positioning pin As shown in Fig., tighten the VVT fixing bolts by jamming the hexagonal casting on the camshaft with a wrench.

  • Page 84: Removal/Installation Of Valve Gear

    Cylinder head and valve mechanisms Removal/installation of valve gear Remove the cylinder head (See——Disassembly of Cylinder Head). Disassemble as per the order shown in the Fig. Assemble in the reversing order of disassembly. Special tool designated to the disassembly and assembly Special tool designated to the disassembly and assembly Part replacement is necessary after...

  • Page 85: Disassembly Of Valve Oil Seal

    Cylinder head and valve mechanisms Disassembly of valve oil seal Use a special tool to remove the valve oil seal. Valve spring puller Valve seal Valve guide tube Assembly of valve oil seal Adjust the special tool and enable the encasing depth L to meet the requirements. Depth L Intake: 22.1mm (0.87in);...

  • Page 86: Valve Spring

    Cylinder head and valve mechanisms Valve spring Fit the valve spring and face the end with dense thread pitch toward the cylinder head. A larger than B Cylinder head Installation of valve split collets Use a special tool to press the valve spring seat and fit the valve split collet. Valve spring puller Pivot Inspection of valve clearance...

  • Page 87: Adjustment Of Valve Clearance

    Cylinder head and valve mechanisms If the valve clearance exceeded the standard value, replace the tappet (See——Adjustment of Valve Clearance). (3) Turn clockwise the crankshaft for 360 , enabling the piston to locate on the TDC of cylinder no.4, i.e.: allow the valve check signs on the intake and exhaust VVTs to locate as shown in Fig.
  • Page 88 Cylinder head and valve mechanisms (Intake: 0.22mm{0.0087in}; exhaust: 0.30mm{0.0118in}) Contain the selected tappet into the tappet hole. Reconfirm the valve clearance (See the Valve Clearance, Inspection of Valve Clearance). Attention The thickness of tappet will be marked in 3 digitals at the side of tappet as shown in Fig., below.

  • Page 89: Check/Repair Of Cylinder Head

    Cylinder head and valve mechanisms Check/repair of cylinder head Make a defect test on the cylinder head. Replace the cylinder head when necessary. Check the following items and repair or replace as necessary. (1) Whether the valve seat is sunken. (2) Whether the journal and end clearances of camshaft are too large.

  • Page 90: Check Of Valve And Valve Guide

    Cylinder head and valve mechanisms If the distortion measured by the 6 step exceeded the max.value, grind the surface or replace the cylinder head. Max.grinding tolerance: 0.20mm (0.0078in) Check of valve and valve guide Measure the edge thickness of each valve head and replace the valve when necessary. Standard thickness: intake valve: 0.85mm{0.034in};...

  • Page 91: Replacement Of Valve Guide

    Cylinder head and valve mechanisms Measure the inner diameter of each valve guide, at three points of A, B and C shown in Fig, respectively in the directions X and Y, replace the valve guide when necessary. Standard I/D Standard: 5～5.012mm{0.1968～0.1973in} Extra size: 5.012～5.022mm{0.1973～0.1977in} In absence of lower seat of valve spring, measure the size A, the protrusion height of each valve guide.

  • Page 92: Check/Repair Of Valve Seat

    Cylinder head and valve mechanisms Special tool Special tool Special tool Press in the valve guide from the back of combustion chamber until the special tool gets in touch with the cylinder head. Special tool Special tool Special tool Cylinder head Valve guide tube Check whether the height of valve guide meets the technique index(See——Check of Valve Guide).

  • Page 93: Check Of Valve Spring

    Cylinder head and valve mechanisms Check of valve spring Apply the pressure on the valve spring. Check the spring height. Replace the valve spring when necessary Pressure: 203～225N{20.71～22.95kgf, 45.68～50.631bf} Standard height: 38.8mm {1.528in} Measure the perpendicularity of valve spring. If the perpendicularity exceeded the standard, replace the valve spring.

  • Page 94: Check Of Spring

    Cylinder head and valve mechanisms Check of spring Place the journals of camshafts No. 1 and 5 on the V-block, measure the radius run-out of camshaft. Replace the camshaft when necessary. Radius run-out: 0.03mm {0.0012in} Measure the height of two convexes as shown in Fig. Replace the camshaft when necessary.

  • Page 95: Check Of Tappet

    Cylinder head and valve mechanisms matching with the bearing width, and then place it on the journal in the axis direction. Axis direction Clearance gauge of plastic line (4) Fit the camshaft cover (See——Removal/Installation of Cylinder Head, Precautions to the Installation of Camshaft).
  • Page 96 Cylinder head and valve mechanisms Measure the diameter of each tappet hole at two points of A and B shown in Fig, respectively in the directions X and Standard diameter: 30.964～30.980mm{1.2191～ 1.2197in} Calculate the clearance between the tappet and appropriate tappet hole. Replace the tappet or cylinder head if necessary Standard clearance: 0.020～0.061mm{0.00079～0.00240in} Max.

  • Page 97: Flywheel And Clutch

    Flywheel and clutch Flywheel and clutch Removal/installation of flywheel and clutch If necessary to disassemble the crankshaft rear cover, the oil pan body shall be removed at first (See——Lubrication System, Disassembly/Assembly of Oil Pan Body). Disassemble as per the order shown in Fig. Assemble in the reversing order of disassembly.

  • Page 98: Disassembly Instructions Of Flywheel

    Flywheel and clutch Gear ring fixture component Positioning tool of clutch disc Disassembly instructions of flywheel Use a special tool (as shown in Fig.) to clamp the flywheel. Dismantle evenly the mounting bolts in several times according to the criss cross order (as shown in Fig.) Remove the flywheel.

  • Page 99: Assembly Instructions Of Rear Oil Seal

    Flywheel and clutch replacement. Remove the oil seal by use of a screwdriver wrapped with protective cloth. Protective cloth Assembly instructions of rear oil seal Add clean oil on the oil seal. Fit the oil seal with hands. Use a special tool and hammer to press in the seal. Press depth: 0～0.5mm{0～0.019in} Rear cover Hammer...

  • Page 100: Assembly Instructions Of Pilot Bearing

    Flywheel and clutch Prior to the installation, clean the bolt threads and hole. As shown in the following Fig., smear evenly the sealant on the threads. Attention It is unnecessary to smear sealant when a new bolt is used It is necessary to smear sealant when the bolt is reused.

  • Page 101: Assembly Instructions Of Clutch Disc Plate

    Flywheel and clutch Sleeve mounting device Handle Assembly instructions of clutch disc plate Use as special tool (as shown in Fig.) to hold the position of clutch disc plate. Clutch disc positioning tool Assembly instructions of clutch compressing disc Use a special tool to jam the flywheel and localize the clutch (as shown in Fig.). Evenly tighten the bolts according to criss cross order (as shown in Fig.) Gear ring fixture component Clutch disc positioning tool...
  • Page 102 Flywheel and clutch Use as knife straight edge and feeler to measure the flatness of press disc. If the standard exceeded, the clutch assembly shall be replaced. Max. clearance: 0.05mm {0.0019in} Fit the dial gauge on the cylinder block, turn the flywheel to check the radius run-out of diaphragm spring.

  • Page 103: Check Of Clutch Plate

    Flywheel and clutch Check of clutch plate Use a vernier caliper to measure the rivets at both sides and the depth of disc plate between the surfaces. If the standard exceeded, the clutch disc plate shall be replaced. Depth: ≥0.3mm {0.012in} Use a dial gauge to measure the radical run-out of clutch disc plate If the standard exceeded, the clutch disc plate shall be replaced.

  • Page 104: Check Of Flywheel

    Flywheel and clutch Check of flywheel Fit the dial gauge on the cylinder block. Turn the flywheel and measure the radical run-out of flywheel. If the standard exceeded, the flywheel shall be replaced. Radical run-out: ≤0.13mm{0.0051in}...

  • Page 105: Cylinder Block And Crank Connecting Rod Mechanisms

    Cylinder block and crank connecting rod mechanisms Cylinder block and crank connecting rod mechanisms Break down/installation of cylinder block and crank connecting rod mechanisms Remove the cylinder head (See——Cylinder Head), Oil Pan Body, Oil Pump (See——Lubrication System), Crankshaft Rear Cover (See——Flywheel and Clutch). Disassemble as per the order shown in Fig.

  • Page 106: Disassembly Of Connecting Rod Cap

    Cylinder block and crank connecting rod mechanisms Disassembly of connecting rod cap Check the end gap of connecting rod (See——this section, Check of Connecting Rod). Disassembly of piston and connecting rod Check the crankshaft pin clearance (See——this section, Check of connecting rod). Disassembly of piston pin As shown in Fig.

  • Page 107: Disassembly Of Crankshaft

    Check the main journal clearance (See——this section, Check/Repair of Crankshaft). Installation of main bearing cap Measure the length of each bolt. Replace when the standard value is exceeded. Standard length: 67.7～68.3mm {2.665～2.689in} Max.length: 68.7mm {2.705in} Tighten the bolts in several steps as per the order shown in Fig.

  • Page 108: Installation Of Piston Pin

    Cylinder block and crank connecting rod mechanisms Installation of piston pin Fit the special tool as shown in Fig. Piston pin Piston pin Piston pin assembling tools assembling tools assembling tools Piston pin Screw assembling tools Guide apparatus Insert the special tool no.2 into the piston pin and tighten it on the special tool no.1 Measure the guide portion length L of the tool no.2, and calculate as per the －1.75mm;...
  • Page 109 Cylinder block and crank connecting rod mechanisms Insert the piston pin and the special tool fitted as per the 2 step into the piston and connecting rod as shown in Fig.,below; Special tool No.1 Mark “F” of piston side Piston pin Special tool No.2 Use a press to press in the piston pin into the piston and connecting rod until the special tool no.2 (guide tube) gets in contact with the special tool (stop bolt).

  • Page 110: Installation Of Piston Ring

    Cylinder block and crank connecting rod mechanisms Installation of piston ring As shown in Fig., below, contain the corrugated ring into the groove of piston ring, and then contain one end of the oil control ring into the groove, and then press in other parts in place.

  • Page 111: Installation Of Connecting Rod Cap

    Positioning sign Installation of connecting rod cap Measure the length of each bolt. Replace when the standard value exceeded. Standard length: 46.7～47.3mm {1.838～1.862in} Max.length: 47.6mm {1.874in} Check/repair of cylinder block Use a straight edge ruler and feeler to measure the distortion on the surface of cylinder block as per 6 directions shown in Fig.
  • Page 112 Cylinder block and crank connecting rod mechanisms If the distortion of cylinder block exceeded the max.value with the height within the range of standard value, grind the height or replace the cylinder block. Max. grinding size: 0.20mm {0.008in} As shown in the following figure, measure the I/D of cylinder with an I/D dial gauge at 37mm{1.45in} away from the surface, in the directions of X and Y, .

  • Page 113: Check Of Piston, Piston Ring And Piston Pin

    Cylinder block and crank connecting rod mechanisms I/D of cylinder mm{in} Size Diameter 84～84.03{3.3071～3.3083} Standard 84.25～84.28{3.3169～3.3181} Oversize: 0.25{0.01} 84.50～84.53{3.3268 3.3280} Oversize: 0.50{0.02} Check of piston, piston ring and piston pin Measure the piston diameter in the direction perpendicular to the axis of the piston pin hole and 28mm {1.10in} below the lower edge of oil ring groove.
  • Page 114 Cylinder block and crank connecting rod mechanisms Place manually the piston ring into the cylinder, use the piston to push the piston ring to the stroke end of cylinder bore. Measure, with a feeler, the gap of each piston ring. Replace the piston ring when necessary.

  • Page 115: Check Of Connecting Rod

    Cylinder block and crank connecting rod mechanisms Calculate the clearance between the piston pin and piston pin hole. Replace the piston and / or piston pin when necessary. Standard clearance: 0.005～0.013mm{0.0002～0.0005in} 10. Measure the diameter of connecting rod small end (See——Check of Connecting Rod), calculate the clearance between the connecting rod small end and piston pin.

  • Page 116: Check Of Piston And Connecting Rod

    Cylinder block and crank connecting rod mechanisms clearance gauge of plastic line, whereby the journal clearance will be achieved. If the clearance exceeded the max., value, replace the connecting rod bearing or grind the crankshaft pin, and use the bearing applicable to the reduced size of crankshaft pin to meet the standard clearance.

  • Page 117: Check/Repair Of Crankshaft

    Cylinder block and crank connecting rod mechanisms Check/repair of crankshaft As shown in the following Fig., fit the dial gauge, push forward/rearward the crankshaft from its back, measure the end gap of crankshaft. If the end gap exceeded the max. value, replace the stop bearing or grind the crankshaft, and fit the bearing applicable to the reduced size of crankshaft to meet the standard end gap.
  • Page 118 Cylinder block and crank connecting rod mechanisms mm{in} Crank pin Diameter 44.980～45.000{1.7709～1.7717} Standard 44.730～44.750{1.7610～1.7618} Reduce size: 0.25{0.01} 44.480～44.500{1.7512～1.7520} Reduce size: 0.50{0.02} Measure the main journal clearance in the following way. (1) Wipe out the oil on/in the crankshaft journal and bearing seat. (2) Cut the clearance gauge of plastic line so that it can match with the bearing width and then place it on the top of journal and perpendicular to its axis.
  • Page 119 Electrical System of Engine Charging System ........GI-2 Installation/Removal of Battery ..GI-2 Inspection of Battery ......GI-2 Pre-charging of Battery ..... GI-3 Removal/Installation of Generator ..GI-3 Removal/Installation Instruction Generator .......... GI-3 Inspection of Generator..... GI-3 Removal/Installation of Ignition Coil ..............

  • Page 120: Charging System

    Min. Voltage Inspection of Battery of battery 21℃ (70°F) 15℃ (59°F) 10℃ (50°F) 4℃ (39°F) -1℃ (30°F) -7℃ (19°F) 12℃ (10°F) 18℃ (0°F) Table of Discharging test Battery Discharging current (A) 75D23L Dark current Turn ignition switch to ON position and Battery clamp then take off the key.

  • Page 121: Inspection Of Generator

    Electrical System of Engine Pre-charging of Battery Removal/Installation of Generator Caution: (The part is the same with HM483Q Engine Maintenance Manual for details) Negative battery cable must Warning disconnected at first and installed at last to avoid damage of electrical If terminal B of generator contacts components and battery.
  • Page 122 Electrical System of Engine to Drive Belt, Inspection of Drive Belt). If not, inspect the charging alarm indicator, harness between the battery, Disconnect the negative battery cable. indicator and terminals of generator. If charging alarm indicator and harness Connect a current meter with 120A or is both normal, replace the generator bigger range between terminal B of generator and harness.
  • Page 123 Electrical System of Engine Install in reverse order of removal. Inspect ground voltage of ignition coil (between terminals 1B and 2B) If it is incorrect, inspect ground system harness (Between terminals 1B, 2B and ground point on vehicle body) Standard value: 0(V) Use a needle tool (terminal remover) to push terminals 1C and 2C out of ignition coil connector.

  • Page 124: Starting System

    Starting system If the voltage is within specified range, Starting system remove starter, inspect electromagnetic (The part is the same with HM483Q Engine switch and starter. Maintenance Manual for details) Standard value: >8V Removal/Installation Starting Zero–Load Test System Make sure that battery has been fully Warning charged.
  • Page 125 Continuity Inspection ........F-6 Removal/Installation of Accelerator Pedal ... F-2 Open/Short Circuit Inspection ...... F-7 Fuel System ............F-3 Removal/Installation of Fuel filter ....F-7 Preparation for Maintenance ......F-3 Carbon Canister Inspection ......F-7 Safe Operation Procedures ......F-3 Carbon Canister Solenoid Valve Inspection.

  • Page 126: Air-Intake System

    Air-intake System Air-intake System Vacuum Hose Diagram Vacuum Hose II To Fuel Tank Carbon Canister Unit Carbon Canister Solenoid Valve Vacuum Hose I Air-intake System Removal/Installation...

  • Page 127: Removal/Installation Of Accelerator Pedal

    Air-intake System Removal/Installation of Accelerator Pedal Warning 1. Remove with sequence shown in the figure； When the temperature of engine and intake 2. Installation sequence: system is too high, it will burn people. Therefore, the intake system can be removed only after the engine and intake system have been turned off and cooled down.

  • Page 128: Fuel System

    Fuel System The fuel hose should be put into the fuel pipe Fuel System with the length of more than 25mm { 0.98in }. If there is an inhibiting device on the fuel pipe, Preparation for Maintenance hose should be fitted into fuel pipe until it Warning touches the inhibiting device.

  • Page 129: Removal/Installation Of Fuel Tank

    Fuel System Turn the ignition switch to the position “ON” Finish preparation work before so that the oil pump can work. maintenance (see Preparation Maintenance ) Oil conduit should be pressurized at least 5 minutes by using the above-mentioned method Loosen negative battery cable to check for any leakage.

  • Page 130: Check Valve Inspection

    Therefore, clean them before removal or installation and make sure no 7. Apply pressure to +2.0kpa (15mmHg, 0.5inHg), foreign objects access the fuel pipe and the inspect whether there is airflow from port B.

  • Page 131: Fuel Pump Assembly Removal/Installation

    Fuel System DLC terminal F/P and car body (GND ground) Disassemble with sequence indicated in the are short connected by jumper. figure. Assemble in reversed order of disassembly. Jumper Turn ignition switch “ON” to operate the fuel pump. Measure maximum pressure of fuel line. Standard: 380～420kpa (3.9～4.1kgf/cm Flange Unit...

  • Page 132: Open/Short Circuit Inspection

    Fuel System Partially uncover the carpet. Refit carpet. Remove cover of service hole. Install second-row seat. (Refer to Second-Row Seat Removal/ Installation) Release connector of fuel pump assy. Reconnect negative battery cable. Inspect continuity between terminals B and D of fuel pump connector. Removal/Installation of Fuel filter If the continuity is good but the Simulation Remove with sequence shown in the figure...

  • Page 133: Carbon Canister Solenoid Valve Inspection

    Fuel System Carbon Canister Solenoid Valve Open/Short Circuit Inspection Inspection Inspect for any open or short circuit in the following wiring harnesses. Simulation Test If any, repair or replace relevant wiring Inspect carbon canister solenoid valve. (Refer harnesses. to Troubleshooting, Inspection of Engine Control System, Inspection of Carbon Canister Open Circuit Solenoid Valve)

  • Page 134: Exhaust System

    Exhaust System Exhaust System Inspection of Exhaust System Start engine to inspect leakage of exhaust gas pipeline If there is any leakage, check and replace as required. Exhaust System Removal/Installation Warning As hot engine and exhaust system components may cause scalding, any removal operation should be conducted with engine cooled down.

  • Page 135: Precautions For Maintenance

    7) During inspection of ignition system, perform the sparking test only when necessary and the testing time should be as short as possible. Throttle can not be open, or unburned fuel will enter into the exhaust pipe resulting in three-element catalyst converter damaged.

  • Page 136: List Of Maintenance Tools

    General Precautions of EFI System Maintenance List of Maintenance Tools Tool name: Electronic fuel injection system Instrument Function: Read/clear P-CODE of electronic fuel injection system and observe data flow, motion test of spare parts and so on. Tool name: Ignition Timing Light Function: Check the ignition timing of the engine.
  • Page 137 General Precautions of EFI System Maintenance Tool name: Digital Multimeter: Function: Check characteristic parameters of electronic fuel injection system like voltage, current, resistance and so on. Tool name: Vacuum Meter Function: Check the pressure of intake manifold and so on. Tool name: Cylinder Pressure Gauge Function:...
  • Page 138 General Precautions of EFI System Maintenance Tool name: Fuel Pressure Gauge Function: Check the pressure situation of fuel system and judge the working condition of fuel pump and fuel pressure regulator in the fuel system. Tool name: Exhaust Analyzer Function: Check the exhaust emissions of vehicles and it helps to make a sound judgment on the malfunctions of electronic fuel injection system.
  • Page 139 General Precautions of EFI System Maintenance II. Diagnosis Flow for Inspection and Maintenance by ME7 System according to P-CODE Descriptions: Te following items of inspection and maintenance are performed only after the malfunction has been confirmed to be a steady-state malfunction currently, and otherwise it will lead to diagnostic errors. The “multimeter”...
  • Page 140 General Precautions of EFI System Maintenance 1. P000A Abnormal Operation of Air Intake VVT Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Description about Malfunction Cause: The actual position deviates greatly from the target position of VVT. Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II...
  • Page 141 General Precautions of EFI System Maintenance 3. P0010: Malfunction of Air Intake VVT Open Circuit P2088: Malfunction of Air Intake VVT Short Circuit to Ground P2089: Malfunction of Air Intake VVT Short Circuit to Power Supply Schematic Circuit: Main relay Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram)
  • Page 142 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II P-CODE Present P-CODE Present P0012 P0012 Maintenance tips: Maintenance tips: VVT hardware malfunction Unstable idling speed or rough running of engine may appear.
  • Page 143 Unstable idling speed or rough running of engine may appear. Please check VVT mechanism and replace it when necessary. 7. P0016 Improper Relative Position of Crankshaft and Air Intake Camshaft Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Description about Malfunction Cause: Large deviation of relative mounting position between crankshaft and camshaft or skidding in belt.
  • Page 144 General Precautions of EFI System Maintenance 8. P0017 Improper Relative Position of Crankshaft and Air Exhaust Camshaft Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Description about Malfunction Cause: Large deviation of relative mounting position between crankshaft and camshaft or skidding in belt.
  • Page 145 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 146 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 147 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 148 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 149 General Precautions of EFI System Maintenance Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0037...
  • Page 150 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 151 General Precautions of EFI System Maintenance 16. P0054 Downstream Oxygen Sensor Internal Resistance Irrational Description about Malfunction Cause: Heater of oxygen sensor is diagnosed through monitoring over the internal resistance of heater. The internal resistance of heater is determined by temperature of ceramic, while the temperature of ceramic is subjected to the impact of waste gas temperature in the heater and the catalyst converter.
  • Page 152 General Precautions of EFI System Maintenance 18. P0102 Air Flow Meter Sensor Voltage Too Low Description about Malfunction Cause: The signal of air flow meter sensor is obtained by the transformation of temperature difference signal to voltage signal. After the start of engine, if the continuously checked voltage signal of air flow meter sensor is below the threshold value, low voltage failure is determined by the system.
  • Page 153 General Precautions of EFI System Maintenance 19. P0103 Air Flow Meter Sensor Voltage Signal Too High Description about Malfunction Cause: The signal of air flow meter sensor is obtained by the transformation of temperature difference signal to voltage signal. After the start of engine, if the continuously checked voltage signal of air flow meter sensor is above the threshold value, high voltage failure is determined by the system.
  • Page 154 General Precautions of EFI System Maintenance Main relay Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off...
  • Page 155 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 156 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 157 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0118 P0118 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction.
  • Page 158 General Precautions of EFI System Maintenance 5V Power supply Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off...
  • Page 159 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 160 General Precautions of EFI System Maintenance 28. P0131 Upstream Oxygen Sensor Signal Circuit Voltage Too Low (Malfunction of Circuit Short to Ground) Description about Malfunction Cause: After engine has been started, ECU examines voltage of upstream oxygen sensor circuit. If signal voltage is less than 0.06V longtime, it is determined to be the malfunction of upstream oxygen sensor signal circuit short to ground.
  • Page 161 General Precautions of EFI System Maintenance Main relay Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off...
  • Page 162 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0133 P0133 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction has not been finally confirmed;...
  • Page 163 General Precautions of EFI System Maintenance 32. P0136 Downstream Oxygen Sensor Signal Irrational Description about Malfunction Cause: After engine has been started, ECU performs measurement on circuit voltage of downstream oxygen sensor, and will determine it to be the signal circuit of downstream oxygen sensor short to ground, when signal voltage is lower than 0.4V for a long time.
  • Page 164 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 165 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0138 P0138 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction.
  • Page 166 General Precautions of EFI System Maintenance 36. P0170 Offline Test Air-Fuel Ratio for Self-learning under Closed-Loop Control Irrational Description about Malfunction Cause: When quick diagnosis is performed for offline test using diagnostic instrument to trigger fuel self-learning value, through about 50S, the self-learning value of mixed gas is always failed to be stabilized, hence this malfunction is reported.
  • Page 167 General Precautions of EFI System Maintenance MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0201 P0201 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction.
  • Page 168 Whether or not the coil of fuel injector is in open circuit Whether or not the connection of the pin for connector of fuel injector to the Pin #7 of ECU Whether or not the connection for the pin of is under good condition...
  • Page 169 General Precautions of EFI System Maintenance 42. P0204 4 -Cylinder Control Circuit Open Description about Malfunction Cause: After engine has been started, the circuit voltage is to be measured by the drive module of fuel injector inside ECU, and when the voltage complies with the voltage in the mode of open circuit, it is determined to be the malfunction of open circuit.
  • Page 170 General Precautions of EFI System Maintenance 44. P0221 Electronic Throttle Opening Sensor 2 Signal Irrational Description about Malfunction Cause: The system performs continuous monitoring over the signal circuit voltage of the throttle opening sensor, and when the voltage exceeds the normal voltage range, it is determined to be the malfunction of signal irrational. Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function) Step I: Use diagnostic instrument to read the malfunction information...
  • Page 171 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 172 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 173 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 174 General Precautions of EFI System Maintenance 49. P0264 2 -Cylinder Fuel Injector Control Circuit Short to Ground Description about Malfunction Cause: After engine has been started, the circuit voltage is to be measured by the drive module of fuel injector inside ECU, and when the voltage complies with the voltage in the mode of short to ground, it is determined to be the malfunction of short to ground.
  • Page 175 General Precautions of EFI System Maintenance Main relay Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off...
  • Page 176 The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction. Inspect the following items: 1) The circuit connected to Pin 7# short to ground 1) The Circuit Connected to the Pin 7# Short to Ground 52. P0268 3...
  • Page 177 General Precautions of EFI System Maintenance 53. P0270 4 -Cylinder Fuel Injector Control Circuit Short to Ground Description about Malfunction Cause: After engine has been started, the circuit voltage is to be measured by the drive module of fuel injector inside ECU, and when the voltage complies with the voltage in the mode of short to ground, it is determined to be the malfunction of short to ground.
  • Page 178 General Precautions of EFI System Maintenance Main relay Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off...
  • Page 179 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0300 P0300 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction has not been finally confirmed.
  • Page 180 General Precautions of EFI System Maintenance to be cleaned at the same time) Air intake passage needs to be cleaned Air leakage with the valve of the 1 cylinder valve Ignition system malfunction of the cylinder 1 (inspect ignition wire, spark plug and replace as required) Serious wear of the 1 cylinder...
  • Page 181 General Precautions of EFI System Maintenance 58. P0303 3 -Cylinder Misfire Description about Malfunction Cause: Misfire indicates that the engine fails to release effective ignition energy (malfunction of ignition) in the cylinder due to the ignition system arising from deviation in fuel injection volume (deviation in concentration of mixed gas), too low cylinder compressed pressure, or any other factors, leading to the interruption or malfunction of combustion in the burning process inside the cylinder, which will give rise to emission over standard, or damage of catalytic converter due to over heat.
  • Page 182 General Precautions of EFI System Maintenance Related Malfunction Symptoms: 1. Idling Jitter 2. Weak Acceleration 3. Increased Fuel Consumption 4. Emission over Standard Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II...
  • Page 183 General Precautions of EFI System Maintenance The rotational speed signal may be detected but the crankshaft software reference point signal (BM) cannot be detected. The crankshaft software reference point signal (BM) is frequently missing. The schematic diagram for the crankshaft software reference point signal (BM) frequently found before or behind the expected position is given as follows: 1.
  • Page 184 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 185 General Precautions of EFI System Maintenance 62. P0327 Circuit Voltage of Knock Sensor Signal Too low Description about Malfunction Cause: The knock sensor is installed on the engine body. The engine vibrates in different frequency of vibration under different operating conditions, and generates voltage signals containing various frequencies. The voltage signal may not only reflect whether or not the engine has experienced knock but also reflect the background noise value of the engine (the noise of mechanical parts).
  • Page 186 General Precautions of EFI System Maintenance P0328 High signal circuit voltage of shock sensor Description about Malfunction Cause: The knock sensor is installed on the engine body. The engine vibrates in different frequency of vibration under different operating conditions, and generates voltage signals containing various frequencies. The voltage signal may not only reflect whether or not the engine has experienced knock but also reflect the background noise value of the engine (the noise of mechanical parts).
  • Page 187 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 188 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0341 P0341 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction.
  • Page 189 General Precautions of EFI System Maintenance 67. P0343 Phase Sensor A Short to Power Supply Description about Malfunction Cause: The operation principle for phase sensor is to use Hall component to induce a triggered wheel that rotates along with the camshaft, thus to monitor the position of camshaft. The phase signals received by ECU shall be changing alternately on a regular basis between high level and low level, and ECU shall determine the circuit of phase signal short to power supply if phase signals located at high level are successively detected.
  • Page 190 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 191 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 192 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 193 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0368 P0368 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction.
  • Page 194 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0420 P0420...
  • Page 195 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 196 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 197 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 198 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp On P-CODE Present SVS lamp Off P-CODE Present...
  • Page 199 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp On P-CODE Present SVS lamp Off P-CODE Present...
  • Page 200 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present...
  • Page 201 General Precautions of EFI System Maintenance 80. P0507 Idling Control Rotational Speed Lower than Target Idling Speed Description about Malfunction Cause: The idling rotational speed of electronic throttle is actuated by ECU control DC motor and achieved through throttle opening controlled by drive mechanism. If ECU commands the idling speed equals to target value, but the actual engine speed is still higher than the target idling speed by certain value, it is then determined to be the malfunction of large opening jam.
  • Page 202 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0508, P0509, P0511 P0508, P0509, P0511 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it...
  • Page 203 General Precautions of EFI System Maintenance Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II P-CODE Present P-CODE Present P0562 P0562 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it may following problems may possibly exist possibly be a random malfunction.
  • Page 204 General Precautions of EFI System Maintenance P0571 Brake Switch Signal Circuit Malfunction or Nonsynchronous Ignition switch Battery Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp On P-CODE Present SVS lamp Off P-CODE Present P0571 P0571...
  • Page 205 General Precautions of EFI System Maintenance 87. P0604 Electronic Control Unit RAM Malfunction P0605 Electronic Control Unit ROM Malfunction Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0604, P0605...
  • Page 206 General Precautions of EFI System Maintenance Schematic Circuit: Battery Main relay Fuel Pump Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On...
  • Page 207 General Precautions of EFI System Maintenance Battery Main relay Fuel Pump Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present...
  • Page 208 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P0629 P0629 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction.
  • Page 209 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp On P-CODE Present SVS lamp Off P-CODE Present P0645 P0645 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction.
  • Page 210 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp On P-CODE Present SVS lamp Off P-CODE Present...
  • Page 211 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp On P-CODE Present SVS lamp Off P-CODE Present...
  • Page 212 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II 1. MIL Lamp On P-CODE Present Malfunction Lamp Off P-CODE Present...
  • Page 213 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp On P-CODE Present SVS lamp Off P-CODE Present...
  • Page 214 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp On P-CODE Present SVS lamp Off P-CODE Present P0692 P0692 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction.
  • Page 215 General Precautions of EFI System Maintenance Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction. Inspect the following items: Circuit between ECU Pin 68# and cooling fan relay Pin 85# short to ground.
  • Page 216 General Precautions of EFI System Maintenance 101. P0704 Improper Clutch Pedal Switch Signal Description about Malfunction Cause: After the start of engine, circuit control module of ECU performs monitoring over the brake switch circuit voltage, and if the voltage exceeds the reasonable voltage range preset in ECU, this malfunction is reported. Schematic Circuit: Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and...
  • Page 217 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS 灯 SVS 灯 P-CODE Present P-CODE Present P1336 P1336 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist may possibly be a random malfunction.
  • Page 218 General Precautions of EFI System Maintenance 104. P1558 Too Large Resistance for Electronic Throttle Opening Description about Malfunction Cause: Dirt in electronic throttle shall result in this malfunction. Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp P-CODE Present...
  • Page 219 General Precautions of EFI System Maintenance Read Result I Read Result II SVS Lamp P-CODE Present SVS Lamp P-CODE Present P1568 P1568 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction is not ultimately confirmed and it following problems may possibly exist: may possibly be a random malfunction.
  • Page 220 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp flickers P-CODE Present SVS lamp Off P-CODE Present P1610 P1610...
  • Page 221 General Precautions of EFI System Maintenance 113. P1612 Communication Between Anti-theft Device and ECU Disconnected Description about Malfunction Cause: In the case when engine is not started if the key is placed at “ON”, the anti-theft device will send messages to ECU for two times, and this malfunction will appear, when ECU has failed to receive the message from the anti-theft device for the first time.
  • Page 222 General Precautions of EFI System Maintenance Anti-theft Device Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II SVS lamp flickers P-CODE Present SVS lamp Off P-CODE Present P1613...
  • Page 223 General Precautions of EFI System Maintenance 116. P1651 Malfunction Indicator Lamp (SVS) Circuit Malfunction Description about Malfunction Cause: After engine has been started, the circuit voltage of SVS lamp is to be measured by the control module of SVS lamp circuit inside ECU, and when the voltage complies with the voltage in the mode of circuit malfunction, it is determined to be the circuit malfunction.
  • Page 224 General Precautions of EFI System Maintenance 117. P2106 Electronic Throttle Driver Stage Malfunction Description about Malfunction Cause: After the start of engine, the driver stage diagnostic module inside ECU performs diagnosis over driver circuit of ECU. If the voltage of driver circuit exceeds reasonable voltage range, this malfunction is determined. Schematic Circuit: Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and...
  • Page 225 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MI lamp On P-CODE Present MI lamp off P-CODE Present...
  • Page 226 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MI lamp On P-CODE Present MI lamp off P-CODE Present...
  • Page 227 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MI lamp On P-CODE Present MI lamp off P-CODE Present...
  • Page 228 General Precautions of EFI System Maintenance Malfunction Diagnostic Guide: Required Equipment: (Diagnostic Instrument with EOBD Diagnostic Function, Digital Multimeter, and Correct Circuit Diagram) Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MI lamp On P-CODE Present MI lamp off P-CODE Present...
  • Page 229 In order to optimize the integrated transformation efficiency of catalytic converter to HC, CO, and NOx, the air-fuel ratio of the mixed gas shall be controlled at 14.7:1. If it is found the deviation in manufacture of parts, the sedimentation of colloidal matters in gasoline on the fuel injector, the air intake pipeline, or the back of valve, and air leakage exists with intake and exhaust system, all these factors will give rise to a deviation from 14.7:1 in the air-fuel ratio to different degrees (rich or lean), which will lead to deteriorated emission and...
  • Page 230 In order to optimize the integrated transformation efficiency of catalytic converter to HC, CO, and NOx, the air-fuel ratio of the mixed gas shall be controlled at 14.7:1. If it is found the deviation in manufacture of parts, the sedimentation of colloidal matters in gasoline on the fuel injector, the air intake pipeline, or the back of valve, and air leakage exists with intake and exhaust system, all these factors will give rise to a deviation from 14.7:1 in the air-fuel ratio to different degrees (rich or dense), which will lead to deteriorated emission and...
  • Page 231 In order to optimize the integrated transformation efficiency of catalytic converter to HC, CO, and NOx, the air-fuel ratio of the mixed gas shall be controlled at 14.7:1. If it is found the deviation in manufacture of parts, the sedimentation of colloidal matters in gasoline on the fuel injector, the air intake pipeline, or the back of valve, and air leakage exists with intake and exhaust system, all these factors will give rise to a deviation from 14.7:1 in the air-fuel ratio to different degrees (rich or lean), which will lead to deteriorated emission and...
  • Page 232 General Precautions of EFI System Maintenance Step I: Use diagnostic instrument to read the malfunction information Read Result I Read Result II MIL Lamp On P-CODE Present MIL Lamp Off P-CODE Present P2188 P2188 Maintenance tips: Maintenance tips: The malfunction has been confirmed, and the The malfunction has not bee finally confirmed, and following problems may possibly exist wait for system to fulfill diagnosis.
  • Page 233 General Precautions of EFI System Maintenance 128. P2196 Upstream Oxygen Sensor Deteriorated (Lower Limit of Deterioration Factor Exceeded) Description about Malfunction Cause: Normally, air-fuel ratio of combustible mixed gas is changed between thick and thin alternatively. Correspondingly, amplitude of oxygen sensor signal varies frequently as series of pulse. If sensor deteriorates, its sensitivity to the mixture may decrease and the characteristic curve deviates, causing slow adjustment of mixed gas.
  • Page 234 General Precautions of EFI System Maintenance 130. P2271 Downstream Oxygen Sensor Deteriorated (Oxygen Sensor Malfunction - Rich Mixed Gas) Description about Malfunction Cause: Under normal circumstances, the signals of downstream oxygen sensor shall fluctuate up and down the control target value. The system will dilute the mixed gas if it deviates from control target to be too rich. If the voltage signal of sensor is not diluted in the desired direction and keeps to be too rich for a certain period, the system will determine it to be the malfunction of oxygen sensor on the too rich side.
  • Page 235 General Precautions of EFI System Maintenance III. Diagnostic Flow for Inspection and Maintenance by M7 System according to Malfunction Symptoms Before enabling the malfunction diagnostic steps as per engine malfunction symptoms, please firstly perform the primary inspections below 1. Confirm that the engine malfunction indicator lamps are working normally 2.
  • Page 236 General Precautions of EFI System Maintenance Normal start with unstable idling speed after warming up. Normal start with unstable idling speed or flameout when partly loaded (i.e. with A/C operating). 10. Normal start with high idling speed. 11. Slow rotation or flameout when accelerating. 12.
  • Page 237 General Precautions of EFI System Maintenance II. Engine rotates but without being started. General malfunction Locations: 1. Empty Fuel Tank; 2. Fuel Pump; 3. Rotational Speed Sensor; 4. Ignition Coil; 5. Mechanical Part of Engine. General Diagnostic Flow: Operating Steps Test Result Follow-up Step Link up the fuel pressure gauge (the linking point to be on the...
  • Page 238 General Precautions of EFI System Maintenance 3. Difficult warming-up start of engine. General malfunction Locations: 1. Water-containing Fuel 2. Fuel Pump; 3. Coolant Temperature Sensor; 4. Vacuum Pipe of Fuel Pressure Regulator; 5. Ignition Coil. General Diagnostic Flow: Operating Steps Test Result Follow-up Step Link up the fuel pressure gauge (the linking point to be on the...
  • Page 239 General Precautions of EFI System Maintenance 4. Difficult cold start of engine. General malfunction Locations: 1. Water-containing Fuel; 2. Fuel Pump; 3. Coolant Temperature Sensor; 4. Fuel Injector ; 5. Ignition Coil; 6. Throttle Body; 7. Mechanical Part of Engine. General Diagnostic Flow: Operating Steps...
  • Page 240 5. Difficult start of engine at any time with normal rotation speed. General malfunction Locations: 1. Water-containing Fuel 2. Fuel pump 3. Coolant Temperature Sensor; 4. Fuel Injector ; 5. Ignition Coil; 6. Throttle Body; 7. Air intake passage; 8. Ignition Timing; 9. Spark Plug; 10. Mechanical Part of Engine...
  • Page 241 6. Normal start with unstable idling speed at any time. General malfunction Locations: 1. Water-containing Fuel 2. Fuel Injector ; 3. Spark Plug; 4. Throttle Body; 5. Air intake passage; 6. Ignition Timing; 7. Spark Plug; 8. Mechanical Part of Engine General Diagnostic Flow:...
  • Page 242 53#, 80# and 61# is normal. repaired 7. Normal start with unstable idling speed during warming up General malfunction Locations: 1. Water-containing Fuel; 2. Coolant Temperature Sensor; 3. Spark Plug; 4. Throttle Body; 5. Air intake passage; 6. Mechanical Part of Engine...
  • Page 243 General Precautions of EFI System Maintenance Operating Steps Test Result Follow-up Step Diagnostic Help Link up the adapter of the electronic injection system, turn on the ignition switch, and examine whether or not the power Corresponding supply for Pins 12#, 63#, 44# and 45# is normal. Inspect lines to be whether or not the grounding of Pins 79#, 17#, 35#, 36#, 51#, inspected and...
  • Page 244 General Precautions of EFI System Maintenance 9. Normal start with unstable idling speed or flameout when partly loaded (i.e. with A/C operating). General malfunction Locations: 1. Air Conditioning System; 2. Fuel Injector. General Diagnostic Flow: Operating Steps Test Result Follow-up Step Related parts and components Inspect whether or not carbon accumulation exists on the...
  • Page 245 General Precautions of EFI System Maintenance 10. Normal start with high idling speed. General malfunction Locations: 1. Throttle Body; 2. Vacuum Pipe; 3. Coolant Temperature Sensor; 4. Ignition Timing. General Diagnostic Flow: Operating Steps Test Result Follow-up Step Inspect whether or not the throttle cable is jammed or too Adjustment tight.
  • Page 246 11 .Slow rotation or flameout when accelerating. General malfunction Locations: 1. Water-containing Fuel 2. Air Flow Meter and Throttle Opening Sensor; 3. Spark Plug; 4. Throttle Body and Idling Bypass Air Circuit; 5. Air Intake Passage; 6. Fuel Injector ; 7. Ignition Timing; 8. Exhaust pipe...
  • Page 247 12. Slow actions when accelerating. General malfunction Locations: 1. Water-containing Fuel; 2. Air Flow Meter and Throttle Opening Sensor; 3. Spark Plug; 4. Throttle Body; 5. Air Intake Passage; 6. Fuel Injector; 7. Ignition Timing; 8. Exhaust pipe General Diagnostic Flow:...
  • Page 248 13. Poor acceleration with poor performance. General malfunction Locations: 1. Water-containing Fuel; 2. Air Flow Meter and Throttle Opening Sensor; 3. Spark Plug; 4. Ignition Coil; 5. Throttle Body; 6. Air Intake Passage; 7. Fuel Injector; 8. Ignition Timing; 9. Exhaust pipe...
  • Page 249 General Precautions of EFI System Maintenance Operating Steps Test Result Follow-up Step Related parts and components Inspect whether or not carbon accumulation exists on the to be cleaned throttle body. Next Step Next Step Line to be Inspect whether or not the air flow meter, the throttle opening inspected and sensor, and their lines are under normal conditions.
  • Page 250 General Precautions of EFI System Maintenance IV. Attachment Description of Family Vehicle This maintenance rule is applicable to family vehicles. The time intervals for maintenance are determined according to the readings of odometer or time intervals, whichever comes first shall apply. The maintenance rule is based on the assumption as per design during normal use of vehicle, and must be strictly observed.
  • Page 251 General Precautions of EFI System Maintenance V. P-CODE List EUIV EOBD Whether Whether P-CODE UAES Description CLASS MIL lamp lamp lights lights × × P000A Abnormal Operation of Air Intake VVT × × P001B Abnormal Operation of Air Exhaust VVT ×...
  • Page 252 General Precautions of EFI System Maintenance EUIV EOBD Whether Whether P-CODE UAES Description CLASS MIL lamp lamp lights lights Irrational Circuit Voltage of Electronic Throttle Opening √ √ P0122 Sensor Too Low Circuit Voltage of Electronic Throttle Opening √ √ P0123 Sensor Too High ×...
  • Page 253 General Precautions of EFI System Maintenance EUIV EOBD Whether Whether P-CODE UAES Description CLASS MIL lamp lamp lights lights to Ground 1st-Cylinder Fuel Injector Control Circuit Short × √ P0262 to Power Supply 2nd-Cylinder Fuel Injector Control Circuit × √ P0264 Short to Ground 2nd-Cylinder Fuel Injector Control Circuit...
  • Page 254 General Precautions of EFI System Maintenance EUIV EOBD Whether Whether P-CODE UAES Description CLASS MIL lamp lamp lights lights Control Circuit Voltage of Carbon Canister × √ P0458 Control Valve too Low Control Circuit Voltage of Carbon Canister × √ P0459 Control Valve too High Cooling Fan Relay Control Circuit Open (Low...
  • Page 255 General Precautions of EFI System Maintenance EUIV EOBD Whether Whether P-CODE UAES Description CLASS MIL lamp lamp lights lights × × P0688 Improper Output Voltage of Main Relay Control Circuit of Cooling Fan Relay Short to √ × P0691 Ground (Low Speed) Control Circuit of Cooling Fan Relay Short to √...
  • Page 256 General Precautions of EFI System Maintenance EUIV EOBD Whether Whether P-CODE UAES Description CLASS MIL lamp lamp lights lights ground √ √ P2106 Electronic Throttle Driver Stage Malfunction Too Low Signal Voltage of Electronic Throttle √ √ P2122 Pedal Position Sensor 1 Too High Signal Voltage of Electronic Throttle √...

  • Page 257: Body Accessories

    Disassembly/assembly of rear license lamp Disassembly/assembly of rear doors .... S-5 cover ............S-25 Adjustment of rear doors ......S-7 Disassembly/assembly of luggage rack ..S-25 Disassembly/assembly of door lock latch ..S-7 Disassembly/assembly front wheel Power window system .......... S-8 mudguard............
  • Page 258 Content Repair of heating wire ........ S-33 Disassembly/assembly of rear trim cover of Disassembly/assembly of rear windshield trunk ............S-49 defroster relay (the pictures of this part cannot Disassembly/Assembly of roof ....S-49 be applied as the fuse box has been amended) Floor covering ............

  • Page 260: Engine Bonnet

    Engine hood Engine bonnet Adjustment of engine bonnet Disassembly/assembly of engine bonnet Loosen the mounting bolt of engine bonnet, and readjust the engine bonnet position. Caution: It is dangerous to remove the engine bonnet without the support, because the engine bonnet may drop down to hurt you.

  • Page 261: Front Fender

    Front fender Adjustment of front fender clearance Front fender Clearance: Disassembly/assembly of fender Disconnect the negative cable of battery. Remove the front steering indicating light (See Part T——External Lighting System ); Remove the front combined headlight (See Part T——External Lighting System ); Remove the front bumper;...

  • Page 262: Doors

    Doors Doors Snap Disassembly/assembly of front doors Disconnect the negative cable of battery; Remove the hinge bolts of front doors and dismantle the connection of front hinge; Connector Remove the front doors limiter bolt and Rubber sleeve dismantle the connection of limiter; 10.
  • Page 263 Doors Trim panel of front doors Exterior handle bar Front door diaphragm Exterior handle base Front door glass Front door lock Guide groove of front door glass Hole plug Front door window regulator Hole cap Front door interior handle Stop pad Lock cap Door lock cable snaps...

  • Page 264: Adjustment Of Front Doors

    Doors Adjustment of front doors Hinge bolt Measure the clearance between the front door and bodywork; If abnormal, loosen the mounting bolt of door hinge or the mounting screw of door lock latch, and readjust the door position. Clearance: Hinge bolt Limiter bolt Harness connector (See Disassembly Instructions )
  • Page 265 Doors Remove trim panel rear door The assembly is in the reverse order with that (See——Disassembly/Assembly Front of disassembly. Doors and Trim Panel of Front Door). Break down in the order as shown in the Table below: Trim panel of rear door (See——Removal of Exterior handle base of rear door Trim Panel of Rear Door) Lock cap...

  • Page 266: Adjustment Of Rear Doors

    Doors Adjustment of rear doors Disassembly/assembly of door lock latch Measure the clearance between the rear door Remove the screws; and bodywork. Remove the door lock latch; l If abnormal, loosen the mounting bolts of Door lock latch door hinge or and mounting screws of Screw door lock and readjust the position of door.

  • Page 267: Power Window System

    Power window system Power window system Disassembly/assembly of the main switch of power window Disconnect the negative cable of battery; Remove the front door trim panel (See——Disassembly/Assembly of Trim Panel of Front Doors); Remove the main switch panel; Remove the screws and the main switch of power window. Main switch panel Clamp Screw...

  • Page 268: Check Of The Main Switch Of Window Regulator

    Power Window System Check of the main switch of window regulator At the driver side Attention: Pins 1A (1M), 1B, 1C (1K), 1D, 1J and 1L correspond to the occupant side or the rear row. Remove the main switch of power window (See——Disassembly/Assembly of Main Switch of Power Window);...

  • Page 269: Doors Other Than The Driver Side

    Power Window System Doors other than the driver side Remove the main switch of power window (See——Disassembly/Assembly of the Main Switch of Power Window); Rotate the power off switch to the UNLOCK position; Check, with an ohmmeter the terminal connection of power window main switch l If abnormal, replace it.

  • Page 270: Disassembly/Assembly Of Auxiliary Switch Of Power Window

    Power Window System Disassembly/assembly of auxiliary switch of Switch panel power window Front doors at the occupant side Disconnect the negative connection of battery; Remove front door trim panel (See——Disassembly/Assembly of Trim Panel of Front Doors); Regulator switch Remove the switch panel; Remove the screws and auxiliary switch of power window;...

  • Page 271: Rear Doors

    Rear doors Rear doors Disconnect the negative connection of battery; Switch panel Remove trim panel rear door(See——Disassembly/Assembly of Rear Door Trim Panel); Remove the switch panel; Remove the screws and PW auxiliary switch; 10. The installation is in the reverse order with the Regulator switch removal.

  • Page 272: Disassembly/Assembly Of Rear Pw Regulator

    Rear doors Disassembly/assembly of rear PW regulator Disconnect the negative cable of battery; Remove the rear door glass; Disconnect the connector of rear PW window regulator; Remove the nut and then dismount the PW regulator; Tightening torque: 6.87-9.80N·M{70-100kgf·cm, 60.8-86.7in·lbf} The installation is in the reverse order with that of removal.

  • Page 273: Check Of Pw Motor

    Rear doors Check of PW motor At the driver side Remove the PW motor; Connect the battery positive respectively with the terminals A and C of the electric motor and check their performance. Connection Motor performance B＋ Upward B＋ downward Up ward Downward Connect the terminal B of PW motor by the 5V voltage with the terminal F grounded.

  • Page 274: Setting Of Driver-Side Pw Motor

    Rear doors Setting of driver-side PW motor Attention: As the initial value of new regulator has been preset, it is unnecessary to reset. As the initial value of new PW motor has been preset, start from the 3 step; In case of the following phenomena, the power door will be unable to return normally. —...

  • Page 275: Check Of The Lifting Function Of Power Window

    Rear doors Close the window; Check of the lifting function of power window Confirm that the glass moves downward with ca 200mm opening left, once in contact with Attention the hammer handle. If any abnormal, check the In the check, do not extend your body e.g. faults.

  • Page 276: Power Door Lock System

    Power door lock system Power door lock system Disassembly/assembly of power door lock Disconnect the negative cable of battery; Dismantle the cap of interior handle (See——Disassembly/Assembly of Interior Handle Cap); Dismantle the door trim panel (See——Disassembly/Assembly of Door Trim Panel); Dismantle the component of interior handle (See——Disassembly/Assembly of Interior Handle Component);...

  • Page 277: Back Door

    Power door lock system Back door Disassembly/assembly of back door Warning: It is dangerous to dismount the back door without support; The back door is likely to drop down and hart your body. After completely opened and propped up the back door, two persons at least shall be work together;...
  • Page 278 Power door lock system Disassembly/assembly of back door Remove the trim panel of back door; Disassemble in the reverse order as shown in the Table; The assembly is in the reverse order with that of disassembly Back door lock Right mounting base Exterior handle of back door Gas spring (L) Rear trim cover of trunk...

  • Page 279: Adjustment Of Back Door

    Back door Loosen the mounting nut of back door; Back door Rear combinatio n lamp Reposition the back door; Side-wall Clearances A- A: 5.5-7.5mm Back door Back door B- B: 4-6mm Back door glass Rear bumper C- C: 4-6mm Rear combinatio n lamp D- D: 3.5-6.5mm...

  • Page 280: Filler Cap And Opener

    Filler cap and opener Filler cap and opener Disassembly/assembly of filler cap and opener 11. If desirous to dismount the filler cap opener, remove first the trim panel at the left side of trunk (See——Trim Panel, Disassembly/Assembly of Trim Panel at the Side of Trunk) 12.

  • Page 281: Bumper

    Bumper Disassembly/assembly of front bumper Bumper Disassembly as per the reverse order as Disassembly/assembly of front bumper indicated in the table below; Disconnect the negative cable of battery; Assembly in the reverse order with that of Dismount the front wheel mudguard (See disassembly;...

  • Page 282: Disassembly/Assembly Of Rear Bumper

    Bumper Disassembly/assembly of rear bumper Reversing radar harness Disconnect the negative cable of battery; Reversing radar Remove the rear bumper mudguard (See Part T——Disassembly/Assembly Rear Bumper Mudguard) Detailed description of rear bumper removal Dismount as per the order as indicated in the table;...

  • Page 283: External Accessories

    External accessories External accessories Disassembly/assembly of front wall grille Remove the windshield wiper arm and wiper blade (See Part T——Disassembly/assembly of Wiper and Washer, Windshield Wiper Arm and Wiper Blade) Remove the front wall grille as per the order Snap A set out in the Table.

  • Page 284: Disassembly/Assembly Of Engine Mudguard

    External accessories As per the order set out in the Table, Remove the bolt; Remove the rear license lamp cover; Install as per the reverse order with that of the removal. Disassembly/assembly engine Install as per the reverse order with that of mudguard the removal.

  • Page 285: Disassembly/Assembly Of Side Wall

    External accessories Install as per the reverse order with that of the removal. Disassembly/assembly of side wall Remove the snap A of front/rear ends; Remove the lower snap B; Remove, by use of a clamp opener the snap C installed on the sheet metal of side wall. Remove the side wall.

  • Page 286: Removal And Installation Of Radiator Grille

    External accessories Removal and installation of radiator Removal and installation of ventilation grille cavity Remove the fastening bolt and snap A; Remove the front wall grille (See——Front wall grille, removal and installation of front Remove the snap B; wall grille); Pull out the grille snap from the bumper and Remove the snaps;...

  • Page 287: Molding

    Molding Molding Removal of windshield molding Attention: ● The windshield molding is replaceable; ● Remove the windshield after the windshield molding removed (See——Window Glass, Removal of Windshield) Mounting of windshield molding Attention: ● While installing the windshield, install the windshield molding (See——Window Glass, Mounting of Windshield) Removal of rear windshield molding Attention:...

  • Page 288: Disassembly/Assembly Of Front Door Molding

    Moldings Disassembly/assembly front door molding Completely open the front door glass; Pry up the molding end, by use of a flathead screwdriver wrapped with tape, draw up the front door molding and remove it. Installation: Align the rear end of molding with outer sheet metal compressed by tapping, and then the entire molding.

  • Page 289: Exterior Rear-View Mirrors

    Exterior rear-view mirrors Clamp Exterior rear-view mirrors Rear-view mirror lens Disassembly/assembly electric/ manual rear-view mirrors Disconnect the negative cable of battery ; Remove front door trim panel; Lens frame Lens holder Clamp (See——Trim Panel, Disassembly/Assembly of Trim Panel of Front Door) ; Remove the corner window trim panel;...
  • Page 290 Exterior rear-view mirrors Performance of rear-view mirrors Upper Lower Left Right Closed Right Left Lower Upper Outward extended/retracted motor Check, with an ohmmeter, the continuity between two pins A and B outside the electric rear-view mirrors. Check, with an ohmmeter, the continuity between two pins C and D outside the electric rear-view mirrors.

  • Page 291: Interior Rear-View Mirror

    Interior rear-view mirror Mounting of rear-view mirror pedestal Interior rear-view mirror Scrape the original sealant with a blade; Removal of Interior rear-view mirror Clean the ceramic membrane on the pedestal Insert a flathead screwdriver wrapped with and glass and remove grease thereon. tape, between the rear-view mirror and pedestal.

  • Page 292: Rear Windshield Defroster

    Rear windshield defroster Repair of heating wire Rear windshield defroster Clean with unleaded gasoline, the damaged Check of heating wire part of heating wire; Place the ignition switch in the ON position; Paste the tape on the upper/lower damaged Turn on the switch of rear windshield parts of heating wire.

  • Page 293: Check Of Rear Windshield Defroster Relay

    Rear windshield defroster Check of rear windshield defroster relay Relay of rear windshield defroster Remove the rear windshield defroster relay (See——Disassembly/Assembly Rear Windshield Defroster Relay) Relay plug of rear Check, with an ohmmeter, the continuity between the pins of rear windshield defroster windshield relay.

  • Page 294: Window Glass

    Window glass Attention: Window glass ● If it is difficult to remove the sealant of a Removal of front windshield certain component, use a piano string as Remove interior rear-view mirror shown in Fig., according to the steps as indicated “When the Windshield is Reused”. (See——Rear-view mirrors, Removal...

  • Page 295: Mounting Of Windshield

    Window glass Caution: Roof cover Front windshield ● molding To prevent the sealant scratch, or glass pushed out when the doors closed, all windows shall be opened, until the sealant hardened. Front top beam Cut old sealant on the windshield frame by use of blade and save a layer in thickness of ca 1—2mm.

  • Page 296: Removal Of Rear Windshield Glass

    Window glass width 8.0mm. Bodywork Mark Pad A Remove the front windshield; 13. Align the mark on the glass with V-groove of pad A, and install the glass on the vehicle; As shown in Fig., install the fixer at the mark position of glass.
  • Page 297 Window glass Fixer Fixer Protective strip Locking Locking Joint Joint block block Pass the SST (piano string) through the small hole. Protective strip Warning: ● Wear gloves in use of piano string, otherwise it will result in hand injury, thus gloves must Section view A-A be worn in use of the piano string;...
  • Page 298 Window glass Fixer Fixer Central line Bodywork Locking Locking Joint Joint block block Mounting of rear windshield Warning: ● Wear gloves in use of scraper to prevent injury. Remove the rear windshield; Caution: As shown in Fig., install the fixer on the ●...
  • Page 299 Window glass strip and glass, a layer of sealant to seal up the gaps. The thickness of sealant is 14.0mm {0.55in} and the width 8.0mm {0.31in}. 13. Align the mark on the glass with V-groove of pad A, and install the glass on the vehicle; 14.

  • Page 300: Dashboard And Control Panel

    Dashboard and control panel 15. Remove the bolt; Dashboard and control panel Disassembly/assembly of dashboard Remove the combination switch (See Part T——External Lighting System, Disassembly/Assembly Combination Switch) Remove the mounting bolt, and then shift the steering shaft assembled on the dashboard (See N——Engine Speed Sensing Power Steering, Disassembly/Assembly of Steering Wheel and Dowel pin...

  • Page 301: Disassembly/Assembly Of Side Panel

    Dashboard and control panel Defrosting duct assembly A/C duct Central vent A/C outlet (L) A/C outlet (R) Dashboard panel Dashboard frame Disassembly/assembly of side panel Remove the clamp A by use of a flathead screwdriver wrapped with tape ; Clamp Install as per the reverse order with that of removal.

  • Page 302: Disassembly/Assembly Of Combination Instrument

    Dashboard and control panel Disassembly/assembly Combination instrument Remove the screw; Hold the lower end of combination instrument cover and draw out forcibly the snaps. Take out with a Phillips screwdriver, 4 screws locking the HI-FI host, and then draw out slightly the host, pull out two connectors behind the host, and then take out the HI-FI host;...

  • Page 303: Disassembly/Assembly Of Driver/ Occupant-Sided Outlets

    Dashboard and control panel Radio; performance, air volume and mode of Hold the lower baffle and loosen the hook C. air compressor); Snap Install the HI-FI host and fix the screws Insert the wiring connector behind the HI-FI panel, and align the panel snap with the slot on the dashboard, knock clockwise the snaps into the panel from the left upper corner;...

  • Page 304: Disassembly/Assembly Of Auxiliary Fascia

    Dashboard and control panel Open the armrest box behind the auxiliary Disassembly/assembly of auxiliary fascia fascia console and turn over backward; console Remove the panel of auxiliary fascia console; Break down in the order as shown in the Table below: Loosen the screws and move out the auxiliary fascia console;...

  • Page 305: Inner Trim

    Inner trim panel Disassembly/assembly of upper trim panel Inner trim of column B Disassembly/assembly of column A trim Remove the fixer on the front safety belt (See panel ——Seat Safety Belt, Disassembly/ Assembly Turn over the sealing strip. of Front Safety belt) Use the removal tool of fastening screw to Remove the lower trim panel of column B loosen the snap A;...

  • Page 306: Disassembly/Assembly Of Inner Pedal Of Front Doorsill

    Inner trim panel Pedal of rear door Disassembly/assembly of inner pedal of front doorsill Loosen the snap A from the bodywork Pull upward to remove the pedal. Pedal of front door Install as per the reverse order with that of removal.

  • Page 307: Disassembly/Assembly Of Side Trim Panel Of Trunk

    D. to loosen the snap A, to remove the trunk Trim panel on the trim panel; column D 7. Install in the reverse order with that of removal. Install in the reverse order with that of removal. S-48...

  • Page 308: Disassembly/Assembly Of Rear Trim Cover Of Trunk

    Inner trim panel Disassembly/assembly of rear trim cover of trunk Take out the trunk carpet and base plate. Dismantle the snaps A and C to remove the trim panel Rear trim cover of trunk Disassembly/Assembly of roof Disconnect the negative cable of battery; Dismantle connecting gibs and sealing strips;...

  • Page 309: Floor Covering

    Floor covering Disassembly/assembly of trim panels of Floor covering front doors Disassembly/assembly of front carpet Disconnect the negative cable of battery; Remove front seats (See——Seats, Removal/Installation of Front Seats) Remove the trim panel of trunk; Remove the rear seats (See seats——Seats, Disassembly/Assembly of Rear Seats);...
  • Page 310 Floor covering Remove the snap F. 12. To loosen 8 snaps M, you need to insert your hand into the slot of switch panel and pull outward the panel so as to disengage the locking pin from the hole of sheet metal; 13.

  • Page 311: Disassembly/Assembly Of Trim Panel Of Rear Door

    Remove the screws E (two pcs). Pull 15. Install as per the reverse order with that of removal. 7. Remove the pad F. 8. Remove the screw G; Disassembly/assembly of trim panel of rear Remove the switch panel H; door 10.
  • Page 312 Floor covering 13. Draw upward the trim panel of rear door, so as to disengage the upper edge curls of door panel from the sheet metal; Pull 14. Install as per the reverse order with that of removal. S-53...

  • Page 313: Seats

    Seats safety belt (lateral harness plug), confirm that Seats the buckle switch plug of safety belt passes Disassembly/assembly of manual front through below the mobile connection cable. seats Mobile connection cable Disconnect the negative cable of battery. Dismount as per the order as indicated in the table Install as per the reverse order with that of removal.

  • Page 314: Manually Adjustable Occupant Seats

    Seats Manually adjustable occupant seats Break down as per the order as indicated in the table; Assemble in the reverse order with that of disassembly. Headrest Front guide rod 1#, front guide rod 2# Side hook Angle adjuster handle Outside protective cover Angle adjuster assembly Inside protective cover Backrest trim...

  • Page 315: Electric Adjustable Driver Seat

    Seats Electric adjustable driver seat Break down as per the order as indicated in the table; Assemble in the reverse order with that of disassembly. Headrest Adjusting motor of backrest Front guide rod 1#, front guide rod 2# Cushion trim Side hook Front seat cushion Seat harness...

  • Page 316: Electric Adjustable Occupant Seats

    Seats Electric adjustable occupant seats Break down as per the order as indicated in the table; Assemble in the reverse order with that of disassembly. Headrest Backrest frame Front guide rod 1#, front guide rod 2# Adjusting motor of backrest Side hook Backrest trim Seat harness...

  • Page 317: Disassembly/Assembly Of Rear Seats

    Seats Disassembly/assembly of rear seats Dismount as per the order as indicated in the table; Install as per the reverse order with that of removal. Cushion of rear seats Backrest of rear seat Rear backrest hinge S-58...
  • Page 318 Seats Disassembly/assembly of rear seats Break down as per the order as indicated in the table; Assemble in the reverse order with that of disassembly. Mounting bracket (R) Backrest of rear seat (R) Adjusting bracket (R) Backrest holder of rear seat (R) Seat trim (R) Headrest of rear seat (L) Cushion of rear seat (R)

  • Page 319: Removal Of Front Drainage Hose

    Seats dormer frame; Removal of front drainage hose Remove the rear drainage hose from the Remove the roof (See——Disassembly/ clamp; Assembly of Roof); Draw the rear drainage hose into the cabin. Remove the front drainage hose from the dormer frame; Remove the rear drainage hose.

  • Page 320: Disassembly/Assembly Of Dormer Unit

    Dormer Connect the plug of dormer motor; Disassembly/assembly of dormer unit Connect the plug of dormer; Disconnect the negative cable of battery; Connect the negative of battery cable; Remove reading lamp (See—— Disassembly/Assembly of Reading Lamp); Toggle the ignition switch to the ON position Remove the roof (See——Disassembly/ Press down the dormer switch Off until the...

  • Page 321: Disassembly/Assembly Of Interior Belt Line Molding

    Inclined upward Install in the reverse order with the removal Inclined downward (Tightening torque of nut (3): 7.8～11.8N.m) Attention shall be paid to align the mounting snaps of luggage rack with the mounting hole of bodywork and then compress by beating.

  • Page 322: Disassembly/Assembly Of Interior Handle

    Dormer Disassembly/assembly of interior handle To dismount: Pry up the screw cap A; Remove the self-tapping screw B; Remove the interior handle cover C; Remove the door trim panel D (See—— Disassembly/Assembly of Door Trim Panel). Remove the interior handle E. Install in the reverse order with the removal.

  • Page 323: Disassembly/Assembly Of Exterior Handle

    Handle/ Inside Belt Line Molding Disassembly/assembly of exterior handle Disassembly: Remove the plug cap A; Remove the fastening screw B; Remove the lock cap C; Remove the door trim panel; Remove the fastening screw D; Remove the exterior handle lever E and the mounting base F.
  • Page 324 Clutch General Steps ........... H1-1 Clutch Pipe Removal/Installation ..H1-1 Clutch Pedal ..........H1-1 Clutch Pedal Inspection/Adjustment ..............H1-1 Clutch Master Cylinder ......H1-2 Clutch Master Cylinder Removal/ Installation ........H1-2 Clutch Master Cylinder Disassembly/ Assembly ......... H1-3 Clutch Slave Cylinder ......H1-3 Clutch Slave Cylinder...

  • Page 326: General Steps

    General Steps General Steps Clutch Pipe Removal/Installation Attention: Pedal free travel Clutch and brake system share one Pedal free travel fluid reservoir. If the clutch has been disassembled for any purpose, please replenish brake fluid and bleed air in it; check for oil leakage after reinstallation.

  • Page 327: Clutch Master Cylinder

    Clutch Pedal Clutch pedal Total travel: 131mm (5.50in) (for reference) Clutch Pedal Removal/Installation Clutch Separation Point 1. Remove in order 1-2-3-4-5 as shown in the diagram. Clutch Pedal Total Travel 2. Install in reverse order 5-4-3-2-1 as of Clutch Pedal Separation Travel removal.

  • Page 328: Clutch Master Cylinder Disassembly/Assembly

    Clutch Master Cylinder Clutch Master Cylinder Disassembly/ Clip Assembly Clip 1. Remove in order 1-2-3-4-5 as shown in Fluid Reserve Pipe the diagram. Split Washer 2. Separate the piston split washer and Piston cylinder with slotted screwdriver in the Bush removal of piston assembly.

  • Page 329: Clutch Slave Cylinder Disassembly/Assembly

    Clutch Pedal Clutch Slave Cylinder Disassembly/Assembly 1. Disassemble in order 1-2-3-4-5-6-7-8 as shown in the diagram. 2. Install in reverse order 8-7-6-5-4-3-2-1 as of removal. Dust Boot Fixed Block Piston Assembly Return Spring Piston Stopper Dust Cover Bleed Screw Cap...

  • Page 330: Gearshift

    Flywheel Gearshift Gearshift Removal/ Installation Remove with the sequence shown in the diagram. Install in the reverse order of removal. Verify the whether the gear shift runs smoothly after installation. Shift Lever Handle Control Cable Gearshift H1-5...
  • Page 331 Disassembly/installation of brake master cylinder ................... P-5 Service of liquid level sensor ........................P-6 Disassembly/assembly of brake master cylinder ..................P-6 Check of vacuum booster ......................... P-7 Removal/installation of vacuum booster ....................P-9 Check of front disc brakes ..........................P-10 Introduction to the repair tips of brake judder ..................

  • Page 332: Brake System

    Brake system General steps Removal and installation of wheels and tires This chapter does not include the removal and installation steps of wheels and tires. If necessary to remove the wheel, they shall be retightened up at the installation time, to the specified torque in 88-127N.m {9.0-13.0kgf.m,65-94ft.lbf}.

  • Page 333: Inspection And Adjustment Of Brake Pedal

    Brake system 7. Check whether the brake is in normal operation. 8. Verify whether there is any spilled fluid, if yes, wipe it off. 9. When exhausting of the brake is finished, fill the brake with the brake fluid to the highest liquid level.

  • Page 334: Removal/Disassembly/Installation Of Brake Pedal

    Brake system. pedal is depressed with the force in 147N {15kgf}. Specified vale: 130mm (min) Removal/disassembly/installation of brake pedal Dismantle in the order of 6-7-8-9-10-11-2-3-5-1. Dismantle order 4-12-13-15-14-16-17-19-18 Install in the reversing order of removal.

  • Page 335: Service Of Brake Switch

    If inconsistent to the case as specified in the table, replace the brake switch. Disassembly/installation of brake master cylinder Remove in the order of 1-2-3-4-5-6-7-8. Liquid level sensor plug Install in the reversing order of removal. Pipe clamp Inlet hose of clutch master cylinder...

  • Page 336: Service Of Liquid Level Sensor

    Brake system Service of liquid level sensor Circuit put through Pull out the sensor plug; Terminal Conditions Connect an ohmmeter on the plug; Start measuring when the liquid level is more Below the Min value Above the Max value than the max. value, and confirm the circuit is not through at this moment.

  • Page 337: Check Of Vacuum Booster

    Brake system Installation instructions of stop pin Aim the piston bore at the stop pin and fit on the 2nd piston and return spring. Fit on the stop pin. Push in and release the piston to confirm that the piston can be locked by the stop pin. Check of vacuum booster Check the function of vacuum booster (simple method) Attention:...
  • Page 338 Brake system (Check with a measuring instrument) Vacuum gauge Pedal dynamometer As shown in Fig., connect respectively with the SST vacuum gauge and pedal pressure detector. Attention: Exhaust the air in the SST at the instrument A with a special instrument and a pedal pressure detector.

  • Page 339: Removal/Installation Of Vacuum Booster

    Brake system Start the engine and step down the brake pedal when the vacuum degree achieved 66.7kPa{500mmHg}. If the fluid pressure is within the specified range, it means that the brake device is in normal operation. Pedal pressure Fluid pressure MTX 196N 7100kPa{72kgf/cm }min...

  • Page 340: Check Of Front Disc Brakes

    Check of front disc brakes Check of front disc brakes Introduction to the repair tips of brake judder There are three features as shown below in the problems of brake judder: (1) Vibration of steering wheel. The steering wheel vibrates in the direction of rotation and such feature is the most notable when braked at the speed between 100～140 km/h {62～87 mph};...

  • Page 341: Removal And Installation Of Front Disc Brakes

    Check of front disc brakes After all hub nuts screwed up to the same torque, place the dial gauge on the friction surface of brake disc, at ca.,10 mm{0.39 in} away from the edge of disc. Turn once the brake disc and measure the lateral run-out. Run-out limit: 0.05 mm {0.002 in}.
  • Page 342 Check of front disc brakes Brake hose Guide pin cover Caliper bolt Guide pin Front caliper assembly Guide pin bushing Compressing spring Front brake disc See——P Essentials to Removal of Internal/external friction plate Brake Disc See——P Essentials to Brake Disc See——P Essentials to the Installation of Internal/External Friction Plates Installation...
  • Page 343 Check of front disc brakes Guide pin cover Guide pin Compressing spring Internal/external friction plate Support beam Brake caliper assembly Disassembly and assembly of front brake caliper Disassemble as per the order shown in the Table. Assembly in the reversing order of disassembly Piston dust cover Piston See——P...

  • Page 344: Removal And Installation Of The Rear Disc Brake

    Check of front disc brakes Essentials to the Disassembly of Piston Seal Ring: Push out, with the SST, the piston seal ring from brake calipers. Removal and installation of the rear disc brake Remove in the order as shown in the Table Assemble in the reversing order of disassembly After installation, step down the brake pedal several times, turn manually the wheel to confirm that no brake blocking exists.
  • Page 345 Check of front disc brakes Brake disc removal essentials Prior to the removal, mark on the hub bolt and brake disc for reference at the installation time. Mark Essentials to the Installation of Brake Disc Clean up any rust or grime on the contact surface of brake disc and hub.
  • Page 346 Check of front disc brakes Disassembly/assembly rear brake calipers Disassemble as per the order shown in the Table. Assembly in the reversing order of disassembly Piston dust cover Piston See——P piston disassembly essentials to the Piston gasket: See——P piston gasket disassembly essentials to the Bleed screw cover Bleed screw...

  • Page 347: Parking Brake System

    Parking Brake System Parking Brake System Removal and Installation of Parking Brake Handle Disassemble in the order as shown in the Table. Assemble in the reversing order of disassembly. Adjust the travel of parking brake handle. Auxiliary instrument panel: See——S Support spring and clamping pin of Auxiliary Instrument Panel brake shoe...

  • Page 348: Removal And Installation Of Rear Parking Brake

    Parking Brake System Removal and installation of rear parking brake Disassemble in the order as shown in the Table. Assemble in the reversing order of disassembly. After installation, adjust the brake shoe clearance and carry out the following jobs. (1) Step the brake pedal several times and then confirm that no brake blocking exists (2) Check the clearance between the pedal and floor.
  • Page 349 Check the inner drum head of rear brake disc Measure the I/D of the drum head of rear brake disc. I/D maximum value: 188 mm {7.40 in} Check whether there are any scratches, unevenness or abnormal wear on the inner drumhead of rear brake disc.

  • Page 350: Adjustment Of Parking Brake Handle

    Check the parking brake handle Pull the parking brake handle several times. Pull, by the force in 98 N {10 kgf, 72.3 ft.Ibf}, the parking brake handle and check the travel of parking brake for 3－7 teeth. Adjustment of parking brake handle Adjusting nut Pull apart the jacket zipper of parking handle.

  • Page 351: Anti-Lock Brake System (Abs Control Unit

    Anti-lock brake system (ABS control unit) Anti-lock brake system (ABS control unit) Check of ABS control unit and control unit Check of the system Precautions to the maintenance diagnostics of ABS control unit The ABS control unit concerns the safety parts; therefore, the following diagnostic precautions have to be taken when other than in compliance with the general safe and preventive measures while other maintenance diagnostics are carried out.
  • Page 352 Anti-lock brake system (ABS control unit) For the imperfect measure of harness grounding, the connector, where water and moisture ingress, under the effect of siphon, through the pore passages in the harness, into the ECU of ABS control unit, will cause the function ineffective.

  • Page 353: Steps Prior To Determine The Replacement Of The Abs Control Unit

    The product warranty period provided by the Haima vehicle to the customer is 2 years, i.e. 60,000kms. For the products, which are returned for the Haima vehicle analysis, an visual check shall be made at First with the items as below:...
  • Page 354 Anti-lock brake system (ABS control unit) No rust and water stain on the ECU slot of ABS control unit Relevant Information to be supplied by the customer for the failure analysis made on the Haima vehicle: Information of dealer/maintenance and repair network...
  • Page 355 Anti-lock brake system (ABS control unit) of ABS control unit HU/CM mean that the solenoid works properly. Confirm that the wheels can rotate even if the brake pedal was depressed. Non-use of SST Completion of preparations Attention：Wrong connection with the data cable Jumper may result in faults.

  • Page 356: Exhaust Braking

    Anti-lock brake system (ABS control unit) Exhaust braking The brake system can be exhausted artificially. The customer service may choose the following three exhaust processes: — To exhaust by a filling unit (2 bar exhaust) — To exhaust by the artificial pedal —...
  • Page 357 Anti-lock brake system (ABS control unit) Close the exhaust screw Release the brake pedal Check the travel of pedal If failed, repeat the air exhaust Check the level of brake liquid, and assure that it is kept between the max. and min. levels.
  • Page 358 Anti-lock brake system (ABS control unit) X- braking look Vacuum degree: 2bars Braking look 2 Braking look 1 Backflow 2 Backflow 1 Right rear Left front Right front Left rear input input valve Accumulator input valve Accumulator input valve valve Right front Right rear Left rear...

  • Page 359: Removal And Installation Of Hu/Cm Of Abs Control Unit

    Anti-lock brake system (ABS control unit) Removal and installation of HU/CM of ABS control unit Caution ● Do not let the ABS control unit drop down to the floor. If they are subject of an impact, then they shall be replaced.
  • Page 360 Anti-lock brake system (ABS control unit) Removal of plug Confirm that the locking rod of plug is completely tightened; Pull up completely the locking rod at the removal time; Pull out the ABS electric connector. Thrust bar Removal and installation of ABS control unit holder Removal and installation bolt.

  • Page 361: Brake Line Connection Diagram Of Abs Control Unit 8

    Anti-lock brake system (ABS control unit) Brake line connection diagram of ABS control unit 8 Vacuum booster Braking liquid tank Brake master pump Braking pedal Braking pipe of master pump 1 Braking pipe of master pump 2 ABS hydraulic regulator Motor of backflow Damper Damper...

  • Page 362: Diagram Of Hydraulic Pressure Regulator Of Abs Control Unit With Ecu

    Anti-lock brake system (ABS control unit) ECU terminal definition Diagram of hydraulic pressure regulator of ABS control unit with ECU Check the HU/CM of ABS control unit Disconnect the negative connection of battery. Turn off the ignition switch and the tester between the HU/CM of ABS control unit and harness joints.
  • Page 363 Anti-lock brake system (ABS control unit) Terminal Code Implications Testing Standard voltage 12V continuous power supply-40A ←→GND(38) UBMR 9.3～16.9 fuse MOTOR Warning light of active ABS control ←→GND(38) NEBVSILA 9.3～16.9 unit Speed sensor signal of right front FR WS wheel ＜0.5V MGND Motor of grounding reflux pump...

  • Page 364: Removal And Installation Of Wheel Speed Sensor On The Rear Abs Control Unit

    Anti-lock brake system (ABS control unit) Removal and installation of wheel speed sensors of front/rear ABS control units Disassemble in the order as shown in the Table, the wheel speed sensor of front ABS control unit (R same as L). Assemble in the reversing order of disassembly.

  • Page 365: Check Of Front/Rear Abs Control Unit Wheel Speed Sensor

    Turn every wheel at the speed by one turn per second and check each sensor. If the voltage value doesn’t meet the requirements, replace the wheel speed sensor of ABS control unit. Current value: 7.15—14.3 mA Inspection of voltage waveform Jack up the vehicle on a level ground by use of a jack, shore up with a safety bracket.

  • Page 366: Obd

    Anti-lock brake system (ABS control unit) Fault diagnostic guide ABS control unit Foreword Understand the basic process of fault diagnostic for the correct operation. Prior to take the operation steps for the fault diagnostic symptom, check the fault diagnostic first. Carry out the inspection steps according to the fault diagnostic codes Statement When making the check or maintenance of ABS control unit, pay attention to the following points:...
  • Page 367 Anti-lock brake system (ABS control unit) Description of ABS control unit during the maintenance process The ABS control unit is composed of the electric and mechanical parts. When the faults are diagnosed, it is necessary to divide those faults into the electric system and hydraulic pressure unit. 1.

  • Page 368: Troubleshooting

    Anti-lock brake system (ABS control unit) Symptom Turn the ignition switch in the ON position, but the warning light of ABS control unit is not lit up Turn the ignition switch in the ON position, the warning light of ABS control unit keeps lit for more than 4s.
  • Page 369 Anti-lock brake system (ABS control unit) When the ignition switch is turned in the ON position, the alarm light of ABS control unit is not lit Tips of The alarm light line of ABS control unit alarm light is short circuited to earth troubleshooting Steps Check items...
  • Page 370 Anti-lock brake system (ABS control unit) Check and maintain the harnesses Disconnect the control modular joint of ABS between modular control unit, connect the SST only at the harness grounding of ABS control unit side of vehicle. Use the SST joint and connect the lead of alarm light to the bodywork Check repair...
  • Page 371 Anti-lock brake system (ABS control unit) Carry out the DTC test. Check as per the corresponding DTC. See——Reappearance of Diagnostic Function, Test of ABS Control Unit/TCS and DTC Go to the next step Whether the DTC has been recorded？ Go to the next step Whether the battery voltage is normal？...
  • Page 372 Anti-lock brake system (ABS control unit) Potential failure DTC(16hex) Description of DTC symptom Left front wheel speed sensor open-circuited or C0032 0x4032 0100 short-circuited C0031 0x4031 1000 Left front wheel speed sensor in intermittent operation Right front wheel speed sensor open-circuited or C0035 0x4035 0100...
  • Page 373 Anti-lock brake system (ABS control unit) Potential failure DTC(16hex) Description of DTC symptom C1095 0x5095 0100 Fault of solenoid C0010 0x4010 0100 Fault of left front inlet valve C0011 0x4011 0100 Fault of left front outlet valve C0014 0x4014 0100 Fault of right front inlet valve C0015 0x4015...

  • Page 374: Ecu Faults

    Anti-lock brake system (ABS control unit) brake fluid on the brake slave-pump of blocked wheel back to the line of brake master-pump and decrease the pressure of brake slave-pump. In the stage of EBD pressure reduction: Brake fluid flown back after stored in the accumulator, but, if the accumulator has been filled up with the brake fluid, and the deceleration of rear wheels are still faster than the front wheels, the ECU of ABS control unit controls the action of reflux pump, and pump back the excessive brake fluid into the circuit of brake master-pump.

  • Page 375: Steering System

    Disassembly Instructions of Steering Lock Bolt and Bracket ................. N-5 Removal/installation of steering and connecting rod ..................N-6 Disassembly instructions of steering and joint ....................N-7 Check of Steering and joint ........................... N-10 Removal/installation of power steering oil pump ..................N-14 Disassembly/assembly power steering oil pump ...................

  • Page 376: Common Steps

    Power steering Engine speed sensitive power steering Common steps Air exhaust Removal/installation of wheels and tires Check the oil level of power steering (Refer to ● The description of this chapter doesn’t include Check of Power Steering OIL; Check of Liquid the installation steps of wheels and tires.

  • Page 377: Check Of Steering Wheel And Steering Column

    Steering system Turn back and forth several times the steering wheel to the maximum the steering wheel and measure the hydraulic pressure produced in the steering casing. ● If the pressure is not within the specified range, repair or replace the steering components. Pressure of steering liquid: 9.85-10.35Mpa Thermometer Exhaust the air from the system.
  • Page 378 － Whether there is air in the system? － Whether there are any leakages in the hose or joints? － Whether the performances of power steering oil pump and gear are in sound condition? Steering force: 7.8N·m {80kgf }.cm , 69in.lbf [maximum value]...

  • Page 379: Removal/Installation Of Steering Wheel And Steering Column

    Steering system Removal/installation of steering wheel and steering column Warning ● Improper handling of safety airbag module will induce sudden opening of safety airbag and result in personnel injury, thus if it is necessary to process the safety airbag, please read first the “Warning of the Safety Airbag”(Refer to the Safety Airbag System;...

  • Page 380: Disassembly Instructions Of Steering Lock Bolt And Bracket

    Steering system Disassembly instructions of steering wheel Caution ● When removing the steering wheel, do not use the hammer to hit the steering shaft, for this will result in steering column. Park your vehicle while orienting the wheels to the front. Installation instructions of steering shaft Use a suitable puller to remove the steering Caution...

  • Page 381: Removal/Installation Of Steering And Connecting Rod

    Steering system ● Confirm that the steering shaft is loosened Removal/installation of steering and when the adjusting rod is locked. connecting rod Caution ● Carry out the following operations, if the wheel speed sensor in the ABS system is not going to Locking be removed first.

  • Page 382: Disassembly Instructions Of Steering And Joint

    Steering system Disassembly Instructions of steering tie rod Disassembly instructions of steering end ball and joint Remove the end rod nut. ● Pull out the steering and joint from the right side. Use a special tool to remove the steering knuckle from the ended column.
  • Page 383 Steering system Decomposition of steering pinion and torsion rod ● Decompose as per the order shown in the Table. Oil pipes 1 and 2 Pinion shaft Inlet pipe Valve body components Outside tie rod assembly Oil seal: Refer to the Decomposition Description Tie rod lock nut Upper bearing: Small clip...
  • Page 384 Steering system Precautions to the decomposition of pinion Precautions decomposition of shaft components steering tie rod ● If difficult to pull out the pinion shaft, remove Take out the dust cover it by use of compression way; Remove the steering tie rod By use of the method as shown in Fig.

  • Page 385: Check Of Steering And Joint

    Steering system Decomposition description of inner guide sleeve and oil seal Install the special tool onto the valve side; Install the special tool in the gear chamber. Extrude the oil seal and inner guide sleeve. Check of Steering and joint Check of gear rack Check the gear rack for any fracture, damage and broken teeth.
  • Page 386 Steering system Rotation torque: 0.4-2.7N·m {3.5-26.0kgf.Cm, 3.1-22.5in.lbf} Reading on the spring balance 3.4-25.5N {0.35-2.60kgf, 0.8-5.71bf} Check of steering tie rod Check whether the tie rod is bent or damaged. Replace it when necessary. Check whether the ball nodes are loosened and replace them when necessary.
  • Page 387 Steering system Installation of steering and joint Install in the order shown in the Table. Dust cover of steering tie rod ball Seal ring: Refer Installation ·Refer to the Installation Instructions instructions Control valve Rubber cushion block: Refer to the Installation Instructions Spring snap ring Steering casing Lock bolt...
  • Page 388 Steering system Installation instructions of steering tie rod ball dust cover Wipe out greasy dirt on the ball joint; Add a few grease in the new dust cover. Use a special tool and a presser to fit up the dust cover onto the tie rod end ball. Wipe out all exposed grease.

  • Page 389: Removal/Installation Of Power Steering Oil Pump

    Drive Belt and Drive Belt). Standard Position of gear rack when it is in the center (in the middle of steering wheel) 1.0-1.4N.m {10-14kgf.cm, 8.7-12.1 in.lbf} [Reading of spring balance] 9.9-13.7N {1.0-1.4kgf, 2.2-3.Olbf} Use a special tool to fit up the lock nut Tightening torque: 40-49N·m {4.0-5.0kgf.m, 29-36ft.lbf}...

  • Page 390: Disassembly/Assembly Power Steering Oil Pump

    Steering system Disassembly/assembly power steering oil pump Attention The following operations can be carried out only when the “O” ring and oil seal are to be replaced. If necessary to check other items, the component of pump body shall be replaced. Disassemble in the order as shown in the Table.

  • Page 391: Decomposition Description Of Power Steering Oil Pump Components

    Steering system Installation instructions of internal cam Decomposition description of power ring steering oil pump components Face the mark upward and contain the internal Caution cam ring into the front pump body. ● When clamping with a vice, a special tool shall be used to prevent damage on the oil pump.
  • Page 392 Suspension system Suspension system General procedures ..........R-1 cross-beam..........R-10 Precautions to the suspension system ..R-1 Rear suspension ..........R-11 Wheel alignment ......... R-1 Removal/installation of rear shock absorber ..............R-11 Front suspension..........R-4 Check of rear shock absorber ....R-11 Removal/installation of front shock absorber and spring ............

  • Page 393: General Procedures

    Add the brake fluid, exhaust residual gas from (mm) -1±3 the brake system if any of the braking lines is Total toe-in ′ -0°2＇30＂±7＇ disconnected in the process and check if there is any leakage after the completion of Inside wheels 37±3° Maximum operation.
  • Page 394 Fit up and tighten the mounting nuts as per the Tighten the end locknut of steering linkages. specified torque. Tightening torque: 72-92N.m Tightening torque: 69-98N.m {7.0-10.0kgf.m, 50.7-72.3ft.lbf}; Adjustment of total toe-in Confirm that the dust cover is not distorted, Fix the steering wheel in the middle position and install the clamp of dust cover;...
  • Page 395 General procedures Rear wheel Left wheel Right wheel toe-out Increasing direction Counterclockwise Clockwise of toe-out Decreasing direction Clockwise Counterclockwise of toe-out Right wheel Left wheel Increasing Decreasing Increasing direction of direction of direction of toe-out toe-out toe-out...

  • Page 396: Front Suspension

    Front suspension Front suspension Removal/installation of front shock absorber and spring Attention: Carry out the following procedures prior to the removal of ABS wheel speed sensor. If the sensor pulled by inadvertence, it may result in break-circuit of harness. before carrying out the following procedure, remove the ABS wheel sensor corresponding to the axle, and fix it in a suitable position to prevent the wheel sensor from inadvertent drawing during the maintenance process.

  • Page 397: Check Of Front Damping Column Assembly

    Front suspension Install at first the lower rubber mat of helical Essentials to the removal of piston rod nuts spring on the shock absorber; Warning: After the helical spring, stop block, dust cover, It is dangerous to remove the piston rod nuts. The upper rubber mat of helical spring and upper shock absorber and helical spring may pop up under spring seat have been placed in a proper place,...

  • Page 398: Removal/Installation Of Lower Swing Arm Of Front Suspension

    Front suspension operating force has not changed and no Removal/installation of lower swing arm of abnormal noise exists; front suspension (1) Compress the shock absorber piston and then release it. (2) Confirm that the extended piston returned to the normal position at a normal speed and there is no abnormal compression force.
  • Page 399 Front suspension Removal instruction of front bushing of swing Remove the front bushing of swing arm while pressing down with the SST Press-in by a hydraulic presser Installation instruction of front bushing of swing Front bushing Use the SST maintenance tool to compress the new bushing into the swing arm body.

  • Page 400: Check The Lower Swing Arm Of Front Suspension

    Front suspension Removal instructions of dust cover Use a chisel to remove the dust cover. Be careful not to damage spherical joint and rocker. Installation instructions of dust cover Wipe out the grease on the ball bolt; Fill in the grease to the inside of new dust cover; Use the SST maintenance tool to press the dust cover on the spherical joint;...

  • Page 401: Removal/Installation Of Front Stabilizer Bar

    Front suspension Removal/installation of front stabilizer bar Remove the front beam assembly; Remove in the order as shown in the Table; Install in the reversing order of removal. Control connecting rod; Fixing plate of stabilizer bar: Refer to the Installation Instructions of Fixing Plate of Stabilizer Bar and Rubber Sleeve;...

  • Page 402: Removal/Installation Instructions Of Front

    Front suspension Removal/installation instructions of front cross-beam Remove the front cross-beam elements; Remove the front exhaust pipe (Refer to F Removal/Installation of Exhaust System); Remove the engine support beam (Refer to B, Essentials to the Removal of Engine Support Beam); Undo the linkage between the engine suspension 1# and front cross-beam;...

  • Page 403: Rear Suspension

    Rear suspension Rear suspension Removal/installation of rear shock absorber Attention: Carry out the following procedures prior to the removal of ABS wheel speed sensor. If the sensor pulled by inadvertence，it may result in break-circuit of harness. Before carrying out the following procedure, remove the ABS wheel sensor (at the axle side) corresponding to the axle and fix it in a suitable position, at the...

  • Page 404: Removal/Installation Of Rear Helical Spring

    Rear suspension Removal/installation of rear helical spring Remove the rear shock absorber assembly (See Removal/Installation Rear Shock Absorber) Remove in the order as shown in the Table. Install in the reversing order of removal. Helical spring Upper rubber mat of helical spring Installation notes of rear helical spring After the bolt connecting the rear shock absorber with the rear tow arm released，pull out firstly...
  • Page 405 Rear suspension Nuts(connection of rear tie rod(Lower) with the rear tow arm) Nuts(connection of rear tie rod(Upper) with the rear tow arm) Bolt Rear tie rod(Upper) Rear tie rod(Lower) Removal instructions of nut, cam disc and cam adjusting bolt Prior to unscrew the cam nut, mark on the spacer and bodywork mounting bracket for reference during the mounting process;...

  • Page 406: Removal/Installation Instructions Of Rear Frame Plaque

    Rear suspension Removal/installation instructions of rear frame plaque Remove in the order as shown in the Table. Install in the reversing order of removal. 43～68 {4.3～6.9,31.8～50.3} Bolt Rear frame plaque Removal/installation instruction of rear beam Remove the tie rod of upper/lower rear beams(Refer to the Removal/Installation Instructions of Rear Suspension and Tie Rod);...
  • Page 407 ............6 troubleshooting procedure ......43 disassembling and assembling of blower evaporator assembly ........7 a/c compressor removal/installation ....7 a/c compressor installation instruction .... 8 condenser removal/installation ......8 condenser installation instruction ....8 condenser inspection ........8 cooling system pipelines removal/ installation 8 refrigerant pipelines removal instruction ..

  • Page 409: Usage Of Refrigerant

    Service warnings 带格式的: 字体: 五号, 加粗 带格式的: 字体: 五号 system components to prevent moisture absorption. Service warnings Service procedures Usage of refrigerant Avoid breathing in air conditioning refrigerant or Maintenance procedure of refrigeration lubricant vapor， which may irritate eyes, nose and system throat.
  • Page 410 49 c06l 001. if the reading reservoir. has changed, inspect for leakage and then repeat from step 7. if the reading has not place the refrigerant reservoir on the scale. changed, go to the next step.

  • Page 411: Refilling Refrigerant

    If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat charging procedures from step 7. 26. remove the ssts 49 c061 006a，49 c061 007 from charging valves.

  • Page 412: Pressure Inspection Of Cooling System

    Service warnings to air purge valve of sst 49 c061 001. service cans or refrigerant reservoir, running the engine with the high-pressure side valve open is connect sst 49 c601005 to center joint of sst 49 dangerous. Pressure within the service cans or c061001.
  • Page 413 Service warnings close all doors and windows. measure ambient temperature and record pressure readings high-pressure low-pressure side of sst 49 c061 001. 10. verify that the intersection of pressure reading of the sst 49 c061 001 and ambient temperature is in the shaded zone. If not, diagnose and eliminate the faults of cooling system.

  • Page 415: Performance Test Of Cooling System

    Performance test of cooling system Performance test of cooling system 11. wait until the central air port temperature is stable, and then the outlet air temperature is follow refrigerant charge inspection and also stable. The a/c compressor is repeatedly cooling system pressure inspection procedure. turned on and off under control of the (refer to section u, refrigerant charge inspection) temperature sensor.

  • Page 416: Basic System

    Basic system Basic system Structural view Removal installation blower Air intake evaporator assembly Blower evaporator assembly disconnect the negative battery cable. Warm air blower assembly remove the dashboard. (refer to section s, Reat airducting dashboard removal /installation) A/c compressor remove in order as shown in the table. Condenser install in reverse order as of removal.

  • Page 417: Disassembling And Assembling Of Blower Evaporator Assembly

    Basic system A/c compressor removal/installation Disassembling and assembling of blower evaporator assembly disconnect the negative battery cable. disassemble in order as shown in the table. drain refrigerant from the system. assemble in reverse order as of disassembly. remove the mudguard. loosen the drive belt and remove it.

  • Page 418: A/C Compressor Installation Instruction

    Basic system A/c compressor installation instruction Condenser installation instruction when replacing the a/c compressor, discharge when installing a new condenser, add a part of compressor oil from the new a/c supplement quantity of atmoscu 10 compressor compressor. oil into the condenser inlet. discharging quantity: 160ml (160cc, 5.40fl oz) supplemental quantity: 30ml (30cc, 1.0 fl oz) (compressor oil discharged from the used...

  • Page 419: Refrigerant Pipelines Removal Instruction

    Basic system A：8.8～12.8n·m B：18.7～27.5n·m C：7.8～11.8n·m D：7.8～11.8n·m E：8.8～12.8n·m add a supplemental quantity pag105 Condenser assembly compressor oil. Compressor assembly supplemental quantity: 10ml {10cc, 0.3fl oz} Pipe subassembly apply some compressor oil to the o-ring and Fluid reservoir assembly connect the joints.

  • Page 420: Control System

    Control system Control system Structural view of control system Blower motor Condenser fan Speed regulation resistance Electromagnetic clutch A/c relay Condenser fan relay Blower relay Refrigerant pressure switch Thermal protector Thermistor A/c amplifier U-10...

  • Page 421: Blowe Motor Removal/Installation

    Control system Blowe motor removal/installation Electromagnetic clutch disassembly/assembly disconnect the negative battery cable. disassemble in order as shown in the table. remove in order as shown in the table. assemble in reverse order as of disassembly. install in reverse order as of removal. adjust the electromagnetic clutch clearance.

  • Page 422: Bolt Removal Instruction

    0.5 mm {0.020 in} disconnect the refrigerant pressure switch Standard clearance connector. 0.3-0.7 mm {0.012-0.028 in} inspect the reading of high-pressure side on manifold pressure gage and the conduction between all terminals. If the result nonconforming...

  • Page 423: A/C Relay Inspection

    Control system install in reverse order as of removal. Connector Front blower relay Blower relay inspection remove the bracket. inspect continuity between the blower relay A/c relay terminals with an ohmmeter. If it is not as A/c relay inspection specified, replace the blower relay. remove a/c relay.

  • Page 424: Troubleshooting

    Troubleshooting Troubleshooting The areas and steps for inspection are determined according to various malfunctions. Use the chart below to verify the malfunction symptoms in order to diagnose the related area. Insufficient airflow and/or no airflow from air ports Insufficient airflow and/or no airflow from air ports. Malfunction malfunction in air port or passage description...
  • Page 425 Troubleshotting Step Inspection Action Inspect air port. Remove obstruction, then go to step Is air port clogged? Go to next step. Verify that defroster duct is installed. Check air passage for clogging, deformity, and air leakage, then go Is defroster duct properly installed? to next step.

  • Page 426: Troubleshooting Procedure

    Troubleshooting Step Inspection Action Inspect blower assembly. Go to next step. Inspect blower fan for the following items: Remove obstruction, repair — Is fan free of interference with blower case? replace fan and blower case, and then go to step 5. —...

  • Page 427: Troubleshotting

    Possible causes Malfunction in front climate control unit (recirculate and fresh signal) system, steps 7,10—12 Malfunction in air intake door of blower assembly, steps 13, 14 When performing an asterisked (*) troubleshooting, shake the wiring harness and connectors to verify whether the intermittent malfunctions are caused by poor contact.

  • Page 428: Troubleshooting Procedure

    Troubleshooting Troubleshooting procedure Step Inspection Action Inspect whether malfunction is in a/c system Go to next step. or defrost system Go to step 1 of troubleshooting index no. Does cold air blow out when switch on both a/c and fan of front climate control unit.
  • Page 429 Troubleshotting Step Inspection Action Turn ignition switch to lock position. Replace climate control unit, and then go Does one of climate control unit connector to step 15. (6-pin for air intake mode) terminals below short to ground? — Terminal c (fresh signal) —...
  • Page 430 Malfunction in front climate control unit air mix cable or cable clamp of bevel Possible causes gear set 2. step 4 Malfunction in air mix control valve of front a/c unit. Steps 5 and 6 Malfunction in heater pipeline. Step 7 U-20...

  • Page 431: Troubleshooting Procedure

    Troubleshotting Troubleshooting procedure Step Inspection Action Inspect coolant temperature. Go to next step. Is coolant warmed up sufficiently? Preheat engine to normal operation temperature, go to step 8. Go to next step. Inspect air mix system of front a/c unit. Inspect following items of front a/c unit air Apply grease or install links, rocker, and mix links, air mix rocker, shaft and cable...

  • Page 432: Troubleshooting Procedure

    Go to next step. Does air blow out under vent mode? Inspect air ports Remove obstruction, go to step 7. Are any air ports clogged? Go to next step. Verify that roof duct is installed. Inspect the rear cooling ducts 1 and 2 for...

  • Page 433: Troubleshooting Procedure

    Malfunction in rear main fan switch or related wiring harness. Step 5 Possible causes Malfunction in rear blower resistor, rear blower relay or related wiring harness. Step 6 Malfunction in rear a/c unit. Step 7 Troubleshooting procedure Step Inspection Action...
  • Page 434 — Rear main fan switch. — Related wiring harness Are all above items normal? Verify whether malfunction is in rear a/c unit Go to step 7. fan or elsewhere. Go to next step. Does air blow out from the rear air port with rear main fan switch turned on? Go to next step.

  • Page 435: Troubleshooting Procedure

    Malfunction in signal circuit of rear climate control unit of airflow mode control actuator. Steps 4, 5 and 6 Malfunction in airflow mode door of rear a/c unit. Steps 7 and 8 When performing an (*) marked troubleshooting, shake the wiring harness and connectors to verify whether the intermittent malfunctions are caused by poor contact.
  • Page 436 Troubleshooting Step Inspection Action Inspect airflow mode actuator Go to next step. Inspect airflow mode actuator. (see u-30, Replace airflow mode actuator, go to airflow module actuator inspection) step 9. Is it normal? Inspect continuity of wiring harness between Go to next step. rear climate control unit and airflow mode actuator.
  • Page 437 Troubleshotting Step Inspection Action Inspect rear a/c unit Remove obstruction, go to step 9 Is there any foreign material or obstruction Go to next step. in a/c unit airflow mode control valve? Inspect rear a/c unit airflow mode control Replace the rear climate control unit, go valve.

  • Page 438: Troubleshooting Procedure

    Troubleshooting Troubleshooting procedure Step Inspection Action Inspect coolant temperature Go to next step. Is coolant warmed up sufficiently? Warm up engine to normal operation temperature, then go to step 21. Go to step 6. Verify whether malfunction is in air mix actuator (+5v signal) system or elsewhere.
  • Page 439 Troubleshotting Step Inspection Action control unit and air mix actuator to climate control unit and air mix actuator, determine whether it is short to ground. and then go to step 21. Is there continuity between terminal e Go to next step. (voltage divider signal) of air mix actuator and ground? Inspect wiring harness between rear climate...
  • Page 440 Troubleshooting Step Inspection Action Inspect continuity of wiring harness between Go to next step. rear climate control unit and air mix actuator. Repair wiring harness between rear climate control unit and air mix actuator, Is there continuity between the following go to step 21.
  • Page 441 Troubleshotting Step Inspection Action Verify whether malfunction is in air mix Go to next step. actuator or elsewhere. Go to step 18. Turn ignition switch to on position. Set rear main fan switch at 3rd position. Does temperature of air blown out change easily with air mix rocker operated manually? Go to next step.

  • Page 442: Troubleshooting Procedure

    Troubleshooting X. Air is not cold as specified. Air is not cold as specified. Malfunction Magnetic clutch operates, but malfunction is in a/c unit. symptom Drive belt malfunction. Step 1 Malfunction in blower assembly, rear a/c unit and/or condenser. Steps 4, 5 Malfunction in reservoir/drier, expansion valve (valve closes too much).
  • Page 443 Troubleshotting Step Inspection Action Inspect condenser Adjust refrigerant to specified quantity, then go to step 19. (excessive quantity of Inspect condenser (see u-16, condenser refrigerant) inspection) Is it normal? Replace condenser, or repair and clear condenser vanes, then go to step 19. Go to next step.
  • Page 444 Troubleshooting Step Inspection Action Inspect refrigerant pipeline Go to next step. Inspect refrigerant pipeline If any damage or crack found, replace following items. the damaged parts, then go to step 19. — Is refrigerant pipeline free of damage and If no damage or crack found, go to step crack? —...
  • Page 445 Troubleshotting Step Inspection Action Tighten joints to specified torque. If the Inspect pipe joints for looseness. compressor generates noise, add 10ml Are refrigerant pipeline joints loose? (l0cc.0.338 fl oz) of compressor oil to the a/c compressor. Verify that the noise is no longer heard.
  • Page 446 Troubleshooting Step Inspection Action Adjust compressor oil Go to next step. Set front fan switch at 4th position. Conduct as step 1-10, till oil volume of Turn the a/c switch on. compressor is 100ml (l00 cc, 3.38 fl oz). Set to fresh mode. Set the temperature control to max cold.

  • Page 447: Troubleshooting Procedure

    Electromagnetic clutch doesn’t work. symptom A/c compressor system malfunctions. Step 2 Incorrect refrigerant quantity. Step 3 A/c switch indicator malfunctions. Steps 4-7 Pcm a/c cut-off control system. Step 8 Pcm (igi signal) system malfunctions. Steps 9-22 Possible causes Temperature sensor and a/c switch malfunctions. Steps 10-15 Pcm (a/c signal) system malfunctions.
  • Page 448 Troubleshooting Step Inspection Action Inspect continuity of wiring harness between Go to next step. fuse block and front climate control unit. Repair wiring harness between fuse Turn ignition switch to on position. block and front climate control unit, go Turn both a/c switch and fan switch on. to step 28.
  • Page 449 Troubleshotting Step Inspection Action Verify whether malfunction is in temperature Go to step 16. sensor system or elsewhere. Reconnect refrigerant pressure switch, Turn ignition switch to lock position. go to next step. Disconnect the refrigerant pressure switch. Turn ignition switch to on position. Set front fan switch at 1st position.
  • Page 450 Troubleshooting Step Inspection Action Inspect continuity of wiring harness between Go to next step. temperature sensor and refrigerant pressure switch. Repair wiring harness between refrigerant pressure switch Turn ignition switch to lock position. temperature sensor, then go to step 28. Inspect continuity between...
  • Page 451 Troubleshotting Step Inspection Action Verify whether malfunction is in a/c relay Go to step 23. system (at coil side) or elsewhere. Turn ignition switch to on position. Go to next step. Turn off a/c switch. Measure voltage at pcm connector terminal 69 (ig1 signal).
  • Page 452 Troubleshooting Step Inspection Action Inspect continuity of wiring harness between Go to next step. fuse block and a/c relay (at switch side). Repair wiring harness between fuse Turn ignition switch to on position. block and a/c relay, go to step 28. Measure voltage at a/c relay connector terminal d (a/c control signal).

  • Page 453: Troubleshooting Procedure

    Troubleshotting Troubleshooting procedure Step Inspection Action Inspect a/c compressor skidding noise Go to step 9. Is there a strident sound (a/c compressor Go to next step. skidding noise)? Inspect a/c compressor interference noise Go to step 12. Is there a squeaking or whirling sound Go to next step.
  • Page 454 Troubleshooting Step Inspection Action Inspect drive belt Go to next step. Check drive belt Replace drive belt, go to step13. — Gy: (see b-1, drive belt inspection.) Is it normal? Remove foreign materials and oil Inspect condition of drive belt. fouling or replace drive belt, go to step Is drive belt worn out? Is there any foreign materials inserted in it...
  • Page 455 ................T-6 ................T-13 Removal/installation of license plate lamp ..T-6 Check of combination instrument ....T-14 Removal/installation of license plate lamp bulb T-7 Speedometer ............. T-14 Removal/installation of reading light ....T-7 Use of input/output inspection mode ....T-14 Removal/installation of reading light bulb ..
  • Page 456 Content Removal/installation of horn ......T-17 Operation of lateral safety airbag module ..T-52 Tweeter ............. T-17 Operation of components ......... T-53 Low-tone horn ..........T-18 Repeated use of components ......T-53 Removal/installation horn relay ....... T-18 Removal/installation of pretensioning safety belt ................
  • Page 457 Content Removal and installation of rheostat ....T-67 Test of flasher unit ..........T-71 Check of rheostat..........T-67 Removal/installation of headlamp relay ... T-71 Installation/removal of level adjustment switch Check of headlamp relay ........T-72 (optional) ............T-68 Removal/installation of front fog lamp relay ... T-72 Check of level adjustment switch .....

  • Page 459: Power Supply System

    Power supply system Power supply system Precautions to fuse use After the burn-out reason identified and troubleshooting performed, replace burn-out fuse by a specified type of fuse. Failure troubleshooting prior replacement may make the fuse be blown again. Removal/installation of main fuse Snap Remove the negative cable of battery;...

  • Page 460: Removal/Installation Of Key-In Reminder Switch

    Power supply system Continuity Connection terminal Position of ignition switch Terminal Key position Inserted key Non-inserted key Element side connector (viewed from the terminal side) Start Start Lock Lock Element side connector (viewed from the terminal side) Removal/installation of cigar-lighter Remove the negative cable of battery;...

  • Page 461: Essentials To Removal Of Socket

    Lighting system Essentials to removal of socket Essentials to removal of ring Pass through the socket hole with a flathead Press the barb and pull forward the ring. screwdriver wrapped with tape, hold the flange of ring and turn the socket at the meantime. Cigar-lighter fixing disc Ring...

  • Page 462: Lighting And Signal System

    Up/down adjustment Take out the fixture on a suitable place, and then withdraw manually the plugs 6, 7 and 8 The installation procedure is in reverse order adjustment with that of the removal (Note that the installation procedure is in order of 1, 2, 3 and...

  • Page 463: Removal/Installation Of Front Fog Lamps

    Rear combined lamps Removal/installation of front fog lamp bulb Plastic snap Remove front fog lamps; Nut HQ99940-0503 (4.5～7.0 N·m) Rotate counterclockwise the bulb holder; Location pin sheath Take out the bulb (bulb integrated with the nutHQ99940-0503 (4.5～7.0 N·m) bulb holder);...

  • Page 464: Removal/Installation Of Rear Combined Lamp Bulbt-6

    Power supply system Attention: When removing the taillight, after Removal/installation of high-positioned unscrewed the nuts 3 and 5, a certain tension is brake light required when the taillight is pulled out along the Remove the negative cable of battery and then axis X because there is the location pin sheath No.4, the hole plug;...

  • Page 465: Removal/Installation Of License Plate Lamp Bulb

    Lighting system directly, by hand the lamp toward the mounting Removal/installation of reading light hole instead of using a screwdriver. Remove the negative cable of battery; Open the flip of glasses case. Take out two screws with a cross screwdriver. Take out the indoor light from the ceiling;...

  • Page 466: Removal/Installation Of Indoor Light And Bulb

    Power supply system Press down one end of the snap with a small Bulb 12V5W (W5W) screwdriver through the small hole, so as to Bulb 12V5W (W5W) enable the snap come off the ceiling and obliquely take out the fixture; Reading light holder Disconnect connector;...

  • Page 467: Removal/Installation Of Dome Lamp Bulb

    Lighting system Removal/installation of dome lamp bulb Remove the negative cable of battery. Remove the door trim panel. Rotate counterclockwise the bulb holder to the clamping position and loosen it out. Take out bulb. The installation procedure is in reverse order with that of removal.

  • Page 468: Wiper And Washer

    Wiper and washer Wiper and washer Removal/installation of windshield wiper motor Disconnect battery negative cable; Remove the wiper arm and wiper blade (See the Removal/Installation of Windshield Wiper Arm and Wiper Blade). Remove the front wall grille (See the Removal/Installation of Front Wall Grille); Remove as per the order indicated in the Table;...

  • Page 469: Essentials To Installation Of Windshield Wiper Armt-9

    Wiper and washer Removal/installation of windshield wiper arm and wiper blade Remove as per the order indicated in the Table; Mark The installation procedure is in reverse order with that of removal; Adjust the windshield wiper arm and wiper blade; (See the Adjustment of Windshield Wiper Arm and Wiper Blade) Removal/installation of the fluid reservoir of washer...

  • Page 470: Check Of Windshield Washer Motor

    Wiper and washer Windshield wiper nozzle Deep socket wrench Windshield washer motor (2 pcs) Installation of windshield washer nozzle Gasket Connect the windshield washer hose with the windshield washer nozzle; Press down the windshield washer nozzle into Check of windshield washer motor the mounting hole;...

  • Page 471: Cleaning Of Windshield Washer Nozzle

    Wiper and washer Cleaning of windshield washer nozzle Removal/installation of rear wiper motor Insert an needle or similar tool into the nozzle of Disconnect battery negative cable; washer and clean it by pulling forward/backward. Remove rear wiper arm and blade (See the Remove the hose from the nozzle if the nozzle still Removal and Installation of Rear Wiper Arm plugged after the cleaning.

  • Page 472: Removal/Installation Of Rear Wiper Arm And Blade

    Wiper and washer Auto-Off Switch Connector at element side (viewed from the terminal side Removal/installation of rear wiper arm Adjustment of rear wiper arm and blade and blade Enable the rear wiper to operate so as to make Remove in the order as shown in Fig.; the wiper to stop at the Stop position.

  • Page 473: Adjustment Of Rear Washer Nozzle

    Wiper and washer Removal/installation of rear washer hose Disconnect battery negative cable; Remove necessary trim panel above the right side wall; Remove the washer hose from the clamp; Partly lift up the right fender and remove the hose from the clamp; Lock latch Remove the hose from the washer tank;...

  • Page 475: Removal/Installation Of Combination Instrument

    Alarm and Indication System Removal/installation combination Disassembly/assembly combination instrument instrument Disconnect battery negative cable; Attention: Pull down the adjusting handle of tilting If the combination instrument comes off or the PCB steering wheel and press down the steering is damaged, the system will be unable to work wheel;...

  • Page 476: Check Of Combination Instrument

    Alarm and Indication System Use of static speed tester Check of combination instrument Attention: Speedometer If the engine speed exceeded the allowed scope, it Use of input/output inspection mode will be damaged, thus, do not let the engine speed Set the speedometer at the DTC 12 under the be higher than the range as permitted by the input/output inspection mode and check the tachometer...

  • Page 477: Water Temperature Gauge

    Wiper and washer Water temperature gauge Set the water temperature gauge at the DTC 24 under the input/output inspection mode and check the water temperature gauge. Repair of combination instrument Attention When the pointers of speedometer and engine tachometer will possibly jitter back and forth and is unable to indicate correctly the speed or revolution during the normal operation, please check as per the Pointing to zero...

  • Page 478: Removal Of Water Temperature Sensor Unit

    Water temperature Resistance 65.6 104.5 156.6 225.6 position (height) 49.8-50.2{121.7- 122.3} 189.4-259.6 Removal of water temperature sensor unit Remove the negative cable of battery; Disconnect the connection of connector; Remove the water temperature sensor. Water temperature In terms of engine TRITEC, except the water...

  • Page 479: Check Of Oil Pressure Switch

    Wiper and washer Check of oil pressure switch Confirm that the oil pressure warning light is lit when the ignition switch is in the ON position; Confirm that the oil pressure warning light goes off when the engine starts. If the oil pressure warning light keeps lit, check the oil pressure warning light and relevant harness.

  • Page 480: Low-Tone Horn

    Alarm and Indication System Low-tone horn Bodywork metal Plug sheet Screw Input/output inspection mode combination instrument Note: Under this mode, you can check the items listed in the table below. Horn List of diagnostic trouble code (DTC): Check items Relevant items The installation procedure is in reverse order Buckle switch of safety Buckle switch...

  • Page 482: Instrument

    Alarm and Indication System When the diagnostic trouble code is not DTC 10, Attention the inspection of input/output mode will be The diagnostic trouble codes not incorporated may cancelled, if the front wheel has been driven before be possibly displayed but unable to check. The the speed signal is inputted into the combination diagnostic trouble codes are displayed in numerical instrument.
  • Page 483 Alarm and Indication System Check sequence Attention: When checking more than two DTCs, the check shall be operated as per the priority listed in the following table: Position of ignition Check priority Check of code switch 22, 24 01, 04, 05, 07, 08, 09, 10, 11, 12, 13, 14, 15, 16, 17, 18, 20 ,21, 23, 25, 26, 27, 29, 40, 41, 42 LOCK Check of diagnostic trouble code...

  • Page 484: Diagnostic Program

    Alarm and Indication System DTC 04 Door switch Signal On/Off Combination instrument connectors Harness side connector (Viewed from the harness side) XMET18W018 Diagnostic program Steps Check Display Measures Open the driver-side Close the driver-side door and then go to the next door step.
  • Page 485 Wiper and washer Steps Check Display Measures Open occupant-side After closing the occupant-side rear door, go to the rear door (Door switch next step. Measure the voltage of combination instrument terminal 1L. Is the voltage equal to 0V？ If this value is satisfied, replace the combination instrument.
  • Page 486 Alarm and Indication System Diagnostic program Steps Check Display Measures button Go to the next step. driver-side door lock to the Lock position (switch of Measure the voltage of combination door lock linkage in the instrument terminal 3F. Off position ) Is the voltage equal to 0V? If this value is satisfied, replace the combination instrument.
  • Page 487 Wiper and washer Diagnostic program Steps Check Display Measures Current climate control Go to the next step.. unit display OFF. Open rear windshield switch. Measure the voltage of combination instrument terminal 3R Is the voltage equal to 5V？ If this value is satisfied, replace the combination instrument;...
  • Page 488 Alarm and Indication System Diagnostic program Steps Check Display Measures Set the headlight in the Go to the next step. TNS position. (TNS replay On) Measure the voltage of combination instrument terminal 1E. Is the voltage equal to B+？ If this value is satisfied, replace the combination instrument;...
  • Page 489 Wiper and washer Diagnostic program Steps Check Display Measures Set the headlight switch in Go to the next step. the Headlight position. Measure the voltage of combination instrument terminal 3Q. Is the voltage equal to 0V？ If this value is satisfied, replace the combination instrument.
  • Page 490 Alarm and Indication System DTC 11 Engine speed input signal Check Display Measures Start the engine signal input combination instrument is normal. Check the following parts. Harness (PCM—combination instrument) DTC 12 Working signal to the speedometer Check Display State Measures Wait for 2s after the speedometer pointer...
  • Page 491 Alarm and Indication System DTC 15 Working signal to the rear fog lamp relay Check Display State Measures Wait for 2s after The rear fog lamp indicator on Rear fog lamp relay normal. and off for three times. chosen. (Flashing) Other than the above cases.
  • Page 492 Alarm and Indication System DTC 18 Illumination light signal On/Off/ of ignition switch keyhole Combination instrument connectors Harness side connector (Viewed from the harness side) XMET18W017 Diagnostic program Check Display State Measures Wait for 2s after Illumination light signal of The illumination light signal of ignition switch keyhole on and ignition switch keyhole is normal.
  • Page 493 Wiper and washer Check Display State Measures Wait for 2s after the Put through and cut off the rear The rear windshield defroster DTC 20 chosen. windshield defroster relay for relay is normal. (Flashing) three times. Other than the above cases. Measure voltage combination instrument terminal...
  • Page 494 Alarm and Indication System DTC 22 Fuel level signal Combination instrument connectors Harness side connector (Viewed from the harness side) XMET18W017 Steps Check Display Measures Disconnect the connector of Go to the next step. fuel gauge sensor and choose DTC 22. Other than Replace the combination instrument.
  • Page 495 Wiper and washer DTC 23 Working signal to the fuel gauge Check Display State Measures Wait for 2s after the The fuel gauge will display as per The fuel gauge is normal. DTC 23 chosen. the following order every 2s: F→1/2→E→F (constant display)
  • Page 496 Alarm and Indication System Steps Check Display Measures Use the special tool (fuel and Go to the next step. temperature tester) resistance input resistance 60Ω into combination instrument terminal 3E. Other than Replace the combination instrument. above-said display. Use the special tool (fuel and Go to the next step.
  • Page 497 Wiper and washer Check Display State Measures 1. Set the indoor The indoor light is on and off for The indoor light is normal. light switch in three times. DOOR (Flashing) Other than the above cases. Measure voltage position. combination instrument terminal 2.
  • Page 498 Alarm and Indication System Steps Check Display Measures Confirm that the rear The signal input of combination lamp indicator instrument is normal. light is lit. Press the switch of Measure the voltage of combination rear fog lamp (rear instrument terminal 3T. fog lamp switch Off) Is the voltage equal to 0V？...
  • Page 499 Wiper and washer Steps Check Display Measures Pull out the ignition switch Measure the voltage of combination from the steering lock. instrument terminal 2J. (Key-reminder switch Off). Is the voltage equal to 0V？ If this value is satisfied, replace the combination instrument.
  • Page 500 Alarm and Indication System Steps Check Display Measures Turn off the front fog lamp signal input combination switch. (Disconnect the instrument is normal. front fog lamp relay). Measure the voltage of combination instrument terminal 2N. Is the voltage equal to 0V？ If this value is satisfied, replace the combination instrument.
  • Page 501 Wiper and washer Steps Check Display Measures Set the shift lever in the Measure the voltage of combination shift position P instrument terminal 4B. Is the voltage equal to 5V？ If this value is satisfied, replace the combination instrument. If this value is unsatisfied, check the following parts.

  • Page 502: Disassembly And Assembly Of Audio Assembly

    Alarm and Indication System panel and push out forcibly to make snaps of Disassembly and assembly of audio audio panel partly come off. ② Grasp again assembly with hands both sides of panel and exert outward so as to let the upper snap of panel Necessary tools: come off.

  • Page 503: Removal/Installation Of 4D Loudspeaker

    Audio system Resistance Assembly method: Terminal Insert all connectors behind the audio host and Testing conditions the A/C controller; Under any conditions Before the audio and A/C controller assemblies are fit into the dashboard, it is recommended to check first whether all parts are operating normally (audio, Radio, A/C compressor operation, air volume and mode);...

  • Page 504: Antenna

    HI-FI System Removal/installation of signal line of rear antenna Remove the negative cable of battery; Remove the audio unit; Remove inner trim panel occupant-sided column A; Remove the roof lining; Disconnect the connection between the signal lines of front/rear antennae; Remove in the order indicated in the Table;...

  • Page 505: Check Of Rear Antenna Signal Line

    Audio system Check of rear antenna signal line Remove rear antenna signal line; Confirm by use of an ohmmeter that there is no continuity between the signal line terminals A and B of rear antenna Confirm by use of an ohmmeter the continuity between the signal line terminals of front antenna;...

  • Page 506: Safety Airbag System

    Safety airbag system Safety airbag system Electrical schematic of safety airbag Note: “”means the short-circuit ring. When the connector is not connected, the short-circuit presents between two wires connected by short-circuit ring. T-42...

  • Page 507: Parts Relevant To The Safety Airbag

    Audio system arts relevant to the safety airbag The fault indicator, located in the combination instrument and in red color, is designated to indicate the state of SRS airbag system. PFAB passenger side front row airbag module, located below the dashboard and in front of the front passenger, is designated to pop up the airbag for the front passenger protection in case of collision.

  • Page 508: Faults Table Of Safety Airbag System

    Safety airbag system Faults table of safety airbag system B1301 ECU internal fault, B1302 Power supply voltage too high B1303 Power supply voltage too low B1304 Driver-sided airbag resistance high B1305 Driver-sided airbag resistance low B1306 Driver-sided airbag short-circuited with the grounding B1307 Driver-sided airbag short-circuited with the power supply B1308...
  • Page 509 Safety airbag system Handle as per the following fault log. (1) Check whether the connectors between the driver airbag module and clock spring, between Fault indicator constant on the clock spring and harness and between the Whether the fault log can be read out through harness and controller of safety airbag the diagnostic apparatus.
  • Page 510 Safety airbag system driver airbag module and clock spring, between (1) Check whether the connectors between the the clock spring and harness and between the driver airbag module and clock spring, between harness and controller of safety airbag the clock spring and harness and between the controller are plugged in place.
  • Page 511 Safety airbag system (1) Check whether the plugs between the driver clock spring and harness and between the airbag module and clock spring, between the harness and controller of safety airbag clock spring and harness and between the controller are plugged in place.. harness and controller of safety airbag (2) Check whether the resistance between the controller are plugged in place.

  • Page 512: Vehicle Disposal Procedure Of Airbag Effect

    Safety airbag system 11. There is “Setting Errors” fault in the fault log. (1) Replace combination instrument test whether the fault disappeared. Please check if the ECU type is correct. (2) Replace safety airbag controller to test whether the fault disappeared. 12.

  • Page 513: Disassembly/Assembly Of Each Part Of Safety Airbag

    Safety airbag system The replaced module shall be handled as per Disassembly/assembly of clock spring “VIII. Disposal Procedure of Obsolete Safety Airbag Module” Disassembly/assembly of each part of safety airbag Warning:: After Disconnected the electrode wire of battery, the harness connector of safety airbag controller (ECU) can be removed at least in 15mins, for other parts, it Screws shall wait at least for 2mins, otherwise it will result...

  • Page 514: Essentials To Installation Of Clock Spring

    Safety airbag system 11. Reassemble the rest of parts in the reverse Align with the mark order. Essentials to installation of clock spring Attention If failure to adjust the clock spring, the wire of clock spring will be broken due to excessive tension when turning the steering wheel.

  • Page 515: Disassembly/Assembly Of Safety Airbag Computer

    Safety airbag system Remove the harness connector of the SRS Take out auxiliary safety airbag module from module. the vehicle. Remove 3 screws fixing the SRS module. Warning: The tightening torque for reassembling the The airbag module shall be kept facing upward. No screw: 8 N.m.

  • Page 516: Check Of Safety Airbag Module

    Safety airbag system Operation of lateral safety airbag module When the lateral safety airbag module released due to a collision, the internal padding frame of seat backrest etc, may be damaged. If the seat backrest is Check of safety airbag module repeatedly used and the lateral safety airbag module The safety airbag module checked with an is unable to normally release, a severe accident may...

  • Page 517: Release Procedures Of Safety Airbag Module And Pretensioning Safety Belt

    The components are contaminated by oil and grease If the special release tools and switch harness not etc. which, in case of an accident, may cause the available, please consult the nearest Haima safety airbag module and pretensioning safety belt automobile agent for help...

  • Page 518: Driver-Sided Safety Airbag Module

    Safety airbag system Attention release safety airbag module pretensioning safety belt inside the vehicle may result in the internal damage. If the vehicle is not going to be scrapped, do not release the safety airbag module and pretensioning safety belt inside the vehicle.

  • Page 519: Driver-Sided Safety Airbag Module

    Safety airbag system Connect the red clamp of special release tool Connect the red clamp of special release tool with battery positive terminal, and the black with battery positive terminal, and the black clamp with battery negative terminal. clamp with battery negative terminal. Confirm that the red light on the special release Confirm that the red light on the special release tool is lit.
  • Page 520 Safety airbag system Tire with rim Tire Bolt Tire with the module of driver-side safety airbag Module connector of driver-side safety airbag Use wires to bundle up all tires. Warning: If the safety airbag module incorrectly installed on the tire, the release of module may result in serious personnel injury.
  • Page 521 Safety airbag system Tire with rim Occupant-sided safety airbag module Remove the occupant-sided safety airbag module. Install the bolts on the occupant-sided safety airbag module. Warning: Tire If the safety airbag module incorrectly installed on the tire, the release of module may result in serious personnel injury.
  • Page 522 Safety airbag system Tire with rim Trigger switch Tire with pretensioning safety belt Tire Pretensioning safety belt Remove the pretensioning safety belt. Warning: If the safety airbag module incorrectly installed on the tire, the release of pretensioning part may result Bundle up all tires with wires.

  • Page 523: Released Safety Airbag Module And Pretensioning

    Safety airbag system Trigger Clamp switch Connector A Green light Connector B Trigger switch Red light Released safety airbag module pretensioning safety belt After the safety airbag module and pretensioning Checking procedure safety belt just released, the high temperature may result in scald.
  • Page 524 Safety airbag system Trigger switch Connector A Connector B T-60...

  • Page 525: Rke (Remote Control System

    RKE (Remote Control System) Reversing radar system RKE (Remote Control System) Removal/installation of reversing radar Removal/installation of remote controller host Remove the negative cable of battery; Remove the negative cable of battery; Disconnect the connector of remote controller; Disconnect the connector of reversing radar Dismantle with a wrench the remote controller host;...

  • Page 526: Removal/Installation Of Reversing Radar Sensor

    Safety airbag system radar sensors, if three beeps like “BI”“BI”“BI”, it means there may be faults in two or more reversing radar. If there is a fault in the reversing radar sensor, please replace the fault reversing radar sensor. If everything is in order after check mentioned as above, it means there are faults in the remote controller and need to replace the remote controller.

  • Page 527: Anti-Theft System

    Anti-theft system parts and harnesses are in order, but the system Anti-theft system is still unable to work properly, replace the Removal/installation of anti-theft host controller of anti-theft host and redo the matching. Please pay special attention to the controller matching precautions.

  • Page 528: Check Of Anti-Theft Coil

    Safety airbag system Connector at harness side Note: When checking, connect the PIN A with the PIN C. If failed to get through, it means that the anti-theft coil is damaged. Replace the anti-theft coil. The installation procedure is in reverse order with that of removal.

  • Page 529: Switch And Relay

    Switch and relay Switch and relay Screw Wiper and washer switches Removal/installation of combination switch Auto lamp switch Disconnect battery negative cable; Combination switch Remove the driver-sided safety airbag module (See T—Removal/Installation of Driver-Sided Safety Airbag Module); Removal/installation of auto lamp switch Remove steering wheel...

  • Page 530: Removal/Installation Of Middle Switch

    Switch and relay The method of installation is in reverse order with that of removal. Flashing High Headlamp Switch circuit diagram Middle switch (incl. hazard warning light switch and door lock switch) Auxiliary fascia console Element side connector Maintenance of middle switch Steering switch Remove the switch;...

  • Page 531: Check Of Front/Rear Fog Lamp Switch

    Switch and relay Compress by hands the upper/lower snaps on the switch behind the dashboard until the switch is able to pass through the mounting hole; Definition of the front/rear fog Take out the switch; lamp switch terminals The installation procedure is in reverse order with that of the removal.

  • Page 532: Circuit Diagram

    Switch and relay Test by use of a multimeter, the continuity between the rheostat terminals according to the diagram. If it fails to meet the technique requirements, Replace rheostat. Diagram Circuit diagram Installation/removal of level adjustment switch (optional) Disconnect the negative cable of battery; Installation/removal of folding switch of rear-view mirrors (optional) Remove the side panel of dashboard;...

  • Page 533: Mirrors (Optional

    Switch and relay Check of folding switch of rear-view mirrors Remove the folding switch of rear-view mirrors; Check, with a multimeter the continuity of switch terminal according to the diagram. If it fails to meet the technique requirements, replace the switch. Folding state Left front door assembly...

  • Page 534: Installation/Removal Of Auxiliary Power Window

    Switch and relay Confirm other harnesses properly Installation/removal of front door switch connected and the ignition key in the ON Remove the negative cable of battery; position; Unscrew the fastening screws; Observe whether there are pulses under AUTO gear. If yes, it means that the main switch of Undo the inner trim panel and pull out the plug.

  • Page 535: Removal/Installation Of Flasher Unit

    Ignition switch Alarm fuse 15A Power Alarm Instrument position Alarm supply switch fuse 15A Fixing nut HQ99940-0600 (torque: 7.2～12 switch Ignition Alarm N.m) switch switch LOCK Flashing relay or ACC Bracket component state Disconnect battery negative cable; Remove the cover of main fuse box;...

  • Page 536: Check Of Headlamp Relay

    Switch and relay Removal/installation of front fog lamp relay Disconnect the negative cable of battery; Remove the bracket; Remove the plug of front fog lamp relay; Pry out the lock part at the side of relay with a flathead screwdriver to remove the relay. The installation procedure is in reverse order with that of removal.

  • Page 537: Check Of Rear Fog Lamp Relay

    Remove the bracket and draw toward yourself; Check the continuity between all terminals of rear fog lamp relay with an ohmmeter. If it fails to meet the technique requirements; replace the relay of rear fog lamp relay. Screw HQ99786-0616 (torque: 7.2～12N.M) Continuity Bodywork Connection terminal Steps...

  • Page 538: Check Of Horn Relay

    Switch and relay cover; Check of horn relay Pull out all connectors connecting the lower Remove the horn relay; end of clock spring; Check and confirm the continuity between the Dismantle three screws fixing the clock spring. terminals of horn relay, with an ohmmeter. If it fails to meet the technique requirements, Take out the clock spring from the steering replace horn relay.
  • Page 539 Switch and relay Turn counterclockwise the clock spring for 2 and 3/4 circles. Align the mark on the clock spring with that on the outer circle. Align with the mark T-75...
  • Page 540 Ground point Hub (F) Middle harness Front harness (F) Harness (EM), emission control system 1# harness Engine harness (E) Instrument harness (R1#), liftgate...
  • Page 541 Harness marking:...
  • Page 542 High-speed fan 20A TNS relay Fan control system Low-speed fan 20A High beam 15A Horn 15A Low beam Horn Headlamp Brake lamp 7.5A Brake Front fog lamp relay lamp/high-mounted brake Main relay 40A Headlight control, 7.5A Front fog Engine/ Control...
  • Page 543 Charging system/starting system Battery Ignition switch Alternator Starter relay Starter Part of early models Combination instrument Starter (E) Starter (E) Starter (E) Part of early models...
  • Page 544 Mark on harness: Front harness (F) - Instrument harness (I) Alternator Starter Front harness (F) - Middle harness (D) Ignition switch Middle harness (D) - Instrument harness (I) EM harness (EM)- Instrument harness (I) Fuse block (see section FB) EM harness (EM)-Front harness EM harness (EM)-Engine harness (E) Junction box (see section JB)
  • Page 545 Engine control system (484Q) Battery Main relay Ignition switch Mass airflow sensor Ignition Coil Fuel injector Canister solenoid Main relay Front/rear oxygen sensor Compressor relay High-speed fan relay Low-speed fan relay Fuel pump relay...
  • Page 546 Mark on harness: Front harness (F)- Instrument harness (I) Ignition switch Middle harness (D) - Instrument harness (I) EM harness (EM) - Instrument harness (I) Fuse block (see section FB) Junction box (see section JB)
  • Page 547 Engine control system (484Q) Main relay Main relay Rear oxygen sensor Front oxygen sensor Main relay Main relay Fuel control system VCT (intake) VCT (exhaust) Fuel injector 2 Canister solenoid valve Fuel injector 1 Fuel injector 3 Fuel injector 4 Fuel injector 4 (EM) Fuel injector 2 (EM) Fuel injector 3 (EM)
  • Page 548 Mark on harness: VCT (intake) Fuel injector 1 Fuel injector 2 Fuel injector 3 Crankshaft position sensor Canister solenoid valve Fuel injector 4 VCT (exhaust) Front oxygen sensor Rear oxygen sensor Fuse block (see section...
  • Page 549 Engine control system (484Q) Combination Main relay instrument Coolant Accelerator pedal temperature Electronic throttle body Mass airflow sensor sensor Knock sensor High-speed cooling fan relay Low-speed cooling fan relay Headlight relay Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4 Main relay Ignition coil 1 (EM)
  • Page 550 Mark on harness: Knock sensor Ignition coil 1 Electronic throttle body Mass airflow sensor Ignition coil 2 Ignition coil 3 Ignition coil 4 Accelerator pedal Engine coolant temperature sensor Fuse block (see section EM harness (EM)- front harness (F)
  • Page 551 Engine control system (484Q) Combination Combination Anti-theft Anti-theft control Compressor Refrigerant pressure Diagnostic instrument instrument control unit unit relay interface switch Phase sensor 2 Phase sensor 1 Power steering switch Clutch switch Brake switch Phase sensor 1 (EM) Phase sensor 2 (EM) Power steering switch (EM) Clutch switch (EM)
  • Page 552 Mark on harness: Middle harness (D)- Instrument harness (I) Front harness (F)- Instrument harness (I) Ignition switch Power steering switch EM harness (EM)- Instrument harness (I) Accelerator pedal Phase sensor 2 Phase sensor 1 Fuse block (see section Front harness (F)- Middle harness (D) EM harness (EM)- Front harness (F) Clutch switch...
  • Page 553 Fuel control system Battery Oil pump 20A Main relay Fuel pump relay Fuel pump Diagnostic interface Fuel pump (d)
  • Page 554 Mark harness: Front harness (F)-Middle harness Fuse block (see section EM harness (EM)-Front harness (F) Fuel pump...
  • Page 555 Fan control system Battery Low-speed cooling fan 20A High-speed cooling fan 20A Mani relay Mani relay Low-speed cooling fan relay High-speed cooling fan relay Low-speed cooling fan High-speed cooling fan High-speed cooling fan (F) Low-speed cooling fan (F)
  • Page 556 Mark on harness: High-speed cooling fan Low-speed cooling fan Fuse block (see section...
  • Page 557 Combination instrument Battery Combination instrument Ignition switch Speedometer Fuel meter Tachometer Coolant temperature gauge Key reminder switch Odometer display Key reminder switch Combination instrument (I) Combination instrument (I)
  • Page 558 Mark on harness: Middle harness (D) - Instrument harness Combination instrument Ignition switch Key reminder switch Fuse block (see section Junction box (see section JB)
  • Page 559 Combination instrument Control unit of Illuminator of ignition switch remote controlled Audio door lock Combination instrument A/C control ABS control unit A/C control Fuel gauge sensor Fuel gauge sensor (D) Combination instrument (I) Combination instrument (I)
  • Page 560 Mark on harness: Middle harness (D) - Instrument harness (I) Combination instrument Fuel sensor...
  • Page 561 Combination instrument Flashing unit Headlamp relay Control unit of remote controlled door lock Combination instrument High beam Right turning Left turning Warning lamp Brake lamp Brake fluid level sensor Headlamp switch ABS control unit Parking switch Brake fluid level sensor (F) Combination instrument (I) Combination instrument (I) Parking switch (D)
  • Page 562 Mark on harness: Front harness (F) - Instrument harness (I) Brake fluid level sensor Combination instrument Middle harness (D) - Front harness Parking switch...
  • Page 563 Combination instrument Front /rear fog lamp switch Front fog lamp relay Airbag ECU Combination instrument Rear Front lamp lamp warning warning lamp lamp Oil pressure switch Oil pressure switch (E) Combination instrument (I) Combination instrument (I)
  • Page 564 Mark on harness: Oil pressure switch Combination instrument EM harness (EM) - Engine harness (E) EM harness (EM) - Instrument harness (I)
  • Page 565 Combination instrument Combination instrument Charge Seat Check fault Check belt engine indicator emission warning lamp lamp s lamp lamp Reset switch of odometer Driver seat belt switch Generator Driver seat belt switch (D) Combination instrument (I) Combination instrument (I)
  • Page 566 Mark on harness: Combination instrument Middle harness (D) - Instrument harness Driver seat belt switch...
  • Page 567 Combination instrument Anti-theft control unit Combination instrument Door unclosed indicator Anti-theft warning lamp Central control unit of remote control Right front Right rear Left front Left rear door switch door switch door switch door switch Right rear door switch (D) Combination instrument (I) Combination instrument (I) Right front door switch (D)
  • Page 568 Mark on harness: Combination instrument Middle harness (D) - Instrument harness Left rear Left front door switch door switch Right front door switch Right rear door switch...
  • Page 569 Windshield wiper and washer Ignition switch Single contact switch Windshield wiper and washer switch Washer switch Intermittent relay of wiper Automatic stop switch Circuit breaker Front windshield washer motor Front windshield wiper motor Front windshield wiper Front windshield washer Windshield wiper and washer switch (I) motor (F) motor (F)
  • Page 570 Mark on harness: Middle harness (D) - Front harness (F) - Instrument harness (I) Instrument harness (I) Ignition switch Front windshield wiper motor Front windshield washer motor Windshield wiper and washer switch Middle harness (D) - Instrument harness (I) EM harness (EM) - Instrument harness (I) Fuse block (see section Front harness (F) - Middle harness (D) Junction box (see section JB)
  • Page 571 Windshield wiper and washer Battery Ignition switch Rear window washer Some models Rear wiper motor Intermittent relay of rear window wiper Washer Washer Automatic stop switch Washer switch of rear Some window wiper models Rear windshield washer Rear windshield wiper Windshield wiper and washer switch (I) motor (F) motor (R1#)
  • Page 572 Mark on harness: Middle harness (D) - Front harness (F) - Instrument harness (I) Instrument harness (I) Ignition switch Intermittent relay of rear wiper Front windshield washer motor Windshield wiper and washer switch Middle harness (D) - Instrument harness (I) EM harness (EM) - Instrument harness (I) Fuse block (see section FB) Liftgate (2#) harness (R2#)
  • Page 573 Headlight Battery Headlight Combination Combination Position lamp 15A Front fog lamp 15A adjusting switch Instrument Instrument TNS relay Headlight relay Front position lamp License lamp Taillight Lighting lamp Front rear fog lamp Lighting lamp Overtake flash Right headlight Left headlight Headlight Headlight switch Headlight switch (D)
  • Page 574 Mark on harness: Front harness (F) - Instrument harness (I) Left headlight Headlight switch Left headlight Fuse block (see section FB) Front harness (F) - Middle harness (D)
  • Page 575 Headlight adjusting system Headlight adjusting switch Headlight relay Left headlight actuator Right headlight actuator Headlight switch (D) Left headlight (F) Right headlight (F) Headlight adjusting switch (I)
  • Page 576 Mark on harness: Left headlight Front harness (F) - Instrument harness (I) Left headlight Headlight adjusting switch...
  • Page 577 Front fog lamp and rear fog lamp Battery Front fog lamp 10A TNS relay Front fog lamp relay Front/rear fog lamp switch Combination instrument Combination instrument Left front fog lamp Right front Left rear fog lamp fog lamp Front/rear fog lamp switch (I) Left front fog lamp (F) Left rear fog lamp (D) Right front fog lamp (F)
  • Page 578 Mark on harness: Front harness (F) - Instrument harness (I) Front/rear fog lamp switch Headlight Right front fog lamp adjusting switch Middle harness (D) - Instrument harness Left front fog lamp Fuse block (see section FB) Left rear fog lamp...
  • Page 579 License lamp/position lamp/taillight LNS relay Some models Left position lamp Right position lamp Right taillight Left taillight Left license lamp Right license lamp Some models Left license lamp (R1#) Right license lamp (R1#) Right taillight (D) Left position lamp (F) Left taillight (D) Right position lamp...
  • Page 580 Mark on harness: Right front position lamp Instrument harness (I) -Middle harness (D) Liftgate 2# harness (R2#) -Middle harness (D) left front position lamp Fuse block (see section FB) Left taillight Left license lamp Right license lamp Right taillight Liftgate 2# harness (R2#) - Liftgate 1# harness (R1#)
  • Page 581 Turn lamp and hazard warning lamp Battery Steering switch Ignition switch Flash unit Hazard warning lamp Left outside rear-view Right outside rear-view Right front Right rear Left front turn lamp Left rear turn lamp mirror / turn lamp mirror / turn lamp turn lamp turn lamp Combination instrument...
  • Page 582 Mark on harness: Front harness (F) - Middle harness (D) - Instrument harness (I) Instrument harness (I) Flash unit Ignition switch Right front turn lamp Steering switch Combination instrument Middle harness (D) - Instrument harness (I) Middle harness (D) – front door harness (DR1) Left front turn lamp Left outside rear-view...
  • Page 583 Backup lamp Battery Ignition switch Backup lamp Audio unit Right backup lamp Backup sensor controller Backup lamp switch (EM) Right backup lamp (D)
  • Page 584 Mark on harness: Front harness (F) - Instrument harness (I) Ignition switch Middle harness (D) - Instrument harness Backup lamp switch EM harness (EM) - Instrument harness (I) EM harness (EM) - Instrument harness (I) Fuse block (see section Junction box (see section JB) Right backup lamp Junction box (see section JB)
  • Page 585 Brake lamp/ High mount brake lamp Battery Brake lamp Brake switch (D) Ignition switch High mount brake lamp Left brake lamp Right brake lamp ABS control unit Brake switch (D) High mount brake lamp (R2#) right brake lamp (D) Left brake lamp (D)
  • Page 586 Mark on harness: Front harness (F) - Instrument harness (I) Ignition switch Middle harness (D) - Instrument harness (I) Fuse block (see section EM harness (EM) - Instrument harness (I) Front harness (F) - Liftgate 2# harness (R2#) - High mount brake Middle harness (D) Middle harness (D) lamp...
  • Page 587 Horn Battery Horn relay Remote keyless entry control unit Clock spring Base loudspeaker High pitch loudspeaker Horn switch Base loudspeaker (F) High pitch loudspeaker (F) Horn switch (I) (Clock spring) Base loudspeaker (F) High pitch loudspeaker (F)
  • Page 588 Mark on harness: High pitch loudspeaker High pitch loudspeaker Front harness (F) - Instrument harness (I) Base loudspeaker Base loudspeaker Fuse block (see section FB) Horn switch...
  • Page 589 A/C system Batter Ignition switch A/C control unit Blower relay Blower speed adjuster Blower Circulated inside/outside air door Blower relay (I) Blower (I) Blower speed adjuster (I) A/C control unit (I) Circulated inside/outside air door (I)
  • Page 590 Mark on harness: Front harness (F) - Instrument harness (I) Ignition switch A/C control unit Circulated inside/outside air door Blower relay Blower speed adjuster Blower Fuse block (see section FB) Front harness (F) - Middle harness (D)
  • Page 591 Heating and A/C systems Blow mode Actuator Temperature control actuator Ambient temperature sensor Cold Heat Defroster Ventilation Automatic A/C Sunlight sensor Automatic A/C control unit Automatic Evaporator Inside temperatur temperatur e sensor e sensor Combination instrument Defroster relay Refrigerant pressure switch Evaporator temperature sensor A/C control unit (I) Inside temperature sensor (I)
  • Page 592 Mark on harness: Refrigerant pressure switch Front harness (F) - Instrument harness (I) Sunlight sensor Ambient temperature sensor A/C control unit Blow mode Actuator Inside temperature sensor EM harness (EM) Temperature control Evaporator temperature sensor -instrument harness (I) actuator...
  • Page 593 Compressor control system Battery Main relay Compressor relay Electromagnetic clutch Electromagnetic clutch...
  • Page 594 Mark on harness: Electromagnetic clutch Fuse block (see section FB) EM harness (EM) - Front harness (F)
  • Page 595 Reversing radar system Backup lamp switch Reversing radar control unit Left Left middle Right middle Right Reversing radar sensor Reversing radar control unit (IN) Left reversing radar Left middle reversing Right middle reversing Right reversing radar sensor (RA) radar sensor (RA) radar sensor (RA) sensor (RA)
  • Page 596 Mark on harness: Electromagnetic clutch Fuse block (see section FB) EM harness (EM) - Front harness (F)
  • Page 597 Backup camera system EM harness (EM) - Front harness (F) OSD power supply Backup camera control unit (OSD controller) Input signal ground (D) Input signal ground (D) Shielded wire Shielded wire Input signal + (D) Input signal + (D) Input signal ground (I) Input signal + (R2#) Input signal + (R2#) Input signal + (I)
  • Page 598 Mark on harness: Video signal transmission line Female connector (R1#)-Male connector (R2#) Video signal transmission line Flat square connector (I) Video signal transmission line Female connector (D)-Male connector (I#) Backup camera control unit Liftgate 2# harness (R2#) -Liftgate 1# harness (R1#) Middle harness (D)-Liftgate 2# harness (R2#) Video signal transmission line...
  • Page 599 Cigarette lighter/rear defrost system Battery Defrost 30A Ignition switch Defrost relay A/C control unit Some models Defroster Outside rear-view mirror heater Cigarette lighter OSD power supply Some models Cigarette lighter (R1#) Defroster (R1#) Cigarette lighter (I) Defrost relay...
  • Page 600 Mark on harness: Front harness (F) - Middle harness (D) - Instrument harness (I) Instrument harness (I) Ignition switch Defrost relay Middle harness (D) - Instrument harness (I) Fuse block (see section Liftgate 2# harness (R2#) - Middle harness (D) Defroster Junction box (see section JB) Cigarette lighter...
  • Page 601 Lighting lamp Lighting lamp TNS relay Some models Illumination of front Instrument Illumination Illumination of Illumination of audio rear fog lamp switch audio CD unit CD + GPS unit Instrument panel lamp control switch Illumination of audio CD (I) Instrument Illumination (I) Illumination of audio CD + GPS (I) Illumination of front rear fog lamp switch (I)
  • Page 602 Mark on harness: Audio illumination Illumination of front rear fog lamp switch Instrument illuminator...
  • Page 603 Lighting lamp TNS relay Instrument lamp control switch Illumination of Illumination of Control circuit Illumination of headlight A/C control rear-view mirror fold adjusting switch switch Lighting lamp Lighting lamp Headlight adjusting Illumination of A/C control (I) Illumination of rear-view mirror fold switch (I) Illumination of instrument switch (I) lamp control switch (I)
  • Page 604 Mark on harness: Illumination of rear-view mirror fold switch Illumination of instrument lamp control switch Illumination of headlight adjusting switch) Illumination of A/C control...
  • Page 605 Lighting lamp Battery TNS relay Illumination of ignition switch Illumination of Illumination of hazard cigarette lighter warning lamp switch Instrument panel lamp control switch Illumination of cigarette lighter Illumination of ignition switch (I) Illumination of hazard warning lamp switch...
  • Page 606 Mark on harness: Illumination of ignition switch Middle harness (D) - Instrument harness (I) Fuse block (see section Junction box (see section JB) Front harness (I)-Middle harness (D) Illumination of hazard Illumination of cigarette lighter warning lamp switch...
  • Page 607 Interior lamp/reading lamp /courtesy lamp /trunk lamp Left front door courtesy lamp Trunk lamp Right front door courtesy Interior lamp Remote keyless entry control unit Liftgate lock unit Reading lamp Left rear door courtesy lamp Some models Trunk lamp switch Right rear door courtesy lamp Some models Right rear door courtesy lamp...
  • Page 608 Mark on harness: Front harness (F)-Middle harness (D) Junction box (see section JB) Middle harness (D)-rear door harness (DR3) Left front Interior door lamp Reading courtesy Middle harness (D)- Interior harness (IN) lamp Left rear door lamp Middle harness (D) -Front door harness Fuse block (see section FB) courtesy lamp (DR1)
  • Page 609 Audio system Battery Audio quick dial key module Ignition switch Clock spring Audio unit Backup switch Right rear door speaker Left front door speaker Right front door speaker Left rear door speaker Left front door speaker (DR1) Right front door speaker (DR2) Audio unit (I) Left rear door speaker (DR3) Right rear door speaker (DR4)
  • Page 610 Mark on harness: Ignition switch Audio unit Audio fast key module Middle harness (D) - Instrument harness (I) Front harness (F)-Middle harness (D) Fuse block (see section FB) Left rear door speaker Left front door speaker Junction box (see section JB) Right front door speaker Right rear door speaker Audio unit...
  • Page 611 Audio system Battery Audio quick dial key module Input signal ground Ignition switch Input signal + (D) Clock spring Audio unit + GPS Backup switch Combination instrument Right rear door speaker Left front door speaker Right front door speaker Right small tweeter Left rear door speaker Left small tweeter Right rear door speaker (DR4)
  • Page 612 Mark on harness: Ignition switch Audio unit + GPS Backup camera signal line flat square connector Audio system fast key module Middle harness (D)-Instrument harness (I) Front harness (F)-Middle harness (D) Left minor high pitch Fuse block (refer to FB Front left door loud speaker sections)
  • Page 613 Power door window system Battery Ignition switch Power door window main switch Power switch Automatic Power window control module Rear Front Power window Rear left right right auxiliary switch Pulse generator Power window Limiting switch regulator Front left window regulator Front right Rear left Rear right...
  • Page 614 Mark on harness: Front harness (F)-Instrument harness (I) Ignition switch Middle harness (D)-Instrument harness (I) Front harness (F)-middle harness (D) Front left window regulator Fuse block (refer to FB Middle harness (D)-rear door harness Power door window sections) (DR3) main switch Middle harness (D)-front door harness (DR1) Rear left power window regulator Front right power...
  • Page 615 Remote/Central control door lock system Battery Central door lock unit Left front door lock gang switch Central lock switch Unlock Locked Door lock actuator Remote keyless entry Remote keyless entry control unit control unit (SECTION (K-2C) (SECTION (K-2C) Central door lock unit (D) Central lock switch (D) Front left door lock actuator (DR1)
  • Page 616 Mark on harness: Middle harness (D)-Instrument harness (I) Central door lock unit Fuse block (refer to FB sections) Junction box (refer to JB sections) Central lock switch...
  • Page 617 Remote/Central control door lock system Central door lock unit Some models Locked Locked Locked Locked Locked Front left Front right Rear right Rear left Lift gate door lock door lock door lock door lock lock actuator Unlock actuator Unlock Unlock actuator Unlock Unlock...
  • Page 618 Mark on harness: Front left door lock actuator Middle harness (D)-rear door harness (DR3) Rear left door lock actuator Middle harness (D)-front door harness (DR1) 2# harness (R2#), lift gate-middle harness (D) 2# harness (R2#), lift gate-1# harness (R1#), lift gate Middle harness (D)-front door harness (DR2) Trunk opening motor Front right door lock actuator...
  • Page 619 Remote/Central control door lock system Battery Combination instrument Ignition switch Remote keyless entry control unit Combination instrument Interior lamp Lift gate lock unit Horn relay Central door time delay Central door lock unit Combination instrument lock unit (SECTION 1-3) (SECTION K-2a) Remote keyless entry control unit (I)
  • Page 620 Mark on harness: Middle harness Front harness (F)-Instrument harness (I) (D)-Instrument harness (I) Ignition switch Middle harness (D)-Instrument harness (I) Remote keyless entry control unit Fuse block (refer to FB sections) Junction box (refer to JB sections)
  • Page 621 Outside rear-view mirror heater / Outside electric rear-view mirror Battery Outside electric rear-view mirror switch Upper Lower Upper Lower Left Rear Left Rear Rear defroster relay Left Right outside Electric outside outside rear-view Rear Left Rear Left rear-view mirror rear-view mirror heater fold switch mirror...
  • Page 622 Mark on harness: Middle harness Front harness (F)-Instrument harness (I) (D)-Instrument harness (I) Ignition switch Outside electric rear- view mirror switch Rear-view mirror fold switch Middle harness (D)-Instrument harness (I) Middle harness (D)-Instrument harness (I) Middle harness (D)-Instrument harness (I) Fuse block (refer to FB sections) Left outside rear-view mirror...
  • Page 623 Sliding sunroof Battery Sunroof motor Ignition switch Sunroof controller NO. 1 Sunroof relay NO. 2 Sunroof relay Limit switch 1 Limit switch 3 Limit switch 2 Sunroof switch (IN) Sunroof motor Sunroof switch - sunroof relay Sunroof switch Sunroof relay...
  • Page 624 Mark on harness: Front harness (F)-Instrument harness (I) Ignition switch Middle harness (D)-Instrument harness Fuse block (refer to FB Sunroof switch sections) Middle harness (D)-Interior harness (IN) Sunroof motor Junction box (refer to JB sections)
  • Page 625 Anti-lock brake system Battery Diagnostic Combination Brake interface instrument switch Ignition switch ABS control unit Left, front Right, front Left, rear Right, rear Combination instrument ABS wheel speed sensor ABS control unit (F) ABS wheel speed sensor ABS wheel speed sensor (left, front) (EM) (right, front) (EM) ABS wheel speed sensor...
  • Page 626 Mark on harness: Front harness (F)-Instrument harness (I) ABS wheel speed sensor (right, front) ABS control unit Ignition switch ABS wheel speed sensor (left, front) Middle harness (D)-Instrument harness Front harness (F)-Middle harness (D) Fuse block (refer to FB sections) EM harness (EM)-Front harness (F) ABS wheel speed sensor (left, rear) Junction box (refer to JB sections)
  • Page 627 Power seat Battery Power seat 20A Part of early models Power seat 30A Rear Front Front Lower Upper Lower Upper Rear Front Front Rear Angle adjusting Slide rail Rear regulator Angle adjusting Slide rail motor motor motor motor motor Front regulator motor Driver side power seat Passenger side power seat Driver side power seat...
  • Page 628 Mark on harness: Front harness (F)-Middle harness (D) Fuse block (refer to FB Junction box (refer to JB sections) sections) Power seat Passenger power seat...
  • Page 629 Airbag/seat belt pretensioning system Battery Diagnostic Combination interface instrument Ignition switch Airbag ECU Clock spring Jumper sheet Jumper sheet Jumper sheet Jumper sheet Air charging device Air charging device Air charging device Air charging device Driver’s seat belt Passenger’s seat belt Passenger’s airbag Driver’s airbag pretensioning...
  • Page 630 Mark on harness: Front harness (F)-Instrument harness (I) Ignition switch Passenger’s airbag Driver’s airbag Clock spring Airbag ECU Middle harness (D)-Instrument harness (I) Fuse block (refer to FB sections) Driver’s seat belt pretensioning Junction box (refer to JB sections) Passenger’s seat belt pretensioning...
  • Page 631 Anti-theft coil Battery Battery Combination Instrument Ignition switch Anti-theft control unit Diagnostic interface Anti-theft coil Anti-theft coil (D) Anti-theft control unit (D)
  • Page 632 Mark on harness: Front harness (F)- Middle harness (D)- Instrument harness (I) Instrument harness (I) Ignition switch Anti-theft coil Anti-theft control unit Middle harness (D)-Instrument harness (I) Front harness (F)-Middle harness (D) Fuse block (refer to FB sections) Junction box (refer to JB sections)
  • Page 633 Diagnostic interface (DLC) Battery ABS control unit Ignition switch Diagnostic interface (DLC)-2 Part of early models Anti-theft control unit Air bag ECU Diagnostic interface (DLC) Fuel control system Diagnostic interface (DLC) (EM) Diagnostic interface (DLC)-2(I) Caution: This figure is shown when viewed from the harness terminal. Caution: This figure is shown when viewed from the harness terminal.
  • Page 634 Mark on harness: Front harness (F)-Instrument harness (I) Ignition switch Diagnostic interface (DLC) Diagnostic interface (DLC) Middle harness (D)-Instrument harness (I) Front harness (F)-Middle harness (D) Fuse block (refer to FB sections) EM harness (EM)-Front harness (F) Junction box (refer to JB sections)
  • Page 635 Wiring diagram on fuse block Part of early models...
  • Page 636 Fuse block Power seat (main) Part of early models SN Fuse description SN Fuse description Fuse description SN Relay description Blower Low beam High-speed fan Power seat Front fog lamp Starting (main) Position lamp Main relay Headlamp Low-speed fan Low-speed fan Hazard warning lamp Front fog lamp Main relay...
  • Page 637 Fuse block Engine harness (E) Engine harness (E) Front harness (F) Engine harness (E) EM harness (EM) Front harness (F) Front harness (F) Part of early models...
  • Page 638 List of generic plugs Front harness (F)-Instrument harness (I) Front harness (F)-Middle harness (D) Ignition switch (I) Engine harness (E)-EM harness Engine harness (E)-Instrument harness (I) (EM) Part of early models...
  • Page 639 List of generic plugs Middle harness (D)-Instrument harness (I) Instrument harness (I)-Middle harness (D) EM harness (EM)-Front harness (F) Liftgate 1# harness (R1#)-Liftgate 2# harness (R2#) Liftgate 1# harness (R1#)-Liftgate 2# harness (R2#)
  • Page 640 List of generic plugs Liftgate 2# harness (R2#1)-Middle harness (D) Middle harness (D)- Front door harness (DR1) Middle harness (D)-Left rear door harness (DR3) Middle harness (D)- Front door harness (DR2)
  • Page 641 List of generic plugs Middle harness (D)- Right rear door harness (DR4) Middle harness (D) - Reversing radar harness (RA) Middle harness (D)- Liftgate 2# harness (R2#2) Middle harness (D)-Interior harness (IN) Middle harness (D)-Instrument harness Middle harness (D)-Instrument harness...
  • Page 642 Wiring diagram on junction box A/C controller B+ Interior lamp/courtesy lamp Cigarette lighter Audio system Generator/OBD diagnostic interface A/C controller Sun roof Backup switch Instrument cluster/turn signal lamp/brake switch...
  • Page 643 Junction box Instrument harness (I) Middle harness (D) Middle harness (D) Middle harness (D) Fuse description Fuse Fuse description Fuse Middle harness (D)
  • Page 644 Special Tools Special Tools Special Tools ..........ST-1 Engine ............ST-1 Lubrication System ........ST-3 Cooling System ......... ST-3 Fuel and Emission System ......ST-3 Clutch ............ST-4 Manual Transmission ........ ST-4 Automatic Transmission ......ST-4 Front and Rear Axles ........ ST-5 Steering System ........

  • Page 645: Special Tools

    Special Tools Special Tools Engine Extractor 1026 Pull out adapter 8539 Crankshaft shock absorber motion and insertion 6827A Crankshaft sprocket installer Crankshaft shock absorber / Pull out sliding hammer 8386 sprocket installer 8385 C-3752 Extractor 5048 Spark plug pipe remover 8819 Spark plug pipe installer 8447 Spark plug pipe seals installer Valve spring compressor...
  • Page 646 Special Tools Spring compression adapter Camshaft sprocket wrench Camshaft sprocket holder 6779 8435 8446 Conrod installation guide 8388 Crankshaft front seal installer Drive handle C-4171 6780 Crankshaft rear seal guide rod Barometer C-3292 Engine positioning support and installer 6848 6926-1 and 6926-2 Mobile cart 6135 Bracket 6710 A Regulator 8406...

  • Page 647: Lubrication System

    Special Tools Lubrication System 49 0187 280 49 S120 281 49 G014 001 Connecting device Oil pressure meter Oil filter wrench Cooling System 49 9200 145 49 D015 0A0 Radiator cap Radiator cap Tester connecting component Tester connecting component Fuel and Emission System 49 S120 215B 49 N013 1A0A 49 H018 001...

  • Page 648: Clutch

    Special Tools Clutch 49 0259 770B 49 1285 071 49 E011 1A0 Needle bearing remover Ring gear brake Connecting nut wrench 49 E027 002 49 F028 202 49 B001 797 Handle Accessory Shaft bushing installer (49 B001 795 Component ) 49 SE01 310A Clutch disc centering tool Manual Transmission...

  • Page 649: Front And Rear Axles

    Special Tools Number of program card changes with language · 49 T088 044A (UK/Spain) · 49 T088 045A Program card (v5.0) (UK/Portugal) Front and Rear Axles 49 T028 303 49 T028 304 49 T028 3A0 Accessory Accessory Ball head remover component (49 T028 3A0 Component) (49 T028 3A0 Component) 49 F027 0A1...

  • Page 650: Steering System

    Special Tools 49 B025 006A 49 B025 009 49 W027 003 Installer accessory Sensor rotor installer Bearing installer 49 W001 795 49 F026 102 49 H034 201 Bracket block Oil seals installer Bearing installer 49 G030 797 49 B025 004 49 H027 002 Handle Dust-proof seals installer...
  • Page 651 49 B032 336 49 G032 3A1 Hose (49 G032 3A1 Component ) Connecting hose component Adapter component 49 L011 0A0B 49 L011 007 49 G032 354 Guider (49 L001 0A0B Component ) Adjustment wrench Piston pin installer Tools Component ST-7...

  • Page 652: Braking System

    Special Tools 49 F032 3A2 49 F032 321 49 F032 303 Installer B Handle (49 F032 3A2 Component) Installer component 49 N032 319A 49 H032 338 49 S032 317 Connecting shaft Socket wrench Support plate Braking System 49 U043 004 49 U043 005 49 U043 0A0 Adapter...

  • Page 653: Body

    Special Tools 49 T034 1A0 49 8038 785A 49 0180 510B Pre-tightening measurement accessory Spring compressor device Dust shield installer 49 T034 101 49 T034 102 49 T034 103 Hook Base Spring compressor (49 T034 1A0 Component) (49 T034 1A0 Component) (49 T034 1A0 Component) 49 T034 105 49 0107 680A...

  • Page 654: Heater And A/C

    Special Tools 49 D066 801A 49 N088 0A0 49 H066 022 Fuel and temperature gauge Removing tool Extension tool tester 49 D066 002 Adapter harness Heater and A/C 49 C061 0A0A 49 C061 012 49 C061 013 Check valve (R-134a) Manifold meter device...

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